Welding International

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Arc welding in shielding gases with alternate

pulsed supply of dissimilar gases

R. G. Tazetdinov , O. M. Novikov , A. S. Persidskii , B. A. Khasyanov , E. N.

Ivanov & L. T. Plaksina

To cite this article: R. G. Tazetdinov , O. M. Novikov , A. S. Persidskii , B. A. Khasyanov , E. N.

Ivanov & L. T. Plaksina (2013) Arc welding in shielding gases with alternate pulsed supply of
dissimilar gases, Welding International, 27:4, 311-314, DOI: 10.1080/09507116.2012.715912

To link to this article: https://doi.org/10.1080/09507116.2012.715912

Published online: 03 Oct 2012.

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Welding International, 2013
Vol. 27, No. 4, 311–314, http://dx.doi.org/10.1080/09507116.2012.715912
Selected from Svarochnoe Proizvodstvo 2012 65(1) 38 – 42

Arc welding in shielding gases with alternate pulsed supply of dissimilar gases
R.G. Tazetdinova, O.M. Novikova, A.S. Persidskiia, B.A. Khasyanova, E.N. Ivanova and L.T. Plaksinab
a
Moscow Aviation Institute, State Technical University, Moscow, Russia; bUral’sk Polytechnical University, Uralsk, Russia

A new process of arc welding in shielding gases with alternate pulsed supply of dissimilar gases – helium and argon, and
also the welding technology based on the process are described. It is shown that as a result of combining the advantages of
argon-arc and helium-arc welding in the new process it is possible to increase the strength properties, precision and leak
tightness of the welded joints, to ensure absence of defects and to reduce the volume of welding operations. Various physical
effects, accompanying the process, are discussed. These processes accompany the process and produce the weld metal with
the equiaxed fine-grained structure.
Keywords: welding; shielding gas; argon; helium; technology; technological process; arc column; pulse; complete fusion;
plasma

The need for removing defects, formed in welded joints in
aluminium, creep-resisting alloys and high-strength steels
with low weldability, requires additional measures and
means to be taken in welding technology. In most cases,
the defects described in Table 1 are removed by repair
welding.
To prevent the formation of defects, investigations have
been carried out to develop various welding technologies,
methods of preparation of the weld edges and a large
number of types of electrode and filler wire [1 –3].
However, none of these measures fully prevents the
formation of these defects.
Argon-arc welding (AAW) is at present one of the most
widely used method of welding of important structures.
As a result of the relatively low ionization potential
and low thermal conductivity of argon (Table 2), the arc
is characterized by high stability so that it can be used
for welding materials of small thickness at high current
densities [4]. However, AAW has a shortcoming: the
penetrating capacity of the arc is lower, and the molten
metal of the weld pool is characterized by low mobility [5].
For example, the experimental results with the deposition
of X-ray contrast powder based on tungsten carbide on the
weld edges show that in the welded joint the powder is
distributed mostly in the centre of the joint in the vicinity of
the surface, and not through the entire depth of the melt.
Helium-arc welding (HAW) has a significant advan-
tage in comparison with AAW – high penetrating capacity
of the arc, determined by the higher ionization potential
and excitation of the helium atoms (Table 2). The strength
of the field in the arc column in helium is higher than
in argon. For example, at an arc current of 10 A in helium
E ¼ 0.3 V/m and in argon 0.08 V/m. Correspondingly, at
the same current the energy density in the arc column in
helium is approximately 3.75 times higher than of the arc in
argon. Therefore, the temperature in the arc column is [3]
T col ø 800U e ;
where Ue is the effective ionization potential whose value
in the pure gases is accepted to be equal to Ui. For helium,
Ui is approximately 1.5 times higher than for argon.
q 2013 Taylor & Francis
Consequently, both the degree of ionization (excitation)
and, consequently, the energy and the concentration of the
electrons, ensuring the penetration of the material in the
straight polarity arc, are higher in the helium arc than in
the argon arc.
A shortcoming of HAW is the low stability of the arc
(especially in welding metals of small thickness) and the
susceptibility to undercutting, which is also determined
by the properties of helium, including its high thermal
diffusivity and other properties of the arc in helium.
In this study, investigations were carried out into a new
technological process of welding in shielding gases with
alternate supply of argon and helium into the arc gap [6].
This method combines the advantages of AAW and
HAW and, at the same time, greatly reduces the negative
consequences of the shortcomings of these processes. The
ultimate pulsation of the flows of argon and helium in a
wide frequency and consumption range is produced using
a specially developed device1.
The results of investigations of the new process and
evaluation of its efficiency for certain alloys show that the
helium pulse in the investigated processes ensures deep
penetration of the welded joint, and the argon pulse is used
for stabilizing the arc and near-surface heat treatment of
the joint.
However, the effect of the alternate pulses of different
gases on the quality of the welded joint is not limited
to this effect. There are also other physical effects,
showing that the new technological process is not a formal
combination of these two processes. Some of the effects
are described in this study.
Figure 1 shows the oscillograms of current Ia and arc
voltage Ua with the alternating supply of argon and helium
in TIG welding with straight polarity direct current. It may
be seen that the voltage in the helium pulse is 36 –39%
higher than Ua in the argon pulse. This is caused by the
differences in the ionization parameters of these gases.
The oscillations of welding current Ia with the industrial
frequency of 50 Hz are associated with the rectification
system of the power source and have no relationship with
the special features of the described process. However, the
312 R.G. Tazetdinov et al.

