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BOC shielding gases For the serious welder Argoshield, Stainshield, Alushield, Specshield 03 05 The role of shielding gas T he two product lines Competence Line and Performance Line Frequently asked questions Shielding gas codes Shielding gas selection chart Shielding gases H ave you got the right gas working for you? The GMA arc projector Weld cost calculation
06 08 09 10 28 33 35
Argoshield, Alushield, Stainshield, Specshield, Competence Line and Performance Line are registered trademarks of BOC Limited.
02
Metal transfer
The type of metal transfer is strongly influenced by the shielding gas. The shielding gas also influences the size and forces acting on the droplets.
Arc stability
Arc stability and arc ignition are influenced by the shielding gas.
Surface appearance
The amount of spatter and surface slag is also influenced by the shielding gas.
Environment
The emission of fume and gases is influenced by the shielding gas.
Weld geometry
The profiles of the weld bead and penetration are influenced by the shielding gas
Shielding effect
Molten or heated metal is shielded from the air in a controlled shielding gas atmosphere.
Welding speed
Also the choice of shielding gas will affect the welding speed and the total welding cost
The influence of shielding gas upon GMA welding The influence of shielding gas upon GMA welding
Environment The emission of fume and gases is inuenced by the shielding gas Shielding effect Molten or heated metal is shielded from air in a controlled shielding gas atmosphere Metal transfer The type of metal transfer is strongly inuenced by the shielding gas. The shielding gas also inuences the size and forces acting on the droplets. Surface appearance The amount of spatter and surface slag is also inuenced by the shielding gas.
Metallurgy and mechanical properties The loss of alloying elements and pick-up of oxygen, nitrogen and carbon is inuenced by the shielding gas. This loss and pick-up will inuence the mechanical properties of the weld metal. Weld geometry The proles of the weld bead and penetration are inuenced by the shielding gas.
Arc stability Arc stability and arc ignition are inuenced by the shielding gas.
Welding speed Also the choice of shielding gas will affect the welding speed and the total welding cost.
03
Helium
Helium (He) is like argon an inert gas. Helium is used together with argon and a small percent of CO2 or O2 for GMA welding of stainless steel. In its pure state, or mixed with argon, it is used as a shielding gas for GTA and MIG 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 with helium as a shielding gas, however, and the arc is more difficult to strike when TIG welding.
Hydrogen
Hydrogen (H2) 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 commonly used. It is not recommended for root protection of austeniticferritic (Duplex) steels. For this application, argon or high purity nitrogen should be used.
Nitrogen
The metal transfer and penetration profile can be changed by selecting different argon-carbon dioxide mixtures. The figure shows the type of metal transfer in spray arc and typical penetration profile for mixtures with 2% CO2 up to pure CO2. higher CO2 content gives better side wall penetration but more spatter and fume. For most applications, the penetration given by a few percent of CO2 is acceptable. A spray arc cannot be achieved when using 100% CO2. Nitrogen (N2) is used as an additive in shielding gases for GTA welding of austenitic, duplex and superduplex stainless steels. These steels are alloyed with up to 0.5% nitrogen in order to increase the mechanical properties and resistance against pitting. If the shielding gas contains a few percent of nitrogen, nitrogen losses in the weld metal can be reduced. Nitrogen with 5% hydrogen is a common root protection gas that delivers a good reducing effect. Pure nitrogen will further increase pitting resistance at the root when welding austenitic duplex and superduplex stainless steels.
04
A versatile tool in the value-added process. The two product lines Competence Line and Performance Line.
