FREE
Technical Paper Entitled;
"MIG Shielding Gas Control and Optimization"
The paper presents key points of technical
presentations mad
e
in US and International Welding Conferences about shielding gas
flow problems and solutions.
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The Following
is a Summary of What is Covered:
A key statement made in one of the first MIG patents (1950) reveals gas
shielding must be; “… none turbulent to exclude air from the arc.”
Several recent published references show shielding gas flow rates can not
exceed about 50 cubic feet per hour (CFH) to achieve this none
turbulent flow.
Our tests show, at a weld start excess stored gas in the hose from the gas supply to
wire feeder exits the torch nozzle at a peak flow rate often exceeding
200 CFH. This causes very turbulent flow that lasts for several seconds
causing excess spatter, weld defects and considerable shielding gas waste.
Published data shows the average MIG welder uses 3 to 6 times the
amount of shielding gas they should! A number of fabricators have
documented that much of this waste is caused by weld start gas flow surge.
Past attempts to reduce gas surge and gas waste have often met with
objections by welders. The reasons welders frequently rightfully
reject
these solutions or counter there use by setting excess steady state flow rates are documented. Examples of where fabricators had to remove these devices are presented.
A recently patented Gas Saver System
limits peak gas flow rate at the weld start and reduces surge gas waste by
over 80%. It has no moving parts to set, adjust or maintain. By
not altering system pressure it maintains automatic flow compensation
so
flow does not vary with spatter buildup etc. Details of this important
principle are defined.
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