WA T echnology

www.NetWelding.com

MIG Shielding Gas Control and Optimization

Also Available as a Short Movie: http://youtu.be/H5nabh9deLE
By: Jerry Uttrachi
Find Out How To:
• Save money by reducing the high gas surge waste at each weld
start. Slash total MIG shielding gas use typically “in half.”
• Improve weld quality and reduce weld start spatter by
limiting the “gas blast” at each weld start that also pulls in air.
• Achieve these benefits easily and at low cost. Our patented
gas saving products eliminate past problems with gas surge
control devices, like simple orifices and low-pressure
devices. Prices start at $80.00.
• Over 15,000 of our patented Gas Saver Systems are in use. Payback is often
measured in months or one cylinder refill!

This Technical Paper Provides:

• A “one page” summary
• History of MIG shielding gas flow control
• Maximum usable shielding gas flow rates documented
• Methods of setting shielding gas flow
• Maintaining consistent flow when inevitable flow restrictions occur in production
• Why some extra gas is needed at each weld start to purge air in the weld zone and gun nozzle
• High pressure is needed to achieve “coked flow” but causes excess stored gas
• Excess stored gas blasts out at each weld start and causes significant gas waste
• Published reports show average MIG welder wastes up to 80% of shielding gas used
• Fabricator testimonial- shows a 63% total gas savings using a starting gas surge reduction
• Details of patented, inexpensive Gas Saver System provided that reduces starting surge
• Gas Saver System improves weld start quality –includes fabricator testimonials
• Low pressure, surge reducing, “Gas Guard” devices cause significant problems
• Orifices or other flow control at the wire feeder cause problems and frustrate welders
• Causes of gas flow restriction variations when welding are outlined
• Calculations show average industrial MIG welder may waste 7 tons CO2/year/welder
• References: support comments and findings
• Appendix A: Case examples of fabricators savings with Gas Saver System
• Appendix B: Fabricators report major problems with low pressure, surge reducing devices
• Appendix C: Q & A; other reasons for gas loss;-1) leaks and 2) excess flowmeter settings
• Appendix D: Why Gas Saver System purchases should be made at www.NetWelding.com?
• Appendix E: Check flow at nozzle/cup and demonstrate gas waste:
• Appendix F: Argon has recently tripled in Price. See why it will continue.
• Appendix G: Author & Company background:

As a Past President of the American Welding Society (a volunteer position)

Jerry Uttrachi gave technical talks about MIG Shielding Gas Control
Optimization at over 20 locations in the USA and conferences in Peru,
Denmark, and South Korea. The talk was also presented at the International
Institute of Welding (IIW) Annual Assembly in the Czech Republic. This report
summarizes the details presented in those talks. Author/company details in
Appendix G.
 Page 2 of 24
One Page Report Summary
From the introduction of MIG welding in the 1950’s the developers knew excess shielding
gas flow rate created weld quality problems. Key claims as well as the teaching in the
original MIG patent state gas shielding must be: “… none turbulent to exclude air from
the arc.” Several references sited in this report show MIG shielding gas flow rates cannot
exceed about 50 to 60 cubic feet per hour (CFH) to achieve this non turbulent flow.
The engineers that designed the gas flow control systems understood spatter buildup in the
MIG gun nozzle and gas diffuser, bending of the small gas passage in the gun cable, etc,
could cause significant variations in gas flow restrictions. They used a “choked flow” design, requiring a
minimum of 25 psi upstream of the flow control device to automatically keep shielding flow at the preset
level. However, the use of this high pressure stores excess gas in the gas delivery hose when welding stops,
up to 7 times the physical hose volume. Most of this stored gas “blasts out” of the MIG gun nozzle at every
weld start! Most of this excess gas is wasted. About 87% of the excess gas volume is caused by the
Gas Pressure/Gas Volume relationship while ~13% is due to hose expansion created by the high pressure.
At each weld start, this excess stored gas in the hose from the gas supply to wire feeder exits the MIG gun
nozzle at a peak flow rate often exceeding 200 CFH! This causes considerable shielding gas waste and very
turbulent flow. The turbulent flow lasts for several seconds even after the preset level is reached, which
mixes moisture-laden air into the gas stream. This creates inferior quality weld starts with excess spatter
and possibly internal weld porosity.
Published data shows the average MIG welder uses 3 to 6 times the amount of shielding gas they should!
After conducting extensive laboratory and field tests, we have determined a major cause of this waste is the
gas surge at the weld start and not the often-blamed gas leaks. A 1982 patent is cited showing that some
extra shielding gas is needed at each weld start to purge air from the gun nozzle and weld start area.
However, this initial extra purge gas must not occur at a high flow rate that creates excess turbulence - as
occurs with most standard shielding gas flow control systems.
A patented, inexpensive device (our GSSTM) that reduces shielding gas waste is discussed. A fabricator
employing it was able to weld 632 parts with one cylinder of gas using the same steady state shielding gas
flow rate where one cylinder and their existing system was only sufficient to weld 236 parts. An appendix
presents tests of other fabricators who saved 40% to 50% shielding gas use with this gas saving system. In
addition to gas savings, the reduced peak gas surge, flow rate at the weld start reduces spatter and internal
weld porosity. Welders appreciate the system benefits.
Past attempts at reducing gas surge and gas waste have frequently met with objections by welders. Some
devices tried reducing starting gas surge by using either: (a) low pressure, (b) orifices near the gas solenoid
or (c) other flow controls mounted at the wire feeder like regulators or flowmeters. Some combine low
pressure devices with mounting at the wire feeder. Welders often rightfully reject these solutions or counter
their use by setting excess flow rates since they either eliminate: (a) automatic flow compensation by using
low pressure causing flow variations or (b) the purge gas needed at the weld start by controlling flow at the
feeder. Or, in the worst case, (such as employed for a ”Gas Guard” foolish product) using a low-pressure
device mounted at the feeder creating both problems! Examples are presented where fabricators removed
this and other devices because of poor weld performance.
The patented GSS does not alter pressures and allows the welding operator to set any reasonable, shielding
gas flow rate. It eliminates the excess “gas blast” at each weld start and limits peak gas flow rate avoiding
excess turbulence. The GSS has no moving parts to maintain, set or adjust. Welders appreciate its
starting benefits. Over 15,000 are in use in industrial shops! It is inexpensive, easy to install with payback
measured in weeks. A patented flowmeter “Flow Rate Limiter and Lock” is discussed that can control the
maximum allowed gas flow setting. Argon has doubled in price- See Why in Appendix F.

No time to read report? Watch this short summary: http://youtu.be/H5nabh9deLE

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 Page 3 of 24

REPORT: A 1950 patent by Airco (reference 2)

was the first that many sources
MIG SHIELDING GAS CONTROL
acknowledge as producing the first
AND OPTIMIZATION
workable MIG process. One of the key
History of MIG Welding elements was a MIG gun that provided
quality shielding. In Claims 8, 9, 11
and 12 they state the shielding must
be, “..nonturbulent to exclude air from
the arc.”
Turbulent MIG Gas Flow Rate
Only a few technical publications
discuss the maximum shielding gas
flow rate needed to produce a non-
turbulent or minimum turbulence gas
shielding. Two references that discuss
the subject do quantify this maximum
flow level. The first is by The Welding
Institute (TWI) in Cambridge England
(reference 3.) This research discusses
Several sources quote MIG welding as
tests made using a number of methods
being invented in the 1930’s; however,
to measure air intrusion in the shielding
these systems did not work. An
gas stream. For a common 5/8-inch
example is shown in the figure above
size ID industrial MIG gun nozzle the
from a 1936 General Electric patent
transition from desirable laminar to
(reference 1.) When reading the
turbulent flow occurs at 48 CFH.
In another published article (reference
4), Kevin Lyttle, then, Manager Welding
R&D for Praxair states; “In many
instances production site surveys (of
fabricators using MIG sold and cored
wire) determine that shielding gas flow
rates typically are set in excess of
50 CFH. This can contribute to poor
weld quality as atmospheric gases are
drawn into the arc zone because of
excess gas turbulence. Optimized flow
enhances quality and reduces shielding
gas usage.” This supports The
Welding Institute findings of 48 CFH
being the maximum flow rate producing
patent teaching it’s obvious, some no or low turbulence.
elements required to produce quality
welds were missing. One of these More information on desirable flow
missing elements was proper quality rates is available in our Lean
gas shielding. Manufacturing Study Programs at:
www.NetWelding.com/prod03.htm

