International Journal of Hydrogen Energy 25 (2000) 369376

Experimental research of the eect of hydrogen in argon as a shielding gas in arc welding of high-alloy stainless steel
J. Tus ek a,*, M. Suban b
a

Faculty of Mechanical Engineering, Askerceva 6, 1000, Ljubljana, Slovenia b Welding Institute, Ptujska 19, 1000, Ljubljana, Slovenia

Abstract The paper treats the eect of hydrogen in argon as a shielding gas in arc welding of austenitic stainless steel. The studies were carried out in TIG (Tungsten Inert Gas) welding with a non-consumable electrode and MIG (Metal Inert Gas) welding with a consumable electrode, in both cases with dierent volume additions of hydrogen to the argon shielding gas, i.e., 0.5, 1.0, 5.0, 10 and 20%. The studies showed that hydrogen addition to argon changes the static characteristic of the welding arc. The hydrogen addition to argon increases arc power and, consequently, the quantity of the material melted. In TIG welding a 10% addition of hydrogen to argon increases the quantity of the parent metal melted by four times. The hydrogen addition increases thermal and melting eciencies of the welding arc too. The process stability in TIG welding in the mixture of hydrogen and argon is very good. Also in MIG welding, the hydrogen addition to argon increases melting rate and melting eciency of the arc, but the increase is much smaller than in TIG welding. Since hydrogen is a reducing gas, the weld surface produced by hydrogen addition to argon is in both cases very clean and without oxides. # 2000 International Association for Hydrogen Energy. Published by Elsevier Science Ltd. All rights reserved.

1. Introduction Gas-shielded arc welding is at present widely used in practice. New techniques and various solutions constantly widen its applicability. In fusion arc welding an important part is the type of shielding gas used since it aects the arc shape, material transfer mode and energy distribution, i.e. temperature distribution, in the

* Corresponding author. Tel.: +386-061-136-7474; fax: +386-061-136-7222. E-mail address: janez.tusek@guest.arnes.si (J. Tus ek).

arc. At present, almost exclusively mixtures of two, three or even more dierent gases are used to protect the arc and the molten pool. The most frequently used gases are CO2 and Ar in various mixtures. A smaller portion of oxygen, in some cases also helium, hydrogen or nitrogen, is often added to these two gases. Composition of a shielding mixture in arc welding depends mostly on the kind of material to be welded. The selection of the shielding gas should, by all means, take into account chemical-metallurgical processes between the gases and the molten pool that occur during welding. Welding of high-alloy stainless steels seems to be a

0360-3199/00/$20.00 # 2000 International Association for Hydrogen Energy. Published by Elsevier Science Ltd. All rights reserved. PII: S 0 3 6 0 - 3 1 9 9 ( 9 9 ) 0 0 0 3 3 - 6

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very exacting task of joining materials. This group of steels is made of not only austenitic steels, but also of high-alloy ferritic, martensitic, duplex, and superduplex steels. These steels are mostly TIG or MIG welded. In TIG welding pure argon is used as a shielding gas; in MIG welding, however, 2% of oxygen is added to argon to ensure better fusion of the ller material and droplet formation. Hydrogen has been added to argon in welding of high-alloy stainless steels only lately. An argon-hydrogen mixture may be used in TIG and MIG welding processes. 2. Basic characteristics of hydrogen and argon Physical-chemical properties of each of the two gases are very dierent. It is the very dierence between them that contributes to a very high-quality gas mixture which may be used as a shielding gas or a plasma gas in thermal cutting and welding. Thermal conductivity of each of the gases is shown in Fig. 1. The diagram shows that thermal conductivity of hydrogen in the temperature range between 3000 and 4500 K is almost ten times higher than that of argon. This temperature range is namely prevailing in the welding arc [1,2]. Thermal conductivity of the arc aects its shape and the welding process as such. Fig. 2 shows enthalpy of four dierent gases. Hydrogen gas enthalpy is higher than that of argon almost in the entire temperature range. Enthalpy of a shielding gas aects arc formation, arc shape, and temperature distribution in the arc as well. Electrical conductivity as a function of temperature is shown for four gases in Fig. 3.

Fig. 1. Thermal conductivity of gases as a function of temperature.

Fig. 2. Gas enthalpy as a function of temperature.

Fig. 3. Electrical conductivity of gases as a function of temperature.

