1/27/2014 The Evolution of Shielding Gas

The Evolution of Shielding Gas

From the early years of single-gas arc welding to present-day blends, the gas industry
continues to grow

BY NATHAN MOYER

The advent of gas-shielded arc welding processes can be traced back to the 1920s.
However, because of limited research, these processes did not become commercially viable
until the 1940s and 1950s. The basic push for research initially was World War II.
Over the last 50 years, the industrial gas industry has made significant contributions to the
welding industry through the production and purification of different gases and gas mixtures.
Today, there are still many hours of research being done on new gas blends and the effects
they have on welding.

Early Research
It started with the gas tungsten arc welding (GTAW) process. At the beginning of World War
II, the aircraft industry looked for a better way to construct aircraft. The GTAW process,
shielded with helium, was the result. This step got the ball rolling for more research and
development on the gas metal arc welding (GMAW) and flux cored arc welding (FCAW)
processes. Helium (He) and carbon dioxide (CO2) were the main options the welder had at
the time due to limited gas manufacturing capabilities.

Gas Fundamentals
The fundamental purpose of shielding gas is to keep the nitrogen and oxygen in the
atmosphere out of the molten weld pool as it cools. The shielding gas of choice during the
development of the GMAW process was CO2. This gas was chosen as a result of analyzing
the gas produced from the flux of a shielded metal arc welding (SMAW) electrode.
Researchers found CO2 to be the predominate gas in the shielding surrounding the molten
pool during the SMAW process. In a few cases, this gas is still the gas of choice for GMAW
and FCAW. GTAW process needs were different from GMAW. This process needed a truly
inert shielding gas, and helium was the only inert gas available at the time until argon (Ar) came
along.

Argon Makes an Impact

Known in the industrial gas business as "the big A," argon is an inert gas. This means it does
not oxidize and has no effect on the chemical composition of the weld metal. Pure argon
cannot be used for GMAW of steels since the arc becomes too unstable. An oxidizing gas
component is therefore used to stabilize the arc and to ensure a smooth metal transfer during
welding. This oxidizing component may be either CO2, oxygen (O), or a combination of these
gases. The amount of the oxidizing component added will depend on the steel type and
application.
The electric arc in gas shielded arc welding can be divided into three parts: the arc plasma, the
cathode area, and the anode area. In GMAW, when the electrode constitutes the positive (the
anode), the cathode area is on the workpiece as one or more cathode spots. The oxidizing
additive is necessary to stabilize these cathode spots; otherwise the arc will tend to flicker
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around on the surface of the workpiece, forming spatter and an irregular weld bead. There are
often advantages in using only CO2 with argon. One is the slight improvement in weld
geometry and appearance over Ar-O mixtures. This occurs because of differences in weld
pool fluidity, surface tension, and oxides in the molten metal. With CO2 instead of O, there is
also less oxidation and slag formation, which can have an effect on the appearance of the weld
as well as the need for cleaning the weld. Another advantage is improved joint penetration,
especially in the sidewall. This is mainly a factor of the higher arc voltage and energy employed
when welding with CO2 in the mixture.

Ar-CO2-O Mixes
Throughout the industrial gas market, many different combinations of the Ar-CO2-O mixture
are available. There are several goals of these three-part blends: reducing spatter, ability to
weld thinner material, and a wider "sweet spot" window where the parameters can be set on a
welding machine. Some argue these goals can all be achieved with Ar-CO2 and proper
parameter settings, but some end users who swear by these three-part blends state they will
never go back to using traditional Ar-CO2 mixes.

Establishing a Standard
Recently, with so many different mixes and so many different manufacturers of these mixes,
the American Welding Society recognized a need to regulate the quality and consistency of
shielding gases. Therefore, in 1997, AWS A5.32/A5.32M-97, Specification for Welding
Shielding Gases, was produced. This established specifications for purity and moisture of raw
components, i.e., argon, carbon dioxide, oxygen, and helium. The standard also established
mix tolerances of components and methods for testing and recording these specifications. This
provided an end user with a way to know what is being bought and assurance a purchase is
what it claims to be.

Developments in Shielding Gases

The latest developments in shielding gas technology have included some new additions,
namely, helium, hydrogen, nitrogen, and nitric oxide. Of course, as stated previously, helium
has been used for many years in welding. However, it is now being used in some new
applications. Helium, like argon, is an inert gas that can be used together with argon and a few
percent of CO2 or O for gas metal arc welding of stainless steel. In its pure state, or mixed
with argon, it is used as a shielding gas for GTA and GMA aluminum welding. Compared with
argon, helium provides better side wall penetration and higher welding speeds by generating a
more energy-rich arc. The process is more sensitive to arc length variations when helium is the
shielding gas, and the arc is more difficult to strike in GTA welding. Helium and helium
mixtures can be used as a root protection gas in installations where it is necessary for the gas
to rise in order to force out trapped air. Helium rises because it has a lower density than air.
Hydrogen (H) can be added to shielding gases for GTA welding of austenitic stainless steels in
order to reduce oxide formation. The addition also means more heat in the arc and a more
constricted arc, which improves penetration. It also gives a smoother transition between weld
bead and base metal. For root protection purposes, hydrogen addition is beneficial due to its
reducing effect of oxygen. Nitrogen with 10% hydrogen is commonly used for root protection.
It is not recommended for root protection of austenitic-ferritic (duplex) steels. Here, argon or
high-purity nitrogen should be used.
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Nitrogen (N) is used as an additive in shielding gases for GTA welding of super-austenitic and
super-duplex stainless steels. These steels are alloyed with up to 0.5% nitrogen to increase
mechanical properties and resistance to pitting. If the shielding gas contains a few percent of
nitrogen, nitrogen losses in the weld metal can be prevented. As stated earlier, nitrogen with
10% hydrogen is a common root protection gas that delivers a good reducing effect. Pure
nitrogen will further increase pitting resistance at the root side when welding super-austenitic
and super-duplex stainless steels.

Reducing Ozone
The addition of nitric oxide (NO) to shielding gases reduces ozone emissions in the welding
zone. This technology was first developed by AGA Gas, Inc., in an effort to reduce the ozone
in the welder's atmosphere. The name MISON was attached to this family of NO-containing
gases produced by AGA Gas. Reduction of ozone can significantly enhance the quality of the
welding environment and reduce the incidence of mucous irritation. There are also possible
beneficial effects on concentration, productivity, and consistency in welding quality. When
trials were done with this gas, it was discovered NO also served to stabilize the arc to good
effect when welding high-alloyed stainless steels and aluminum.
Research continues to look for ways to reduce spatter, increase deposition rates, and improve
weldability through shielding gases. We've come a long way in the past 50 years; just think
what the next 50 years will bring.

NATHAN MOYER (nathan.moyer- @us.lindegas.com) is Regional Welding Specialist,

AGA Gas ​
Member of the Linde Gas Group, Cleveland, Ohio.

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