In order to achieve both technically and economically high-quality weld seams, everything involved in the process material, equipment, process gas and welding technology has to do its part. This requires a new attitude towards our products. Shielding gases are much more than welding consumable commodity, they also:
Influence the arc both electrically and thermally etermine viscosity and surface tension both of the drop D and of the pool Control wetting properties Control penetration, seam geometry and seam surface eact metallurgically with filler metal and pool R Influence radiation, heat transfer and arc efficiency etermine metal transfer and energy distribution in the arc D Influence certain pollutant emissions These properties have to be optimally utilised in order to reap the full potential of gases in the welding process. Through our understanding of how this tool functions, we are able to make an active contribution towards the added value in our customers production processes Our customers continue to demand specialised solutions to keep pace with the growing requirements in the field of welding. Advances made in equipment and materials science, new measuring technologies and simulation techniques require state-of-the-art, innovative gas products. Expensive specialised materials require customised solutions sometimes even at a molecular level. Gases require the same diversification as materials and joining processes. To improve product transparency and to make selecting a product easier, we will be offering two product lines in the future. Both lines contain shielding gases for every conceivable material and process combination.
Competence Line
Proven gases and gas mixtures offering the very highest quality and supported by outstanding BOC service. This line contains our all-rounders, such as Argoshield Universal, Stainshield Light and argon, products that are indispensable to everyday welding technology and are ranked amongst some of the best-selling gas products in the world. Reliability Quality Versatility User-friendliness
Performance Line
Highly productive specialists with ad mixtures of helium, nitrogen or hydrogen. These components improve arc efficiency and enhance heat transfer from the arc to the joint, resulting in higher welding speeds. If improvements in quality alone are required, helium or hydrogen can be used without increasing the welding speed. For example, helium can be used as an additive in many robot applications to better compensate for component tolerances. The wider acting arc improves edge wetting and reduces lack of fusion problems resulting in greater output and improved quality.
A TIG arc with Argon (Competence Line) and Stainshield TIG Plus (Performance Line) as the shielding gas. Argon Argoplas 5
Are you using the right gases correctly? Frequently asked questions
Here are a few of the many thousands of questions BOC engineers are asked every year. Some of you will know the answer but for others, the answer may not be what you were expecting.
incorrect choice of shielding gas shielding gases containing hydrogen and/or nitrogen are beneficial for some materials but can cause porosity in others poorly maintained equipment if hose fittings are not tightened or if there are gas leaks in the power source or torch, air can be entrained into the shielding gas. Also some types of hose are permeable and can allow moisture to enter the shielding gas. Surface contamination oil, grease, water and other contamination on the welded component can add hydrogen into the weld metal This is not an exhaustive list but most causes of porosity are caused by poor housekeeping and/or poor welding procedures.
Why can I not use pure argon for GMA welding steels?
While it is possible to GMA-weld steels with pure argon, the arc produced is very unstable and erratic, and the resultant weld will have a lot of spatter and an unsatisfactory penetration profile. When GMA welding steels, a small amount of oxidising gas (either carbon dioxide or oxygen) is needed to help to stabilise the arc and produce sound welds.
TIG Arc
Cold cracking, properly called hydrogen cracking, occurs in welds that are intolerant of hydrogen (e.g. martensitic stainless steels). Hydrogen dissolves in the weld metal while it is molten then after solidification it diffuses to small defects in the weld and hydrogen gas forms, building up in pressure as the weld cools. Then, when the pressure is sufficiently high and the weld is cool and more brittle, this internal pressure can cause the weld to crack. This may not occur until many hours after welding.
