Rating of the best gas reducers for welding for 2022

A gas welding reducer is extremely necessary when gas in cylinders is used as an active substance in a welding machine. Such a simple device is designed to reduce the pressure in the balloon tank, as well as to monitor the performance of the injection of a gaseous substance.

Design features of the device and the principle of operation

The main function that any gas reducer for semi-automatic welding performs is the fine adjustment of the injection of carbon dioxide or other gaseous substance supplied to the welding torch. Regulation is required not only to lower / increase the level, but also to equalize it. The design of the gear unit consists of:

• intake/exhaust valves;
• Chambers equipped with membrane regulators;
• Sealing elements;
• Control and upper springs;
• connecting fittings;
• outer case;
• Various manometers;
• The valve responsible for the manual closing / opening of the gas supply.

The simplest version of the considered device has only one functioning camera. The gas from the balloon tank is transferred into the device under pressure, which is set by the inlet pressure gauge. Then it is in the primary fitting, and then, bypassing the chamber, the gas flow meets resistance from the spring. Due to the fact that the pressure is quite large, the spring moves back and the gas jet rushes into a special cavity. The cross section of the chamber has a diameter many times larger than at the inlet to the fitting, therefore, the second pressure gauge registers a decrease in pressure.

A special screw allows you to adjust the degree of tension of the main spring.It adapts to the initial pressure in the cylinder. The control spring moves down together with the membrane. Thus, the gas flow is able to approach the shut-off valve without any obstacles. Finally, the gas goes directly to the burner.

Most often, the diaphragm is made of an oil-resistant rubber base and can be clearly positioned relative to the outlet. Hence, there is a decrease in the flow pressure inside the cylinder. The gearbox can also be controlled in manual mode - for this you just need to screw in / unscrew the screw to the required mark. However, such a control mode requires special accuracy and constant verification with the pressure gauge parameters.

Types of gases for which the use of reducers is mandatory

When using a certain gas when welding with a semi-automatic device, you should be fully familiar with its physical and chemical characteristics. For welding, the following classification of working gases is used:

• Active;
• inert;
• gas mixtures.

The choice of welding machine and the reducer used in it will depend on the choice of working gas.

Hydrogen

It is widely used for aluminum parts welding and stainless steel plasma cutting. It is odorless and colorless, has explosive properties. When interacting with water / air forms an explosive mixture. It is produced through the synthesis of water by separating hydrogen and oxygen molecules in special generators. Regulatory documents of the Russian Federation in the field of industrial safety prohibit the storage of such gas in cylinders where the pressure exceeds 15 MegaPascals, which must be regulated using a reducer.

Acetylene

This organic compound is the most widely used.This gas is lighter than air and has no color, despite the fact that it has a specific odor and an increased combustion temperature. It is used specifically for cutting metal objects. Acetylene, in industrial conditions, is produced using special generators, where water interacts with calcium carbide. The main disadvantage is the complexity of storage, because carbon carbide is sensitive to the absorption of moisture from the environment.

Natural gas group

These include hydrocarbon compounds such as butane, propane or methane. The gases of this group are excellent for welding and are amenable to reducer regulation. Their main advantages are low price and wide distribution. Even the requirements for their storage are not very complicated - it is quite possible to store them in a cylinder on the street in a special cage (open) under a canopy. Artificial production is impossible, mining is carried out only from natural deposits.

coke oven gas

It is an accidental product of the coke industry, formed during the coke production. He himself has no color, but has a pungent odor. Gas belongs to the category of explosive, however, the rules for its storage do not impose particularly strict requirements (unlike hydrogen). Traditionally, the movement of gas occurs through long pipelines. It is not very popular due to the peculiarities of obtaining and is used only in the locations of the coke industry.

Pyrolysis

This type is qualitatively different from others, because it does not need to be generated specially. Pyrolysis is a natural process that occurs during the breakdown of petroleum products.Prior to use, it is subjected to pre-cleaning in order to remove excess chemical activity that can harm the welding machine torch and gearbox design. Equally good for welding and cutting metal.