J. Tusek, M. Suban / International Journal of Hydrogen Energy 25 (2000) 369376 Table 1 Basic chemical and physical properties of argon and hydrogen Type of gas Content in the Boiling point air (vol.%) at 1.013 bar (8C) Atomic weight Density at and mean 158C, 1 bar molecular (kg/m3) weight reps Relative density with regard to the air (=1) at 158C, 1 bar 0.06 1.38 0.14 0.91 Chemical Dissociation and ionization activity energies (eV)c

371

Hydrogen H2 Argon Ar Helium He Nitrogen N2 Carbon dioxide CO2 Oxygen O2

a b

0.5 106a 0.934 5.2 106a 78.084

252.9 185.9 268.9 195.8

2.016 39.948 4.002 28.013

0.085 1.669 0.167 1.170

4.48 13.59 15.76 27.50 24.56 54.10 9.76 14.55 29.60

Reducing Inert Inert Reactive

0.033a 20.946

78.5b 183.0

44.011 31.998

1.849 1.337

1.44 1.04

5.08 13.62 35.20

Oxidizing Oxidizing

It is not obtained from the atmosphere. Sublimation temperature. c 1 eV=1.6 106J; ionization energy of the majority of metals ranges between 6 and 9 eV.

Table 1 shows some chemical and physical properties of argon and hydrogen [3]. The energy required for ionization of a particular gas is also very important for the welding arc, arc power and energy distribution in the arc. Voltage drop across the arc is, however, directly dependent on ionization energy. Dependence between voltage and current intensity at a certain arc length is called the static characteristic of

the arc. Fig. 4 shows two characteristics which dier strongly and have been taken from dierent literature references. The rst, left diagram, shows the static characteristic for TIG welding in various shielding gases [3]. The second, right diagram, however, shows the static characteristic for TIG welding with three dierent arc lengths and arc burning in argon with 2 vol.% of hydrogen [4]. The two static characteristics of the welding arcs dier strongly. Most certainly it is

Fig. 4. Static characteristic of the welding arc: left [3], right [4].

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the static characteristic shown in the right diagram which is more reliable (Fig. 4). From the diagram in Fig. 4 (left) it may be found and conrmed that voltage drop at a constant current depends on the type of shielding gas used and that it is the highest with hydrogen as a shielding gas. 2.1. Argon Argon is a gas without color, odor and taste. It is not ammable, not toxic and is neutral which means that it does not react with other elements to form compounds. Argon is obtained from the atmosphere although it occurs in the atmosphere only to the extent of 0.934%. Being 1.38-times heavier than the air it provides a very ecient and stable protection of the arc and the molten pool. Due to its low ionization energy, arc ignition under protection of argon is very reliable. Its burning is very stable also with longer welding arcs. Thermal conductivity of argon is very low (Fig. 1) which aects both the arc shape and the weld shape. In MIG welding under pure argon shielding a wineglass-shaped weld is obtained [5]. In gas-shielded arc welding, argon assuredly plays the most important part. It is used as a basic shielding gas with O2, CO2, He, H2 additions or as an addition to CO2 gas. 2.2. Hydrogen Hydrogen is a gas without color, odor and taste and is non-toxic. It is ammable (ignition point at 5608C). It is much lighter than the air (see Table 1) and explosive in a mixture with the air and oxygen in a very wide range. Of all gases it has the highest thermal conductivity, high enthalpy and is reducing, which means that it combines with oxygen and hinders oxide formation. Hydrogen as a shielding gas is used as an addition to other gases, mainly argon, but also helium in smaller quantities. Hydrogen is used to a larger extent with argon as a plasma gas or as a component in the argon-hydrogen mixture for root shield in welding of high-alloy stainless steels [8]. According to EN 439 the nitrogen hydrogen mixture (forming gas) is used as a root shield. The hydrogen content in the mixture ranges from 050%. 2.3. Argonhydrogen mixture The argon-hydrogen mixture is used in practice mostly as a plasma gas in plasma welding and plasma cutting. The argon-hydrogen mixture has been lately increasingly used as a shielding gas in arc welding of

austenitic stainless steels, ferrite and martensitic steels. The majority of the authors of studies on shielded-gas welding recommends from 0.55% hydrogen in argon [37,9]. Hydrogen addition to argon increases voltage drop in the arc, and consequently arc power. Due to high thermal conductivity of hydrogen, the arc gets narrower and energy concentration in it increases, which entails a deeper penetration. Hydrogen as a reducing gas hinders oxide formation on the surface of the nal layer of the weld. Weld appearance is consequently nicer. Hydrogen addition to a shielding atmosphere may, however, raise some diculties. Hydrogen solubility in molten metals is namely very high. Hydrogen in steel and other metals, however, may produce gas bubbles and cracks.

