Shielding Gases

Introduction
Air in the weld zone is displaced by a shielding gas in order to prevent contamination of the molten weld
puddle. This contamination is caused mainly by nitrogen, oxygen and water vapor present in the
atmosphere.
As an example, nitrogen in solidified steel reduces the ductility and impact strength of the weld and can
cause cracking. In large amounts, nitrogen can also cause weld porosity.
Excess oxygen in steel combines with carbon to form carbon monoxide (CO). This gas can be trapped in the
metal, causing porosity. In addition, excess oxygen can combine with other elements in steel and form compounds that produce inclusions in the weld metal.
When hydrogen, present in water vapor and oil, combines with either iron or aluminum, porosity will result
and underbead weld metal cracking may occur.
To avoid these problems associated with contamination of the weld puddle, three main gases are used for
shielding. These are argon, helium and carbon dioxide. In addition, small amounts of oxygen, nitrogen and
hydrogen have proven beneficial for some applications. Of these gases, only argon and helium are inert
gases. Compensation for the oxidizing tendencies of other gases is made by special wire electrode
formulations.
Argon, helium and carbon dioxide can be used alone, in combinations or mixed with others to provide defect
free welds in a variety of weld applications and weld processes.

Properties of Gases
The basic properties of shielding gases that affect the performance of the welding process include:
1) Thermal properties at elevated temperatures.
2) Chemical reaction of the gas with the various elements in the base plate and welding wire.
3) Effect of each gas on the mode of metal transfer.
The thermal conductivity of the gas at arc temperatures influences the arc voltage as well as the thermal
energy delivered to the weld. As thermal conductivity increases, greater welding voltage is necessary to
sustain the arc. For example, the thermal conductivity of helium and CO2 is much higher than that of argon;
because of this, they deliver more heat to the weld. Therefore, helium and CO2 require more welding voltage
and power to maintain a stable arc.
The compatibility of each gas with the wire and base metal determines the suitability of the various gas
combinations. Carbon dioxide and most oxygen bearing shielding gases should not be used for welding
aluminum, as aluminum oxide will form. However, CO2 and 02 are useful at times and even essential when
GMAW welding steels. They promote arc stability and good fusion between the weld puddle and base
material. Oxygen is a great deal more oxidizing tham CO2. Consequently, oxygen additions to argon are
generally less than 12 percent by volume whereas 100 percent CO, can be used for GMAW mild steels.
Steel wires must contain strong deoxidizing elements to supress porosity when used with oxidizing gases,
particularly mixtures with high percentages of CO2 or 02 and especially 100 percent CO2.
Shielding gases also determine the mode of metal transfer and the depth to which the workpiece is melted
(depth of penetration). Tables (4-1 and 4-2) summarize recommended shielding gases for various materials
and metal transfer types. Spray transfer is not obtained when the gas is rich in CO2. For example, mixtures
containing more than about 20 percent CO2 do not exhibit true spray transfer. Rather, mixtures up to 30
percent CO2 can have a spray-like shape to the arc at high current level but are unable to maintain the arc
stability of lower CO2 mixtures. Spatter levels will also tend to increase when mixtures are rich in CO2.

Binary (2) Shielding Gas Mixtures

Argon-Oxygen
The addition of srnall amounts of 02 to argon greatly stabilizes the weld arc, increases the filler metal droplet
rate, lowers the spray arc transition current, and improves wetting and bead shape. The weld puddle is more
fluid and stays molten longer allowing the metal to flow out towards the toe of the weld. This reduces
undercutting and helps flatten the weld bead. Occasionally, small oxygen additions are used on non- ferrous
applications. For example, its been reported by NASA that .1% oxygen has been useful for arc stabilization
when welding very clean aluminum plate.

Argon-1% O2 This mixture is primarily used for spray transfer on stainless steels. One percent oxygen is
usually sufficient to stabilize the arc, improve the droplet rate, provide coalescence and improve
appearance.

Argon-2% O2 This mixture is used for spray arc welding on carbon steels, low alloy steels and stainless
steels. It provides additional wetting action over the 1% 02 mixture. Mechanical properties and corrosion
resistance of welds made in the 1 and 2% 02 additions are equivalent.