Pure gas group

This group includes the following gaseous substances:

• Argon - in its pure form is used for argon arc welding. It can be included in various mixtures as one of the elements. Its chemical inertness makes argon an ideal choice for machining refractory metals. It is characterized by low thermal conductivity and low ionization potential.
• Helium is another representative of the group of chemically inert gases. Unlike argon, it has a higher degree of thermal conductivity and a higher ionizing potential. However, these properties of it create a greater heat input than argon, due to which the welding profile is expanded.
• Carbon dioxide gas is the cheapest gas, which provides it with sufficient popularity when carrying out welding work in limited conditions. Its positive qualities can be called deep penetrating ability, which is especially important when processing thick steel. The main disadvantage is the poor stabilization of the gas welding arc, which creates a large amount of unnecessary spatter. It is characterized by the fact that its use is allowed without combination with inert gases.

Gas components of the mixture

These include such a gaseous substance as oxygen. Its increased chemical activity affects the percentage in the mixture - the mass fraction does not often exceed from 7 to 10%. For example, a mixture of oxygen and argon has a high degree of penetration. The resulting weld is extremely similar to the "nail head" (for visual similarity).Modern gearboxes are able to work perfectly with multicomponent mixtures, for example, carbon dioxide + argon + oxygen, the percentage ratio of which will not play a special role.

Current regulations in the Russian Federation, types of gearboxes and technical standards

For semi-automatic welding purposes, multi-chamber regulators are commonly used. Although, single-chamber designs are traditionally used. Nevertheless, the presence of several chambers will be justified when welding work is carried out at low ambient temperatures - in this case, a gearbox model is required with at least two chambers, the compartments of which are arranged in a sequential order.

The Russian Federation has its own and interstate regulatory documents governing the circulation of gas reducers for welding:

1. State Standard No. 12.2.052 of 1980 - safety requirements when working with gaseous oxygen;
2. State Standard No. 13861 of 1989 - operation of gearboxes in flame treatment;
3. ISO (international) No. 2503 of 1983 - Specification for gearboxes in flame applications.

Most carbon dioxide welding regulators can vary in terms of use. Ramps are used in multi-post areas for welding. Network models can receive flow from a stationary gas pipeline that communicates with a carbon dioxide industrial plant. For small construction sites and at home, balloon reducer units are classically used. They, in most cases, are created, counting on a somewhat underestimated specific consumption of carbon dioxide and an extended spread in pressure indicators. Opening and closing of the inlet valve assembly can be performed in reverse or direct manner.

The oxygen reducer functions in much the same way as its carbon dioxide counterpart. The differences are only in the ways of connecting to the valves and in the number of pressure gauges used (most often 2 pieces). They must meet stringent performance requirements. The reason lies in the fact that oxygen is not able to be contained in a liquefied form, therefore, the pressure inside the cylinder may well reach 200 atmospheres, in contrast to carbon dioxide, for which this figure is 70-80 units. If you try to conduct oxygen through a carbon dioxide reducer, then the sealing membranes will collapse over time. But the reverse replacement (CO2 wiring through the oxygen regulator) is quite acceptable. This is possible due to the fact that the oxygen reducer unit is connected to the cylinder through a clamp, which makes the connection safer in terms of fire or explosion, and the supply itself occurs by unscrewing the swing nut.

IMPORTANT! If there are any doubts about the purity of the gaseous substance used, in order to prevent premature wear of the regulator design, it is worth using special filters!

The domestic industry produces all known types of gas regulators. Especially popular is the type "UR 6-6", as the most versatile. The standard requirements that apply to the technical characteristics of the samples under consideration are:

• Execution of the body of the device from a heat-resistant material;
• Gas pressure heterogeneity is set to a maximum of 0.3 units;
• The safety block must operate at an indicator of 1200 KiloPascals;
• It is desirable to equip with two pressure gauges - it is easier to monitor the gas pressure;
• The maximum flow rate is 6 cubic meters per hour.

In principle, these parameters are not universal - if they are not enough, then it is possible to use additional devices with rotors. They are able to instantly set and record the flow rate. However, these systems will cost the user far from cheap.