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 Page 4 of 24

Setting Gas Flow However, restrictions occur in

production that will alter flow such as
Several devices are used to set
spatter build-up in the MIG gun nozzle,
shielding gas flow rates. One type is
bends occurring in the small gas
used on cylinder or pipeline
passages in the MIG gun cable, and
gas supply, a flowmeter with
debris build-up in the gun conduit gas
flow control knob. The knob
passage (that often doubles as the wire
adjusts a needle valve where
liner retainer.) When the MIG process
the small opening sets the gas
was developed in the 1950’s the
flow velocity. Assuming the
engineers used a technique to assure
proper pressure above the needle
constant flow rates regardless of these
valve, that velocity establishes the flow
normal flow restrictions. This principle
rate. A float ball is visible and rises in
is called “choked flow” or critical flow.
the flow tube as flow rate increases.
When used on cylinder gas supply a How Choked Flow Woks
regulator precedes the needle valve Understanding how the “choked flow”
and is set for a fixed delivery pressure system works will help avoid the pitfalls
ranging from 25 psi to 80 psi of products sold which do not maintain
depending on the specific model. For constant flow and cause flows to vary
example, to prevent ice particle when the inevitable production
formation, flowmeters designed for restrictions occur.
CO2 service may use pressures from
50 to 80 psi. The following is a short explanation of
“critical flow or choked flow.” A
The second type of flow technical paper on the subject was
control is used for published in The Welding Journal and
cylinder gas supply and has more details (reference 5.)
employs a very small
outlet orifice. The When gas passes through an orifice,
pressure upstream of the orifice is the flow
varied to control flow using a regulator. rate
These are called regulator/flowgauges. depends
The output gauge, although actually on the
measuring pressure, is calibrated to pressure
read flow based on the orifice size and difference
gas type. Pressures for typical flow across the hole. However, once the
rates range from 40 psi to 80 psi. The gas flow velocity reaches the speed of
orifice is very small usually about sound, the flow though the orifice
0.025-inch diameter. cannot increase above that velocity.
Therefore, even with changes in
In pipeline gas service, other devices downstream restrictions the flow will
such as fixed orifices or simply needle remain content. A specific minimum
valves may also be employed. pressure difference causes this
Consistent Gas Flow “choked flow” to exist. When the
pressure upstream of the orifice is
It is important that the flow rate set on
greater than 2.1 times the downstream
the flowmeter or regulator/flowgauge
pressure the velocity will have reached
remain constant while welding.

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 Page 5 of 24

the speed of sound in the orifice throat Some Extra Gas Needed at Each
(for that gas at the upstream Weld Start
pressure.) The preceding defined that it is
important not to have an excessive gas
flow rate to avoid turbulence in the
shielding gas stream causing air to be
pulled into and mixed with the shielding
gas. However, it is necessary to purge
the weld start area of air. In addition,
air enters the MIG gun and MIG gun
Note: all pressures are measured as nozzle when welding stops. Stauffer in
absolute, i.e. gauge pressure a 1982 patent (reference 6) defines the
+ 14.7 psi (~15 psi for our purposes.) need stating: "... air leaks back into the
MIG gun and lines when welding is
Using this fact, we can define the
stopped. The air must be quickly purged
pressure needed above an orifice or
and replaced with inert gas to produce
needle valve to produce “choked flow”
high quality welds. Also, it is critical to
in a MIG (or TIG) system. The
displace the air at the weld zone of the
pressure needed at the wire feeder to
work piece upon initiating the weld." His
achieve normal MIG shielding gas flow
rates will vary from 3 to 8 psi. The patent defined a device that mounted
exact value will be dependent on the near the wire feeder providing the extra
MIG gun length, number, and gas needed at the weld start. He
tightness of bends in the gun cable, added a reservoir (item 112 in his
spatter build-up in the nozzle and gas patent figure below) to store some
diffuser etc. If we assume an average initial gas to be expelled at the weld
of 5 psi is required, then that would be start. Unfortunately, the device also
5 psi + 15 psi to get absolute pressure uses relatively low pressure to avoid
stated as 20 psia. To achieve excess surge, requiring the large
constant flow regardless of normal reservoir and reducing the “Automatic
downstream restrictions will require Flow Compensation” feature!
over ~twice that pressure above the
orifice or needle valve or 40 psia.
Stated as normal gauge pressure that
is 40 psia – 15 psi = 25 psi. It is no
coincidence that quality
regulator/ flowmeters use a minimum
of 25 psi regulators! The engineers
that developed gas flow systems in the
1950’s new MIG welding, were smart
and knew what was needed!
Information is presented later in this
report showing the significant flow
variations that occur if lower pressure
devices are used.

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 Page 6 of 24

High Pressure Causes Initial Gas of gas at 70 degrees and atmospheric

Surge pressure (that is what you pay for.)
We defined that a minimum of 25 psi The shielding gas delivery hose is
was needed to have automatic flow subjected to the same pressure
compensation. However, this relationship. Therefore for an 80 psi
pressure is much higher than the 3 to regulator/flowmeter and only 3 psi
8 psi that is typically needed at the needed to achieve the desired flow
feeder inlet to flow the desired amount rate: (80 psi+15 psi)/(3 psi + 15 psi) =
of shielding gas. The pressure will 5.3 times the physical hose volume of
reduce in the gas delivery hose to that EXCESS gas is stored in the hose
needed to flow the gas volume coming when welding stops.
out of the needle valve or orifice Hose Expansion Causes ~13% More
through the feeder, MIG gun cable and Excess Stored Gas
nozzle. However, when welding stops,
gas continues to flow through the In addition to the excess stored gas
needle valve or the orifice and very due to increased pressure, our tests
quickly fills the delivery hose. That show a standard 1/4-inch ID gas
flow continues until the regulator delivery hose expands
pressure (or if on pipeline supply, the when subjected to
pipeline pressure) is reached. these pressure levels.
Pressure in some regulators and The volume increased
pipeline gas supply is as high as 13% with the internal
80 psi. The higher pressure causes pressure increase.
an excess quantity of gas to be stored Therefore, the amount of excess gas is
in the gas delivery hose from gas 5.3 (due to pressure) X 1.13 = 6 times
supply to wire feeder. The amount of the physical hose volume. Every time
excess is dependent on the absolute the MIG gun switch is pulled, this
pressure difference and the hose excess gas is rapidly expelled out the
volume. If the absolute pressure gun nozzle; most of it wasted!
increases 5 times then the gas volume Excess Gas Expelled at the Weld
increases 5-fold as well. Start Causes Significant Waste
To help with understanding excess Most welders
gas storage, consider understand that the
a typical gas cylinder excess surge
holding 310 Cubic creates problems;
Feet (CF) of gas. It they can hear it!
has only 1.8 CF of However only a few
physical volume. How published
does it hold all that documents quantify
gas? By raising the the typical amount of
gas pressure to waste.
2500 psi (= 2515 psia.)
Therefore, the gas Looking first at documentation on
volume will be waste. An article in Trailer Body
2515/14.7 times 1.8 Builders magazine (reference 7) quotes
(physical) CF =310 CF a representative from Praxair, a leading

