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Shielding Gases for Gas Tungsten Arc Welding
Argon and helium, which are inert, monatomic gases, are used as shielding gases for gas tungsten arc welding (GTAW). Argon is most commonly used because it provides lower arc voltage at any given current value and arc length, a smoother and quieter arc, and easier arc initiation. Helium is used for welding heavy sections where higher arc voltage characteristics offer advantages or greater penetration is desired or both. Argon-helium mixtures are used when a balance of the characteristics of each are desired. For some special applications, additions of hydrogen and nitrogen are used. Table 1 lists the advantages of different shielding gases for use when welding a variety of metals.

The purpose of the shielding gas is to prevent the atmosphere from contaminating the weld area and the tungsten electrode. Critical factors in shielding efficiency are nozzle size, flow rates and the type of gas used. Welding grade argon and nitrogen are supplied with a purity of 99.995% or greater. Since argon is a heavy gas with an atomic weight of 40, lower flow rates are required for it to provide a good shield.

Generally, the shield gas is delivered around the tungsten electrode through a concentric nozzle, which must be of adequate size to provide coverage of the weld area. Automatic welding setups may include leading or trailing shields to increase the coverage area.

Argon is obtained from the liquefaction of air, and argon, oxygen and nitrogen are the primary products of air separation plants. Argon is readily available even though it makes up less than 1% of the yield. Helium is mostly obtained from wells controlled by the U.S. Bureau of Mines. Limited availability places a premium on helium. Shielding gas systems using less than 10,000 ft3 per month normally use individual cylinders. For higher consumption rates, distribution manifolds fed by cylinder banks or trailers are used.

MetalWelding TypeShielding GasAdvantages
AluminumManual Welding ArgonBetter arc starting,cleaning action and weld quality; lower gas consumption.
and Magnesium Argon-HeliumHigh welding speeds possible.
 Machine WeldingArgon-HeliumBetter weld quality, lower gas flow than required with straight helium.
  Helium (DCSP)Deeper penetration and higher weld speeds than can be obtained with helium.
Carbon SteelManual WeldingArgonBetter pool control, especially for position welding.
 Machine WeldingHeliumHigher speeds obtained than with argon.
Stainless SteelManual WeldingArgonPermits controlled penetration on thin-gauge material (up to 14 gauge).
 Machine WeldingArgonExcellent control of penetration on light-gauge materials.
  Argon-HeliumHigher heat input, higher welding speeds possible on heavier gauges.
  Argon-HydrogenPrevents undercutting, produces desirable weld contour at low current (up to 35% H2) levels, requires lower gas flows.
  Argon-Hydrogen
(up to 35% H2)
Prevents undercutting, produces desirable weld contour at low current levels, requires lower gas flows.
  Argon-Hydrogen-HeliumAn excellent selection for high-speed tube mill operation.
  HeliumProvides highest heat input and deepest penetration.
Copper,Nickel, and Cu-Ni alloys ArgonEase of obtaining pool control, penetration and bead contour on thin-gauge metal.
  Argon-HeliumHigher heat input to offset high heat conductivity of heavier gauges.
  HeliumHighest heat input for welding speed on heavy metal sections.
Titanium ArgonLow gas flow rate minimizes turbulence and air contamination of weld; improves heat-affected zone.
  HeliumBetter penetration for manual welding of thick sections (inert gas backing required to shield back of weld against contamination).
Silicon-Bronze  ArgonReduces cracking of this "hot short" metal.
Aluminum-Bronze ArgonLess penetration of base metal.
 
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