Gas Shielded
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Shielding gas for welding. What is the optimum blend for welding P.O., Galvaneal and Galvanized steel sheet?
We currently employ a 95% Argon 5% oxygen mixture. Is this blend optimal for 10-14 Ga. steel sheet welding? We manufacture detention equipment (doors, frames, equipment etc.)
Hmmmm.......sounds like you've been "Sold." (Note: It's a bad idea to rely on salespersons for welding advice....confusion=profits.) Let me guess, are you getting your gasses from Hobart, or BOC by chance?
You should stick to the highly affordable and time tested 85% Ar + 15% CO2 mix. This works great for nearly all carbon and low-allow steel applications, including galvanized.
Adding oxygen to the shielding gas merely lowers the weld energy thereby increasing the potential for fusion and penetration problems. Note this is less of a concern for such thin materials, but the oxygen will still make it more difficult to produce a consistant, uniform weld.
Oxygen also, of course, vastly increases the risk of porosity, as the whole point of having shielding gas is to PROTECT the weld from oxygen, which is incredibly reactive.
In short, oxygen provides no weld benefits and many weld liabilities. It's just a sales gimmick to justify the higher price.
I'd wager you're producing unusually brittle welds with lots of porosity, dross, and surface oxidation, particularly on outside corners.
If burn through or too much heat input is a problem, then there are other changes you can make which won't adversely affect the weld quality. For example, use a smaller diameter wire, or switch to using short-circuit transfer, as opposed to spray transfer. (Oh yeah, FYI spray transfer is impossible with the mix you're using, only globular or short-circuit, so you've probably set your machines for short-circuit already.)
Hope that helps.
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