Pulsed Arc
Code 060 065 064 068 070 071 095 066 107 075 119 092 093 094 114 079 069 133 143 144 145 077
Classification SG-ACO-5/3.1 SG-ACO-16/2.75 SG-AC-18 SG-AO-5 SG-AC-25 SG-ACO-7/1.5 SG-AHeC-25/10 SG-AC-10 SG-AC-50 SG-AO-1.5 SG-AC-2.5 SG-AHeC-35/2.8 SG-ACH-2.8/1 SG-AHeO-35/0.9 SG-AN-2 SG-AHe-27 SG-HeA-25 SG-AHe-50 SG-AH-5 SG-AH-20 SG-AH-35 SG-AO-0.7
Argoshield Heavy Argoshield 40 Argoshield 52 Argoshield 54 Argoshield 100 Argoshield MCW Argoshield Pipeline Stainshield Stainshield Light
08
Shielding gas selection chart (For GMA, flux-cored, metal-cored, solid wire welding)
MaterialThickness(mm)
112 13+
WeldCharacteristics
Penetration Spatterfree Speed Filletshape Finish
PrincipalBenefits
GMAWCarbonandLowAlloySteels ArgoshieldLight ArgoshieldUniversal ArgoshieldHeavy ArgoshieldMCW Argoshield40 Argoshield52 Argoshield54 Argoshield100 ArgoshieldPipeline IndustrialCO2 FCAWCarbon,AlloyandStainlessSteels Argoshield52 IndustrialCO2 MCAWCarbonandLowAlloySteels ArgoshieldMCW
Excellentappearance,lowslag. Goodweldappearance,superior controlinpositionalwelding. Somewiresdesignedforuseunder CO2only,highcylindercontents. Versatileforthinmaterial, Minimalspatter. Mostversatilewideworkingrange. Goodappearance Lowdefectlevelsonthickmaterial. Versatilesuitableforsolidand MetalCoredwire,upto12mm. Lowprofilebeadshape Minimalspatter,downhandwelding. Idealforfluxcoredwelding Goodpenetration. Excellentfinish,with minimalclean-up. Highweldappeal, mechanisedwelding. Goodpenetration. Goodpenetration.
Argoshield52
GMAWStainlessSteels Stainshield StainshieldLight StainshieldHeavy Stainshield66 Stainshield69 GMAWAluminiumandAlloys AlushieldLight AlushieldUniversal AlushieldHeavy WeldingArgon
Goodpenetration.
Downhandfilletwelding,thinplate. Generalpurposemixture,good wettingaction,smoothweldsurface. Versatileonthickmaterial Excellentarcstability,fast speed,goodpenetration. Minimalsurfaceoxidation for300seriesstainless. Versatileonthickmaterial Excellentarcstability,fast speed,goodpenetration.
C P
P P
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Shielding gases
Argon Welding Grade, Compressed (Ar) Gas Code 061
Gas Argon Purity >99.995% Cylinder Sizes J G2 G E2 E
NOTE:Highergradesandpurities ofthisproductareavailablefrom BOC.Specificationsareincludedin theScientificGasesandEquipment Manual.Contact1800658278to obtainacop y.
Content (m3 @ STP) 13.8 10.5 8.6 4.1 4.0 2.0 1.6 227.2 207.7 136.3 60.6
Gauge Pressure (kPa @ 15C) Outlet Connection 30,000* 30,000 16,900 20,000 15,800 20,000 15,800 30,000* 30,000* 30,000* 30,000* AS 2473 Type 10 AS 2473 Type 10
D2 D
Pack Sizes
KAY15 JAY15 KAY9 KAY4
Argon Welding Grade, Liquid (Ar) Gas Code 731 Argon, PT 700 Liquid (Ar) Gas Code 791
10
Features
Benefits
MIGweldingmildsteel Forweldingcarbonand alloysteelandstainless steelwithfluxcoredwires Shieldinggasinplasmacutting Liquidforsubstratecoolingto controltheheatbuild-upwhen thermalandplasmaspraying BOCrecommendstheuseof theArgoshieldrangeasthe preferredmildsteelMIG weldinggas Suitableforinertingapplications BalancingpHlevelsin swimmingpools Cryogenicliquidcarbon dioxidecanalsobeusedin smallpipefreezingapplications
Acolourlessandodourlessgas thatcancausethenosetosting inhighconcentration Toxicinhighconcentrations Anasphyxiant (doesnotsupportlife) Slightlycorrosiveinthe presenceofmoisture Heavierthanair,carbondioxide willcollectinducts,drainsand low-lyingareas Highlysolubleinwaterat moderatepressuresAtelevated temperatures,carbondioxide reactswithmanysubstances Diptubesareusedinliquid withdrawalcarbondioxide cylinderstoextracttheliquid fromthecylinder.Thetube runsdownthecentreofthe pressurisedcylinderanddraws theliquidupthroughthevalve. Toidentifythesecylinders,a blackstripeispainteddownthe lengthofthecylinder
Pack Sizes
MAN15 MAN9
NOTE:Highergradesandpurities ofthisproductareavailablefrom boc.Specificationsareincludedin thescientificgasesandequipment manual.Contact1800658278to obtainacop y.
