Another way to provide an estimate of shielding GAS Waste can be made using the data in the far right column.  Select the wire type and size from the chart above and the average amperage used.  Not sure about the amperage - use the highest shown in the table to be conservative.  These data is based on using 35 CFH flow rate.

More complete deposition rate data is available for solid and flux cored wire in a WA Technology bulletin entitled “What Causes MIG Wire to Melt?” Click for FREE COPY. It covers the effects of welding parameters and wire stick out on deposition  rate.

Purchasing CO₂ in pounds?  1 pound of CO₂ = 8.7 CF gas at STP

Purchasing liquid argon in gallons?   1 gallon of liquid Argon = 113 CF gas At STP

Want More Details of Calculating Gas Waste?

A MAJOR CAUSE OF GAS WASTE

The accompanying figure schematically shows a typical MIG welding system.  The regulator/ flowmeter drops the pressure from the cylinder or gas pipeline to that needed to deliver the required amount of shielding gas to the torch.

A small restriction orifice or a valve is used to control the gas flow.  Regulator/Flowmeters (Photo Below Left) outlet pressures range from 25 to 80 psi.  For CO₂ shielding 80 psi is used to help prevent ice formation.  Flowmeters on pipelines allow pipeline pressure to exit the flow control valve when welding stops.  A typical  pipeline pressures 50 psi. 

Flowgauge/Regulators (Photo  Right) operate by setting a pressure above a critical orifice.  For most MIG shielding gas flow rates the pressure when welding stops will range from 40 to 70 psi.

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In addition to wasting shielding gas, the high gas surge at the weld start will cause very turbulent flow with any size gas cup.  This causes air to be pulled into the center of the shielding gas stream creating poor weld starts.  This turbulent flow takes a short time to stabilize into a more laminar, quality shielding gas stream even when flow returns to the normal desired level.  Therefore weld starts will contain entrained air in the gas stream even after the flow reaches the preset level.

Restriction Orifices have been occasionally used to minimize the gas flow surge at the weld start.  However, assuming flow is still controlled at a regulator/flowgauge or flowmeter, significant gas waste still exists! If a pressure gauge is put in the shielding gas hose line the gas pressure changes observed are at similar levels as if the restrictor was not present.  Instead of the gas surge taking about a second to occur it takes longer at a lower flow rate. Significant gas waste occurs but over a longer time!  

If the restrictor is used to control the steady state flow then insufficient extra gas is available at the start to purge the torch nozzle and weld start area of moisture laden air.  This causes similar problems to those caused by the high surge flow!  See Why there is a need for this extra gas and a special gas storage device defined by Stauffer in his 1982 patented system.

Low Pressure Devices appear at first to be a possible solution.  However delivery systems have used pressures of a minimum of 25 psi since the introduction of TIG and MIG for very good reason.  That is the minimum pressure needed to provide automatic compensation of hose and torch flow restrictions that occur in production!  We have measured changes in flow of 35% up to 65% in tests with low pressure systems without any change in flow settings,  See Why.

Higher pressure also helps to quickly delivery some extra gas at the weld start to purge the torch nozzle and weld start area of moisture laden air.

PATENTED GAS SAVER SYSTEM

There is a simple way to significantly reduce MIG shielding gas waste due to gas flow surge.  First, employ a shielding gas hose with a much smaller internal diameter/volume.  At the low flow rates used for welding this creates a minimum pressure drop.  Secondly, incorporate a flow restriction orifice on the wire feeder end of the gas hose.  This has the benefit of reducing gas waste for very short time torch trigger actuation such as when inching the wire to cut off the end.  The surge restricting orifice also has the benefit of improving weld starts by minimizing turbulence of the shielding gas stream.  Note a sufficient amount of extra shielding gas is still available to quickly purge the weld start area and weld nozzle of moisture laden air improving start weld quality.

 The patented WA Technology Gas Saver System (GSS^TM) incorporates an 1/8 inch ID hose with a flow restrictor built into the hose connection at the wire feeder end.  The flow restrictor size is selected to reduce the surge at the start but allow the operator to have full control of the welding flow rate. It is also sized to allow a small amount of extra gas flow to assist in purging air that diffuses into the torch gas line during the stoppage. It has a large OD and fiber reinforced construction to provide a robust product which will not kink or flattened when stepped on.  The hose volume is proportional to the hose ID squared therefore it results in a 4 fold or 75% reduction. The total % reduction is calculated from this volume decrease and the small pressure drop in the GSS hose and surge restrictor and exceeds 80%.

Just as the high gas surge causes wasted gas; if gas flow control is attempted at the wire feeder with an orifice, flowmeter or needle valve then the surge is eliminated but now little or no extra gas is available at the weld start to purge the torch nozzle and weld start area of gas.  We have found in these instances welders raise the steady state gas flow in attempt to compensate so they are not starting in air!  Check out the details of why this is necessary.  This creates considerable gas waste!