Table 1. The length of the pool can be calculated from the

equation [7]
Brief characterization of the effect of
the defects on the strength and
Defect leaktightness of the welded joint
L ¼ pU a I a ;

Undercutting in parent Formation of stress concentration at where p is the coefficient also determined by experiments;
metal alongside the loading of the joint may result in for example, for welding with the open arc with a coated
welded joint failure of the joint
electrode p ¼ (1.7 –2.3) £ 1026 m/(VA).
Pores in the welded Disruption of leaktightness and also a
joint reduction in the mechanical properties The relationship between tHe and tAr is also determined
Oxide and tungsten Reduction in integrity and of the by experiments using the condition of ensuring the high
inclusions mechanical properties quality of the welded joint. For TIG welding, k < 0.75.
Reduced strength of Reduction in the cross-section and The total pressure in the arc column is equal to the sum
the welded joint strength of the welded joint
of the static and dynamic pressures. Static pressure is
Very large convex part Increased internal stresses
of the welded joint determined mainly by the current intensity in the arc [8]
which is approximately constant in the period of the pulses
of both gases. However, dynamic pressure, for Ar and He
Table 2. may differ as a result of different densities of the gases.
In fact, the dynamic pressure of the gas at the outlet of
Parameter Helium Argon the nozzle is
Ionization potential (V) 24.5 15.7
Excitation potential (V) 19.3 11.6 rv 2
pd ¼ ;
Heat conductivity at normal conditions 141.5 16.2 2
(mW/(m K))
Viscosity at normal conditions (Pa s) 0.189 0.221 where v is the rate of discharge of the gas from the nozzle.
Density at normal conditions (kg/m3) 0.178 1.784 In turn,

G
peaks of increase in Ia when argon is replaced by helium v¼ ;
S
are determined by marked changes in the ionization
potential of the gas in the inter-electrode gap and by the where G is the consumption of the gas; S is the free cross
appropriate short-term ‘jumps’ in the degree of ionization section of the nozzle.
of the gas. Consequently
The pulsation period, equal to the sum of the periods of
helium tHe and argon tAr pulses, should correspond to the rG 2
pd ¼ :
holding time of the liquid metal in the weld pool tl: 2S 2

tHe þ tAr ¼ ktl ; For the same flow rate of the gas in both pulses of
2.3 £ 1024 m2/s (approximately 14 l/min), the nozzle
where k is the coefficient determined in the experiments. diameter (external 16 mm, internal 3 mm), the dynamic
For TIG welding in shielding gases with a pulsed arc pressure of argon is approximately 24 times higher than
k ¼ 1.4. that for helium. It may be assumed that the same ratio for
In turn, the dynamic pressure is also found in the arc column,
whereas the absolute values of the dynamic pressure will
L
tl ¼ ; be many times higher in comparison with the outlet of the
vw nozzle because of the powerful thermal effect on the flow
where L is the length of the pool; vw is the welding speed. in the arc. Correspondingly, the force effect of the argon
arc at deceleration of the arc on the surface of the pool is
tens of times higher than that of the helium arc. Thus, the
114 solidifying metal on the side of the argon pulse is subjected
110 to the effect of vapours alternating at a specific frequency.
106 The effect of the vapours is similar to the effect of
Ia, A

102 vibrations or ultrasound used in welding, but the effect of

98 the vapours is considerably more powerful and more
94 localized than the latter. This force effect, which may be
referred to as the ‘anvil’ effect, evidently extends to the
entire depth of the pool and cannot have any effect on
Ua, V

