Arc Welding Equipment Selection: "So You're The New Welding Engineer" AWS Seminar

Arc Welding Equipment Selection
“So You’re the New Welding Engineer” AWS Seminar

Mike Flagg – The Lincoln Electric Co.
1
So You’re the New Welding
Engineer
• You may be responsible for the welding equipment selection in

your shop.
• So what type of equipment do you chose?
2
Basic Fundamentals of Arc Welding
Power Sources
3
Conventional Technology
• Static (stationary) machines

 Transformer or transformer / rectifier
machines
- Power converted or transformed and
rectified at 60 Hz frequency
- Machines are large and heavy (big
transformer)
- Conventional Technology: (1970s – 1990s)
- Silicon Controlled Rectifier (SCR)
- Old Technology: (Pre 1980s)
- Mechanically controlled components
• Rotary (rotating or moving) machines
 Motor Generators
 Pure DC Generator Engine Drive
 Alternator Engine Drive
4
New Technology
• Inverters
• Choppers
5
Inverters
• Inverter power sources are smaller, lighter and more portable

than conventional transformer / rectifier type machines
• They also have high speed power conversion which allows for
quick response to changing arc conditions
• The key is high speed switches (IGBTs), which greatly increase
the frequency (80,000+ Hz vs. 60 Hz.).
• Key benefits are:
 Reduction in the physical size and weight of
the transformer required for the power source
 Higher transformer efficiency
 Lower input power consumption
IGBT
 Faster reacting arc results in smoother output Isolated Gate
Bi-polar Transistor
6
Inverter Technology Benefits
• Lighter weight – more portable

• Smaller, more compact size – takes up less floor space
• Smoother output – superior arc performance
• Advanced design – reliable components
• More efficient transformer – less heat waste
• Lower power consumption – lower operating cost
7
Power Electronics Technology
• Technology improvements across whole family of

power sources
• Electronic devices to control and
convert power
 Low power consumption
 High efficiency
 High power density
 Significant energy and cost savings
Inverter power source

Chopper
circuitry
8
Pulsed Spray Arc Welding
Advanced Technology: Pulse Welding

• Welding Output Varies (Pulses)
Between a High (Peak) Current
and Low (Background) Current
• Still a Spray Arc Metal Transfer
• Doesn’t Reduce Penetration Level
• Standard Pulsing Variables:
– Amplitude
• Peak & Background Current Levels
– Balance
• Time per Pulse at Peak & Background
– Frequency
• Number of Pulses / Second
9
Pulse MIG Equipment with
Waveform Control Technology
• Waveform Control Technology™ Equipment
– The Equipment Family with Waveform Control Technology™ are
the “Power Wave®” Machines and “Power Feed™” Wire Feeders
– They Must be Used Together as a Package
• Power Wave® Machines

– Inverter based machines
– Higher speed switching
10
Synergic Wire Feeders
• Power Feed™ Wire Feeders

– Most controls on wire feeder
– 40V DC drive motor
– MAXTRAC drive system
– Optional Memory panel
11
Software Driven Output
• Waveform Control Technology™ - The capability of

electronically controlling and changing the arc welding
waveform from just one machine to produce the ideal arc
characteristics for unlimited welding needs.
– Wide range of applications
– Varying material thicknesses
and specifications
– All weld positions
– Different appearance
requirements
12
Pulse Waveform Variables
• Standard Pulsing Machines Control 4 Variables:

– Peak Current, Background Current, Balance, Frequency
• Waveform Control Technology™ Machines Control 18 Variables
– Allows Precise Control of Arc
– The Area Under the Waveform Controls Desired Melt-off Rate
– 9 Inner Loop Variables and 9 Outer Loop Variables
“Inner Loop” Variables “Outer Loop” Variables

1. Front Flank
• Controls Adaptability
2. Percent Overshoot
3. Peak Current • Trim and Arc Control
4. Peak Time – Peak Time
5. Tail-out – Peak Current
6. Tail-out Time – Step-Off Current
7. Step-off Current – Background
8. Background Current – Frequency
9. Frequency
13
The “Ideal” Welding Output Varies
CV Steel Pulse Steel Pulse Aluminum
Pulse on Pulse® Alum. STT Steel Flux Core Steel
14
Easy to Operate
Adjust Wire Feed Speed

