Fig.

1 – High thermal conductivity gases like Helium promote globular transfer (left side
sketch). Low thermal conductivity gases like Argon, expand the plasma column and
promote spray transfer( right side sketch).
Fig. 2 – Addition of 5% CO2 to pure Argon, improves weld bead wetting for mild steel
GMAW welds
Fig. 3 – Addition of 2% O2 to pure Argon, improves weld bead wetting for mild steel
GMAW welds. Similar effect can be seen for stainless steel welds.
Fig. 4 – Effect of gas composition on fume generation rate. X-axis numbers are
percentages
Fig. 5 –In GMAW aluminum welding, addition of oxygen to Argon shielding was shown
to increase arc speeds by 20%, due to arc stabilization. In one case Argon + 1.5% O2
mixture was used, in another case pure Argon was used as shielding, but 0.3 L/min flow
of oxygen was introduced through the contact tip. The surface oxide was easy to remove
by wire brushing.
 Fig. 6a: Pure Argon
Fig. 6b: Ar+He+ CO2

Fig. 6c: Ar+ μ CO2 Fig. 6d: Ar+He+ μ CO2

Fig. 6e: Ar+H2+ μ CO2

Fig. 6 – Up to 25% improvement in arc speeds of PULSED GMAW welding of high

nickel alloys, can be obtained by micro addition of CO2 to Argon, Argon-Helium and
Argon-Hydrogen mixtures while improving the bead appearance
Fig. 7 - Carbon variation in stainless steel weld deposits with Ar/CO2 mixes (Ref. 10)
Fig. 8 – FCAW consumable inadequately stored in a shop for several days

Fig. 9 - Worm-tracking porosity in a weld bead deposited with inadequately stored

FCAW consumable
Fig 10. – Deleterious effect of Nitrogen on impact energy of carbon steel weldmetals