14
10 the structure of the weld metal. The effect results in
Argon Helium
6 disintegration of the growing columnar dendrites charac-
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 τ, s
terized by very low strength in the growth process.
Figure 1. Oscillograms of current and arc voltage in welding Correspondingly, the number of additional solidification
with alternate supply of argon and helium. centres rapidly increases, the weld metal forms with the
 Welding International
equiaxed fine-grained structure characterized by high
plasticity and strength.
The mechanical oscillations of the pool also support
rising of the gas bubbles in the pool. Evidently, this effect,
which is identical to the one described previously, can
also be obtained at a different combination of different
shielding gases, for example, Ar and CO2, and also at a
variable consumption of the same gas.
This effect has been confirmed many times in
experiments in welding components for aviation technol-
ogy. In particular, metallographic studies of the macro-
structure of the welded joints in aluminium alloys, alloyed
with lithium or scandium, show that in welding without
pulsations the surface of the welded joint contains
elongated columns of the dendrites along the weld axis.
The length of the dendrites is equal to half the width of the
welded joint. Welding with pulsations of Ar and He
prevents the formation of this unfavourable structure – a
fine-grained equiaxed structure forms along the welded
joint.
Another important special feature of the arc with
alternate of supply of different gases is the presence of
transition processes when the gas type is changed
(Figure 1). A sharp increase in current when helium is
replaced by argon results in additional constriction of the
arc column and the static pressure in the arc increases
for a short period of time. The reversed effect – short-
term reduction in static pressure – is observed when
argon is replaced by helium. This also results in a positive
effect.
The combination of the pulses of dissimilar gases is
also other additional advantages in comparison with using
each gas separately: helium easily penetrates between
the weld edges, protects also the reverse side of the
joint; helium also prevents the formation of lack of fusion
defects, ensures efficient penetration of the joints and
melting of the edges with straight flow of the melt without
sagging; the geometry of the welded joint with the ratio of
the depth of penetration to the width, close to unity, is
produced.
The argon pulse melts the weld metal in the solidifying
phase and support rising of the gas bubbles, smoothing
of the excess metal and filling of undercutting and
depressions, healing of microcracks in the welded joints
containing hot solidification cracks, and prevents the
propagation of the latter, and also prevents cold cracking
by equalization of the temperature throughout the entire
volume of the welded joint.
The efficient qualitative and quantitative determi-
nation of the relationship between the dynamic structures
of the arc with the alternate supply of dissimilar gases on
the properties of the resultant welded joints requires
further investigations. However, even this brief analysis
and the experimental results show that the new
technological process, and also the welding technology
developed on the basis of this process, has considerable
advantages in comparison with traditional technologies.
Figure 2 shows the cross sections of the welded joints
produced by traditional AAW and by the new process. The
large increase in the penetrating capacity of the arc in
313
(a)
70 A 80 A 90 A
100 A 110 A
(b)
70 A 80 A
90 A 100 A
Figure 2. Cross sections of single-pass welded joints: (a)
traditional technologies of arc welding in argon without pulsations;
(b) arc welding with pulsed supply of argon and helium, steel
KVK-26, d ¼ 3.0 mm kg/m3.
welding with the pulsation of the flows of dissimilar gases
is clearly visible.
The results of a large number of experimental studies
of welding of components of aluminium alloys and steels
of different grades, including creep-resisting alloys of the
KVK-26 type, using the new process show that the quality
of the welded joints is greatly improved:
. the residual amount of defects in the form of cracks,
lack of fusion defects, undercutting and non-metallic
inclusions does not exceed the level indicated in the
technical conditions for the components;
. the strength properties increase by 20%;
. the residual stresses decrease by 10– 15%;
. the density of the welded joint improves by
15 –20%;
. the accuracy of manufacture of the welded structures
corresponds to the requirements of design
documents.
In addition, in welding by the new technology, the
volume of operations in X-ray and other inspection
methods is smaller, and also the number of dressing
operations is lower because there is no need to repair the
defective areas; the consumption of energy, shielding
gases in welding materials decreases by 30 – 40%,
including welding materials for root welding; metal is
saved as a result of a smaller number of rejects.
The new technology does not require the development
of any special power sources and assembling in welding
equipment. Special gas equipment with the control device,
required for alternate supply of dissimilar gases (He, Ar,
CO2, etc.) in a wide range of frequency and consumption
has already been developed. Standard welding conditions
and algorithms for controlling the formation of the welded
joints have already been determined for some components
in aviation technology.
314 R.G. Tazetdinov et al.
Arc welding using alternate supply of Ar and CO2 has
already been successfully tested for welding low-alloyed
steels of 09G2S type.
Conclusions
(1) The application of alternate pulsed supply of
dissimilar gases (helium and argon) in arc welding
in shielding gases was used as the basis for
developing a completely new welding process
combining the advantages of AAW and HAW.
(2) The pulsed variation of the pressure in the arc
column, caused by differences in the density and
ionization potential of argon and helium, results in
the periodic impact effect on the weld pool leading to
the formation of the metal of the welded joint with a
fine-grained structure, high plasticity and strength of
the metal.
(3) The advantages of the welding process with alternate
pulsed supply of dissimilar gases, and also of the
technology developed on the basis of this process, in
comparison with the traditional technologies of AAW
and HAW, have been confirmed by a large number of
experimental investigations in welding of specimens
of different metallic alloys resulting in the high
quality and accuracy of the welded joints, the almost
complete absence of weld defects and also a
reduction in the volume of pulsed welding operations,
with considerable savings of metal.
Note
1. Patent 2049618 (Russian Federation).
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