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Using CO2 MIG Shielding Gas?
Average MIG Welder Wastes
Over 8 Tons CO2/Year
See
Calculation Details
Cut Gas Cost in Half by Reducing Waste and Go Green with our
Gas Saver System (GSSTM)
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 The
Blast of Shielding Gas Occurring When a MIG Torch Trigger is Pulled Causes
Problems:
1)
Significant Shielding Gas Waste
2)
Inferior Starts Since Air is "Sucked" Into The Resulting
Turbulent Shielding Gas Stream
Waste is a
problem when using CO2 shielding gas since the regulator pressure
can be as high as 80 psi to avoid ice particles restricting flow
(It's Also A Problem With Argon Shielding, Click To See Why.)
That high
pressure stores excess gas in the gas delivery hose each time you stop
welding that's expelled when starting. Our patented
Go Green
Gas Saver System
eliminates these problems and saves from 30 to 60% of gas use!
The
GSS:
 |
 Is
simple to install; just replace the existing gas delivery hose
from gas supply to welder or wire feeder with our prefitted
GSS hose
system. It reduces the gas surge volume by 80% and limits peak surge
flow rate. Works with existing regulator or flow control. You still
control the steady state flow.
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Is
inexpensive. A commonly used 6 foot
GSS system
(Part Number
FB6 )
cost less than $60 and will typical cut shielding gas use by 50% so you'll
have a very quick payback!
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Reduces the gas surge at
the start producing better shielding for sounder welds with less starting
spatter so wasteful repair or grinding may not be needed.
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Reduces the
CO2
waste going into the
atmosphere and also the number of times your gas supplier
will have to expend energy to fill and delivery the ~200 pound cylinders or
to delivery to your bulk tank
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(Note:
Using published gas waste information quoted by a Praxair representative and
validated with our own findings- one
industrial MIG welder typically wastes over 150,000 ft3
(CF) of CO2
per year. That's over 16,000 pounds (8 tons!) of wasted CO2
per welder per year!
If your using Argon gas mixtures your
wasting a similar weight of gas per year per welder and have similar
distribution and much higher production electric energy costs (with
accompanying CO2 pollution)
SEE Why. )
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How
Much Shielding Gas is
Wasted on Each Weld Start or Torch Pull?
What
Causes Shielding Gas Waste?
CLICK TO SEE |
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CALCULATION OF CO2 WASTE:
Assumptions and
Calculation:
| Industrial MIG welder operating at 50% duty
cycle with flow setting of 35 ft3/hr (CFH) on flowmeter |
| 4 times this amount of
shielding gas needed is wasted. See References below which states
up to 5 times needed is wasted. |
| Then 40 hrs/wk * 50% duty
cycle * 50 weeks = 1000hrs/year arc-on time. |
| Waste consumption = 35 ft3/hr
*4* 1000 hrs/yr = 140,000 ft3 CO2/year |
| 140,000 ft3 CO2
* 0.115 lb CO2/ft3 @ STP (Standard Temperature and
Pressure) = |
| 16,10000 lbs = 8 tons of CO2
wasted per year |
Calculation Cross
Check:
| Industrial welder
operating at 50% duty cycle (arc on 1/2 time) with 35 CFH
sufficient shielding gas flow rate. |
| Published waste information
indicates up to 30 CF/lb of shielding gas is used. (This is verified by
our own findings) |
| Assume average wire deposition
rate while welding = 7 lbs/hr (typical) |
| Then 35 CFH/ 7 lbs/hr = 5CF/lb
is the amount of shielding gas that should be used. |
| Assume a more conservative 25
CF/lb is measured versus published 30 CF/lb. |
| Then 25 CF/lb / 5 CF/lb = 5
times gas being used versus what is needed. |
| Therefore since 5 CF/lb is
needed and 25 CF/lb is used; 25 CF/lb – 5 CF/lb= 20 CF of gas used per lb
of wire consumed is wasted. Or 20 CF/lb
wasted / 5 CF/lb needed = 4 times what is needed is wasted. |
| Using 4 times for amount of
waste: |
| Then 40 hrs/wk * 50% duty
cycle * 50 weeks = 1000hrs/year |
| Excess CO2 = 35 CFH
*4 times wasted* 1000 hrs/yr = 140,000 CF CO2/year wasted. |
| CO2 = 8.7 CF/lb CO2
(at STP) |
| 140,000 CF /8.7 CF/lb = 16,000
lbs/yr or 1 ton/2000 lbs = 8 tons/yr wasted. |
References:
-
Standifer, L. R., Shielding Gas Consumption Efficiency.
The Fabricator, Volume 30, Number 6, June 2000.
(States 18 to 30 cubic feet of shielding gas is typically used per pound
of wire consumed. Which is 2.5 to 5 times
the amount that is needed)
-
Weber, R., How to Save 20% on Welding Costs.
Trailer/Body Builders, Volume 44, Number 3, January 2003
(Praxair Representative states, their market survey findings show the average fabricator
consumes 30 cubic feet of gas per pound of wire which 5 times
what is needed.)
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 Welders
Setting Flow Rates Too High?
We have measured flow
rates above 125.CFH when the flow ball is
pinned to the top of the tube! Anything over about 50.CFH
is pulling moisture laden air into the shielding gas stream and
causing internal if not visible porosity! The flow rate may be outside
the variable range specified in Procedure Qualifications.
Our Recently Patented
Flow Rate Limiter Locks Flow Setting!
Click on
Picture For More Information |
|
 Free Technical Paper, "MIG
SHIELDING GAS
CONTROL"
CLICK ICON for PDF DOWNLOAD |
Purchase Shielding
Gas Saving
Products
Questions? Email
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