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 Page 7 of 24

producer and marketer of shielding the same shielding gas flow setting.
gases, indicating their fabricator The new cylinder was able to make 632
survey findings show the average MIG doors before it was empty! That was
welder consumes 5 to 6 times the 63% less gas used. Or 2.7 cylinders
amount of gas theoretically needed! would be needed to weld 632 doors
Stated as a percentage, 80 to 83% of with their old system! After about a
the shielding gas used is wasted! year using the 25 GSS’s purchased,
Another article in The Fabricator they expanded their operation and
Magazine (reference 8) confirmed this added 10 more welding
finding of up to 6 times the needed machines. They called and
shielding gas being used in fabrication asked for 10 more of the
shops. “Magic Hose!”
Just how much gas waste is caused Other fabricators test data
by this surge at the weld start? The are shown in Appendix A.
following is a case history of what one What is a GSS?
company found. We’ll also introduce
our patented Gas Saver System The GSS is a patented device
(GSSTM) to help explain this fabricators (reference 9) that eliminates the excess
test results. “gas blast” at each weld start and can
cut gas use in half or more. The GSS
has no moving parts and does much
Truck Box Fabricator Tests GSS more than just save gas! The picture
A fabricator of truck boxes had 25 MIG below shows the cross section of this
welders. They knew they were using custom extruded very heavy wall, fiber
excess gas and reinforced, gas delivery hose.
wanted to
try our
GSS as a
possible solution.
They use pipeline gas
supply but to test the GSS they
purchased two gas cylinders with the
same gas mixture they employ. They
purchased a flowmeter that utilized a
50-psi regulator similar to their pipeline In addition to reduced volume, the GSS
pressure. A part was selected that avoids excess turbulence at the weld
they made by the thousands, truck box start. It accomplishes this by limiting
doors. With their standard gas gas surge flow rate using a built-in
delivery hose and normal welding surge orifice in the feeder/welder hose
conditions, gas flow etc they installed end fitting. Note: the surge-limiting
one of the full cylinders and proceeded orifice does not limit setting any
to welded 236 doors until the cylinder “reasonable, non-turbulent” steady
was empty. Only replacing their gas state flow, with an existing flowmeter,
delivery hose with the small volume regulator/flowgauge or at the gas
patented GSS, they used the same source on pipeline gas supply a fixed
welder, same welding conditions, and orifice or flowmeter.

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 Page 8 of 24

Will this smaller ID gas hose, flow the surge reduce in flow rate! The
required amount of shielding gas? accompanying graph shows flow rates
Yes, even 50 feet of hose will have measured in this application.
only a moderate 4 to 5 psi pressure
drop at normal flow rates. On pipeline
gas supplies with a 50-psi line, some
fabricates use 100 feet of GSS hose.
If longer gas lines are used, email:
[email protected] we
have two recent patents that will allow
any length hose to be used with equal
results. Also, see, Appendix C that
discusses the reason normal gas It clearly shows what he was up against
delivery hose is 1/4-inch ID. It has and the GSS solution.
nothing to do with pressure drop!
The blue line shows the starting gas
More Than Saving Gas: The GSS flow with the standard gas delivery
Improves Weld Start Quality hose. Note, it peaks at 225 CFH! At
The GSS not only saves gas (typically, this high gas flow rate, air is being
40 to 50+% is reported) it improves pulled into the shielding gas stream.
weld start quality. This is best Note the flow rate remains above 100
described with another fabricators CFH for about 3 seconds! Therefore,
experience. air was pulled into the gas stream for
even longer since turbulent flow takes
A manufacturer had several MIG time to return to desired laminar flow!
welders using flux cored wire and CO2
shielding gas to make weld repairs. Note, with the GSS the peak flow is
Working with the welding engineer to under 90 CFH and is only above 60
check the amount of potential gas CFH for a very short time!
savings, a GSS was installed on the Of interest, although they measured
repair welder. All weld repair deposits over a 40% gas savings, the weld
required non-destructive testing before quality improvement saved even more
the repaired welds were accepted and money and avoided the previous
the pipe could leave the welding production bottleneck. After 6 months
station. When making the first weld of use, the operator was asked what he
repair with the GSS installed, the found in terms of repairs. He said he
operator was excited; he could “see” hardly had any need for rewelding,
the improvement! which was a common problem before
Not in gas usage the GSS was installed!
but in the
Nitrogen and Hydrogen Are
reduced initial
Problems
gas surge that he
knew was causing internal weld What’s wrong with air entering the
porosity that made defective welds! shielding gas stream? Plenty! Air
He said he tried to weld with the wire contains three items that create welding
cut back in the MIG gun and with the problems. Nitrogen is 78% of air and
gun held high to have the start gas Oxygen 21%. Both are problems but

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 Page 9 of 24

the water vapor (humidity) can be a regulators mounted at the feeder cause
major problem as well. Elements can lack of sufficient start gas. Excess
be incorporated in the welding wire to starting spatter occurs with these
handle some amount of Oxygen. systems. Also, welders will often set
However, Nitrogen and the Hydrogen higher steady state flow rates in
in water vapor can cause significant attempt to compensate for this lack of
problems and there is no way to sufficient purge gas.
combine these ingredients without Maintaining system pressure and
causing other problems. Only 2% having a surge flow control orifice in the
Nitrogen in the shielding gas is enough feeder end of the GSS hose provides
to produce internal porosity optimized starting gas flow. The
(reference 10.) Ludwig, using a needed extra gas quickly purges the air
bubble chamber and mixtures of in the weld start area and nozzle. The
shielding gas with various amounts of peak flow control orifice prevents
nitrogen, found 1% was sufficient to
excessive flow rate and turbulence.
cause problems (reference 11.)
Assuming 2% Nitrogen will cause Some research conducted by a major
internal porosity and possibly brittle welding manufacturer employing one of
welds; since air is 78% Nitrogen only our patented GSS’s is of interest. They
2%/78% or 2.6% air needs to mix with found the weld start current and voltage
the shielding gas to create problems. in a critical aluminum weld can be
A turbulent shielding gas stream can monitored with an oscilloscope and
mix far more than 2.6% air into the gas improvements shown with flow rate
stream! surge control and good weld start
shielding.
Therefore, the excessively high gas
surge at the weld start caused by most Use of Low-Pressure Devices
standard shielding gas delivery Understanding the problems created by
systems allows air to be mixed with the start gas surge, some manufactures
the gas stream at the weld start and had introduced low-pressure devices in
can cause internal weld porosity. attempt to solve the gas waste
In addition, some extra gas is needed problem. However, they forgo
to purge the MIG gun nozzle, cable automatic flow compensation built into
and weld start area of air. If you ever gas delivery systems since the
inadvertently started welding before inception of MIG welding! In fact, one
turning on your shielding gas cylinder manufacturer who introduced a low-
(haven’t we all) you have seen what a pressure system to their line of flow
weld start looks like without shielding! controls wrote a technical article
A harsh arc, high spatter level, an published in Flow Control Magazine
oxidized weld and porosity was (reference 12) that states: “… there are
probably observed. applications in which a compensated unit
(referring to higher pressure flow
Attempting to control flow at the wire compensating regulator/flowmeters)
feeder is one-way insufficient extra may be required. When long lines from
gas is available to purge the MIG gun the flowmeter to the gun cause back-
nozzle and weld start area. The use of pressure or when wind causes the
flow control orifices or flow control shielding gas to blow off, the compensated