>99.99%
11
Features
Benefits
Sheetmetalengineering industries Automotivecomponents manufacture Vehiclerepair Cabinets/steelfurniture manufacture Airconditioningindustries Domesticappliancemanufacture Lightgaugestoragetanks
Easytouse Lowdefectlevels Lowdistortionlevels Goodappearance andqualityfinish Increasedproductivity Minimalspatterproduction negatestheneedtocleanweld Canbeusedwithmanual, automaticandroboticmachines
Cylinder Sizes J G E2 E
Content (m3 @ STP) 14.0 8.7 4.2 4.0 230.2 138.1 61.4
Gauge Pressure (kPa @ 15C) Outlet Connection 29,700* 16,900 20,000 15,800 29,700* 29,700* 29,700* AS 2473 Type 10
Pack Sizes
KAY15 KAY9 KAY4 AS 2473 Type 10
Horizontal/ Horizontal/ Horizontal/ Horizontal/ Horizontal Vertical Vertical Vertical Vertical 0.80.9 4580 1416 3.55.0 15 350500 0.80.9 60100 1617 4.07.0 15 350500 0.80.9 80120 1618 4.07.0 15 320500 0.91.0 80150 1618 4.07.0 15 280450 0.9 160180 2325 7.59.0 15 8001000
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Features
Benefits
Generalfabrication Lighttomediumplatefabrication Structuralsteelworks Bridgework Pipeandtubejoining Vehiclemanufacture/ heavytrucks Rolledsections Pressurevesselsandboilers Boatsandshipbuilding
Lowdefectlevels Improvedweldfusion Goodweldappearancewith lowreinforcementlevels Easytouse Higherproductivitydueto fasterweldingspeeds Lowersoverallcostsby usinglesswire Lowerspatterreduces clean-uptime Canbeusedwithmanual, automaticandroboticmachines
Outlet Connection
AS 2473 Type 10
Pack Sizes
KAY 15 JAY 15 KAY 9 KAY 4 230.2 207.6 138.1 61.4 27,600* 27,600* 27,600* 27,600* AS 2473 Type 10
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Features
Benefits
Cylinder Size
G2
Outlet Connection
AS 2473 Type 10
Pack Size
MCP9 MCP15 146.7 244.5 30,000 30,000 AS 2473 Type 10 AS 2473 Type 10
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Features
Benefits
Lowdefectlevels Improvedweldfusion Goodappearanceand qualityfinish Minimalclean-uprequired Lowersoverallcostsby usinglesswire Lowerspatterreduces clean-uptime Canbeusedwithmanual, automaticandroboticmachines
Outlet Connection
AS 2473 Type 10
Pack Sizes
MCP15 237.4 30,000 AS 2473 Type 10
Cylindercolour(toAS4484):Peacockbluebody,greengreyshoulder,blackneck. NotallcylindersandpacksareavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranch on131262.Othersizedcylindersandpacksmayalsobeavailableonrequest. *Indicatesfittedwithapressureregulatingvalveoutletconnection,6,0009,000kPa.