• Synergic Control
– Power source and wire feeder
work or communicate together
(synergic relationship) Synergic
welding eliminates the need to
independently set the wire feed
speed and voltage. Voltage or Trim Will Automatically Adjust
• Adaptive Control
– “Adaptive Control” helps
overcome lack of operator skill
and aids in producing more
consistent, higher quality welds,
even as operators are still
improving their welding ability.
15
Basic Pulse
Description:
A waveform that cycles
between a peak and
background current producing
one droplet per cycle
Benefits:
- Easy to use
- Extends the operating
range of traditional CV
- Can produce less heat Equipment:
input
Applications:
- All applications where CV
is used
16
Basic Pulse
17
Precision Pulse™
Description:
A fixed-frequency pulse mode,
designed to produce a very
focused arc at lower voltages
Benefits:
- Extremely stable
- Easier to manipulate
- Very fluid, yet controllable
puddle Equipment:
Applications:
- Out-of-position applications
- Areas where traditional pulse is
producing sub-par results
18
Precision Pulse™
19
Rapid Arc®
Description:
A high-speed pulse mode
designed with an extremely
short arc length & short circuit
response to minimize spatter
Benefits:
- Higher travel speeds
- Low spatter generation
- Shorter arc length allows for
better puddle manipulation Equipment:
Applications:
- Thinner material, high-speed
requirements
- Spatter control is required, and
capital costs are constrained
20
21
STT® -(Surface Tension Transfer)
Description:
A modified short circuit mode,
designed for open root
welding
Benefits:
- Bridge gaps without lack of
fusion issues
- More forgiving that CV short-
arc Equipment:
- Runs well on alloys
Applications:
- Open Root Pipe
- Thin material applications
- Poor fit-up situations
- Weld appearance, or no spatter
22
STT®
23
Rapid X™
Description:
A high-speed, ultra low spatter
pulse mode – the result of
combining Rapid Arc and STT
Benefits:
- High travel speeds
- Lower spatter generation than
Rapid Arc
Equipment:
Applications:
- Thinner material, high-speed
requirements
- Spatter control is required at all
cost
24
Rapid X™
25
AC Pulse -Aluminum
Description:
An aluminum pulse waveform
designed reduce heat input into
the base metal
Benefits:
- Join thinner materials than a
DC+ waveform
- Increased deposition rates
- Improved gap bridgablility Equipment:
Applications:
- Thinner aluminum applications
- Applications where deposition is
required, but heat input is
constraining factor
26
AC Pulse -Aluminum
27
Sync-Tandem MIG
Description:
Pulse wave forms designed to
control two power supplies in
synchronization
Benefits:
- Improves system stability
- Reduces spatter from arc
interaction
- Better looking welds
Equipment:
Applications:
- High deposition Applications
(24-40 lbs./hr.)
- High speed applications
(50-150 ipm)
28
Sync-Tandem MIG
29
Hot Wire -Tandem MIG
Description: 35volts
Pulse wave forms designed to
control two power supplies in 7 volts
synchronization Voltage
Benefits:
- Improves system stability
- Reduces spatter from arc
interaction Amperage
- Better looking welds Equipment:
Applications:
- High deposition applications
(24-40 lbs./hr.)
- High speed applications
(50-150 ipm)
30
Power Wave Manager
• Security
• Memory
Settings
• Limits
• Etc.
31
Control – Weld Sequencer
• x
32
Complex Semi-Auto Assemblies
33
Production of Complex
Semi-Automatic Assemblies
• Increase Productivity and

Quality while Reducing Cost
• Reduce Training Cost

• Optimize Welding Procedures
• Improve Production Cycle
Times
• Improve Product Quality
• Detect Missing/Extra Welds
• Reduce Downstream Inspection
Effort
• Link to Automatic Equipment
and ERP Systems
34
Weld Score™
35
3) Verify:
Software Solutions
True Energy™
• Instantaneous energy value for the weld
• Arc Timer
– Measured in Seconds
• Sampling rate of 10 kHz
• Simple Heat Input Calculations
True Energy (J or kJ)

Heat Input = -----------------------------------------
Distance Traveled (in. or mm)
• Value is recorded in Production

Monitoring™ 2
36
Summary Screen –
Factory Overview
37
Questions to Ask
• Cost?
• Process match your welders
abilities?
• Level of Automation?
– Manual, Semi-automatic,
mechanized, automation
• Complexity of system?
and most importantly…
• Does your equipment allow

you to control your welding
operations as a process?
– Implement, control, verify
38
Questions?
39

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Arc Welding Equipment Selection

“So You’re the New Welding Engineer” AWS Seminar

• You may be responsible for the welding equipment selection in

• Static (stationary) machines

• Inverter power sources are smaller, lighter and more portable

• Lighter weight – more portable

• Technology improvements across whole family of

Inverter power source

Advanced Technology: Pulse Welding

• Power Wave® Machines

• Power Feed™ Wire Feeders

• Waveform Control Technology™ - The capability of

• Standard Pulsing Machines Control 4 Variables:

“Inner Loop” Variables “Outer Loop” Variables

CV Steel Pulse Steel Pulse Aluminum

Pulse on Pulse® Alum. STT Steel Flux Core Steel

Adjust Wire Feed Speed

• Increase Productivity and

• Reduce Training Cost

True Energy (J or kJ)

• Value is recorded in Production

and most importantly…

• Does your equipment allow

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