Argon-5% O2 This mixture provides a more fluid but controllable weld pool. It is the most commonly used
argon-oxygen mixture for general carbon steel welding. The additional oxygen also permits higher travel
speeds.

Ternary (3) Shielding Gas Mixtures

Argon-Oxygen-Carbon Dioxide
Mixtures containing these three components have been termed universal mixtures due to their ability to
operate using short circuiting, globular, spray, pulse and high density type transfer characteristics. Several
triple-mixes are available and their application w ill depend on the desired metal transfer mechanism and
optimization of the arc characteristics.

Argon-5-10% CO2 - 1-3% 02 This ternary mixture range has gained popularity in the U.S. over the last
several years. The chief advantage is its versatility to w eld carbon steel, low alloy steel and stainless steel of
all thicknesses utilizing w hatever metal transfer type applicable. Stainless steel w elding should be limited to
spray arc only due to the stiffness of the puddle at low current levels. Carbon pick-up on stainless steel
should also be considered in some instances. On carbon and low alloy steels, this mixtures produces good
w elding characteristics and mechanical properties. On thin gauge materials, the 02 constituent assists the
arc stability at very low current levels (30 to 60 amps) permitting the arc to be kept short and controllable.
This helps minimize burnthrough and distortion by low ering the total heat input into the w eld zone.

Argon - 10-20% CO2 - 5% 02 This mixture is not common in the U.S. but has found applications in Europe.
The mix produces a hot short circuiting transfer and fluid puddle characteristics. Spray arc transfer is good
and seems to have some benefit w hen w elding w ith triple deoxidized w ires since a sluggish puddle is
characteristic of these w ires.

Argon-Carbon Dioxide-Hydrogen
Small additions of hydrogen (1-2%) have been show n to improve bead w etting and arc stability w hen Pulse
Mig w elding stainless steel. The CO2 is also kept low (1-3%) to minimize carbon pick-up and maintain good
arc stability. This mixture is not recommended on low alloy steels in the excessive w eld metal hydrogen
levels could develop causing w eld cracking and poor mechanical properties.

Quaternary (4) Shielding Gas Mixtures

Argon-Helium - Co2- O2

Commonly known as a quad mix, this combination is most popular for high deposition GMAW using the
high density metal transfer type arc characteristic. This mixture will give good mechanical properties and
operability throughout a wide range of deposition rates. Its major application is welding low alloy high tensile
base materials but has been used on mild steel for high productivity welding. Weld economics are an
important consideration in using this gas for mild steel welding, in that other less expensive mixtures are
available for high deposition welding.
Regardless of the type of welding that need to be done, there is a shielding gas that will best suit the
requirements. Tables 4-1 and 4-2 summarize which shielding gas is best suited for welding a variety of
materials using both the short arc and spray arc process.

Table 4-1 Mig Shielding Gas Selection Chart-Short Arc Welding

ARGONARGON
HELIUM
METAL
ALUMINUM

ARGON

HELIUM

MIXTURES

ARGON-

HELIUM

CO2

C0 2

MIXTURES

MIXTURES

AR-O2-CO2

CO2

(1)

(C-25) OR

STARGON

(HE-75)
CARBON
STEEL

(C-50) OR
(C-8) (4)
(C-15)

HIGH
STRENGTH
STEELS

STARGON

(A-415)

UP TO

OVER 14 GA.

14 GA.

COPPER

(HE-75)

STAINLESS
STEELS
NICKEL

(C-25) (1)

ALLOY

(A-1025)

(HE-75)
(HE-75)

(1) WIRE DESIGNED FOR CO2 REQD.

