Systematic study of effect of cross-drafts and nozzle diameter on shield gas coverage

V. Beyer, Stuart Campbell, Gemma Ramsey, Alexander Galloway, A.J. Moore, Norman McPherson

Research output: Contribution to journalArticle

6 Citations (Scopus)

Abstract

A shield gas flow rate of 15–20 L min21 is typically specified in metal inert gas welding, but is often adjusted to as high as 36 L min21 by welders in practice. Not only is this overuse of shield gas wasteful, but uncontrolled high gas flows can lead to significant turbulence induced porosity in the final weld. There is therefore a need to understand and control the minimum shield gas flow rate used in practical welding where cross-drafts may affect the coverage. Very low gas coverage or no shielding leads to porosity and spatter development in the weld region. A systematic study is reported of the weld quality achieved for a range of shield gas flow rates, cross-draft speeds and nozzle diameters using optical visualisation and numerical modelling to determine the shield gas coverage. As a consequence of the study, the shield gas flow has been
reduced to 12 L min21 in production welding, representing a significant process cost saving and reduced environmental impact with no compromise to the final weld quality.
LanguageEnglish
Pages652-660
Number of pages9
JournalScience and Technology of Welding and Joining
Volume18
Issue number8
DOIs
Publication statusPublished - Nov 2013

Fingerprint

draft
nozzles
gas flow
Flow of gases
Nozzles
Gases
Welds
gases
flow velocity
Flow rate
welding
Welding
gas welding
Porosity
Inert gas welding
porosity
Shielding
shielding
Environmental impact
rare gases

Keywords

  • MIG
  • CFD
  • gas shielding
  • shadowgraphy
  • porosity

Cite this

Beyer, V. ; Campbell, Stuart ; Ramsey, Gemma ; Galloway, Alexander ; Moore, A.J. ; McPherson, Norman. / Systematic study of effect of cross-drafts and nozzle diameter on shield gas coverage. In: Science and Technology of Welding and Joining. 2013 ; Vol. 18, No. 8. pp. 652-660.
@article{d0fd12edf07349a0889bcd0e859fdd2c,
title = "Systematic study of effect of cross-drafts and nozzle diameter on shield gas coverage",
abstract = "A shield gas flow rate of 15–20 L min21 is typically specified in metal inert gas welding, but is often adjusted to as high as 36 L min21 by welders in practice. Not only is this overuse of shield gas wasteful, but uncontrolled high gas flows can lead to significant turbulence induced porosity in the final weld. There is therefore a need to understand and control the minimum shield gas flow rate used in practical welding where cross-drafts may affect the coverage. Very low gas coverage or no shielding leads to porosity and spatter development in the weld region. A systematic study is reported of the weld quality achieved for a range of shield gas flow rates, cross-draft speeds and nozzle diameters using optical visualisation and numerical modelling to determine the shield gas coverage. As a consequence of the study, the shield gas flow has beenreduced to 12 L min21 in production welding, representing a significant process cost saving and reduced environmental impact with no compromise to the final weld quality.",
keywords = "MIG, CFD, gas shielding, shadowgraphy, porosity",
author = "V. Beyer and Stuart Campbell and Gemma Ramsey and Alexander Galloway and A.J. Moore and Norman McPherson",
year = "2013",
month = "11",
doi = "10.1179/1362171813Y.0000000143",
language = "English",
volume = "18",
pages = "652--660",
journal = "Science and Technology of Welding and Joining",
issn = "1362-1718",
number = "8",

}

Systematic study of effect of cross-drafts and nozzle diameter on shield gas coverage. / Beyer, V.; Campbell, Stuart; Ramsey, Gemma; Galloway, Alexander; Moore, A.J.; McPherson, Norman.

In: Science and Technology of Welding and Joining, Vol. 18, No. 8, 11.2013, p. 652-660.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Systematic study of effect of cross-drafts and nozzle diameter on shield gas coverage

AU - Beyer, V.

AU - Campbell, Stuart

AU - Ramsey, Gemma

AU - Galloway, Alexander

AU - Moore, A.J.

AU - McPherson, Norman

PY - 2013/11

Y1 - 2013/11

N2 - A shield gas flow rate of 15–20 L min21 is typically specified in metal inert gas welding, but is often adjusted to as high as 36 L min21 by welders in practice. Not only is this overuse of shield gas wasteful, but uncontrolled high gas flows can lead to significant turbulence induced porosity in the final weld. There is therefore a need to understand and control the minimum shield gas flow rate used in practical welding where cross-drafts may affect the coverage. Very low gas coverage or no shielding leads to porosity and spatter development in the weld region. A systematic study is reported of the weld quality achieved for a range of shield gas flow rates, cross-draft speeds and nozzle diameters using optical visualisation and numerical modelling to determine the shield gas coverage. As a consequence of the study, the shield gas flow has beenreduced to 12 L min21 in production welding, representing a significant process cost saving and reduced environmental impact with no compromise to the final weld quality.

AB - A shield gas flow rate of 15–20 L min21 is typically specified in metal inert gas welding, but is often adjusted to as high as 36 L min21 by welders in practice. Not only is this overuse of shield gas wasteful, but uncontrolled high gas flows can lead to significant turbulence induced porosity in the final weld. There is therefore a need to understand and control the minimum shield gas flow rate used in practical welding where cross-drafts may affect the coverage. Very low gas coverage or no shielding leads to porosity and spatter development in the weld region. A systematic study is reported of the weld quality achieved for a range of shield gas flow rates, cross-draft speeds and nozzle diameters using optical visualisation and numerical modelling to determine the shield gas coverage. As a consequence of the study, the shield gas flow has beenreduced to 12 L min21 in production welding, representing a significant process cost saving and reduced environmental impact with no compromise to the final weld quality.

KW - MIG

KW - CFD

KW - gas shielding

KW - shadowgraphy

KW - porosity

U2 - 10.1179/1362171813Y.0000000143

DO - 10.1179/1362171813Y.0000000143

M3 - Article

VL - 18

SP - 652

EP - 660

JO - Science and Technology of Welding and Joining

T2 - Science and Technology of Welding and Joining

JF - Science and Technology of Welding and Joining

SN - 1362-1718

IS - 8

ER -