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 Page 10 of 24

system may be the solution to these also the downstream pressure that
problems.” varies with flow restrictions. This
foolish device does not operate using
We have found these low-pressure
the historic “choked flow” design.
devices create problems in most
cases, not just where it’s mentioned in For these tests, the controls were left at
the technical paper! A number of the initial settings as if they were
fabricators relayed the significant padlocked. MIG gun restrictions were
problems encountered with a low- then added and removed, and flow
pressure device that mounts at the measured at the gun nozzle with a
wire feeder. It has both problems: portable flowmeter.
1) lack of automatic flow compensation
causing variations in < Typical Production
Flow Restriction Range; psi >
flow from preset Control
levels and 2) since System
mounted at the wire 3 psi 4 psi 5 psi 6 psi 7 psi 8 psi
feeder, insufficient
extra gas at the start Conven-
31 31 31 31 31 31
causing inferior weld tional
CFH CFH CFH CFH CFH CFH
= 25 psi
starts. Tests were
conducted with this
device versus a normal 25 psi Low
Pressure 37 34 31 27 23 16
regulator/flowmeter (photo left).
Device CFH CFH CFH CFH CFH CFH
The following table shows the test = 9 psi
results with a conventional regulator/
flowmeter that
operates at 25 psi With the conventional 25 psi regulator/
and a low-pressure flowmeter the gas flow did not change
“Gas Guard” device with the restriction variations. The
(photo right) both pressure in the gas delivery hose
subjected to varying automatically increased compensating
MIG gun flow for simulated spatter buildup in the gas
restrictions. Both diffuser, clogged gas passage in the
were initially set to MIG gun (which for many MIG guns is
flow 31 CFH (shown also the wire conduit,) spatter in the
in green in the following table.) nozzle, twisted gun cables etc.
Placing a test pressure gauge after the Note with the low-pressure “Gas
low-pressure device showed only 9 psi Guard” device the flow reduced to a low
was required to flow 31 CFH. of 16 CFH and rose to 37 CFH!
As noted previously, 9 psi is well Four fabricators who documented the
below the minimum 25 psi needed to problems with this device and their
provide automatic flow compensation. experiences are outlined in Appendix B.
That means the shielding gas flow will Note, one discarded 50 and another 70
not only be determined by the such systems! Tests of another low-
pressure upstream of the flow control pressure device showed it produced
device (in this instance an orifice) but even more flow variation! This device

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 Page 11 of 24

sets flow by setting essentially starting in air with the

pressure (yellow arrow, accompanying problems. We have
photo right). It reduces the a report showing why the also
surge but creates major foolish EWR device doesn’t work!
flow variation problems Use of an Orifice at Pipeline
more difficult to analyze!
In pipeline gas supply, an orifice is a
BE CAREFUL; SOME OF THESE “SURGE
CONTROL DEVICES” DO NOT MENTION satisfactory way to control shielding gas
THEY USE LOW PRESSURE! flow if placed at the pipeline outlet and
A surge control flowmeter used with our GSS. The flow rate is
(photo right) at least indicates in controlled, and sufficient extra shielding
the literature, “operates at gas is available to purge the weld start
pressures lower than usual.” area and MIG gun nozzle of moisture-
Unfortunately, it does not laden air. The surge orifice in the GSS
mention the problems the also limits peak gas flow to a rate that
lower pressure creates! minimizes turbulence.
Welders just open the needle valve The use of an orifice also maintains
when restrictions occur and leave the automatic flow compensation as long
high setting when restrictions reduce! as the pipeline pressure is greater than
25 psi, which most are.
Use of Restriction Orifices to
Control Flow For very long gas
delivery hoses (>100
Another method that has been used to
feet) we have a
reduce weld start gas surge is
patented device that
restriction orifices mounted at the
uses an orifice flow control with our
feeder:
GSS. Details of our patented OGSS,
1. One approach uses an orifice to are available at:
reduce surge flow but still control http://netwelding.com/Orifice_Flow_
steady state flow back at the gas Control.htm
source. This reduces surge but
What Causes Flow Restrictions?
when welding stops gas
pressure/volume still builds in the Flow restriction variations are inevitable
gas delivery hose. At each start, when MIG welding as the gun cable is
excess gas is expelled but it takes
somewhat longer!
2. Another approach is to use the
orifice to control the steady state
flow. A very expensive electronic
“supposed” gas saving device
(EWR) also does something
similar! With these approaches or
with any flow control placed at the
feeder there is insufficient extra
bent, looped and as spatter builds in
gas to purge the MIG gun nozzle
the nozzle and partially clogs some of
and weld start area. The weld is
the gas diffuser holes.

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 Page 12 of 24

In addition, the gun cable gas • 480 CF/day X 5 days/week X 50

passages often doubles as the weeks/year = 120,000 CF of
passage holding the spring wire liner CO2/year wasted.
in most MIG gun designs. It may
• There are 8.7 CF/lb of CO2
partially clog with wire debris, like
therefore 120,000/8.7 =
copper flakes and lubricant.
13,793 lbs wasted/year
Average MIG Welder Wastes
Or about 7 tons of CO2 wasted per year
~ 7 Tons of CO2 /Year!
for each welder!
If CO2 shielding
Patented GSS Has Significantly
gas is being
Lower Moisture Permeability
used, each
welder is wasting A major industrial gas producer. Air
about 7 tons per Products, purchased more than 200
year! GSS’s for their fabrication shops
making cryogenic tanks and related
Using the market survey results
components. They
reported in reference 7 and validated
use an Argon
by reference 8 (and our findings) the
Helium shielding gas
average MIG welder uses 30 CF of
mixture and needed
shielding gas per pound of welding
to conserve Helium
wire when 5 to 6 CF/lb is needed.
as well as control
(Note: 0.045 solid wire welding at 200
costs.
amps deposits 6 lbs wire/hr.
Assuming a flow rate of 30 CFH is set They historically had porosity problems
on the flowmeter then in aluminum welds in the hot humid
30 CFH/ 6 lbs/hr = 5 CF/lb, validating summer months. They knew the
the assumptions in reference 7.) porosity was caused by moisture
entering the TIG and MIG system gas
Therefore if 30 CF/lb is used and only
delivery hoses. This was most obvious
5 CF/lb is needed, 25 CF/lb is wasted
when welding critical aluminum
or 25 CF wasted/5 CF needed = 5
components. They found after testing
times what should be used is wasted.
the custom extruded GSS hose, that it
Considering the average industrial
has much lower moisture permeability.
MIG welder operates at about a 40%
For two summers after installing the
duty cycle (percentage of time the arc
GSS’s they had no porosity issues!
is on) then:
We prepared a report showing why the
• A welder operating 8 hr day X
GSS could have up to 10 times lower
40% duty cycle = 3.2 hr of arc
moisture permeability than a
on time.
conventional 1/4-inch ID hose made of
• 3.2 hrs X 30 CFH gas flow similar material. If you would like a
which should be used = copy, email
96 CF/day of CO2 that should [email protected]
be used. But 5 times that
amount is wasted, therefore
5 X 96 CF/day = 480 CF of
CO2 /day wasted.