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Features
Benefits
Weldinglightersteel
Composition 5% Balance
Cylinder Sizes G E
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 15,800 30,000* 30,000* 30,000* AS 2473 Type 10 AS 2473 Type 10
Pack Sizes
KAY15 KAY9 KAY4
16
Features
Benefits
Highheatinputefficiency Deeppenetration FasterweldspeedsthanCO2 Preventsporosity Excellentdiptransfer characteristics Usedindipandpulsed transfermodes ApprovedwithmostFCAW andMCAWwires
Cylinder Sizes G E
Gauge Pressure (kPa @ 15C) Outlet Connection 16,000 15,000 26,000* 26,000* 26,000* 16,000 AS 2473 Type 10 AS 2473 Type 10
Pack Sizes
KAY15 KAY9 KAY4 CRA9
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Feature
Benefits
Reducedspatter
Excellentfinish Minimalclean-uprequired
Cylinder Sizes G E2 D2 D
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 20,000 20,000 15,800 29,500* AS 2473 Type 10 AS 2473 Type 10
Pack Sizes
KAY15
Cylindercolour(toAS4484):Peacockbluebody,greengreyshoulder,blackneck. NotallcylindersandpacksareavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranch on131262.Othersizedcylindersandpacksmayalsobeavailableonrequest. *Indicatesfittedwithapressureregulatingvalveoutletconnection,6,0009,000kPa.
Horizontal/ Horizontal/ Horizontal/ Horizontal/ Horizontal Vertical Vertical Vertical Vertical 0.80.9 4580 1416 3.55.0 15 350500 0.80.9 60100 1617 4.07.0 15 350500 0.80.9 80120 1618 4.07.0 15 320500 0.91.0 80150 1618 4.07.0 15 280450 0.9 160180 2325 7.59.0 15 8001000
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Features
Benefits
Cylinder Sizes G E D
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 16,000 16,000 16,9000 AS 2473 Type 10 AS 2473 Type 10
Pack Sizes
MAN9
Cylindercolour(toAS4484):Peacockbluebody,brownshoulder,greengreyneck. NotallcylindersareavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranch on131262.Othersizedcylindersmayalsobeavailableonrequest.
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Features
Benefits
Carbonsteelpipe Heavywallpipe
Deeppenetration Lowerriskofdefectlevels
Gauge Pressure (kPa @ 15C) Outlet Connection 13,700 13,700 13,700 AS2473 Type 10
COP16areavailableinlimitedlocations.ContactyourlocalBOCGas&GearstoreorAccount Managerforfurtherdetails..
20
Features
Benefits
Cylinder Sizes G E
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 15,800 AS 2473 Type 10
21
Features
Benefits
Gauge Pressure (kPa @ 15C) Outlet Connection 20,000 30,000 AS 2473 Type 10
22
Features
Benefits
Lowdefectlevelsonthicker sectionsofmaterial Clean,brightappearanceandfinish Easytouse Highproductivitydueto fasterweldingspeeds Reducedclean-upandrepair X-rayqualitywelds Canbeusedonrobotic andmechanicalmachines
Cylinder Size G
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 16,900 AS 2473 Type 10 AS 2473 Type 10
Pack Size
MAN9
Cylindercolour(toAS4484):Peacockbluebody,brownshoulder,greengreyneck. NotallcylindersandpacksareavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranch on131262.
