Enhance Your Welding by Understanding Industrial Shielding Gases

Welding is vital in various industries and choosing the suitable shielding gas can make all the difference in the quality of the weld. Coregas, a leader in gas solutions, offers a range of industrial gases designed to enhance welding performance. From cylinders to cryogenic bulk gas systems, Coregas provides customised solutions through Proline Industrial to suit different applications, ensuring optimal results in metal fabrication.

One key aspect of welding is selecting the correct gas or gas mixture. Shielding gases play a crucial role in controlling various welding process parameters. The gases can influence metal transfer, weld-pool temperature, penetration depth, and welding speed. Proline Industrial understands the importance of this and offers a wide range of options to help welders achieve optimal results.

Types of Welding Gases

Acetylene is known as the hottest and most efficient of all fuel gases, making it versatile for several applications, including oxyacetylene cutting, welding, and flame heating. Its low ignition energy and minimal moisture content make it ideal for underground use, as it can easily ignite in oxygen and air. In addition to its use in cutting and welding, Acetylene is widely applied in flame hardening, flame straightening, flame cleaning, thermal spraying, gouging, and brazing. Its versatility and efficiency make it an essential fuel gas in many industrial and fabrication settings.

Argon is another important shielding gas used in producing, processing and fabricating metals. It is available as a compressed gas and a cryogenic liquid (often abbreviated as LAR). It is inert, meaning it doesn't react with the welded materials, making it perfect for TIG welding of stainless steel across all thicknesses and MIG and TIG welding of copper and alloys up to 3mm. Argon's lower thermal conductivity compared to other gases and low ionising potential allow for easy formation of a welding arc without reacting with the materials being welded, resulting in cleaner welds with fewer imperfections. This makes it ideal for excluding air during purging and welding processes and plasma cutting.

CO2 is commonly used for MIG welding, especially in carbon steel applications. It is available as an industrial-grade compressed gas in cylinders or a cryogenic liquid in bulk. While CO2 tends to produce more spatter than CO2/Argon mixed gas, it remains a cost-effective option for welders working with thicker materials. It is ideal for MIG welding steel up to 10mm, using dip transfer only, and is also used in welding carbon and alloy steel with flux-cored wire.

Beyond welding, CO2 is applied in plasma cutting, cooling during thermal spraying, inerting, pH balancing, pipe freezing, and in some FCAW applications. Its availability in various volumes makes it a flexible solution for different industrial needs. 

Coregas09, a premium gas blend containing 91% argon and 9% CO2 (also known as Coreshield), is primarily used for MIG welding carbon steel. This argon-carbon dioxide mixture is highly regarded for producing clean, quality, and economical welds. The addition of CO2 improves the shape of the weld bead, while the argon ensures excellent arc stability and strong welds. Coregas09 is ideal for MIG welding steel of all thicknesses, offering good arc transfer with a smooth weld appearance and minimal spatter. It is also well-suited for robotic welding applications, making it a versatile choice for precision and efficiency.

Oxygen, the last standard shielding gas used in welding, is widely used with fuel gases (Acetylene) for cutting, brazing, and soldering and plays a vital role in oxygenating water in industrial processes. Industrial-grade oxygen supports combustion and increases flame temperatures. It is available in various volumes as a compressed gas or cryogenic liquid form (often abbreviated as 'LOX'). In welding applications, oxygen is commonly used with Acetylene to achieve much higher flame temperatures than air, making it ideal for precision welding and cutting tasks. Additionally, oxygen is used to shield gases to stabilise the arc and improve fluidity during welding, ensuring smoother welds and better control.

Optimising Welding with Shielding Gases

The selection of gas mixtures significantly affects the quality of the weld, allowing nearly every factor of the welding process to be controlled and optimised for specific applications. The physical properties of the shielding gas can influence metal transfer, wetting behaviour, penetration depth, welding speed, fume formation, spatter rates, and arc setting. For example, the gas's thermal conductivity affects weld-pool temperature, degassing, and the overall shape of the weld. The right combination of gases is essential for achieving optimal results.

For instance, adding helium to argon markedly increases welding speed and improves penetration when working with aluminium materials. In contrast, hydrogen additions in stainless steel welding help reduce surface oxides, resulting in a cleaner finish and less post-weld processing. Similarly, oxygen can burn off alloy constituents, leading to more fluid weld pools, while carbon dioxide adds carbon to the weld, producing slightly reinforced welds.

Proline Industrial offers a variety of specialised gas mixtures through Coregas that optimise the welding process, from controlling spatter rates to improving the appearance of the weld. Argon and helium, neutral in metallurgical behaviour, contribute to stable welds, while hydrogen is a reducing agent in specific applications. Using these gas mixtures can also bring financial benefits, as a well-selected shielding gas can improve welding efficiency, reduce rework, and lower overall costs. Whether working in an industrial workshop or managing large-scale fabrication projects, Proline Industrial provides tailored solutions to meet the unique demands of each application.

Advanced Welding Techniques

In gas metal-arc welding (GMAW), several arc types are employed depending on the material thickness, shielding gas, and welding position, all of which influence the final welding outcome. For instance, short arcs are ideal for welding thin plates, out-of-position welding, and root-pass welding at low power levels. Metal transfer in short arc welding occurs in a short circuit with minimal spatter. On the other hand, long arcs are better suited for high-power welding of thicker sections under carbon dioxide, where metal transfer is globular, and spatter is more considerable.