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 Page 13 of 24

Benefits of GSS surge that often frustrate welders,

they appreciate the GSS! (Note: If
The patented GSS:
desired, our patented FRLL product
1. Saves about half the shielding allows flow rate settings to be
gas used, is inexpensive and easy locked. It’s covered in Appendix C.
to install. The hose is made with a For full details see:
heavy wall thickness, is fiber www.NetWelding.com/Flow_Rate
reinforced and abrasion resistant _Limiter.htm)
providing a robust product.
We receive questions about the GSS
2. Has no moving parts to wear, and gas delivery systems in general.
repair, or leak. Requires no knobs Some of these are addressed in
or pressures to adjust. Appendix C.
3. Allows a controlled amount of References:
extra gas to flow at the weld 1. Brace, P. H., Welding Apparatus, assigned
start by maintaining the gas General Electric, US Patent number 2,053,417,
pressure in the delivery hose at a September 8, 1936.
restricted maximum flow rate to 2. Muller, A. et all, Electric Arc Welding,
assigned Air Reduction Co., US Patent number
quickly purge air in the weld start 2,504,868, April 18, 1950.
zone. 3. Wilkinson, M. E., Direct Gas Shield Analysis to
4. Retains automatic flow Determine Shielding Efficiency. Report of The
Welding Institute, Cambridge, England,
compensation for the inevitable December 1974.
pressure drops that occur in 4. Lyttle, K. and Stapon, G., Simplifying
production. This occurs when the Shielding Gas Selection. Practical Welding
MIG gun cable is bent and twisted, Today, Vol. 9, No. 1, Jan/Feb 2005.
and with spatter in gun nozzle. 5. Uttrachi, G. D., GMAW Shielding Gas Flow
Control Systems, The Welding Journal, Vol. 86,
5. Lowers moisture permeability. It No. 4, April 2007.
eliminated weld porosity in humid 6. Stauffer, H. R., Application and Method for
Reducing the Waste of Shielding Gas, US
summers at a major industrial gas Patent number 4,341,237, July 27, 1982.
producer’s cryogenic tank 7. Weber, R., How to Save 20% on Welding
fabrication shop. Costs. Trailer/Body Builders, Volume 44,
Number 3, January 2003.
6. Pays for itself in gas waste 8. Standifer, L. R., Shielding Gas Consumption
reduction alone in a matter of a Efficiency. The Fabricator, Volume 30, Number
few months for most industrial 6, June 2000.
applications. The improved weld 9. Uttrachi, G. D., Welding Shielding Gas Saver
Device. US Patent number 6,610,957, August
starts are added benefits.
26, 2003.
7. For new installations, payback 10. MIG Welding Handbook, ESAB Welding &
may be instant – “Just Do It!” Cutting Products, October 1996.
11. Ludwig, H. C., Nitrogen Effects in Argon Arc
Cost about the same as heavy duty Welding Atmospheres, The Welding Journal,
conventional gas delivery hose. September 1955.
12. Uccellini, J., Gas-Saver Flowmeter Regulator.
8. Is appreciated by welders for the Flow Control, Volume 9, Number 5, May 2003.
starting improvement benefits
and since they can still set any
“reasonable” steady state flow rate.
Unlike other attempts at reducing

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 Page 14 of 24

APPENDIX A Needless to say, Ken purchased

systems for all 23 MIG welders. When
Case Examples of GSS Saving he expanded his business 2 years later
Shielding Gas he purchased 20 additional systems.

A number of fabricators have reported OEM Exhaust Manufacturer

their GSS testing results in addition to
the Truck Box Manufacturer whose Tenneco was conducting a Black Belt
data was mentioned on page 7. The Lean Manufacturing study to reduce
following summarizes some of this costs. They only had 6-foot gas
data: delivery hose from their gas pipeline to
their 126 MIG
Truck Body Builder robotic welders.
They purchased
four 6-foot
GSS’s to test all
of their various
weldments.
Since the
robots repeated each joint with
precision, their test data is very
accurate. Although on pipeline gas
supply, they used cylinders for the
tests. Since their pipeline operates at
50 psi they made sure, they used
regulator/flowmeters that matched that
pressure. Since they make many of the
same parts, they could easily count the
Double A Body Builders knew they
number of parts made with a full
were wasting shielding gas and
cylinder of gas and their standard hose
wanted to reduce the high cost. Ken
and with the GSS. After testing all their
Ard, President, set up a test using two
weldments, they found savings ranging
of his 23 MIG welders that were both
from a low of 25% to in excess of 40%.
welding with the same 0.035 wire and
They purchased systems for all 126
the same welding conditions. He
robots! Several other exhaust system
started the test with one welder using
fabricators have also installed GSS’s.
their standard 25-foot gas delivery
hose and the other with an equal
length GSS. Both welders operated at Pipe Fabricator
the same current. He also started with Team Inductries tested the GSS for gas
new coils of wire on each machine. savings. They again used cylinders to
When both cylinders were empty, he define a fixed amount of gas usage. In
weighed the coils of wire. The one their case, they used flux-cored wire
with the GSS had used twice as much and on one job with their standard gas
wire. Since both welders were doing delivery hose, they welded 32 pounds
the same job, the one with the GSS of wire with one cylinder. Just
also welded about twice as long! substituting the GSS with no other

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 Page 15 of 24

changes in welding conditions or gas instantly understood the benefit of

flow; they used reducing weld start gas surge. He
53 pounds of deals with it when painting cars! As he
flux-cored wire notes, “You never trigger the paint gun
with a full on a part, or you get excess paint.”
cylinder. That Too bad we don’t have that option
equates to a when MIG welding!
41% shielding Kyle also appreciated having over twice
gas savings. as much welding time between cylinder
They initially changes since he had run out of gas on
purchased 114 systems and added weekends!
another 80 when they installed more
welding machines in their busy shops. Suggestions for Testing GSS
Chiller Manufacturer To test gas savings, use two cylinders,
even if on
Johnson Controls in Mexico conducted pipeline
tests for their production of chillers. supply. Be
They purchased a 12-foot GSS and sure regulator
found savings ranged from 30% to a pressure is
high of 42% easily justifying the approximately
investment. Since some of their
the pipeline
applications use longer hoses than the pressure.
12-foot system tested, their savings Note: Miller
will be even higher. makes an
Remember it’s the inexpensive
excess gas volume one that
stored in the gas operates at
hose that causes typical
waste and excess pipeline pressure of 50 psi. Many
turbulence on each others operate at only 25 psi, which will
weld start. They initially purchased 60 give false test results.
GSS’s, after a year in use expanded
their operation, and purchased an Use two cylinders of shielding gas and
additional 55 systems. count part production with and without
the GSS using the same gas flow
Street Rod Fabricator settings and welding parameters. If
A very interesting observation was counting parts is not possible measure
made by wire usage with a full cylinder with and
one of our without the GSS. That provides cubic
first users feet of gas per pound of wire used for
of the GSS. comparison.
Kyle Bond,
shown
painting
flames on
our Street
Rod.

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 Page 16 of 24

APPENDIX B same wire, gas, welding conditions etc.

However, one was getting porosity and
Fabricators Reporting Problems the other none. After looking at 30
with Low Pressure Devices and variables using a Fishbone Diagram it
Orifices was discovered the plant having
As mentioned, low pressure devices porosity was using low-pressure
eliminate what was designed into regulator flow
shielding gas delivery systems since control devices
the invention of MIG; “Automatic Flow (the same
Compensation.” A number of device we
fabricators have found these devices tested)
create sufficient problems to have mounted at the
them removed and discarded. The feeders! They
following are four who reported the were removed and the problem was
problems: resolved. Quite probably, the variable
flow rates being encountered were
Automotive OEM Supplier causing either too low or perhaps an
A welding engineer in a plant who excessive flow rate that was pulling air
purchased 32 systems stated: into the shielding gas stream. The
flow-calibrated pressure gauge would
“After purchasing and
not show these variations!
using 32 low pressure
“so called” gas saving Bar Joist Manufacturer
devices (photo right) A Bar Joist
that mounted at the manufacturer with 50
wire feeders we MIG welders also
decided to discard all purchased low-
of them! There were two major pressure regulator
problems: flow controls. They
1) Lack of sufficient extra gas at the found welders were continually setting
start made inferior welds and excessive flow rates. All 50 were
discarded in favor of orifices placed at
2) Large flow variations from preset
the feeders. Although the orifices set
levels were evident when flow was
flow at 45 to 50 CFH, which was more
checked at the MIG gun. In fact, he
than sufficient, welders wanted more
stated; "Even if the flow was blocked,
flow. The welding engineer called us
the flow calibrated pressure gauge
and we found an interesting result. We
supplied with these devices had the
moved the restriction orifice on one
same preset reading!"
welder to the pipeline drop and installed
Heavy Equipment Manufacturer our GSS. This provided a controlled
A very interesting example of amount of extra gas to purge the weld
problems with the same low-pressure start area at a rate that did not produce
device mentioned above was excess turbulence. The welder using
discovered after extensive testing. the GSS instantly stated he saw a
This fabricator had two plants making “better arc!” In bar joist
the exact same part. Both used the manufacture, welders are close to each
other. With the fixed orifice at the

