Gases for welding and cutting: an in-depth analysis

I welding and cutting gases are essential elements in numerous industries, from construction to automotive production. The use of these gases is crucial to ensure optimal results, safety and greater efficiency in production processes. DKRSIAD's more than 90 years of experience in metalworking, offers a wide range of welding gas and cutas well as advanced technological solutions such as equipment, automation and customised welding plant design. In this article, we will delve into the various types of gases used in this sector, their specific applications and safety considerations.

The role of welding and cutting gases

I technical gases applied to welding and cutting operations serve multiple purposes, such as protecting the weld pool from atmospheric contamination, providing the necessary heat for cutting, and influencing the mechanical properties of the weld. Understanding the different types of gases and their specific applications is essential for anyone involved in these processes.

Importance of technical gases in welding

In the welding process, technical gases are an essential rolebut only marginally affecting a company's overall costs. Standard' gas mixtures for welding are mainly used in the MIG/ MAG and TIG welding. However, since the 1990s, the Performing' gas mixturesin which gases such as helium and hydrogen are added to traditional gases such as argon (Ar) and carbon dioxide (CO2) to improve performance.

A significant example of advanced application of technical gases is in the TIG welding (Tungsten Inert Gas), where argon is commonly used to protect the weld area from oxidation and atmospheric contamination. In some cases, hydrogen and helium are added to argon to increase penetration and welding speed, thus improving the efficiency of the process. TIG welding is particularly prized for its ability to produce high quality, precision joints, making it ideal for applications requiring flawless finishes and structural strength.

Advantages of performance gas mixtures

The use of 'Performing' gas blends in welding is a strategic investment that, although it involves higher costs than standard blends, increases welder productivity exponentially. These advanced blends offer significant advantages, including:

Increased process efficiency and speed: performance blends accelerate the welding process, reducing processing time. This is particularly advantageous in high production sectors such as automotive, where speed is essential to maintain competitiveness. Increased productivity allows companies to respond more quickly to market demands, optimising production cycles.

Improved aesthetic and mechanical characteristics: these blends improve the appearance and strength of the welded joint, making them ideal for industries such as food, aerospace, automotive and medical. A high-quality welded joint not only ensures structural safety but also offers superior aesthetics, which is crucial in applications where aesthetics are visible and important.

Reduction of welding defects: the use of performance gases reduces the likelihood of defects such as porosity and inclusions, improving joint integrity. This translates into less need for rework and quality control, further contributing to the overall efficiency of the production process.

In summary, performance blends, while involving a higher initial investment, offer a significant return in terms of productivity, quality and competitiveness, making them a strategic choice for companies striving for excellence in their welding processes.

Role of gases in thermal cutting processes

Also in the thermal cutting processestechnical gases play a crucial role. Whether laser, plasma or combustible gas cutting, gases are used to separate materials such as slabs, sheet metal or pipes.

Improvements in plasma and laser cutting

Here's how technical gases can positively influence cutting processes, improving both speed and quality:

• Plasma cutting: high-performance gas mixtures can improve the speed and quality of plasma cutting, ensuring cleaner and more precise edges. This is essential in applications where precision is critical, such as in the production of electronic components.
• Laser cutting: in laser cutting, the purity of gases and the correct configuration of distribution systems are crucial factors in optimising productivity. The use of high purity pure gases, such as nitrogen up to 5.0 (99.999%) and oxygen up to 3.5 (99.95%), allows cutting speeds of up to 20% to be increased, while reducing the risk of oxidation or etching on cut edges. This is especially important in industries such as aerospace, where cutting precision and quality are critical.

Types of gases used in welding

Protective gas

Shielding gases are used to protect the weld pool from atmospheric gases that can cause defects. The main shielding gases include:

• Argon: used for non-ferrous metals, it offers excellent protection. It is particularly effective in TIG welding, where the quality of the joint is crucial.
• Carbon dioxide (CO2): economical and provides good weld penetration. It is often used in MIG welding for heavy carpentry applications.
• Helium: provides a warmer arc, useful for thicker materials. Helium is often used in combination with argon to improve arc penetration and stability.
• Gas mixtures: combinations of argon, CO2 and helium to optimise the welding process. These mixtures are customised to meet the specific needs of different industrial applications.

Fuel Gases

Combustible gases provide the heat needed for cutting and welding. The main combustible gases include:

• Acetylene: known for its high flame temperature, ideal for cutting steel. Acetylene is preferred for its ability to produce a clean and precise cut.
• Propane: cost-effective and suitable for cutting and heating applications. Propane is often used in applications where cost is a critical factor.
• Natural Gas: economical for large-scale cutting and heating. It is a popular choice in industrial applications where cost efficiency is essential.

Security considerations

Handling and storage

Here are some essential guidelines for safe handling and storage of industrial gases:

• Proper storage: gases must be stored in well-ventilated areas, away from heat sources. Cylinders must be secured to prevent tipping and leakage.
• LabellingAll gas cylinders must be clearly labelled with their contents and associated risks. This is essential to prevent accidents and ensure the safety of operators.
• Leak detection: Check for leaks regularly using soapy water or gas detectors. Never use a flame to check for leaks, as this could cause a fire or explosion.

Personal Protective Equipment (EPI)

Below are some basic safety measures to protect operators during welding and cutting operations:

• Eye protectionUse welding helmets or appropriate goggles to protect against UV radiation and sparks. Eye protection is essential to prevent eye injuries.
• Respiratory protection: Use respirators in confined spaces or areas with poor ventilation to protect against harmful fumes and gases. Welding fumes can contain hazardous chemicals that can cause respiratory problems.
• Protective clothing: wear fire-resistant clothing, gloves and boots to protect against burns and sparks. Protective clothing is essential to ensure the safety of operators during welding and cutting operations.

Ventilation

It is important to take the following measures to ensure a safe working environment during welding and cutting operations:

• Adequate ventilation: Ensure adequate ventilation in the work area to disperse harmful fumes and gases. The use of exhaust systems or fans can help maintain air quality.
• Confined spaces: take extra precautions when working in confined spaces, including continuously monitoring gas levels and having a rescue plan. Confined spaces can present significant safety risks, so taking preventive measures is essential.

We explored how the welding and cutting gases are essential in industrial processescreating the ideal conditions for efficient and effective metalworking. As technology advances, the development of new gas mixtures and cutting techniques will continue to improve the capabilities and safety of welding and cutting operations. DKR, an industry leader, also specialises in food gases and for the cryo-cleaningmaking it the ideal supplier for your needs. We offer standard and high-performance gas mixtures, enriched with helium and hydrogen, for optimise welding efficiency and quality. Our high purity gases improve thermal cutting processesincreasing speed and reducing the risk of oxidation.

With DKR, you have access to customised solutions and state-of-the-art technology to boost productivity and quality in metal fabrication. Contact us for further information.