3. Experimental work In studying the eect of hydrogen in the argon shielding gas on the welding process and weld shape, two welding processes were used. In TIG welding only the workpiece surface was melted using various welding parameters. This means that no ller material was used. In MIG welding, surfacing was carried out on a at plate. In both processes the same parent metal was used. The chemical composition of the ller material and parent metal is given in Table 2. In each welding process three dierent current intensities, namely, 150, 200, and 250 A, were used. Five welds were produced with each current intensity in dierent shielding gases. Shielding gases used were pure argon, Ar+0.5%H2, Ar+1%H2, Ar+5%H2, Ar+10%H2, and Ar+20%H2. In TIG welding a conventional power supply with a drooping static characteristic and a thyristor power supply with feedback control were used. Welding was carried out with a thoriated tungsten electrode. The arc length was 35 mm. In MIG welding a synergic power supply designed for high-production MIG/MAG arc welding of all kinds of steel was used. The unit permits a wire feed speed of up to 35 m/min. A 1.2 mm welding wire was used. The wire extension length was 16 mm. In all cases the width and length of workpieces were
Table 2 Chemical composition of the parent metal and ller material C Si Mn Cr Ni Mo

Parent metal < 0.12 < 0.20 < 1.50 18.25 8.0 < 0.80 Filler material 0.12 0.60 7.00 18.50 9.0

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the same, while workpiece thickness was 8 mm in TIG welding and 10 mm in MIG welding. During welding, welding parameters, gas ow, and welding speed were measured. After welding the workpieces were visually inspected, then cut and macrosections made. On the macrosections, the area of the molten parent metal and ller material was measured, and melting eciency and melting rate were calculated. 4. Results and discussion It has already been mentioned earlier that hydrogen addition to a shielding gas in arc welding aects the static characteristic of the arc and increases arc power which results in a larger quantity of the material melted. But the majority of the authors reporting on such studies welded with a shielding gas which contained only 5% of H2 in argon. Our results will refer to six dierent mixtures. We used argon and its mixtures with 0.5, 1.0, 5, 10 and 20% of H2. 4.1. TIG welding In TIG welding the inuence of hydrogen in argon shielding gas on welding parameters, the quantity of parent metal melted and welding eciency was studied. 4.1.1. Static characteristic of the welding arc Fig. 5 shows the static characteristic of the welding arc in TIG welding with various hydrogen contents in the argon shielding gas at a constant arc length. The static characteristic is in its shape and values similar to the one shown in Fig. 4 (right [4]). With a larger addition of hydrogen to argon the voltage drop across the arc is stronger due to higher electrical resistance. A

strong arc-voltage drop is produced by higher ionization energy and higher thermal conductivity of hydrogen if compared to argon. The arc length was constant, i.e. 4 mm. Fig. 6 shows two curves showing the correlation between arc voltage and welding current intensity at constant welding-rectier settings, at a constant welding arc length and with various shielding gas mixtures. Curve 1 shows a welding arc characteristic with a conventional power supply with a drooping characteristic. Due to hydrogen addition to argon, voltage drop across the arc is getting stronger, therefore, a lower welding current is carried through the whole current circuit. The higher hydrogen content in argon, the stronger voltage drop and the lower welding current intensity at unchanged external power-supply settings. Curve 2 shows a correlation between arc voltage and current intensity with a thyristor-type power supply with feedback control. It may be observed that electric resistance in the arc is increased due to hydrogen addition, current intensity, however, does not essentially decrease. 4.1.2. Eect of hydrogen in argon used in TIG welding on the quantity of the parent metal melted In the experiments, welding was carried out in pure argon and in ve dierent argon-hydrogen mixtures. Three dierent current intensities were selected, i.e. 150, 200 and 250 A, while the arc length (Lo=3,5 mm) and welding speed (vw=0.3 m/min) were held constant. Fig. 7 shows the quantity of the parent metal melted per unit of time as a function of welding current and hydrogen content in argon. The results obtained and shown in the diagram in Fig. 7 are quite surprising. The quantity of parent metal melted strongly increases with hydrogen addition. It is only with hydrogen addition to argon that the quantity of parent metal melted increases several times.

Fig. 5. Static characteristic of the welding arc in TIG welding in various shielding atmospheres (L = 4 mm, electrode negative).