(A-1025)

OR

METALS

(90% HE10% AR)

REACTIVE

STARGON

TABLE 5-1
Mild Steel and Low Alloy Steel Wires Chemical
Composition Requirements (Percent, Balance
Iron)

TABLE 5-2
Mild Steel and Low Alloy Steel Wire Mechanical
Property Reguirements

TABLE 5-3
Stainless Steel Wire Electrodes Chemical
Composi- tion Requirements (Percent, Balance
Iron)

TABLE 5-4
Aluminum Wires Chemical Composition
Requirements (Percent, Balance Aluminum)

TABLE 5-5
Guide to Choice of Filler Metal for General
Purpose Aluminum Welding

TABLE 5-6
Copper Wires Chemical Composition
Reguirements (Percent, Balance, Copper)

TABLE 5-7
Copper and Copper Base Wire Tensile Strength
Reguirements

TABLE 8-1
Welding Conditions Mild Steel Short Arc ER70S-3
(Spoolarc 82)

TABLE 8-2
Welding Conditions Mild Steel Spray Arc ER70S-3
(Spoolarc 82)

TABLE 8-3
Welding Conditions Stainless Steel

TABLE 8-4
Welding Conditions Aluminum Spray Arc Process
5356 Wire Electrode Argon Shie/ding Gas

TABLE 8-5
Welding Conditions Cooper 8 Silicon Bronze

Table 5-1 Mild Steel and Low Alloy Steel Wires Chemical Composition Requirements* (Percent Balance Iron)
SPOOLARC
AWS
CLASS
ER70S-2

DESIGNATION

CARBON

MANG.

SILICON

SULFUR

PHOS.

MOLYB.

OTHER

65

0.07

0.90-1.40

0.40-0.70

0.035

0.025

--

0.05-0.15 Ti
0.02-0.12 Zr
0.05-0.15 AI

ER70S-3

29S or 82

0.06-0.15

0.90-1.40

0.45-0.75

0.035

0.025

--

ER70S-4

85

0.07-0.15

1.00-1.50

0.65-0.85

0.035

0.025

--

ER70S-5

--

0.07-0.19

0.90-1.40

0.30-0.60

0.035

0.025

--

ER70S-6

86

0.07-0.15

1.40-1.8

0.80-1. I 5

0.035

0.025

--

ER70S-7

87HP

0.07-0.15

1.50-2.00

0.50-0.80

0.035

0.025

--

83 or Hi84

0.07-0.12

1.60-2.10

0.50-0.80

0.035

0.025

0.40-0.60

ERSOS-D2
ER70S-G

--

NOT SPECIFIED *

*Requirements are those agreed to by the purchaser and supplier.

0.50-0.90 AI

Table 5-2 Mild Steel and Low Alloy Steel Wires Mechanical Property Requirements*
YIELD
STRENGTH

SPOOLARC
AWS CLASS

ER70S-2

DESIG-

SHIELDING

CURRENT &

TENSILE

NATION

GAS

POLARITY

STRENGTH

OFFSET

MIN. PSI

MIN. PSI

(MPa)

(MPa)

70,000

58,000

DCEP

(480)

(480)

DCEP

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

70,000

58,000

(480)

(480)

65

Al 1.5% O2

CO2
ER70S-3

82

Ar 1.5% O2

CO2
ER70S-4

85

ER70S-5

ER70S-6

ER70S-7

ER80S-D2

CO2

86

87HP

83 or Hi84

ER70S-G

1 Ar-CO

CO2

CO2

CO2

CO2

DCEP

DCEP

DCEP

DCEP

DCEP

NOT SPEC.

NOT SPEC.

can be used for all wires.

*AWS A5.18-69

@ 0.2% ELONG. IN

MINIMUM V

2 MIN.%

NOTCH IMPACT

22

20 ft.-lbs. @-20 0F
(27J @-29 0C)

22

20 ft.-lbs. @O0F
(27J @-18 0C)

22

NOT REQUIRED

22

NOT REQUIRED

22

20 ft.-lbs. @-20 0F
(27J @-29 0C)

22

20 ft.-lbs. @-20 0F
(27J @-29 0C)

17

20 ft.-lbs. @-20 0F
(27J @-29 0C)

22

NOT REQUIRED

Table 5-3 Stainless Steel Wire Electrodes Chemical Composition Requirements* (Percent, Balance Iron)
ESAB
AWS

DESIG-

CLASS

NATION

CARBON

CHROM.

COLU. +

MANGA-

TANT.

NESE

SILICON

PHOS.

SULF.