Labeling and interchangeability issues

First things first, you need to pay attention to the adjusting screw. The best solution would be a model with captive threads, if it does fall out, then the informing font will be completely different, as well as there will be a risk of screwing the saddle. At the same time, the presence of a shut-off valve will also be useful. All these data are also additionally indicated in the accompanying documents for the gear unit.

According to the current gradation, the devices in question differ in the following colors:

• Blue background with black inscriptions - for oxygen;
• Black background with blue inscriptions - for engineering type argon;
• White background and red font - for acetylene;
• Dark background and white font - raw argon;
• The dark background and yellow font are for carbon dioxide.

The issue of interchangeability of reducers for gases of various types is rather complicated. In Prince, it is not forbidden to apply an oxygen regulator to argon gas and vice versa. However, a device designed for oxygen will work much worse with argon if the pressure drops below 1 atmosphere. According to the current GOSTs and ISO, the best device for argon is the AR-40-2 type. If it is supposed to pass both carbon dioxide and argon, then AR-40 / U-30 will be a good choice.

At special production sites, it is preferable to use specialized types, for example, "UR-6-4DM" and analogues.As a rule, in addition, they are equipped with a pair of rotameters, but gas should not be supplied through them simultaneously to two or more burners. The purpose of such models is quite specific - to approach the issue of industrial safety more responsibly. Thus, one flow unit will be busy supplying flow to the burner, and the other will be busy controlling blowing from the opposite side.

The nuances of a competent choice

In order not to make a mistake in choosing the right gas reducer for welding, you should pay attention to the following points:

• Type of welding machine on which the regulator is supposed to be installed;
• Estimated volume of gas consumption;
• Indicators of inlet/outlet pressure;
• Required adjustment accuracy;
• Throughput of the selected device.

Starting operation of the gear unit

Prior to the direct installation of the device on the cylinder, it is imperative to make sure that the thread of the union fitting and the thread of the inlet nut are intact. In addition to integrity requirements, they must be free of any contamination (oil and grease stains, large fragments of dirt, etc.). It is also necessary to check the presence and integrity of the fiber gasket and the inline filter - they must be in good condition. Further, before the first start-up, the cylinder should be purged, for which it is necessary to open the valve for a short time until all foreign fragments come out. Only then does the process of mounting the reducer device directly to the cylinder begin. The operation is carried out using a special key, usually attached to any welding machine.

IMPORTANT! It is forbidden to tighten the union nut of the regulator when the cylinder valve is open!

When carrying out large-scale welding work and within the framework of sufficient logistics, it is preferable to use a gearbox model not with pressure gauges, but with rotameters. They can control the amount of gas flowing qualitatively more precisely and provide more specific visual control of their recording elements, which will allow even the smallest leak to be detected.

Rating of the best gas reducers for welding for 2022

Budget segment

2nd place: "Krass BPO 5 3"

This unit is a single stage model and is used with propane tanks. Its throughput is set at 5 cubic meters per hour at a maximum working pressure of 4 MegaPascals. The case is made of powerful brass, it is sufficiently resistant to mechanical damage, especially since innovative technologies are used in the design. The pressure in the passing stream is measured quite accurately and on an uninterrupted basis. It is worth noting that the diameter of the permeable membrane increased to 38 millimeters, as well as the presence of a protective valve in the chamber. The recommended retail price is 1050 rubles.

• Durable brass body;
• Enlarged membrane;
• Safety valve in the chamber.

• Not detected.

1st place: "Svarog BPO 5-5"

This device is used to work with natural gases, more specialized in propane. The throughput is 5 cubic meters per hour, the maximum inlet pressure is calculated at 2.5 MegaPascals. The standard operating pressure is set to 0.3 MegaPascal. It has a good adjustment accuracy, shows the current consumption figures during welding.The control valve is easy to use and reliable, the pressure gauge has a clear scale with well-read numbers. The design includes a fuse valve and nipple, which are responsible for quick and safe connection. The case is made on the basis of aluminum, slightly susceptible to corrosion. The gearbox itself can also be used at sub-zero temperatures down to -25 degrees Celsius. The recommended retail price is 1200 rubles.