23
Features
Benefits
Composition 2% Balance
Gauge Pressure (kPa @ 15C) Outlet Connection 20,000 30,000 30,000 AS2473 Type 10
24
Features
Benefits
Cylinder Size G
Features
Benefits
Weldingstainlesssteels Allpositionalwelding
Cylinder Size G
25
Features
Benefits
Excellentarcstability Highheatinputefficiency Lowdistortion Flatterweldbeadwith lowreinforcement Fasterweldingspeed Goodfusioncharacteristics Littleornospatter Usedindip,sprayand pulsedtransfermodes
26
Features
Benefits
Cylinder Size G2
27
Argon
Alushield Light
280 A / 25 V
282 A / 27 V
Alushield Light is 27% Helium with a balance of Argon
Alushield Universal
Alushield Heavy
285 A / 30 V
Alushield Universal is 50% Helium with a balance of Argon Parent metal Filler metal Wire feed speed Welding speed EN AW-5754 [AlMg3] ISO 18273 S Al 5183 (Al Mg4.5Mn) 9.7 m/min 62 cm/min
285 A / 34 V
Alushield Heavy is 25% Argon with a balance of Helium t = 10 mm = 1.6 mm
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Features
Benefits
Lowerspatterreduces clean-uptime Improvedweldmetalproperties Easytouse Reducedrejectrates Lowerriskofdefectlevels Goodappearanceandhigh qualityfinishwithlow reinforcementlevels Increasedproductivitydue tofastweldspeeds Canbeusedonroboticmachines
Cylinder Size G
29
Features
Benefits
Composition 5% Balance
Cylinder Size G
Cylindercolour(toAS4484):Peacockbluebody,signalredshoulderandneck. NotavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranchon131262.
30
Weldinggas:Argoplas5 Weldingspeed:55cm/min,mechanisedwelding Parentmaterial:304,t=4mm Fillermetal:308LSi HydrogenandheliumcanacceleratetheTIGweldingprocess duetotheirphysicalproperties.Betterthermalconductivity improvespenetrationandwettingability.Comparedtohelium, hydrogenprovidesanevenmoreeffectiveheatinputbecause ofitsmolecularnature.Beyondthis,ahydrogenadditionto theshieldinggasleadstocleanerweldsurfacesasaresult ofitsreducingaction.Heliumasashieldinggascomponent isthebetterchoicewherehydrogencannotbeuseddueto incompatibilitywiththebaseorfillermetal. rgoplasserieswith5to35%H2forallausteniticstainless A steelgrades Argoplas5is5%H2withabalanceofArgon
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Features
Benefits
Cylinder Size G
Gauge Pressure (kPa @ 15C) Outlet Connection 16,900 16,900 AS 2473 Type 10 AS 2473 Type 10
Pack Size
MAN15
Cylindercolour(toAS4484):Peacockbluebody,blackshoulderandneck. NotallcylindersandpacksareavailableatallBOCoutlets.PleasecheckwithyourlocalBOCbranch on131262.
Operator Panel
Gas 2 (xed)
Gas 3 (xed)
Gas 4 (xed)
Start
Stop
6mm Fillet
Thisreducedproductioncostcanvary,dependingonfactorsspecifictoyourindividualbusinessoperations.
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Sketch:
General Data
1 2 3 4 Typeofseam Weldingposition Platethickness Throat/LegLength mm mm Fillet 7A 7B 8 9 10 5 6 Wirediametermm Wirespec. Weightg/m Steel Alu. Labourcosts Labourcosts Wirecosts Gas1 Gas2 0.8 3.95 1.36 1.0 6.2 2.12 1.2 8.9 3.05 $/h $/min $/kg $/m3 $/m3 1.6 15.8 5.43
Gas 1
V M/min l/min
Gas 2
V M/min i/min
Mm min Min
mm min min
Consumables
18 19 Wireelectrode Shieldinggas (12x16x6) (13x16) G L g l
Costs
20 21 22 23 Labourcosts(th) Labourcosts(th) Wireelectrodecosts Gascosts (7Bx16) (7Bx17) (18x8/1000) (9or10x19/1000) $ $ $ $ $ $ $ $
$ $
$ $
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For more information contact the BOC Customer Service Centre on: Australia
131 262
contact@boc.com www.boc.com.au
BOC Limited
ABN 95 000 029 729
Riverside Corporate Park 10 Julius Avenue North Ryde, NSW 2113 Australia
BOC is a trading name of BOC Limited, a member of The Linde Group. BOC Limited 2011. Reproduction without permission is strictly prohibited. Details given in this document are believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.
MP10-0311
EQAUS 0111 5k