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 Page 17 of 24

feeder, there was little extra gas to feeder actually caused gas waste and
purge the MIG gun nozzle and weld inferior weld starts!
start area. It was obvious that the Catalytic Converter Production
welder with the GSS had less spatter
when starting and for much of the A manufacturer of catalytic converters
short weld. The welding engineer had 70 new robotic MIG welding cells
decided to lower the flow rate to installed. The systems integrator
35 CFH on the welder with the GSS. installed a model of low-
The arc remained very stable, and pressure surge reducing
more important the welder was still flow control regulators at
very happy! The GSS was still quickly each pipeline drop.
supplying a controlled amount of gas However, it was quickly observed by
at the start. After several months of the welding engineer that flow
testing to assure it worked in all draft variations were occurring when
conditions (which it did,) all 50 welders measured at the MIG nozzle for both
were equipped with GSS systems and the MIG welding robots and several
flow controls placed back at the manual MIG welders using the same
pipeline drop. flow device. The welding engineer saw
one of our videos and had the low-
About a year after installing the GSS’s, pressure device manufacturer visit, but
their bulk gas supplier called and they were no help. We recommended
asked if their workload had reduced these “Gas Guard” regulators be
since there was a 30+% reduction in replaced with standard flowmeters.
gas deliveries! It had not! After replacing, flows remained at
Reinforcing the problems preset levels during production. That
associated with lack of purge gas at solved all shielding gas flow problems!
the weld start is a survey made of Tests in Drafts:
another bar joist fabrication shop were
flowmeters had been placed at the gas Some welders believe high gas flow
inlets on 100 MIG wire rates can overcome draft problems.
feeders to eliminate Tests were made to see what flow rates
surge. When examining might assist in up to 5 mph drafts.
flow rates, about half Visual observations of weld quality and
were set at 50 to 55 CFH, X-Ray’s of the deposits to detect
with none less than 50. internal porosity showed interesting
About 25% were set near the top of results. In a ~5 mph-controlled draft,
the flow tube at 65 to 70 CFH. The welds made at 45 CFH with a 5/8 ID
remaining 25% had the flow ball MIG gun nozzle had less internal
pinned to the top of the tube! porosity than welds made at 65 CFH
gas flow rate! This again validates that
Welders were trying to compensate for with this size nozzle 50 CFH is about
the lack of sufficient starting gas purge the maximum flow rate that should be
by setting higher flow rates. That is used. If drafts are present, a small
only a partial help! Therefore, windbreak will often solve the problem
attempting to reduce gas waste by but increasing gas flow beyond 50 to
moving the flowmeters to the wire 55 CFH will not!

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 Page 18 of 24

APPENDIX C wasted every time welding starts.

Fabricators find it causes from 30 to
Some Questions and Answers over 50% wasted gas!
About The GSS Is this large hose size needed to handle
pressure drop? No! The typical
Question: What is the best way to 35 CFH shielding gas flow rate creates
deliver shielding gas to a MIG very little pressure drop. A 100-foot,
system? 1/4-inch ID hose, operating with
Answer: For systems with up to 50 pressures needed to flow 35 CFH, has
feet from gas supply to wire feeder, a pressure drop of less than 1 psi! The
the best system is shown in the picture answer is MIG welding was developed
below (for typical pipeline pressures in the 1950’s by two of the dominant
the GSS can even be 100 feet long.) US industrial gas producers. Working
It consists of a rotameter flowmeter at the Welding R&D Lab at one of these
(one with a flow indicator ball) and our companies, Linde (renamed Praxair) it
Gas Saver System (GSS). was located with our equipment factory.
The major equipment product line
manufactured at the time MIG was
introduced was Oxyfuel welding and
cutting apparatus. The flow rate of
oxygen required when cutting is quite
high. It can use 250 CFH and higher
flows. At a 50-psi regulator pressure
setting 250 CFH will produce an 11-psi
pressure drop in a 100-foot 1/4 inch ID
This system will work for any gas hose versus the less than 1 psi at
supply. The benefits include being 35 CFH flow used for MIG welding.
able to see the actual gas flow while (Note the pressure drop at 35 CFH will
the GSS eliminates the excess “gas be less than 1 psi either at 50 psi or
blast” at each weld start and controls 5 psi hose pressure.) The highest
the gas surge peak velocity improving volume gas hose used for the largest
start weld quality. sales volume sold (25 feet) was 1/4-
inch ID that easily handled the pressure
Option: For pipeline shielding gas drop. Cutting and fitting this size hose
supply an orifice can be used (only at was automated. In addition, the
the pipeline) to set flow. See page 11 Compressed Gas Association (CGA)
“Use of an Orifice at Pipeline.” committee developed gas hose fittings
Question: Why is MIG gas hose a designed for various size hoses. The
wasteful ¼-inch ID? inlet end of these fittings handles hoses
(Hint; it’s not for the Nonexistent up to 3/8-inch ID. Using CGA
Pressure Drop!) designs,1/4-inch inert gas fittings are
relatively easy to make. Production
Answer: Why is most MIG gas starts with heavy wall tubing, making
delivery hose ¼ inch ID? This large drilling the gas passage hole quick and
size causes excess gas to be stored in economical. A minimum amount of
the hose when welding stops and material is required to be removed with

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 Page 19 of 24

this design approach. Functional hose access to the setscrew. See details of
clamps are also readily available for this patented flow lock product at:
1/4inch hose fitted to a hose barb. www.netWelding.com/Flow_Rate_L
Therefore, 1/4-inch hose, hose fittings, imiter.htm
and hose clamps were readily 2. Another thing to consider is leaks.
available and lowest in cost! These can be very wasteful and
Production economics is the reason allow moisture-laden air to enter the
MIG gas delivery hose was ¼ inch ID! shielding gas lines.
The special fittings required for use In addition to fixing leaks on a one-time
with our very heavy wall small ID GSS basis, there needs to be an ongoing
hose are much vigilance to check the gas delivery
more difficult and systems in a systematic way. We offer
costly to several training programs that can be
manufacture. The used to educate. One is called
hose does not "Lean Welding Manufacturing" Learning
expand over the Program Optimizing Shielding Gas Use
fitting as do thinner wall hoses used and Eliminating Waste” (part # LWM-
for TIG, as an example. Even special SG). This 71-page program can be
hose clamps must be used. See the used as a self-study leaning program.
photo above left to view the GSS fitting It includes a method of making a
on the gas supply side of the hose spreadsheet providing a way of
versus a 1/4-inch fitting. quantifying and monitoring leak rates in
As the saying goes, “Follow the pipeline gas supply; as shown below:
Money!”
Question: Is There More We Can Do
in Addition to Purchasing GSS’s to
Reduce Gas Waste?
Answer: Yes.
1. We have found many welders set
flow rates too high. We patented a
Flow Rate Limiter (FRL) that can be
installed on most flowmeters. The
maximum desired flow rate is set
and the billet
aluminum
(FRL) is A shorter 60-page program with less
installed over theory is also available (part # UFG.) It
the knob with a defines shielding gas flow rates,
setscrew, minimums and maximums, and can be
which prevents used to educate welders and welding
the flow rate supervisors. Because of the Pandemic
from being and folks learning via the Net WE
increased. A HAVE MADE UFG FREE!
stainless See: www.NetWelding.com/prod03.htm
blocking pin and brass lock prevent

