Question.

Team , currently we are using GMAW welding , with Argon plus co2 mixture welding
gas ,for heavy structural equipment fabrications ,  i am getting higher production rate ,  but i am
facing field complaints ,cracks generating at the welded structures , toe crack maximum happening
at the fillet weld joints . 

So we decided to go for 100 percent co2 gas welding , to avoid the field failures , kindly give some
ideas and support to achieve good quality welding by Gmaw welding process .

Base metal , Low carbon steel only

Answer.
1. There is an upper limit to the amount of CO2 in the mix if you are using the spray transfer
mode on carbon steel. You didn't mention the particulars of what you are welding, the
parameters, thickness etc.
2. Agreed, From what I've seen, C02 must be less then 22% to allow spray transfer.
3. Why do you think it is shielding gas composition causing the cracks?  There are many
potential causes for cracking, and commonly used shielding gas compositions are not
usually very high on the list.  Although there is the possibility your gas is gas contaminated
with moisture if the cracking goes away when changing gas.

How thick are your base metal welds?  Are you preheating at all?  Do you have any crack
photographs?

Thanks for your replies ..

The root cause of the fillet weld crack  failure , by gmaw welding process ,what we have suspectung
is due to lack of penetration , higher cooling rate of the weld during production , and excessing
welding speed .

The thing is in our work shop we are allocating the components to the welders part per rate , hence
the welder having the tendencies to do in a high speed with a current of 300 to 340 amps and volt
29-32 , to get more outputs , more benefits to him , and all the welding station we cannot able to
allocate the supervisors for monitoring the welders .

many job site failures happened , so what we are thinking in our current  condition argon plus Co2
mix gas , supporting the welder to do with longer arc length and also giving good wetting condition
giving higher productivity rate with poor weld quality , if we go for 100 percent co2 our welders
cannot able to drag the torch excessive and its poor wetting nature , so he will do the welding with
the medium speed only hence ahieve good penetration level and higher heat input level . 

so this idea will really work out or needs to concentrate on other things ...

Waiting for your replies .

4. ake a look at your WPS. My suggestion is to ensure that your welders are staying within the
parameters. Piece work is fine but you need to make sure your welders know the importance
of those parameters, that would be your responsibility. Do they have copies?

Simple solution as I see it. Instead of changing your shielding has composition, hold a
meeting regarding the importance of those parameters, especially with GMAW, and state
any welder caught exceeding those parameters will be disciplined.
 If you're looking for more wetting action, you can try a tri-mix gas with a small amount of
oxygen ( less than 10%) as that will help with the wetting out at the toes of the weld. If you go
with 100% CO2 you will end up with excessive porosity.
5. 10% oxygen? Wow, that's a lot of oxygen! Not saying it can't be done, just saying I would like
to see it for myself.

The typical percentage of oxygen mixed with argon is 2% up to a maximum of 5% when

welding carbon and low alloy steels using spray transfer. More common perhaps is argon
with up to 12% or 15% (max.) carbon dioxide.

100% carbon dioxide or mixed with up to 25% argon is another popular mix when using short
circuiting transfer, but I would limit that to thicknesses of 1/4 inch or less.

Globular transfer can go with 100% carbon dioxide, but there might be some increased labor
associated with the removal of spatter.

Pulse spray is probably not the best choice if the welding is limited to the flat and horizontal
position.

Just my thoughts – Al
6. Most popular shielding gas for mild steel GMAW is 90% Ar/10% CO2. The CO2 content will
widen the penetration profile and help reduce the cracking issue.
7. With parameters like that, It looks like your in spray transfer mode... Have you ran a fillet test,
cut and etch? that's where I would start. Verify the penetration is there.

Also "8mm to 32mm and onwards"- Are you preheating the thicker members?

I've hit those same parameters, with great results, What was your gas? you mention a
Argon-C02 mix but what was it?

Horizontal, is a bit more difficult in the GMAW process.. Have you done any sort of mock up
test to verify the weld can be achieved (with your welders) ? Going all in with weld failures
with just the gas seems a bit off to me. you could be spending all your time chasing your tail..
you need to look at all the other variables that could cause the weld failures and not just the
gas!
Have your welders passed a horizontal weld test?
8. Did you have a chance to check the composition of the blend?
what about the moisture of this blend? Hydrogen and cracks are "friends"!
Are you using cylinders or a mixer?
9. Sounds like there's other issues, 1 being switching gas composition like a light switch
normally just doesn't happen. Depending on code it would require new PQR/WPS then
WQT. Like others have stated 100 Co2 is really great short circuit, which is frowned upon for
your "heavy structural equipment fabrications". I would wonder if welding procedures are
even being used, along with welder qualification. Reminds me of a place I once was
employed for a short amount of time due to management not agreeing with my ethics.
10. As is the case with all welding processes, you have to consider the entire system when
trouble shooting to solve a problem. One must also consider the welder's skill in the system.
If the individual doesn't know how to weld, the rest is going to help. "You can't make a silk
purse out of a sow's ear."

The welding parameters, including the shielding gas have to work together to produce
acceptable results. The transfer mode is dependent on the shielding gas and welding
parameters use. The choice of transfer mode should be based on the base metal, thickness,
and production positions, i.e., flat, horizontal, ...