• It is possible to work at low temperatures;
• Aluminum housing resists corrosion;
• The presence of a protective nipple.

• Not detected.

Middle price segment

2nd place: "BPO-5-4M KEDR 1310005"

Oxygen gas reducer, well proven for small welding applications. Fasteners have a reliable thread and can be attached even to composite cylinders. The maximum throughput is 5 cubic meters per hour, with a maximum working pressure of 4 MegaPascals. The case is made of aluminum, has an anti-corrosion coating. Installation is easy and hassle-free. In addition to working with welding machines, it can also work with gas heat guns. The recommended cost for retail chains is 1300 rubles.

• Quality manufacturing;
• Versatility of application;
• Work accuracy.

• Problems when connecting to some types of composite cylinders.

1st place: "Krass UR 6 6"

A high-quality carbon dioxide single-stage model, which is characterized by a high accuracy of adjusting the pressure of the gas flow coming from the cylinder.The design is equipped with two pressure gauges, the design of which is completely sealed and protected by special covers that provide additional safety during transportation. The case of the device is made of high-quality brass, its resistance to external mechanical damage is noted. The membrane diameter is expanded to 38 millimeters, there is an additional protective valve. The adjustment valve has the qualities of versatility, which improves the accuracy of the whole process. The throughput is 15 cubic meters per hour, with a maximum working pressure of 7 MegaPascals. A special safety nipple ensures quick and easy connection of hoses, and the operating temperature range is from -25 to +50 degrees Celsius. The recommended cost for retail chains is 1600 rubles.

• Extended operating temperature range;
• Increased throughput standards;
• The presence of two manometers.

• Not detected.

Premium class

2nd place: "BAMZ BPO-5-4"

Completely focused on carrying out gas-flame work model. Although the sample is equipped with only one pressure gauge, the correction valve has a convenient location and is easy to operate. The throughput declared by the manufacturer is 5 cubic meters per hour, at an operating pressure of 3 MegaPascals. The high price of this model, with all its more than standard functionality, is due to the presence of a powerful protective valve that can withstand pressures up to 25 MegaPascals. In addition, this model has received special accreditation from Rostekhnadzor and is recommended for use in industrial production.The recommended cost for retail chains is 1800 rubles.

• Accreditation by Rostekhnadzor;
• High protective properties;
• Narrow specialization.

• High price with little functionality.

1st place: "BAMZ BKO-50-4"

This unit is characterized by precise regulation and is able to clearly form and maintain the required pressure at the appropriate level. Its throughput is very high - it can carry up to 50 cubic meters of gaseous substance per hour, despite the fact that the inlet pressure can reach a maximum of 20 MegaPascals. It is equipped with a pair of pressure gauges, the dials of which have clearly distinguishable numbers and a scale. In the main gear assembly there is a valve with a membrane made of a special material, which can successfully resist grease contamination. The adjustment valve easily and simply changes the degree of compression of the control spring, thereby adjusting the flow pressure. The body of the device is made of brass, which means its high resistance to mechanical stress. The recommended price for a store sale is 2300 rubles.

• Extended functional characteristics;
• Durable brass body;
• Two manometers.

• High price.

Instead of an epilogue

In general, it does not really matter what type of gas will be used for welding - a reducer must be installed in any case. Thanks to this device, it is possible to reduce the pressure in the balloon tank in a timely manner, as well as to calculate the gas flow in time. In principle, even the classic models of geared instruments with pressure gauges are able to provide the proper economy mode.However, for long-term work and in conditions of special tasks, it is better to use samples with rotameters.

At the same time, an analysis of the current Russian market found that it is dominated by a domestic manufacturer. First of all, this is due to the fact that, like any measuring device, the welding gearbox must pass the necessary certification in government agencies. And this fact complicates the launch of foreign products on the Russian market. At the same time, domestic models have sufficient functionality and quality at a quite adequate price. This shows that they can easily withstand competition from foreign brands. Moreover, the overwhelming majority of industrial designs recommended for large-scale welding work by Rostekhnadzor are Russian products.