SELECTION OPTIONS AND INSTALLATION

To gain the benefits of this patented system simply replace the existing gas hose with the WA Technology GSS.  For industrial MIG systems hose end fittings are supplied with Compressed Gas Association (CGA) 032, 5/8 inch-18 male threaded connectors (also called “B” size, left in photo).  GSS components and systems may be ordered in from 3 to 50 foot lengths. These lengths are satisfactory with most commercial regulators or gas pipeline pressures. It is possible to use 100 foot or longer lengths however the regulator outlet or gas pipeline pressure must be known before ordering.

For some feeders or regulators where a CGA fitting is not used, such as when a hose barb is on the feeder, the GSS can be ordered with simple hose splice connectors (right in photo).  This allows the existing hose to be cut and the GSS assembly added by splicing to a 1/4 or 3/16 inch ID hose.  Both systems incorporate a flow restriction orifice on the end connected to the feeder and  perform the same.

TIG WELDING?

If you are TIG welding the GSS will also save you money, especially if your system incorporates a gas solenoid.  The gas surge at the weld start is significantly reduced in velocity to improve shielding.  In addition the heavy wall thickness of the GSS hose makes it resistant to leaks caused by abrasion.  A hose splice connection is available for connecting the GSS to an existing 1/8 inch diameter TIG hose.

PRODUCTION RESULTS

A number of fabricators have performed usage measurements comparing the GSS with a conventional delivery hose.  They reported savings in gas usage of from 30 to 63%.  Many also report welders are very impressed with the improved starts from the significant reduction in initial gas flow peak surge.

A fabricator of truck boxes reports his test results with the GSS.  They selected a repetitive application, welding doors.  Using a full cylinder with their standard gas delivery hose they were able to fabricate 236 doors.  With no other changes than to replace the gas delivery hose with our GSS they welded 632 doors with a full cylinder of gas.  That is a 63% shielding gas savings!  They immediately purchased 25 systems for all their welders.  Two years latter they added 10 more MIG welders and called and asked for 10 more “Magic Hose!”

This production example shows why extra gas at the weld start can reduce gas use. Welders at a Bar Joist fabricator wanted more gas flow than the 45 CFH that was set with the orifices installed at their feeders.   In some instances they were drilling the orifice to achieve more gas flow.  A GSS  was installed with gas control at the pipeline drop. This provided a controlled amount of extra gas at the weld start.  By providing extra gas at the start the GSS was able to improve starts and the steady state flow could be reduced to 35 CFH  or less and the welders still saw a significant improvement!  That was because the same amount of extra gas was still provided at the weld start. Overall gas savings were documented at 25% and most important  welders were pleased with the improved weld performance because extra start gas quickly purged the weld area!   Check out the details.

WITH YOUR PURCHASE

When you purchase your GSS it will include simple installation instructions.

A detailed explanation of how the gas waste reduction figures quoted in this publication were developed is available for purchase on a CD Video entitled “Saving Shielding Gas” (or Roll Over Bernoulli).  Recommendations for minimum and maximum gas flow are provided.  The flow values that create turbulence are defined and why increasing gas flow can cause poor shielding is explained. It quantifies how much wind or draft can be tolerated and when a wind break is needed. It is an excellent tool for understanding shielding gas control and to use for operator and supervisor training.

BOTTOM LINE

The WA Technology GSS has no moving parts to wear, repair or leak; no pressures to set or knobs to adjust.  It’s unique, patented design maintains the gas pressure in the delivery hose.  This allows a small amount of extra gas flow at the weld start to quickly purge air and moisture in the weld zone and air that enters the torch shielding gas cup, torch body and cable during weld stoppage.  Maintaining the higher pressure also retains the systems ability to automatically compensate for varying pressure drops in the delivery hose when inadvertently pinched, squeezed, bent, etc.  Pressure drops in the  torch due to conduit bending and spatter build-up in the front end are also automatically compensated to maintain the preset flow. That is a key reason regulator flow systems are designed to operate at these pressures.  Want to understand why high pressure regulator/flowmeters are "A Good Thing?" Click Here. The GSS does not interfere with the welders ability to adjust the shielding gas flow within any reasonable flow level desired.

The GSS hose is made with a heavy wall thickness and with fiber reinforced construction to provide a robust product.  It will continue to flow even when stepped on. The heavy wall thickness makes the hose resistant to leaks caused by abrasion.

For most applications the GSS will pay for itself in gas waste reduction alone in a matter of weeks.  The improved weld starts and the reduced cylinder handling are added benefits which may be more important in some applications. 

The system is backed with a  money back guarantee.

Does Our Patented GSS Solution Appear Too Simple? 

Think There Must Be More Elaborate Devices That Solve This Problem? 

Unfortunately Devices Have Been Tried That Create More Problems Than They Attempt To Solve!  Welders Often Reject These and For Good Reason.    SEE DETAILS

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