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MIG Welding Gases
Carbon Steel
| Metal | Gauge | Mode of Metal Transfer | Recommended Gas | Comments |
|---|---|---|---|---|
| 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 StarGold C-15 StarGold 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
| Metal | Gauge | Mode of Metal Transfer | Recommended Gas | Comments |
|---|---|---|---|---|
| Coated Steels | All | Short, Spray and Pulsed | HeliStar GV |
|
Stainless Steel
| Metal | Gauge | Mode of Metal Transfer | Recommended Gas | Comments |
|---|---|---|---|---|
| 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
| Metal | Gauge | Mode of Metal Transfer | Recommended Gas | Comments |
|---|---|---|---|---|
| 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 HeliStar 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 |