Some of the latest technology welding machines incorporate pulse generator. You may have heard that these high-end welding machines offer high quality welds and make welding work easier. Although you may have to pay higher than initially when you buy pulse welding machines, you know that using these welders will save you money compared to other traditional mig welding machines. In addition to the advantage of reducing overall welding costs, you also earn an income to invest in other long-term jobs.
What is pulse MIG?
In a nutshell, MIG pulses are a method of non-contact movement between electrodes (solder wires) and welding pits. This means that in this method there is no time for welding wire to touch the welding rod. This is done through the high speed variation of the output current of the welding machine. The MIG pulse welding process is less prone to heat generation and less heat generation than sputter transfer or tear drop.
The MIG pulse welding process is operated by the formation of molten metal droplets at the weld head corresponding to each pulse. At that point, an additional amount of streams pushes the drop of metal through the arc into the weld pool. The transition of these droplets occurs through the arc, with each drop corresponding to a pulse.
To understand this procedure in detail, consider a waveform. Unlike the CV (constant voltage constant) mode, the current is a straight line, the MIG pulse decreases at times without additional energy, so cooling the process. This is a “cooling” phase that allows MIGs to weld better than thin materials, control deformation and provide lower wire feed rates. In this process, the welding current rises to the top when the metal droplets form. Then, in the base current phase, the welding current decreases in order to reduce the overall cumulative heat.
Shows transitions in TIG pulses
Advantages when using pulse welding machine
Saving wires and gas protection
The pulse MIG welding machine offers a wider range of applications because of its low to high range of welded wire diameter. For example, with conventional MIG welding machines, welders must use 0.8mm, 1.2mm, 1.32mm welded wire, for various welding applications according to the weld thickness or weld position. But with MIG pulse welding machines, only 1.2mm welded wire can meet the whole application. This means that instead of having to use two or three different wires of different diameters, the welders need only one wire. Only one type of wire minimizes inventory costs and saves time when switching welds. This is also true for gas protection – a gas that can meet the low to high limits of application. In addition, the need to purchase and stockpile all kinds of consumable accessories (welding torches, soldering pins, wires, etc.) also reduces, thus saving additional cost.
Reduce welding and splashing smoke
Compared with conventional MIG welding, MIG pulse welding produces less splash and less welding fumes. Significant reduction in splash savings due to the fact that molten wires engage in maximum welding metal, with little or no splash on the surface of the product or surrounding fixtures, thus requiring less cleaning time after welding. . Reducing welding smoke also makes the work environment in the factory safer and less polluted.
Reduce cumulative heat
Pulse welding current minimizes heat build-up during welding so it limits thermal deformation and improves overall quality thereby reducing product defects. This is especially important when the welded material is stainless steel, nickel steel and other alloys that are sensitive to heat.
Improved welding productivity
Solder MIG pulse for high embossing rate. Also, because the new models are simpler and more adaptable, using the MIG welding machine with pulse welding mode is easier than other arc transfer methods, it does not take much time for training.
Higher welding quality
All the advantages of the pulse MIG welding method mentioned above give better final welding quality and more stable arc. In addition, welders have better working conditions in less welding environments and at the same time because of low splashing, the time spent cleaning or grinding the welding parts is negligible. In addition, another benefit is the synergic source of welding that allows for high quality welding even with less experienced welders.
Some suggested options for Pulsed MIG welding applications:
1. Select the device capable of working on the new expanded range of welding processes
If the welders previously used the welding machine CV with the 300A line, then it is not necessary to choose the pulse MIG 300A. Due to its wider applicability to the pulse MIG machine, it is possible to select a 400A machine with a higher welding current to extend the wire speed range.
2. Use advanced synergic controller
As mentioned above, advanced synergic welding machines provide a simple user interface that minimizes training time for new welder.
3. Be careful when choosing the size of the welding torch
The pulse MIG process can be performed at a higher range and has a greater pulse current, and is “hotter” than traditional MIG processes. For this reason, the welder should choose a water-cooled nozzle if possible and select the appropriate size for the welding current.
4. Consider selecting the solder voltage sensor feature if the welding position is far from the welding source.
Some types of solder sources feature voltage sensing technology that improves pulse performance when the gap between the weld position and the weld source is large. Typically, the voltage sensing device at the output points – one at the weld and the other at the weld point. With this optional feature, the welder can operate the output separately from the weld.
Note that when setting parameters for welding machine settings for pulse MIG welding machine is a little different with the normal MIG welding machine. Care must be taken to ensure that the appropriate instructions comply with safety regulations in welding.
1. Larger pulses require better cooling, and the welder must ensure good electrical connections before welding.
2. Length of cable should be minimized to reduce the resistance. The cable length should not be longer than 15 meters. If you have to use long cables, it is prudent to roll up the cable as the inductance increases. Inductance flattens the pulse and decreases its effect. Also, pay attention not to cables forming large rings or loops around conductors. These factors will give better welding characteristics, especially with pulse MIG welding.
With superior features, cost savings, better quality, improved productivity and ease of operation … making the MIG pulse an indispensable option. Although it’s a high-end segment of the market, with what MIG pulses do for you, this initial investment will be the smartest choice.
(Source: sai of india )