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 Page 20 of 24

gas waste tests in our lab and hundreds at

Appendix D: fabricators. After our extensive testing and
Why Should Purchases of Patented fabricator visits, we have found the gas surge
Gas Saver Systems be Made at at the weld start is often the most significant
www.NetWelding.com? cause of shielding gas waste - NOT LEAKS!
We have evaluated a number of devices to
Or: If MIG Shielding Gas Waste is so reduce waste before inventing and patenting
Common, Why Has My Shielding Gas our simple, low cost Gas Saver System (GSS.)
Supplier Not Told Me How to Fix the Problem? Our customers have quantified the gas savings
Background achieved by properly controlling gas surge at
the weld start (typically, total gas use can be
Understanding and quantifying issues and cut about 40 to 50%.) We understand why
reasons of shielding gas waste is rather other approaches some have tried frustrated
complicated. While managing a >30-person welders and have been altered, misused or
Material Technology R&D Laboratory for a removed such as low-pressure devices, simple
leading producer of industrial gases (Linde orifices, moving the flowmeter to the wire
renamed Praxair, now Linde Germany!) we feeder etc. We have also seen welders
developed MIG and TIG shielding gas appreciate our GSS reducing peak flow at the
mixtures as part of our development effort. At weld start while still quickly providing a
the time, the company was the leading controlled amount of extra gas to purge air in
supplier of Argon with about half the US the weld start area without an excess flow rate
production capacity. Neither myself nor our that causes turbulence. In addition, our GSS
group of engineers, metallurgists, or skilled does not interfere with the welder’s ability to set
welding technicians could have defined the reasonable flow rates. If limiting maximum flow
main reasons shielding gas waste existed! settings is desired, we have another patented
We knew it did, since when Argon was in short device that locks the flow control knob. See
supply, as it often was, the company would our Flow Rate Limiter on previous page.
help large customers with hundreds of MIG
welders in shipyards and offshore drill rig Another obvious reason why welding gas
production, reduce waste by setting the proper suppliers do not take the time to understand the
flow rates, finding and fixing leaks, etc! We issues and help reduce gas waste is their
were aware a minimum of 25 psi gas pressure financial disincentive to do so!
was needed above the flow control orifice or Our simple, low cost GSS is patented; it is
needle valve to achieve "automatic flow unique. It will usually pay for itself in a very
compensation.” That was necessary to keep short time and it will save gas and costs for
preset gas flow constant with the inevitable many years. Over 15,000 are in use - it works!
flow restrictions that occur in the MIG gun When adding new welding machines, our
cables, spatter in the gas diffuser and nozzle customers purchase additional GSS’s. They
etc. We also knew the high gas pressure report significant gas saving and most
created an excessive gas surge at the weld important, “happy welders!”
start that had a negative effect on weld start
quality. However, we did not conduct the field Bottom Line
research to quantify the reasons for gas waste To maintain a focus on saving NOT selling
and often would subjectively blame leaks shielding gas and to help our customers by
since that was out of our control! precisely answering technical questions, we
Of interest, the results of fabricator surveys sell our patented products directly to users.
were mentioned in a recently published article This also keeps our prices low, allowing
by a representative from that same industrial very quick payback of the investment.
gas manufacturing company saying their shop The next page presents a graphic
surveys show the average fabricator uses comparison of our GSS with other
three to five times the amount of gas they devices tried over the years to
should! (See Reference 7, on page 13.)
eliminate excess gas surge, which
Cause of Waste Defined
just frustrated welders and
Since forming WA Technology 18 years ago, management. We defined the
we have made thousands of weld start and reasons they were frustrated!

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 Page 21 of 24

Graphic View Compares Patented flow compensation,” required to manage the

inevitable flow restrictions that occur in production. If
GSS With Other Devices not present, when welding, flows vary significantly,
The following graphs show how our patented while the flow-calibrated pressure gauge gives a
GSS performance compares to other devices false impression, gas flow is constant! In addition, if
these devices are mounted at the feeder they also
that have been tried over the years to
have the problem noted in the next comparison with
eliminate excess starting gas surge. These a simple orifice, air purge is insufficient.
devices often frustrate welders and they may
try to defeat them and may be blamed for not Third: GSS (Red Line) Compared to a
accepting these “so called” gas saving Simple Orifice (or regulator or flowmeter)
devices. In fact, we have found why these Placed at the Wire Feeder to Control the
devices rightfully frustrated welders and Welding Gas Flow Rate
managers! We’ll explain; (also see pictures.)
Note, welders appreciate our patented GSS; it
does not have these past problems of:
1. Eliminating “automatic flow compensation”
by using low pressure or
2. Providing insufficient extra gas at the weld
start that is needed to purge the area of
air, and possibly moisture.
First: GSS (Red Line) Compared to
Conventional ¼ inch ID Gas Delivery Hose.
Mounting a simple orifice at the feeder, sized to
control welding gas flow (or regulator or
flowmeter) reduces surge but does not
provide sufficient extra gas at each
weld start to purge air! It’s like starting
the weld in air. Welders rightfully see
the problem and try to compensate by
increasing flow rates! This only partially helps and
wastes the gas trying to be saved! (See page 17)
Fourth: GSS (Red Line) Compared to Peak
Flow Control Orifice at Feeder
The GSS quickly provides sufficient extra gas to
purge the weld start area of moisture laden air at a
flow rate that avoids excess turbulence. It quickly
reaches the preset, desired gas flow rate. The
¼ inch ID standard hose has peak flows exceeding
150 CFH, which pulls air into the shielding gas
stream creating inferior starts and wasting gas.
Second: GSS (Red Line) Compared to “Gas
Guard” (a Low-Pressure Device)

An orifice can be mounted at the feeder that just

limits peak flow (similar to the GSS) while flow is
controlled at the gas supply with a flowmeter,
regulator/flowgauge or orifice. However, since the
gas volume in the gas delivery hose still increases
significantly when welding stops, about the same
amount of gas is wasted as with any standard 1/4-
inch hose - it just takes longer to be expelled! This
gives a false impression of gas savings! Note, the
Low pressure devices like the “Gas Guard” tested, GSS only holds 15 to 20% of that amount of gas as
eliminate the key feature built into all quality MIG a standard hose; that creates the gas savings.
flow control devices since the 1950’s, “automatic