ER308

308

0.08

19.5-22.0

ER308L

308L

0.03

19.5-22.0

9.0-11.0

1.0-2.5

0.25-0.60

0.03

0.03

9.0-1 1.0

1.0-2.5

0.25-0.60

0.03

0.03

ER309

309

0.12

23.0-25.0

ER330

310

0.08-0.15

25.0-28.0

12.0-14.0

1.0-2.5

0.25-0.60

0.03

0.03

20.0-22.5

1.0-2.5

0.25-0.60

0.03

ER312

312

0.15

28.0-32.0

0.03

8.0-3 0.5

1.0-2.5

0.25-0.60

0.03

ER316
ER316L

316
316L

0.08
0.03

0.03

18.0-20.0 11.0-14.0 2.0-3.0

1 8.0-20.0 11.0-3 4.0 2.0-3.0

1.0-2.5
1.0-2.5

0.25-0.60
0.25-0.60

0.03
0.03

0.03
0.03

ER317

0.08

1 8.5-20.5

1.0-2.5

0.25-0.60

0.03

0.03

ER318

0.08

ER320

0.07
0.08

ER347

*AWS A5.9

347

NICKEL

MOLYB.

13.0-15.0

3.0-4.0

18.0-20.0

11.0-14.0

2.0-3.0

8XC-1.0

1.0-2.5

0.25-0.60

0.03

0.03

19.0-21.0

32.0-36.0

2.0-3.0

8XC-1.0

2.5

0.6

0.04

0.03

19.0-21.5

9.0-1 1.0

10XC-1.0

1.0-2.5

0.25-0.60

0.03

0.03

Table 5-4 Aluminum Wires Chemical Composition Requirements* ( Percent, Balance Iron)
ESAB
AWS
CLASS

DESIGNATION

IRON&
MAGN. SILICON

ER1100

1100 HQ(1)

--

ER1260

--

ER2319

IRON

SILICON

COPPER

MANG.

CHROM.

ZINC

NICK.

TITAN.

1.0

--

--

0.05-0.20

0.05

--

0.10

--

--

--

0.40

--

--

0.04

0.01

--

--

--

--

--

0.02

--

0.30

0.20

5.8-6.8

0.20-0.40

--

0.10

--

0.10-0.20

ER4145

--

0.15

--

0.80

9.3-10.7

3.3-4.7

0.15

0.15

0.20

--

--

ER4043

4043 HQ (1)

0.05

--

0.80

4.5-6.0

0.30

0.05

--

0.10

--

0.20

ER4047

--

0.10

--

0.80

11.0-13.0

0.30

0.15

--

0.20

--

--

ER5039

--

3.3-4.3

--

0.40

0.10

0.03

0.30-0.50

0.10-0.20

2.4-3.2

--

0.10

ER5554

5554 HQ (1) 2.4--3.0

0.40

--

--

0.10

0.50-1.0

0.05-0.20

0.25

--

0.05-0.20

ER5654

5654 HQ (1)

3.1-3.9

0.45

--

--

0.05

0.01

0.15-0.35

0.20

--

0.05-0.15

ER5356

5356 HQ (1)

4.5-5.5

0.50

--

--

0.10

0.05-0.20

0.05-0.20

0.10

--

0.06-0.20

ER5556

5556 HQ (1)

4.7-5.5

0.40

--

--

0.10

0.50-1.0

0.05-0.20

0.25

--

0.05-0.20

ER5183

5183 HQ (1)

4.3-5.2

--

0.40

0.40

0.10

0.50-1.0

0.05-0.25

0.25

--

0.15

R-CN4A

--

0.03

--

1.0

1.5

4.0-5.0

0.35

--

0.35

--

0.25

R-CN42A

--

1.2-1.8

--

1.0

0.70

3.5-4.5

0.35

0.25

0.35

1.7-2.3

0.25

R-SC51A

--

0.40-0.60

--

0.80

4.5-5.5

1.0-1.5

0.5

0.25

0.35

--

0.25

R-SG70A

--

0.20-0.40

--

0.60

6.5-7.5

0.25

0.35

--

0.35

--

0.25

*AWS A5. 10-69

(1) HQ is ESABs designation for shav ed w ire.