What is the Ideal Gas Delivery System?

Question: What is the best way to deliver shielding gas to a MIG system?

Answer: For systems with up to 50 feet from gas cylinder to wire  feeder  or where a hose connects from a pipeline to the feeder (or wherever the gas control solenoid is located); the best system is shown in the picture above.  It consists of a rotameter flowmeter (one with a flow indicator ball) and our Gas Saver System (GSS.) This system will work for any gas supply. 

  The benefits of this system include:

1. The gas flow can be quickly  seen and read by the position of the flow indicator ball to define if your within your Weld Procedure Specifications.

2. The GSS reduces the normal gas waste associated with these systems by about 80%, and controls the gas surge velocity within limits that eliminate start turbulence thereby improving start weld quality. 

3. This arrangement quickly delivers a controlled amount of extra shielding at the weld start to purge the weld start area, torch nozzle and torch gas hose, resulting in higher quality weld starts with less spatter and internal weld porosity.  It delivers this extra gas at a controlled peak surge flow rate that minimizes turbulence.  CLICK to see details of why extra gas at weld start is needed)

4. The GSS also maintains the system pressure so automatic flow compensation is maintained.  This feature maintains flow even when spatter builds in the torch nozzle or torch cables are twisted etc.  It was built into gas delivery systems since the introduction of MIG welding in the 1950's!  (CLICK for more information on that feature.)

Question: What if we have over 50 feet from gas supply to wire feeder?

Answer: The above system will operate up to 100 foot from gas supply to wire feeder if pipeline of cylinder regulator pressure are 50 psi or higher.  Email and define the regulator/flowmeter you are using and the pipeline pressure if on pipeline gas supply.  TechSupport@NetWelding.com 

Question: Suppose we want to lock the flow setting to stay within our Welding Procedure Specifications and to avoid shielding gas waste?

Answer: You can use our Flow Rate Limiter and Lock that fits most flowmeters and regulator/ flowmeters.  You set the flow and lock the control knob so it can not be turned further to increase flow.

CLICK for Details

Question: We don't like to use rotameter flowmeters since they are somewhat susceptible to breakage.  What can we use?

Answer: A flowgauge/regulator will work fine for cylinder gas supply (photo right.)  We have a number of customers using these.  For typical flow rate settings the regulator is often operating at 50 to 80 psi.  Even though your reading flow in CFH on the gauge your actually setting the pressure upstream of a critical orifice.  The GSS  is very beneficial with these systems since significant excess gas is stored in the delivery hose every time welding is stopped.  The amount of stored gas as measured at standard pressure (what you pay for) can exceed 6 times the physical hose volume! SEE WHY

Question: We don't like to use rotameter flowmeters and we are pipeline gas supply.  What can we use?

Answer: Some fabricators use a flow control orifice mounted at the pipeline drop after the required shut-off.  The orifice size is selected to provide the desired flow.  Since it can't be adjusted the flow is set to the highest level that will be needed.  We offer a unique Orifice System for this purpose.  It has a replaceable orifice and can be changed with one of 10 optional sizes!

Others use a needle valve (after the required gas drop shut-off) and measure gas flow at the torch with a portable flowmeter like the one shown on the left.  CLICK on picture to see details of this device which we offer for sale.  It is an inexpensive way to check for actual flow out of the torch nozzle.

With either system the GSS is very important since pipeline pressures are usually 50 psi or higher and weld start gas surge is very high.  This high gas surge causes turbulent flow resulting in inferior start quality as well as significant gas waste.

Question: Is it sufficient to just use the GSS to replace the shielding gas delivery hose (from the gas supply flow control to wherever the gas control solenoid is located?) What about the gas delivery lines and torch lines after the solenoid?

Answer: The excess stored gas (which is mostly wasted) that causes the high flow surge at the weld start only exists between the gas supply flow control and the gas control solenoid.  The gas lines after the solenoid and those in the torch are not exposed to the high pressure when welding stops.  In fact depending on how long the weld is stopped, air will diffuse back into these lines.  SEE Why Some Extra Gas is Needed at the Weld Start.

Question: We have only 6 foot gas delivery hoses, is there a benefit to using a GSS ?

Answer: Yes, there is.  A company with 128 welding robots recently asked the same question.  They were running a Black Belt Lean Manufacturing study.  After purchasing four 6 foot GSS systems (WAT FB6) they ran extensive tests on their various parts.  They found a minimum of 25% and with some parts over 40% gas savings! Their parts are very repetitive so the comparison gas usage test data is  very reliable  See Details.  The Bottom Line is they purchased 128 systems!

Question: We have very long gas lines, is there anything we can do?

Answer: Yes, we have developed patented systems for any length gas delivery hose, even those used in shipyards with gas delivery lines exceeding 200 feet.  Email for details: TechSupport@NetWelding.com