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 Page 22 of 24

Appendix E: Portable Pressure Measurement

Device
CHECK FLOW AND DEMONSTRATE
Pipeline
GAS WASTE shielding
Many fabricators using piped gas supply are pressures
employing flowmeters to set and measure may vary
flow. We have found many are using as
flowmeters calibrated at 25 psi (as are most welders
low-cost flowmeters.) However, they are are turned
being used typically on 50 psi pipelines. If on and off
reading 35 CFH in this situation the flowmeter during the
it is actually flowing 45 CFH. If the pipeline day. The
pressure is 75 psi the actual flow when the amount
flowmeter reads 35 CFH is 53 actually CFH! should be
A table can be used to define the actual flow monitored
since it is proportional to the gas density at the to assure
higher pressure. However, the flow tube flow rates
cannot be recalibrated except with a marker remain in
noting the desired flow ball position. an acceptable range. Our portable pressure
measurement test device, WAT-PTD, (two are
Check Shielding Flow Using shown in the photo above) can provide
Portable Flowmeter valuable information and is easy to connect to a
gas delivery hose for periodic spot checks. It
Portable flowmeters
has a standard inert gas 032 “B” female fitting
operate using basic
on one end and a male CGA 032 “B” fitting on
physics of gas flow.
the other.
They are accurate and
very repeatability. It is also an excellent device to quantify the
When gas is flowing, a pressure buildup in the gas delivery when
float ball rises in a welding stops and to demonstrate why gas
tapered tube. The gas waste exists at each weld start!
pressure forces acting
The WAT-PTD is supplied with full instructions
on the ball balance
showing how to perform gas restriction
gravity as the ball
changes, checks of pipeline pressure at various
rises. The density of
welding stations and well as how to use it to
the gas must be
demonstrate gas waste.
factored into the
calibration. For The WAT-PFM and WAT-PTD can be
welding, measuring the purchased at:
shielding gas exiting a http://netwelding.com/prod02.htm
MIG nozzle or TIG cup
For a limited time, if you purchase a both
is easy and accurate. Just place the
items, we will supply, free of charge, our 70-
nozzle/cup into the tapered bottom and open
page, Self-Study Learning Program,
the gas solenoid. This device is calibrated at
"Optimizing Shielding Gas Use and Eliminating
atmospheric pressure since the gas exits at
Waste;" WAT-LWM-SG, a $19.95 value. See
that pressure.
this page on our web site for details:
We have a very rugged portable flowmeter, http://netwelding.com/Lean_Mfg._Tools.htm
WAT-PFM. It measures Argon and
Argon/CO2 mixtures from 10 to 45 CFH. A
table supplied with the instructions shows how
to measure helium gas mixtures up to
125 CFH.

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 Page 23 of 24

bought Praxair the largest US industrial

Appendix F: gas company.
ARGON PRICES HAVE QUADRUPLED Air Products, headquartered in PA is the
The US Industrial Gas Industry has only US producer of Argon left (Oxygen and
undergone major ownership changes. Nitrogen as well.) In fact, these companies
These changes have must be able to manufacturer, sell and
had a significant distribute the 21% Oxygen and 78%
effect on recent Nitrogen from that liquefied air to make
Argon prices. Argon profitable to produce and distribute.
The market for Argon has increased
What Is Argon? significantly more than that for Oxygen and
Argon is and inert Nitrogen causing it to be in short supply. In
gas, the third most fact, some fabricators have been put on
abundant gas in air, after Nitrogen and allocation based on prior usage.
Oxygen. Although Argon is less than 1%, Welding is the largest market for Argon,
(0.93%) that is 24 times the next most although electronic silicon chip
abundant gas, Carbon Dioxide at only manufacture, use in metallurgical melting
0.039%. Argon is produced by liquefying furnaces, filling thermal pain windows are
air and then distilling the Argon out in also important markets.
large columns. Several steps are required
to achieve welding grade purity. AWS The way demand is controlled is with price.
A5.32, “Specification for Welding Over the past 4 years Argon prices have
Shielding Gases” defines 99.997% increased over 200%. Air Products
required purity and a maximum moisture announced a 20% increase effective Feb
of 10.5 parts per million (ppm) for liquid 2020 and 15% Oct 2020. That followed 20%
and gaseous Argon. A first stage in October 2019. Similar 20% increases
distillation column produces what is called were announced in 2018 and 2017.
“Crude Argon” containing 1 to 2.5% Compounded that is 233% in 4 years!
Oxygen and 1 to 2% Nitrogen. The “Crude Others typically follow. Argon is in short
Argon” can be reacted with Hydrogen to supply, expect price increases to continue
eliminate the Oxygen. Another “Pure to increase.
Argon” distillation tower is then used to
HELIUM
remove the remaining Nitrogen and
Hydrogen. This process equipment adds Unlike Argon, Oxygen and Nitrogen that
over 20% more capital investment to a gas come from the air
plant making Oxygen and Nitrogen. Not all Helium is so light it
gas liquefaction plants built over the years escapes the earths
included this extra capital cost. atmosphere, it’s
only 0.0005%. The
ARGON MANUFACTURERS primary source is
The 4 major Industrial gas companies from natural gas
(including Japan Oxygen, who owns production. In some natural gas deposits,
Matheson Tri-Gas, with ~6% of the Argon it can be 0.5% and can be economically
production capacity.) The other three separated. But Helium supply is so low
produce ~94%. These were all US Worldwide and it’s use for medical MRI’s
companies a few years ago but two for example is expanding significantly.
European Companies bought the largest Prices have increased more than Argon.
US Industrial gas companies. Air Liquide Some Helium balloon filling companies no
from France bought Airgas, who owned longer sell them!
about 30% of the Industrial Gas/Welding If you’re using Helium and Helium mixtures
distributors. Linde AG from Germany had try to substitute Argon or higher
purchased what was AIRCO that had gone percentage Argon mixtures and employ our
through several owners and recently Gas Saver products that cut waste!

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 Page 24 of 24

Laboratory developing welding shielding gases and

Appendix G: filler metals, he became Director of Welding Market
Report Background Development. When the welding filler metals and
equipment division became a separate company, he
was named Vice President of Marketing for the
newly formed company, L-TEC. He was responsible
for business/product management, marketing,
customer/technical service, special customer order
production, training, and communications. When
the business was acquired by ESAB in 1989, he
remained in that position for the L-TEC brand and
for ESAB’s equipment business. In 1999, he left to
form WA Technology.
Mr. Uttrachi is an active volunteer of the American
Welding Society and served on numerous
committees including being on the AWS Board as
Director at Large, three years as Vice President and
the 2007 President of the 75,000-member Society.
He served for 15 years as Trustee on the Societies
Education Foundation and was Chair of that Board
Jerry Uttrachi, President of WA Technology, for 6 years. He also Chairs his local Section of the
was the 2007 President of the American American Society of Mechanical Engineers (ASME.)
Welding Society (a volunteer position.) During
his presidential year, Mr. Uttrachi presented Mr. Uttrachi has a Bachelors degree in Mechanical
technical talks about MIG Shielding Gas Engineering, a Masters degree in Mechanical
Control Optimization at over 20 locations in Engineering (Emphasis Behavior of Metals) and a
the USA and conferences in Peru, Denmark Masters degree in Management from the New Jersey
and South Korea. A technical paper was also Institute of Technology. He has 11 patents in the
presented at the International Institute of welding field, with 4 of 6 issued in the past 15 years
Welding Assembly in the Czech Republic. related to reducing shielding gas waste and
These talks and technical discussions in improving weld start quality. Two patents granted
China, Japan, and the UK reinforced that gas in 2012 define welding helmets that provide filtered
waste and inferior MIG weld start issues are and cooled air, employing a thermoelectric cooling
common worldwide problems. module.

Unlike some Internet information, this Report Many of Mr. Uttrachi’s numerous welding related
is extensively referenced to validate and articles are published in technical journals and
support the information provided. Technical trade publications.
journals and published articles, and US In 2012, Mr. Uttrachi’s book,
patents are quoted with patent numbers. entitled “Advanced
Mr. Uttrachi founded WA Technology, in 1999 Automotive Welding” was
dedicated to helping companies improve published by CarTech and
welding productivity and specializing in includes information about the
products and techniques to eliminate shielding science of arc welding.
gas waste. CarTech published another
book by Mr. Uttrachi in 2015,
Email [email protected] if there entitled “Weld Like a Pro.”
are questions about this Report.
The first book earned a bronze medal in 2013 and
About the Author the second a silver medal in 2016 in a Media
Mr. Uttrachi started his welding career over 50 Competition conducted by the London based
years ago at the Linde Welding R&D labs. Linde International Council for Press and Broadcasting.
(renamed Praxair, now Linde again!) was a The books received excellent independent reviews
leading company developing welding shielding by the editors of Hemming’s Motor News, The
gases, equipment, and filler metals. After Welding Journal and many published by readers at
managing the companies Material Technology retailers such as Amazon.

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