A welding procedure should be available to the welder and should be followed by the welder.
The WPS is the written instruction given to the welder so he or she knows what base metals
are being joined, what weld details are applicable (groove, fillet, plug, etc. along with
information regarding groove angles, dihedral angles, root openings, etc. ), the filler metal
and filler metal diameter, as well as the appropriate voltage range, wire feed speed,
amperage range, electrode extension or contact tip to work distance, and travel speeds, to
name some of the information that can be included.

The welders will quickly recognize if the WPS is "real" or simply "fictional". If the WPS is
pencil whipped to satisfy a requirement, the welders will simply ignore it and it will be used to
light the noon day fire to heat up their ration of soup.

If you are not familiar with writing WPSs and if you can travel, there is an upcoming seminar
you will find very useful. The name of the seminar is "The Atlas of Welding Procedure
Specifications". It is advertised in the Welding Journal and Inspection Trends.

You mentioned some of the weld deficiencies your welders are experiencing. Some of them
sounds like improper welding parameters and some can be attributed to welder technique
and skill. You may find the Welding Handbooks useful. The volumes on welding processes
provide useful information on the proper shielding gas to use and welding parameters for a
select few filler metal types. Regarding the proper parameter, I suggest visiting the electrode
manufacturer's web site to see what is recommended. Often overlooked is the importance of
electrode extension (EE) or contact tip to work distance (CTWD). The WPS should definitely
list EE or CTWD. The distance from the contact tip to the end of the gas nozzle is also
important. If welding with short circuiting transfer, the CT should be slightly recessed (maybe
3 mm). If one is using spray transfer, the contact tip should extend beyond the end of the gas
nozzle by 3 mm. Varying the EE or CTWD while welding has a direct effect on the electrical
resistance, thus the amperage will change even though the wire feed speed is the same as
originally set.  As the EE or CTWD increases, the amperage will decay, as the EE or CTWD
is decreased, amperage will increase. That will have a direct affect on the heat input and
whether acceptable fusion and penetration is achieved or not. Excessive CTWD will also
encourage insufficient shielding gas coverage and porosity can result. The arc length
dictates the arc voltage, i.e., the voltage drop across the arc. As the arc voltage is increased,
the arc length increases. As the arc voltage is decreased, the arc length decreases. Lower
voltage is used for short circuiting, while higher voltages are used for globular and spray
transfer. Low voltage is a relative term and depends on the electrode diameter. For small
diameter filler metal, short circuiting transfer, the voltage may be as low as 13 to 15 volts on
very thin sheet metal. As the filler metal diameter increases, the arc length will increase and
will require high voltage, maybe on the order of 18 to 23 volts for short circuiting transfer. If
the welder is in the spray transfer mode using an argon rich (>80%) mix, the arc voltage will
be above 25 volts, but rarely would it be above 29 volts for diameters typically used for
carbon steel thicknesses of 6 mm and thicker.  
Getting back on the subject of CTWD, the transfer mode and electrode diameter will dictate
the proper range for CTWD. Smaller electrode diameters might only require a CTWD of 8 to
9 mm. If using the spray transfer mode, the CTWD may be on the order of 12 mm.
Welder technique also comes into play, but that should probably be the subject of another
post.
Al
11.GMAW looks pretty. But for heavy structural? Not good. Switch to FCAW!
12 Hmm, if the weld shape is causing some of your problems CO2 will not help!

I have NO vested interest in what shielding gas is used as I'm NOT in the industrial gas
business or a supplier of bulk gases or distributor selling gas BUT in general the right Argon
based shielding gas will be easier for welders to make quality welds.  As someone noted, for
heavy sections perhaps gas shielded flux cored wire or metal cored wire might be easier for
your welders to make quality welds.

However good welders made perfect welds in ~2 inch HY-80 with solid wires and Argon
based shielding gas.   I recall years ago folks fabricating offshore drill rigs making quality out
of position welds in heavy sections with solid wire and Argon based shielding gas.  They had
"skilled welders," as do those making military vessels from thick HY-80 and HY-100.

35 years ago, when managing a welding market development effort for what was Linde (then
became Praxair and now Linde again - LOL) we produced a MIG Welding Handbook that
also had a good welding shielding gases selection section   We also developed a more
universal tri-mix with 90% Argon, 8% C02 and 2% O2. It was similar to 8% CO2 in Argon but
produced a superior spay arc.  Did a good job in short arc mode so no need to switch gases.

Attached a document that defines why and how it was developed and summarizes most
other shielding gas mixtures and their use that has been updated from that original
document.
13. It is interesting.  We all have opinions, but the opinions are based upon what we think is
happening.  We use GMAW on heavy fabrication. to say that it is not appropriate is baloney.
I like the amps and volts being used.  For thicker materials that should work well.  My thought
is in agreement with whoever mentioned preheat.  Toe cracks can be attributable to lack of
preheat.  are you getting this on thicker materials or all materials?  If you are using these
parameters on the thinner materials and getting cracks, we would need to look at other
culprits.  My suggestion is provide all details of the welding that is not working.

I have another comment.  You are paying your welders per piece.  So it doesn't matter that
the piece has cracked or unacceptable welds?  You MUST change your method of
compensation.
14.