Fig. 6. Correlation between arc voltage and welding current intensity with two dierent power supplies and with dierent argonhydrogen shielding mixtures (electrode negative).

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surface is cleaner and without oxides if hydrogen is added to argon. For an easier assessment of the welding process with hydrogen addition, melting eciency of the welding process was calculated too. Eq. 1 gives melting eciency of TIG welding: MEt 100% Z t IUdt
0

Fig. 7. Eect of hydrogen (vol.%) in argon and welding current intensity in TIG welding on the quantity of the parent metal melted (stainless steel 18/8) (Lo=3.5 mm, vw=0.3 m/ min, electrode negative).

where M [g/s]quantity of the parent metal melted per unit of time; E [J/g]energy theoretically required to melt 1 g of austenitic stainless steel; and I [A], U [V], t [s]welding parameters. The energy theoretically required to heat high-alloy austenitic steel to the melting temperature was calculated by means of Eq. 2. E mcp DT 2

Fig. 8 shows two macrosections of the fusion zone obtained in TIG welding in dierent shielding media and at a constant welding current. Arc voltage varied due to dierent shielding media. Practically obtained results are real and may be compared to theoretical calculations shown in Ref. [11]. Lowke et al., mathematically calculated the quantity of the material melted in TIG welding of aluminum and low-alloy steel in argon to which 10% of hydrogen was added. In the theoretical calculation a number of assumptions and simplications were made. A much more important error was, however, that the authors did not take into account dierent arc voltages. Hydrogen addition to argon produces an increase in arc voltage, which, consequently, results in a longer arc and a change of arc shape. Questions immediately arise as to what the quality of the weld metal may be, and whether hydrogen absorption in the molten pool occurred during welding. Separate studies on the quantity of diusible hydrogen in the weld metal are to be conducted in the future. Visual assessment of the weld metal is very favorable and gives rise to no remarks. The weld-metal

where m [g]mass; cp [J/gK]thermal capacity; DT [K]dierence between ambient temperature and melting point of high-alloy austenitic stainless steel. Thermal capacity of the high-alloy stainless steel was calculated by means of a diagram showing cp as a function of the temperature taken from Ref. [10]. The melting point of the austenitic stainless steel was 14508C. The dependence of cp [J/gK] from a temperature T (014508C) can be described by a polynominal of third degree (Eq. 3): cp T 3 109 T 3 5 105 T 2 0:1897T 506:5 3

The mean specic heat of the austenitic stainless steel in the interval (0, 14508C) can be calculated by means of Eq. 4: cp:sr: 1 T2 T1 T2
T1

cp T dT

Fig. 8. Macrosections of the welds made with the same current intensity but in dierent shielding mixtures and at dierent arc voltages (electrode negative). (3X) Left: I = 200 A, U = 14 V, v = 0.3 m/min, Ar; Right: I = 200 A, U = 21 V, v = 0.3 m/min, Ar+10%H2

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cp:sr:

1 1450 0

1450
0

cp T dT 4

cp:sr: 610:8 J kgK

By introducing the values obtained in Eq. 2, the energy theoretically required to heat 1 g of stainless steel to the melting temperature is obtained. This value amounts to 891 J. By considering additional energy required for the transformation from the solid to liquid state, 1160 J/g may be taken as value E in Eq. 1. The results concerning melting eciency in TIG welding as a function of hydrogen content in argon are shown in Fig. 9. With the increase of hydrogen content the melting eciency increases too. Melting eciency is higher also in case of a higher current intensity. 4.2. MIG welding Because of the exceptionally favorable results obtained in TIG welding it was decided to conduct a similar study on consumable electrode MIG welding of a high-alloy austenitic stainless steel in argon with hydrogen addition. Also in MIG welding, three dierent current intensities, i.e. 150, 200 and 250 A, and six dierent shielding media, i.e. Ar, Ar+0.5%H2, Ar+1%H2, Ar+5%H2, Ar+10%H2, Ar+20%H2, were used. The other welding parameters, i.e. welding speed, wire-extension length, gas ow, welding-current source, were held constant. A universal wire 18/8/6 with 1.2 mm in diameter was used. Studies were conducted on the eect of hydrogen in argon on the welding parameters, deposition rate, the quantity of parent metal melted, and the melting eciency of MIG welding. Fig. 10 shows the inuence of