For medium-power, GMAW of moderate plate thicknesses, a globular/transition arc is commonly used with argon-based gas mixtures. The metal transfer is globular and occurs partly in the short circuit, with less spatter than long-arc welding. Spray arc welding, performed under argon-based gas mixtures, provides high deposition rates and smooth welds with minimal spatter, making it an ideal technique for thicker materials. Pulsed arc welding is versatile for all power levels. It is beneficial in argon-rich mixtures for moderate power ranges, where metal transfer is free from short circuits, forming a single droplet per pulse and producing even less spatter. However, pulsed arc cannot be used under carbon dioxide.

A rotating arc is employed for very high deposition rates on thicker structures, especially when paired with Proline Industrial speciality shielding gases. Twin arc welding also supports highly high deposition rates across various materials and material thicknesses, offering a solution for demanding industrial applications. Coregas shielding gas options are designed to help these techniques, providing welders greater flexibility and precision in their welding operations.

Trade N Go Gas™: A Convenient and Cost-Effective Gas Solution

Managing gas supplies can become a logistical and financial burden for many welders, workshops, and engineering firms. Traditionally, businesses rent or purchase gas cylinders, which come with challenges. Renting requires ongoing monthly fees, while purchasing cylinders demands a more significant upfront investment. Coregas, however, offers a more innovative, more flexible alternative with its Trade N Go Gas™ system, specifically designed to provide maximum convenience and cost efficiency.

How Trade N Go Gas™ Works?

The Trade N Go Gas™ system allows users to avoid ownership and long-term rental commitments. Instead, customers simply pay a one-time, refundable deposit for the cylinder and the gas cost, giving them complete control over how long they hold onto the cylinder. Once the gas has been used, the empty cylinder can be traded in at any participating stockist for a total replacement or returned for a complete refund of the deposit if no further gas is required.

This unique "no-strings-attached" approach is ideal for businesses of all sizes. Whether you're a small workshop that only occasionally requires gas or a large-scale operation that needs constant refills, the Trade N Go Gas™ system scales perfectly with your needs. You don't have to worry about lengthy rental contracts or the hassle of cylinder ownership. If your gas usage decreases or your business slows down, there are no hidden costs—return the cylinder and get your deposit back hassle-free.

Benefits of the Trade N Go Gas™ System

1. Flexibility Without Contracts

The most significant advantage of the Trade N Go Gas™ system is its freedom. No contracts exist, and you're not locked into a long-term rental. Once you've purchased your gas and paid the initial deposit, the cylinder is yours to use for as long as needed. When the cylinder runs out, you can trade it for a full one or return it and get your deposit back, with no questions asked.

2. Cost Efficiency

This system is designed to be highly cost-effective, particularly for businesses with fluctuating gas usage. You only pay for what you use, and the one-time deposit ensures that you can always pay ongoing fees for equipment that might sit unused for periods. This cost control is particularly useful for workshops that may not need a constant supply of gas but still want to have it available when necessary.

3. Ease of Access with Over 50 Stockists Nationwide

Trade N Go Gas™ is available through a network of over 50 stockists across New Zealand. This extensive network ensures that no matter where your business is located, you can easily pick up, trade, or return your gas cylinder at a time and location that suits you best. Coregas has carefully selected these stockists to provide easy access, reduce downtime, and make gas management as simple as possible.

4. No Ownership Burden 

The ownership burden is among the most significant issues when purchasing gas cylinders. Owning a cylinder means being responsible for its maintenance, safety inspections, and overall condition, which can be time-consuming and costly. With Trade N Go Gas™, this burden is lifted. Coregas takes full responsibility for the maintenance and safety of the cylinders, ensuring that every cylinder you trade is in optimal working condition. This means fewer worries about compliance or safety checks for your business.

5. Cylinder Safety and Quality Assured

Coregas is committed to providing the highest quality cylinders, all sourced from top European and US suppliers. In particular, the acetylene cylinders supplied through Trade N Go Gas™ are 100% asbestos-free, giving customers peace of mind about safety. Each cylinder undergoes rigorous checks to meet Coregas's stringent safety standards. You can trust that your gas supply is safe and reliable whenever you trade or refill a cylinder.

6. Refundable Deposit

Another significant feature of Trade N Go Gas™ is the fully refundable deposit. You can hold onto the cylinder for as long as necessary, but once you no longer need it, return it with your receipt to get your deposit refunded in full. Whether it's a week, a year, or even longer, the deposit refund system allows users to opt out of the program at any time without penalty. It's a risk-free system that puts you in control.

Meeting the Needs of Diverse Industries

Trade N Go Gas™ has become an indispensable part of gas management in many industries, from welders and fabricators to engineers and workshop owners. Its flexibility makes it perfect for operations that may experience fluctuations in gas demand. Whether a business needs gas for regular production runs, occasional project work, or even emergency repairs, Trade N Go Gas™ provides a straightforward solution that is both affordable and accessible.

For larger businesses that operate across multiple sites, the Trade N Go Gas™ system ensures that each location can manage its gas supply independently, streamlining operations and reducing administrative overhead. With no need to coordinate cylinder returns or worry about contract terms, businesses can focus on their core work rather than logistical concerns.

A Sustainable Approach to Gas Supply

The Trade N Go Gas™ system also offers sustainability benefits. Reducing the need for cylinder ownership and encouraging the reuse of cylinders minimises waste and supports a circular economy. When customers return empty cylinders, they are refurbished and reused, extending the equipment's lifecycle and reducing the environmental impact of producing new cylinders.

Conclusion 

Selecting the suitable shielding gas is essential for achieving quality welds and optimising the welding process. Proline Industrial offers a range of industrial shielding gases, from Acetylene to argon-based mixtures, designed to meet the diverse needs of welders, engineers, and business owners. With the Coregas Trade N Go Gas™ system and industry-leading gas management tools, Proline Industrial makes it easier to maintain gas supplies and improve welding efficiency.

Contact Proline Industrial today to learn how their gas solutions can enhance your welding operations.