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MIG Gases

 

 

 

Metal Gauge Mode of Metal Transfer Recommended Gas Comments

Carbon Steel

Carbon Steel Up to 1/8" Short Arc StarGold C-25; MIG Mix Gold Good penetration/gap bridging ability
Carbon Steel Up to 1/8" Pulsed Spray StarGold C-5; Stargon CS Higher deposition rates without burnthrough; minimum spatter; good puddle control out-of-position
Carbon Steel Over 1/8" Short Arc StarGold C-25; MIG Mix Gold High welding speeds, good penetration and puddle control; applicable for out of position welds
Carbon Steel Over 1/8" Short Arc and Globular Arc (Buried Arc) CO2 Deep penetration and fast travel speeds but with higher burnthrough potential and more spatter; high current mechanized welding
Carbon Steel Over 1/8" Spray Arc  MIG Mix Gold; StarGold C-10; C-15; O-5 Good arc stability; produces a more fluid puddle as O2 equivalent increases; good coalescence and bead contour; good weld appearance puddle control, low spatter
Carbon Steel Over 1/8" Short Circuiting and Spray Transfer StarGold C-15; Stargon CS; MIG Mix Gold Applicable to both short circuiting and spray transfer modes; has wide welding current range and good arc performance; weld puddle has good control which results in improved weld contour
Carbon Steel Over 1/8" Pulsed Spray  StarGold C-5; Stargon CS Used for both light gauge and out of position weldments; achieves good pulsed spray stability over a wide range of arc characteristics and deposition ranges
Coated Steels
Coated Steels All Short, Spray and Pulsed HeliStar GV
  • Lower welding fume than FCAW
  • Good bead shape
  • Low spatter
  • Controlled penetration
  • Low porosity
  • Higher productivity
Stainless Steel
Stainless Steel Up to 1/16" Short Circuiting  Stargon SS; StarGold C-2 Good control of burnthrough and distortion; used also for spray arc welding; puddle fluidity sometimes sluggish, depending on the base alloy
Stainless Steel Over 1/16" Short Circuiting Transfer HeliStar A-1025; Stargon SS; HeliStar SS  Low CO2 percentages in each mix minimize carbon pick up, which can cause intergranular corrosion with some alloys; helium improves wetting action; applicable for all position welding
Stainless Steel Over 1/16" Spray Arc  HeliStar SS; Stargon SS; StarGold 0-1 Good arc stability; produces a more fluid  but controllable weld puddle; good coalescence and bead contour; minimizes undercutting on heavier thickness
Stainless Steel Over 1/16" Pulsed Spray  HeliStar SS; Stargon SS; StarGold 0-1 Used for both light gauge and heavy out-of-position weldments; achieves good pulsed spray stability over a wide range of arc characteristics and deposition ranges
Aluminum
Aluminum Up to 1/2" Spray Arc  Argon Best metal transfer, arc stability, and plate cleaning; little or no spatter; removes oxides when used with DCEP (Reverse Polarity)
Aluminum Up to 1/2" Spray Arc  HeliStar A-25 High heat input; improves puddle fluidity; flat bead contour and deep penetration; minimizes porosity
Aluminum Over 1/2" Spray Arc  HeliStar A-25 ; A-50 High heat input; good for mechanized welding and overhead; applicable to heavy section welding
Aluminum Over 1/2" Pulsed Spray  Argon Good wetting; good puddle control
Nickel and Copper Nickel Alloys
Nickel and Copper/Nickel Alloys Up to 1/8" Short Circuiting HeliStar SS ; StarGold 0-1 Good arc stability ; weld puddle control and wetting
Nickel and Copper/Nickel Alloys Over 1/8" Short Circuiting HeliStar SS; HeliStar A-1025 Higher heat input of helium mixtures offsets high heat conductivity of heavier gauges; good wetting and bead contour; can be used for out of position welding
Nickel and Copper/Nickel Alloys Over 1/8" Pulsed Spray  HeliStar SS; HeliStar A-75; Argon  Used for both light and heavy gauge out of position weldments; achieves good pulsed spray stability over a wide range of arc characteristics and deposition ranges