Tig Welding in Motorsport
Tig Welding in Motorsport
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design. 1911: Manufacturing the first portable welding machine with variable voltage in the world.
Founded in 1895 by John C. Lincoln 1895: Producing first Electric Motors of Lincolns own
Company Profile
2006 : The global Leader in Design, Development and Manufacture of Arc Welding Products, Plasma Cutting, and Robotic Welding Systems
1.8 Billion $ Worldwide Turnover Over 7,000 Worldwide Employees 33 Manufacturing Sites in 19 Countries Representation in over 160 Countries
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Lincoln is the industry leader with product offerings, including: Equipment : Stick welders TIG welders MIG welders Plasma cutting Engine Driven welders Robotic/Automation systems Environmental systems Consumables : Mild steel Low alloy steel Stainless steels Non-ferrous Hardfacing applications
Innovative Technology
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Enhance Image of Lincoln in Motorsport world Drive Technology with car race team Create Brand Awareness Main elements Safety Performance Ease Accessibility Partnership
Motorsports Program
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Officially Licensed Product of NASCAR - 2009 Contingency Sponsor of NASCAR Busch, Grand National and Weekly Racing Series - 2009 NASCAR Technical Institute - Curriculum NASCAR Research Center Involvement Official Welder of the Indy Racing League Official Welder of the Infiniti Pro Series Official Welder of USAC - 2009 Official Supplier to ARCA Re/Max Series - 2009 Series Sponsor ARCA Lincoln Welder Truck Series Major Contingency Sponsor of NHRA Award presenter for the Toyota Atlantic Series Presenting Sponsor of the Valvoline Cup Contingency Connection
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GTAW PROCESS
Welding Current TIG Torch Ceramic Cup Shielding Gas IN Tungsten Electrode Arc Welding Rod Base Material
Water Out (Hot)
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WHY TIG Excellent quality of weld with low porosity WELDING ? Welds made with or without filler metal Precise control of welding variables Precise welding on complex piece Low amperage to weld on thin materials Visually Appealing, no spatters, nice ripples Weld all kind of exotic material used in Motorsport (Aluminium, Titanium, Chromolybdenum, magnesium...) Ideal process for frequently starts / stops and short welds Limitations : Requires greater welder dexterity, low deposition rate, more costly on thick sections
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Why DC- ?
High energy level at High energy level at the welding puddle the welding puddle Low energy at the tip Low energy at the tip of the electrode (sharp) of the electrode (sharp)
DC-
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Why AC ?
AC
Aluminum has a melting Aluminum has a melting point less than 700C point less than 700C Aluminum oxide on the Aluminum oxide on the surface has a melting surface has a melting point above 1800C point above 1800C Reverse polarity, half of Reverse polarity, half of the AC arc, breaks and the AC arc, breaks and clean the oxide skin clean the oxide skin ahead of the weld ahead of the weld
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Why AC ?
Typical Sinusoidal changes polarity gradually Square Wave changes polarity + instantly for smoother and stable arc + The AC TIG processes is using the positive period for cleaning ALU Oxide The Negative period is used for welding. (penetration) As a result: The process efficiency of AC TIG is low as only a part of the period is used for welding Need to optimize Welding by
Cleaning before welding adjusting Balance AC
WHY AC on ALUMINIUM ?
Cleaning
Welding
Balance AC
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The thermal conductivity of Aluminum compared to Stainless is 12 times higher. We need more energy for the Stainless sheet welding: same volume of Aluminum Most used tungsten 1.6 mm The process efficiency is lower Setting approx.. 25>30Amps/mm because of the AC wave form Conclusion: We need much more energy (Welding Amps) to weld the same plate thickness.
Aluminum sheet welding: Most used tungsten 2.4 mm Setting approx.. 30>40Amps/mm
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The Argon TIG arc is spread from itself. As a result the energy per surface is low. Concentrating the arc on a smaller surface with the same welding current will increase energy per mm Increasing the AC Arc frequency will focus the arc. Concentrating the heat on a smaller surface will: Reduce the welding current increase the travel speed reduce the heat input/cm
>> less distortion
Feature: AC frequency
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1. Bring slowly the TIG Features torch electrode on the work piece. 2. Press the trigger of the TIG torch. 3. Lift the electrode from the work piece to start the TIG arc.
Basic
Electronic device minimizes short circuit current before starting. Electrode wear and tungsten inclusions in the weld pool are considerably reduced compared to Scratch start. Used for :
Occasional TIG welding TIG Welding when using appliances sensitive to electromagnetic interference like electronic on racing cars.
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1. Bring slowly the electrode at 2 to 4 mm from the work piece. 2. Press the trigger of the TIG torch. 3. High Frequency spark ignites the arc.
Basic Features
Advantages :
The electrode doesn't touch the piece. No risk of tungsten inclusion in the weld. No wearing of the tungsten electrode tip
2 to 4 mm
Used for :
For outstanding and professional TIG welds
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Start Current
Basic Features
Aluminum is an excellent conductor of heat. The welding of aluminum requires Hot start always.
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Upslope
After the arc starting sequence, current goes from Start level to welding current value
Basic Features
Upslope
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Welding Current
Weld Current
Basic Features
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Downslope
At the end of the weld, the current gradually decreases from Welding value to Crater level
Basic Features
Downslope
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Crater Current
Can be useful in some applications in order to better finish the weld pool and avoid final crater.
Basic Features
Crater Current
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4 steps
Basic Features
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Basic Features
Postflow
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Advanced Features
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Pulse parameters :
Frequency :
Normal Pulse welding in a frequency range between 0,2 to 20 Hz.
Advanced Features
Peak = Preset current
Background Current :
It is the current during the low portion of the pulse waveform. It can be adjusted from 10% to 90% of the welding (peak) current.
Frequency On-time
On-time Control :
Adjust the peak pulsing on-time. The on-time can be adjusted from 10% to 90% of the pulsing period.
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Pulse parameters :
Advanced Features
Pulse Frequency
Time in
Background Current
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Advanced Features
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Index
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TIG DC Applications
To select max Power of the TIG DC machine, Check : Plate Thickness to be welded Input power available on site
Selection Chart
230V 1 phase
400V 3 phases
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TIG AC Applications
To select max Power of the TIG AC/DC machine, Check : Plate Thickness to be welded Input power available on site
Selection Chart
400V 3 phases
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What is PFC ?
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Conclusion
Choose TIG welding for high quality welds on all kind of materials Use ALtenartive Current for Aluminium, DC for the rest of materials
Clean Aluminium plate and adjust balance to optimise AC welding efficiency Play on AC frequency to focus the arc and minimise distortion
Recommended Lift TIG striking mode when welding on car frame, and HF for excellent striking Play with Higher Hot Start and long up-slope to preheat Aluminium plate, long down-slope & lower crater level to avoid shrinking cracks Use Pulse to control the heat input and High Speed Pulse to focus the arc and minimise distortion Select the right machine for the right application (material to be welded, max thickness, input power availability)
QUESTIONS ?
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