Fig. 10. Eect of hydrogen in argon on the quantity of parent metal and ller material melted in MIG welding of austenitic stainless steel (wire f=1.2 mm, vw=0.3 m/min, Lw=16 mm, electrode positive).

hydrogen in argon on the quantity of the parent metal and ller material melted. It can be stated again that with the increase in hydrogen content in the argon shielding gas the quantity of the material melted increases, but in comparison to that in TIG welding, it is much lower. By hydrogen addition to argon also in MIG welding resistance in the arc increases and, consequently current intensity decreases. Owing to melting of the ller material passing through the arc, metal ions are also carriers of electric current. A shielding gas in the arc burning in MIG welding is of lesser importance than in the arc burning in TIG welding. By hydrogen addition to argon, the quantity of the material melted increases by 1030%. It should be mentioned, however, that in spite of numerous trials an optimum quantity of hydrogen in argon, which would ensure stability of the process, has not been achieved. Investigations into the matter are to be continued. Fig. 11 shows the eect of hydrogen in argon on melting eciency in MIG welding. The melting eciency in MIG welding increases with hydrogen addition. 5. Conclusions On the basis of the experimental studies accomplished and the results obtained on the eect of hydrogen in the shielding gas on the TIG and MIG welding processes the following conclusions may be drawn:

Fig. 9. Eect of hydrogen content in argon shielding gas and of welding-current intensity on the melting eciency in TIG welding (electrode negative)

. hydrogen addition to the argon shielding gas changes the static characteristic of the welding arc; . hydrogen addition to the argon shielding gas

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same statement, however, can not be made about MIG welding. In gas-shielded welding of stainless steel in the hydrogen-argon mixture with a consumable electrode it is namely very dicult to achieve a stable process. Investigations in this eld will continue.

References
[1] Lancaster JF, editor. The physics of welding. Oxford: Pergamon Press, 1986. [2] Schellhase M. Der Schweilichtbogenein technologisches Werkzeug. Du sseldorf: Deutscher Verlag fu r Schweitechnik, 1985. [3] Bo hme D. Schutzgase - Physikalische Eigenschaften als Grundlage fu r die Entwicklung und den optimalen Einsatz von Gasen und Gasegemischen in der Schweitechnik. In: Schweitechnische Fertigungsverfahren StrahltechnikLichtbogenschweitechnik. Du sseldorf: DVS-Verlag, 1989. p. 7891 (DVS-Berichte Bd. 127). [4] Onsien M, Peters R, Olson DL, Liu S. Eect of hydrogen in an argon GTAW shielding gas: arc characteristics and bead morphology. Welding Journal 1995;74(1):10s 5s. [5] Hilton D. Shielding gases for gas metal arc welding. Welding and Metal Fabrication 1990;58(6):3334. [6] Bennett B. Gases for TIG and plasma arc welding. Welding and Metal Fabrication 1990;58(6):3356. [7] Lucas W. Shielding gases for arc weldingPart I. Welding and Metal Fabrication 1992;60(5):21825. [8] Farwer A. FormiergaseGase zum Wurzelschutz beim Schutzgasschweien. Der Praktiker 1983;35(3):815. [9] Cresswell RA. Gases and gas mixtures in MIG and TIG welding. Welding and Metal Fabrication 1972;40(4):736. [10] Richter F. Die wichtigsten physikalischen Eigenschaften von 52 Eisenwerkstoen. StahleisenSonderberichte 1973;(8):533. [11] Lowke JJ, Morrow R, Haider J, Murphy AB. Prediction of gas tungsten arc welding properties in mixtures of argon and hydrogen. IEEE Transaction on Plasma Science 1997;25(5):92530.

Fig. 11. Eect of hydrogen in the argon shielding gas on melting eciency in MIG welding of austenitic stainless steel (electrode positive).

increases resistance in the arc and arc energy; . with hydrogen addition to the argon shielding gas the quantity of the austenitic stainless steel melted in TIG welding increases even by four times; . melting eciency of TIG welding increases with the increase in current intensity and hydrogen content in argon; . with hydrogen addition to argon, the quantity of the parent metal and ller material melted in MIG welding of austenitic stainless steel increases by up to 30%; . with hydrogen addition to argon, the melting eciency of MIG welding of stainless steel increases from 30 to 50%. Finally it can be stated that in TIG welding of highalloy austenitic stainless steel in the hydrogenargon mixture a stable process and quality welds with a very clean surface may be obtained. Up to 20% of hydrogen may be added to the argon shielding gas. The