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Welding

In welding, the process gas is a decisive quality factor: it influences arc stability, penetration, heat input and reproducibility. GASYCO supplies digital gas mixing and analysis systems that deliver precise shielding gas mixtures, ppm doping and documented gas quality directly at the point of use.

Request a systemDevices used
Automated welding system with robot arms in a production hall
System overviewWelding
Hover over a device – we'll show you what it looks like and what it can do.Tap a device to see the details.
Cloud DashboardRemote accessAlarms 01Gasyco complete system 02Existing system · Gasyco retrofitted Ar / N2Liquid tankCO2 O2 HeCO2 18 % ZeroTest Gas Mixer GAMIBufferLine rupture & leak monitoringRobotic weldingCalibration gasesGas Analyser GANMechanical mixer · bufferLine rupture & leak monitoringManual welding ArLiquid tankCO2 CO2 CO2 CO2 · cylindersGas Mixer GAMIAr/CO₂ exactly to recipeLine rupture &leak monitoringProtects the ring mainGas Analyser GANContinuous analysisRobotic weldingShielding gas at the weld
Precise shielding gas mixtures for reproducible welding processes
Gas Mixer GAMI

Digital control enables reproducible shielding gas mixtures, from classic percentage mixtures to precise ppm doping. Recipes can be adapted flexibly and process data is documented automatically.

Flow rate0–5,000 ln/min (higher on request)
Gas inletsflexibly configurable
Mixing rangeppm to %
View product page
More safety for central shielding gas supplies
Line Rupture and Leak Monitoring

The system continuously monitors gas lines for unusual flow rates and carries out automated leak tests. Leaks, line ruptures or connections left open can therefore be detected early.

Flow rate2–250 m³n/h
Operating pressure16 barg
AlarmsSMS – Email – Relay
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Continuous monitoring of shielding gas quality
Gas Analyser GAN

The GAN monitors the actual gas composition during the welding process. Deviations are detected, trigger an alarm and are documented together with measurement and calibration data.

Standard gasesCO₂ – O₂ – H₂ – He – H₂O – NO
Measuring rangeppm to %
Calibrationautomatic, with certificate
View product page
01

Make welding gas quality measurable – instead of just trusting it

Modern welding processes place higher demands on shielding and process gases than conventional supply concepts can often meet. Especially with ppm doping, specialty gases, changing recipes or welding processes governed by standards, a mechanically set mixing ratio is often no longer enough. Digital gas mixers control each gas stream precisely, produce reproducible mixtures and document relevant process data automatically.

Where mechanical gas mixers are used in particular, continuous gas analysis offers a decisive advantage: it shows whether the mixture that has been set really stays within the defined limits at all times.

Combined with continuous gas analysis, this creates a verifiable quality chain – from the calibrated measuring system to the finished weld. Deviations are detected early, rejects can be reduced and audits are much easier to prepare.

02

Standard-compliant welding gas quality – measurable and documentable

Welding gases are quality-relevant welding consumables and, depending on the application, are subject to requirements set out in standards, such as EN ISO 14175. In quality-critical welding processes, regulations such as EN ISO 15614-1 for procedure qualification or EN ISO 3834 for quality requirements in welding may also be relevant – EN ISO 3834, for example, in steel construction according to EN 1090-2 depending on the execution class and in railway vehicle manufacturing according to EN 15085-2 depending on the classification level. GASYCO systems make gas quality measurable, controllable and documentable – from precise mixing and continuous analysis to the automatic recording of measured values, calibrations and alarm events.

Applications

Four typical applications in welding.

01

Monitoring mechanical mixers

A mechanical mixer sets a mixture – but it cannot prove it. The gas analyser is retrofitted downstream of the buffer tank, measures the process gas continuously, calibrates itself automatically and reports every deviation immediately. The existing mixer stays.

Signs you need it
  • Audit or end customer demands proof of gas quality
  • Weld defects with an unclear cause
  • The mixture is only spot-checked
  • Several mechanical mixers in the plant
Gas Analyser GAN · retrofittable
02

Exact doping in the ppm range

Small proportions such as 500 ppm O₂ in argon can hardly be kept stable mechanically – even slight fluctuations in pressure or demand shift the mixture. The GAMI controls each gas stream with its own digital flow controller and checks the result with integrated analysis.

Signs you need it
  • Doped mixtures are bought in cylinders
  • Aluminium welding with expensive helium
  • High demands on reproducibility
  • Development and test series
Gas Mixer GAMI with analysis
03

Three gases and more

With every additional gas, a mechanical mixer becomes more complex and less accurate. The GAMI has any number of gas inlets, controls each gas individually and stores recipes – a new mixture is set by touch, with no conversion and no new cylinders.

Signs you need it
  • Mixtures such as Ar/He/CO₂ for stainless steel or Ar/N₂/He for duplex
  • Frequently changing recipes
  • Different materials with their own mixtures
  • New processes or lines being planned
Gas Mixer GAMI
04

Central supply for entire halls

For welding lines with many stations or robot cells, the GAMI mixes standard mixtures such as Ar/CO₂ from a tank and individual gases – up to 5,000 ln/min (300 m³n/h), larger systems made to measure. Inlet and outlet pressure are monitored, and mixture quality too on request.

Signs you need it
  • Many welding stations or robot cells
  • High consumption of cylinder bundles
  • New build or extension of a line
  • Need for central monitoring
Gas Mixer GAMI · up to 5,000 ln/min
Materials & processes

The right mixture for every weld.

