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Reducing or Eliminating the use of Helium
in GMAW and GTAW Applications
on Aluminum
Improve Productivity & Quality; Reduce Total Cost
MATHESON QuickView
Application Review and Summary

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Helium Supply Update
• Helium is a non-renewable resource
• Helium supply is subject to variability
– Helium prices fluctuate … and the future is unpredictable
• For welding applications, alternatives to helium exist
– Many of the alternatives offer advantages
Now is the time to consider shielding gas
alternatives that use less - or zero - helium.

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Why use Helium?
• Helium creates a high energy arc
– High ionization potential (24.5874 eV)
– Produces hotter arc (at higher voltages)
• Produces a shallower, wider bead profile
– Effect is proportional to Helium concentration
• Can be advantageous on thicker aluminum sections
• Useful on aluminum, magnesium, copper alloys
• Helium when blended with Argon, CO2, and other gases, creates a
mixture with blended characteristics
Frequently Specified Applications:
Pure Helium or mixtures containing Helium for Aluminum
Mixtures rich in Helium – typically 90% - for Stainless Steel

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Helium’s Disadvantages
• Helium’s high ionization potential leads to:
– Less stable arc – can lead to inconsistent results Disadvantages
are proportional
– Hotter arc – can lead to distortion & warping to Helium
concentration
• Helium can lead to penetration issues
• Helium can increase spatter
• Helium is a light atom and a less effective shield
– Helium flow rate per unit of deposited metal is higher than other gases
• Helium is subject to supply and price variability
– The cost of Helium must be considered in high production applications
Using more He
is not the only choice;
and is often not the
best choice.

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GOAL: Reduce or Eliminate Helium Use
• Alternatives to Helium exist
• Helium use can be reduced Consider mixtures
or eliminated optimized for the
• With excellent results: process and
– Better weld penetration application.
– Significant reduction in porosity
– Increased travel speed
– Improved arc stability; less spatter and smoke
– Improved puddle and flow control (smaller droplet)
– Reduced Heat Affected Zone (HAZ)
– Less heat-related damage to base material
– Reduced burn-through on thin materials
– More flexibility to use other processes (spray and pulsed spray, in addition to short
circuit)

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GMAW / GTAW on Aluminum

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Aluminum GMAW
• Outdated: 100% Argon
– Good appearance, but rapid solidification traps porosity
– Oxides are not sufficiently cleaned
– Poor, finger-style penetration
– Very little arc energy

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Aluminum GMAW
• Imperfect solutions:
Ar-He mixtures with 25%, 50% or 75% He
– Improved penetration, reduced porosity
– MATHESON Select® He-25 is a good alternative to higher He
concentrations
• Addresses the issues with 100% Argon
• Uses less Helium than other options

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Aluminum GMAW
• MATHESON Select® APN-10
– Uses no Helium
• Hybrid composition includes Nitrogen
– MATHESON patent pending
– Outperforms Ar-He mixtures
• Higher energy, but more stable … at lower voltages
• Improved penetration and shape; reduced porosity Porosity is a
frequent
• Reduced heat affected zone
problem with
100% Argon

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Aluminum GMAW and GTAW No usiv
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rea ixtur our
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its.
• MATHESON offers TWO Helium-free, Nitrogen-doped
shielding gas mixtures
– APN-7 GTAW, GMAW for Aluminum
– APN-10 GMAW for Aluminum
• APN-7 and APN-10 offer:
– Excellent penetration
– Reduced heat affected zone
– Reduced porosity
– Travel speeds at the same level or
better than with Helium addition in
traditional mixes

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In Review …
• Forward thinking leads to better solutions
Thank you
• Use of less – or zero – Helium can: for your
– Produce better results time!
– Improve cost per weld
• Easily applied in GMAW and GTAW on Aluminum
• We are here to support you
• Learn more: contact your MATHESON rep or visit one of
our stores
• Find us fast at: www.MathesonGas.com/contactus.aspx