What is Pulse Mig welding????

[Kylew74]

Hi, i've been a Mig welder (un-coded) for 12 years. Decided to have a look for a better job and saw an advert which wanted the applicant to be able to pulse weld or at least know what it is. As I say i've been an employed Mig welder for 12 years and never heard of it. The Vacancy is for a Mig welder so it's not like it's for a type I dont know i.e. Tig/Arc.

Anyone able to tell me what it is?????

Many thanks

 

[madkayaker]

Hello and welcome pulse is when the voltage is produced at a higher frequency and in different wave format e.g. square in stead of alternating. How it help welding haven't a foggiest but some one like Hitch or Snown (can't remember the rest sorry) will be along soon

 

[shenion]

Pulse MIG is a smart process to allow more than just Short-arc and Spray Transfer modes. Here's Lincoln's blurb on it. Normal MIG is just constant-voltage DC with no feedback.

In its earliest form, it basically runs the wire in spray transfer, but uses short pules to keep the average current low. It allowed what would normally be globular transfer to act like short-arc. You get the clean spray transfer welds with much lower heat input.

Now it is even more advanced. It completely controls the timing of the short arc and the current. It will manage the heat input in the weld. This can be useful on alloys that can not have high heat damage its metallurgical properties. MIG brazing is one area it is used.

 

[Wozzaaah]

Can't give you the exact science on it other than like MK says, instead of a constant power, it fluctuates but here's a pic of a weld done by Matt1978 on one of Lorch's fancy-pants twin-pulse mig machines, beautiful isn't it?

Over to you Matt, the floor is yours .

 

[madkayaker]

Sorry Matt i forgot about you

 

[matt1978]

Pulsed mig welding..............

Pulse is an artificial spray arc, which is where a very high peak current (around 600 amps) is used but for a very short time (milliseconds)

The benefits are quite a few but the main ones are......

1) Virtually Spatter free
2) Can weld very thin and very thick materials with one diameter wire (Eg 1.2mm wire can weld around 0.6mm sheet at around 26 amps and go up too really thick material around 500 amps)
3) No need to change wire sizes such as 0.8, 1.0 etc
4) Amp for amp, better penetration than conventional mig
5) Excellent for welding Aluminium and Stainless Steel

Technique is very simerla to normal mig welding, so no need to worry if you get the job

Good luck.

 

[migmag]

This is interesting.
Link fixed
Pics

 

[matt1978]

If I get chance, I will post some High speed videos of the different arcing phases, so you can see the differences visually.

I think they also have some of TwinPulse in Germany too.

 

[zst]

Pulsed mig welding..............

2) Can weld very thin and very thick materials with one diameter wire (Eg 1.2mm wire can weld around 0.6mm sheet at around 26 amps and go up too really thick material around 500 amps)
3) No need to change wire sizes such as 0.8, 1.0 etc
5) Excellent for welding Aluminium and Stainless Steel

Technique is very simerla to normal mig welding, so no need to worry if you get the job

Good luck.

What wire (Aluminium or stainless steel or both) in 1.2 mm is for base material of thicknes= 0.6 mm?
We have saprom 3 mobil and never were able to seriously weld aluminium less than 1.5 mm in pulse/double pulse mode. We always burnthrough it.

I would be glad to make a try next days, so could you help with some advices? We have all AlSi5, AlSi12, AlMg5 wires, as well as 308L, 309L, 310, 312 etc

 

[matt1978]

What wire (Aluminium or stainless steel or both) in 1.2 mm is for base material of thicknes= 0.6 mm?
We have saprom 3 mobil and never were able to seriously weld aluminium less than 1.5 mm in pulse/double pulse mode. We always burnthrough it.

I would be glad to make a try next days, so could you help with some advices? We have all AlSi5, AlSi12, AlMg5 wires, as well as 308L, 309L, 310, 312 etc

Hello Mate,

You can weld very thin Aluminium with a 1.2mm wire, but you have to take care with the clamping of the material, it requires constant downward pressure or the 2 plates will go in opposite directions......if/when this happens it then becomes almost impossible.

Your better to use just standard Pulse, not TwinPulse on anything below about 2mm-3mm and keep a very short arc.

How large is the fabrication? How fast will the guy weld? This is then dependant on what material thickness to set on the machine, also what joint configuration?

For Stainless Steels, of this thickness I prefer to use a 1.0mm wire.

 

[zst]

We are repairing guys, not fabrication ones. We come across every thickness and sort of material and joint type.

And speed of welding is not so important. The final result: strength, cracking-free deposit, sealing... etc does matter when one engage us.

So this is interesting. I was said, double pulse is for thinner plates, less than 2 mm and pulse is for 2-4 mm and spray is for 4 mm and more...
I will use one pulse, 1.2 mm AlSi5, set thickness of material at 1 mm or so depending the real thickness of Al, clamp it firmly, no gap at butt joint, trim arc on "impedance" controle to minimum and try... We will se the result.

By the way, could the poles at S3 be commuted to make it capable to work at "-" pole with self shielded 71T-11 wires?

 

[matt1978]

By the way, could the poles at S3 be commuted to make it capable to work at "-" pole with self shielded 71T-11 wires?

Its not something that can be changed in the menu etc, but I will ask one of the technical guys if its possible to do manually.

Yes, try what I suggested on the thin Aluminium. The thing with the Pulse welding of the really thin stuff, is its not something that is done all day everyday, the lower limits of 27 amps (Which is about 0.8mm sheet) are possible to use, but everything has to be super perfect........great fit up, excellent clamping, perfect travel speed etc, its not till you get around 1.5mm-2mm where welding becomes very easy.

Either way its still a million times more flexible than conventional mig on simerla applications.

Let me know how you get on

 

[dannyweld]

hi, i usually hold the nozzel 3/4" away from work, i use a miller machine, i find welding aluminium to be succesful, i would love to find some sort of table to show optimum settings for pulsing, the synergic settings on my machine are hopeless, like mma, i find the sound of the process is important, i dont know if this is a good way to judge what i,m doing though.

 

[dannyweld]

ps. found this http://www.weldreality.com/equipment_evaluation.htm which i think sums up the mig pulse thing fairly well, although it being from the US does'nt say a thing about whats happening in europe.

 

[arcstick]

Pulsed arc metal transfer involves pulsing the current from levels below the transition levels (globular) to above it (spray transfer).

 

[matt1978]

hi, i usually hold the nozzel 3/4" away from work, i use a miller machine, i find welding aluminium to be succesful, i would love to find some sort of table to show optimum settings for pulsing, the synergic settings on my machine are hopeless, like mma, i find the sound of the process is important, i dont know if this is a good way to judge what i,m doing though.

Where about are you based Danny?

I was over in Ireland all last week doing various demo's with our dealer from Navan.

 

[dannyweld]

Where about are you based Danny?

I was over in Ireland all last week doing various demo's with our dealer from Navan.

hi, are you involved with miller, my shop is in north city centre, dublin, i'm on holidays at the moment but will be back next week.

 

[matt1978]

hi, are you involved with miller, my shop is in north city centre, dublin, i'm on holidays at the moment but will be back next week.

Hi Mate,

No, I am not involved with Miller.........my dealer in Naven has only been going a few months, prior to that he was a area sales manager for Electroweld in Dublin. Maybe you know him? Dermot Crowley??

 

[dannyweld]

hi, have heard of electroweld, dont know if i had any dealings though, cant remember.
where is your range manufactured.

 

[matt1978]

where is your range manufactured.

In our factory near Stuttgart in Germany.