AluminiumMIG/TIG
MixtureAr + ppm O₂ instead of Ar/He
SolutionGAMI with O₂ analysis
Duplex, super duplexTIG
MixtureAr + 1–2.5 % N₂, often with He; no H₂
SolutionGAMI, N₂ precisely controlled
CrNi steel (austenitic)TIG
MixtureAr + 2–5 % H₂
SolutionGAMI with H₂ analysis
CrNi steelMAG
MixtureAr + 2.5 % CO₂, also with He
SolutionGAMI for three gases
Structural steelMAG, robot
MixtureAr/CO₂, Ar/CO₂/O₂
SolutionGAMI central or GAN on the existing mixer
Plasma welding and cutting
MixtureAr/H₂
SolutionGAMI with H₂ analysis
PurgingRoot protection
MixtureN₂/H₂, Ar/H₂; for duplex N₂ or Ar/N₂
SolutionGAN portable: residual oxygen
All processes
MixtureResidual moisture in line and storage tank
SolutionGAN: H₂O from 0.1 ppm

Typical guide values – the exact composition depends on the material and process.

In practice

Aluminium welding with no helium at all.

In series production of aluminium structures, a redundantly designed Gasyco mixing system replaces the previous argon-helium mixture with argon containing 500 ppm oxygen – mixed on site, analysed continuously and identical every day.

Ar + 500 ppm O₂mixed and analysed on site
Redundantdesigned for high security of supply
0 % heliumin aluminium welding
Solutions

What Gasyco changes in the welding industry.

01

Reproducible shielding gas mixtures

Digital mass flow controllers control each gas stream separately and enable stable mixing ratios in percentage and ppm ranges.

02

More process reliability

Deviations in gas composition, pressure, flow or analysis values are detected, trigger alarms and are documented. Pressure monitoring is integrated as standard.

03

Fewer premixed cylinders

Pure gases or liquefied gases are mixed directly on site – less transport, lead time and logistics.

04

Better verifiability

Data logger, remote access and optional cloud reporting evaluate process data over defined periods.

Standards & regulations

Which regulations apply here.

From our projects we know that these standards and guidelines come up again and again in the industry – at acceptance, in audits or during qualification. Gasyco systems provide the measured values, calibration data and records you need as evidence.

EN ISO 14175Shielding gases for welding – classification, purity and permissible residual moisture; required in steel construction via EN 1090-2.
EN ISO 15614-1Qualification of welding procedures.
EN ISO 3834-2Comprehensive quality requirements for fusion welding – required by EN 1090-2 for EXC3 and EXC4 and by EN 15085-2 for CL 1.
EN 1090-2Execution of steel structures (edition 2018+A1:2024): specifies the welding quality according to EN ISO 3834 for each execution class and requires shielding gases according to EN ISO 14175.
EN 15085-2Welding of railway vehicles and components, requirements for welding manufacturers (edition 2020+A2:2025): specifies the welding quality according to EN ISO 3834 for each classification level.
Frequently asked questions

The right questions. The right answers.

Isn’t a mechanical mixer cheaper?

To buy, yes. Over its service life, a Gasyco system pays off: very low maintenance, no spot measurements by technicians and no on-site calibration – the device does that automatically. Add to that what an undetected wrong mixture costs: rework, rejects, complaints.

Our mixer works fine – why change anything?

It works – but without analysis, nobody knows whether the mixture is right. The gas analyser is simply retrofitted; the existing mixer stays.

Can’t ppm mixtures be set mechanically too?

Set, yes – keeping them stable and proving it, hardly. The GAMI controls each gas stream digitally and measures the result continuously.

We buy ready-made mixtures. What does mixing on site bring?

You save cylinder logistics and waiting times and produce every recipe from ppm to per cent yourself – from the individual gases you already buy.

How do I prove gas quality in an audit?

Measured values, alarms and calibration certificates are stored automatically and are available in the Gasyco Dashboard as a report for any period.

Who notices when something goes wrong?

The device itself: an alarm by SMS, email or relay contact as soon as a limit is exceeded.

How secure is our data?

The Gasyco Cloud is hosted in Austria. With Connect Enterprise you can also integrate Connect into your existing IT – with your own login and in line with your security policies.

Is the GAMI suitable for 20 MAG welding stations, for example?

Yes. An example: 20 stations at 15 l/min each need 300 l/min if all are welding at once – in operation, usually only 60 to 70 % are welding. The GAMI is designed for total flows of up to 5,000 ln/min, supplies all stations centrally via the ring main and is configured to your peak demand and your gases.

When do I need a buffer tank?

A buffer tank is needed when demand fluctuates, for example at several manual welding stations – unless the volume of the ring mains replaces the tank. The GAMI fills it and the stations draw from it. Controlling directly to a target flow is only recommended if the consumer – such as a laser welding system or a welding robot – runs for more than one minute on average, can briefly pre-purge and sends the GAMI an on/off signal, e.g. 24 V DC. Gasyco sizes the tank with you.

What happens if a gas runs low or the line leaks?

The GAMI monitors inlet and outlet pressure as standard and gives early warning of low supply pressure by SMS or email. For the ring main to the stations, there is line rupture and leak monitoring – integrated into the mixer or stand-alone.

Contact

Let’s talk about your system.

From design to commissioning – we plan your gas supply as a connected complete system.

+43 1 595 11 12-0Request a consultation