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Short Circuit, Globular, Spray, and Pulsed Spray data for robotic welding thin gauge applications using an .035 (1mm) wire with argon + 10 to 15 CO2
Material Thickness Weld Transfer mode Wire Feed Rate Welding Voltage Weld Travel Rate In./Min.
20-18 gauge no gaps, weld vert. down Short Circuit 210-240 ipm 16-17.5 30-45 ipm
17-15 with gaps, weld vert down Short Circuit 260 -300 ipm 17-18 30-40 ipm
17-15 gauge no gaps Short Circuit 260-380 ipm 18-19 30-40 ipm
17-15 gauge no gaps Pulsed Spray 350-400 ipm 22-26 30-50 ipm
14 gauge with gaps Short Circuit 280-350 ipm 18-20 30-50 ipm
13-14 gauge no gaps Short Circuit 380-420 ipm 20-21 40-60 ipm
1.9-2mm Spray Transfer 500-650 ipm 23-27 40-70 ipm
12-10 gauge Spray Transfer 600-750 ipm 24-28 50-70 ipm
 
SHIELDING GASES FOR GMAW
Base metal Thickness, in. Shield gas Advantages
GMAW SHORT-CIRCUIT TRANSFER
Carbon steel Up to 14 gage Argon-8 CO2 Argon-10%CO2 Good burnthrough and distortion control. Used also for spray-arc-welding.
14 gage-1/8 Argon-25 CO2 High welding speeds without burnthrough. Minimum distortion and spatter. Best puddle control for out of position welding. Provides best mechanical properties for any given wire.
Over 1/8 Argon-25 CO2 High welding speeds without burnthrough. Minimum distortion and spatter. Best puddle control for out of position welding. Provides best mechanical properties for any given wire.
Over 1/8 50 Argon-50 CO2 Deep penetration; low spatter
Over 1/8 CO2 Deep penetration. Faster welding speeds. High amount of spatter.
Carbon steel Up to 14 gage Ar-8 CO2 Good burnthrough and distortion control. Used also for spray arc welding.
Over 14 gage Ar-25 CO2 For use where corrosion resistance is not mandatory.
Over 14 gage Ar-CO2-He No effect on corrosion resistance. Small heat-affected zone. No undercutting, minimum distortion. Good bead shape and mechanical properties.
Low-alloy steel Up to 14 gage Argon-8 CO2 Argon-10%CO2 Good burnthrough and distortion control. Used also for spray arc welding.
Over 14 gage Ar-CO2-He Excellent arc stability, welding characteristics, bead contour. Little spatter. High impacts.
GMAW-SPRAY TRANSFER
Carbon steel All Argon-5 CO2 Improves droplet rate and arc stability.
Argon- 8% CO2, Argon 10% CO2 Produces a fluid, controllable weld puddle; good coalescence and bead contour. Minimizes undercutting; permits higher speeds.
Argon-18 CO2 Suitable for high current welding.
Low-alloy steel Up to 3/32 Argon-2 O2 Reduces undercutting. Improves coalescence and bead contour. Good mechanical properties.
Over 3/32 Argon-8 CO2 Argon-10%CO2 Excellent arc and weld characteristics.
Stainless Steel More Than 14 gauge. Pulsed spray Argon-1 CO2 Good arc stability. Produces a fluid and controllable weld puddle; good coalescence and bead contour. Minimizes undercutting.
Argon-2 O2 Can be used on the more sluggish alloys to improve puddle fluidity, coalescence and bead contour.
Argon-He-Co2 Used for both light-gauge and heavy out-of-position weldments.
He-Argon-Co2 Achieves good pulsed spray stability over a wide range of arc characteristics and deposition
Argon-Co2-H2 ranges.
Aluminum Up to 1/2"  Spray or pulsed Argon Base metal transfer, arc stability and plate cleaning. Little or no spatter.
  Remove oxides when used with DCEP.
More than 1/2" Argon + He High heat input. Produces fluid weld pool, flat bead contour and deep penetration.
He + 20 to 50% Argon Minimizes porosity.
   
Short Circuit, Globular, Spray, and Pulsed Spray data for robotic welding of steel using .045 (1.2mm) wire and Argon plus 10% to 15% CO2. These parameters are to be used as a starting point

Material
Thickness

 Weld Transfer mode Wire Feed Rate Welding Voltage Weld Travel Rate In./Min. Deposition
14 gauge with gaps Short Circuit 210-280 ipm 18-19 30-60 ipm 6-8lb/hour
13-14 gauge no gaps Short Circuit 280-320 ipm 19-20 40-60 ipm 6-9lb/hour
2mm Spray Transfer 360 ipm 24-26 45-65 ipm 10lb/hour
12-10 gauge Spray Transfer 360-420 ipm 24-26 40-85 ipm 10lb/hour
3/16" Spray Transfer 400-450 ipm 25-27 30-70 ipm 11-13lb/hour
1/4" Spray Transfer 450 ipm 26-28 20-35 ipm 13lb/hour
5/16"-3/8" Spray Transfer 500-600 ipm 27-32 10-18 ipm 14-17lb/hour
 
GMAW PARAMETERS -- STAINLESS STEEL. These parameters are to be used as a starting point.

Base-material
thickness (in.)

 Wire-feed speed
(in./min)
0.035-in.		 VOLTAGE, v Current A
75-Ar-25 CO2 90 He-7.5 Ar-2.5CO2 Ar 98-Ar-2 O2
  0.048 120-150 16 19.7 - - 50-60
  0.060 180-205 17 20 --- --- 70-80
  0.075 230-275 17.7 20.5 --- --- 90-110
  0.10 300-325 18 20.7 20 --- 120-130
  3/16 350-375 18.5 20.7 21 --- 140-150
  1/4 400-425 19 21.2 22 23.5 160-170
  5/16 450-475 19.5 21.5 23 24.5 180-190
  3/8 use 0.045 20.2 --- 24 25 200-210
  7/16 use 1/16 22 --- 25 26.5 220-250
  1/2 and up --- 26 --- 29 31 300