Pulsed MIG Welding Basics
Introduction to Pulse Welding
Overview of Pulse Welding
- Eric Brown, a welding engineer at Miller, introduces pulse welding as an evolving technique in the industry.
- Pulse MIG welding is described as a modified spray transfer process that alternates between high peak and low background currents 30 to 400 times per second.
Mechanism of Pulse Welding
- The peak current pinches off a droplet of wire and propels it into the weld joint while the background current maintains the arc with minimal heat input.
- This low heat input allows for slight freezing of the weld puddle, which helps prevent burn-through.
Types of Pulse Systems
Synergic vs. Non-Synergic Systems
- Two types of pulse systems are discussed: synergic and non-synergic.
- In synergic systems, adjusting wire feed speed automatically adjusts power levels; in non-synergic systems, users must manually set both parameters based on factory references.
Advantages of Pulse Welding
Key Benefits
- Common hesitations about switching to pulse welding include noise and lack of knowledge; however, adapting can yield significant benefits.
- Three main advantages highlighted are reduced spatter, lower heat input, and ease of use.
Reduced Spatter
- Spatter is minimized because the wire does not directly contact the puddle due to maintained arc length.
Lower Heat Input
- Cycling between peak and background currents prevents prolonged exposure to high power levels, reducing overall heat input.
Ease of Use
- The synergic function simplifies setup by allowing adjustments through one knob for stable conditions before fine-tuning if necessary.
Additional Advantages
Enhanced Control Features
- Other benefits include improved directional control over the weld pool and better management of arc starts and stops.
- Faster wire feed speeds contribute to quicker travel speeds while preventing issues like over-welding or poor quality outcomes.