Avoiding Porosity During Welding: How to Achieve Effective Gas Purging

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The production of defect-free welds is crucial if high strength is mandatory. The presence of porosity, in particular, can lead to a significant reduction in mechanical properties.

Joint failure inevitably leads at best to costly repair work but interruption of production can be even more expensive; the worst scenario is injury and loss of life.

Gases such as hydrogen, oxygen, and nitrogen are soluble in many liquid metals. As the metal cools and eventually solidifies, the solubility decreases, and the gas is then released causing porosity. To prevent porosity from forming during fusion welding it is essential that hydrogen, oxygen, and nitrogen are excluded from the welding environment.

This is best achieved by displacing these gases by flushing with an inert gas such as argon which is far less soluble in liquid metal than most other gases. The process is referred to as purging. 

In circumstances where welds have to be designed to withstand stress in service, special consideration needs to be given to their metallurgy and profiles.

The mechanical properties of welds, particularly their fatigue properties, can be influenced significantly by their shape and composition. In particular, at the weld root, a positive reinforcement combined with a smooth transition from weld to base metal is a prerequisite to achieving optimum mechanical strength.

Good Practice

Joints of high quality between cylindrical sections such as tubes and pipes can only be made by ensuring that atmospheric gases are eliminated and positive, smooth weld reinforcement is provided.

The presence of oxygen, and to a lesser extent, nitrogen around the molten weld can lead to wide-ranging defects. The discoloration is unsightly and, in some instances, might indicate a metallurgical imbalance, especially with many stainless steels.

Gross oxidation inevitably results in a reduction of mechanical properties and can cause catastrophic loss of corrosion resistance. Nitrogen contamination can result in brittleness. Gases in the weld may give rise to cracking during or after cooling.

It is clear that a reduction in the weld section at the root, as evidenced by a concave geometry, will reduce the joint strength. Perhaps not so evident, but in many applications of crucial importance is the presence of notches or cracks, which tend to appear at the weld/base metal interface. These can propagate in service and cause failure.

Basic Principles

Weld root quality when making tubular joints can be ensured by applying appropriate safeguards based on the displacement of air from the fusion zone by inert gas. This is achieved by gas purging, and the general principles are shown in figure 1 below.

Purging Gases

The most commonly used purging gas in Europe is commercial quality argon; in the U.S., helium has been in more general use.

The materials being joined and the welding process used are two main factors in the selection of the optimum inert gas or gas mixture. Purge gas flow rate and pressure also need to be established, and once selected, they should be included in the formal welding procedure.

Variation in purge gas quality may arise during welding, and it may be desirable to apply continuous gas monitoring, especially to control oxygen and moisture content. For this purpose, dedicated Weld Purge Monitors and Dewpoint Monitors are available commercially.

Purging Procedure

The first requirement is to provide gas entry and exit points. Gas is fed through one end seal with an exit hole at the other end. Argon has a greater density than air and the gas inlet should be at a lower elevation than the exhaust end so that air is expelled effectively from the pipe bore. The converse applies to helium which is less dense than air.

Purging Techniques

On small pipes and tubes, where the internal volume is small, the cost of continuous flow purging may not be significant. However, problems can arise due to turbulence inside the tube, making air displacement difficult.

The most effective purging systems are those which locate seals on either side of the joint and displace air with inert gas, at the same time monitoring potentially damaging residual gases such as oxygen and hydrogen to ensure that they meet the requirements in the welding schedule.

The presence of oxygen can lead to oxidation and loss of corrosion resistance. Hydrogen is a major cause of porosity in weld metal.

It is also important that potential leak paths in the seals or delivery pipelines are eliminated.

Water-Soluble Purge Film

Soluble barriers cut to pipe size and glued or taped to the internal diameter provide some degree of protection and the discs can be removed by flushing with water after use. The bond to the pipe can be prone to leakage however and the time and skill involved in preparation can be considerable.