SKS Welding Systems
KF Pulse Process
November 26, 2019
SKS Welding Systems
KF Pulse Process
Special pulse process with integrated short
circuit routine for very short arc lengths
• Very short arc possible
• Less heat input per unit length (8-10%)
• Low spatter rate
• Homogeneous and reproducible
penetration
• Good gap filling ability
• Suitable for out-of-position weld seams
• Less undercut
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SKS Welding Systems
KF Pulse Process
In contrast to the generally used pulse methods (I-, U pulse),
where just one parameter is controlled, both, U and I, are
controlled with the KF pulse method. While the classic pulse
methods are using just a single pulse current or amperage
control, with KF pulse, both can be controlled at the same
time.
Additionally, the KF Pulse has a special short-circuit
dissolving functionality, with that the process can be adjusted
up the highest rate, next to the short-circuit border. With that,
the creation of a very short, and spatter-reduced arc with
less heat input and good gap filling features while having a
reproducable penetration can be done. With the help of a
dynamic regulation, a periodic arc length can be calculated
and readjusted automatically. Thus, a constant arc length is
provided within the whole length of the seam.
The arc ignition is done with the proven lift arc ignition
function. A HotStart-function is, as well as the endcrater
filling routine, available.
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SKS Welding Systems
KF Pulse Process
fillet weld (sample sheet)
Welding speed : 100 cm/min
Base material : mild Steel S355 2,5 mm
Wire material : G3Si1 (ER70S) 1.0 mm
Shielding gas: : 92%Ar+8%Co2
Feature: out of position weld, no adjusting during welding
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SKS Welding Systems
KF Pulse Process
overlap seam (sample sheet)
Welding speed : 130 cm/min
Base material : mild Steel S355 0,8 mm
Wire material : G3Si1 (ER70S) 1.0 mm
Shielding gas: : 92%Ar+8%Co2
Feature: low heat input, less distortion
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SKS Welding Systems
General Requirements
General Requirements
Weld equipment
Weld controller
Q84x/ Q80/ Q4/ Q6
Power source
LSQ3/ LSQ5/ LSQ5X
Interface
UNI5x/ FB5
Wire feeder
Power feeder 5, FrontPull
Torch
PowerJoint, PowerClutch, all FrontPull-
torches, wire select torch, Dual wire torch
Option
Q8Tool-Software
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SKS Welding Systems
General Requirements
General Requirements
cable installation
Power Cable
• use shortest possible cable length
• use only SKS supply hose
• don´t coil up the cables
Ground connection
• minimal 70mm²
• avoid addition connections
• don´t coil up the cables
• sensible cable installation (to the fixture) to
avoid magnetic arc blow
shielding gas
• Argon mixed gas
• max 20% active (Co2)
• not possible to use 100%Co2
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SKS Welding Systems
KF Pulse Process
Base setup
• Please select KF-Pulse as weld
process
• Open Material- List and select required
KU/ KF- Characteristic line
• Weld controller will provide default
pulse setup depending on wire feed
speed
• Please find description for available
characteristic line on next page or
system manual
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SKS Welding Systems
KF Pulse Process
Material Process ∅ Description Shildgas Firmware
stainless metal cored wire AWS 5.9 98%Ar + 2%Co2
KU 01 1,2 KF-Pulse/ U-Pulse 1,2 1.4509/ 1.4510/ 1.4511/… 3.11
(ferritic) 400 series 98% + 2%O2
stainless solid wire AWS 5.9 98%Ar + 2%Co2
KU 02 1,0 KF-Pulse/ U-Pulse 1,0 1.4509/ 1.4510/ 1.4512/… 3.11
(ferritic) 400 series 98% + 2%O2
stainless solid wire AWS 5.9 98%Ar + 2%Co2
KU 03 0,8 KF-Pulse/ U-Pulse 0,8 1.4370/ 1.4316/… 3.11
(austenitic) 300 series 98% + 2%O2
stainless solid wire AWS 5.9 98%Ar + 2%Co2
KU 03 1,0 KF-Pulse/ U-Pulse 1,0 1.4370/ 1.4316/… 3.11
(austenitic) 300 series 98% + 2%O2
stainless solid wire AWS 5.9 98%Ar + 2%Co2
KU 03 1,2 KF-Pulse/ U-Pulse 1,2 1.4370/ 1.4316/... 3.11
(austenitic) 300 series 98% + 2%O2
AWS 5.18
KU 04 1,0 KF-Pulse/ U-Pulse 1,0 mild steel solid wire 1.5112/ 1.5125/ 1.5130/… 92%Ar + 8%Co2 3.11
ER 70S-6(e.g.)
AWS 5.18
KF 04 1,2 KF-Pulse 1,2 mild steel solid wire 1.5112/ 1.5125/ 1.5130/… 92%Ar + 8%Co2 3.12
ER 70S-6(e.g.)
AWS 5.18
KF 05 1,2 KF-Pulse 1,2 mild steel solid wire 1.5112/ 1.5125/ 1.5130/… 82%Ar + 18%Co2 3.12
ER 70S-6(e.g.)
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SKS Welding Systems
KF Pulse Process
Wire feed speed
1 Pulse voltage
2 Field charactaristic
3 Base current
4 Pulse time
5 Base current time
6 Downslope
Main settings
1. Deposition rate (main heat input)
2. Arc length control
3. Heat input (fine control)
? Cable length(resistance) correction
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SKS Welding Systems
KF Pulse Process
Wire feed speed
1 Pulse voltage
2 Field charactaristic
3 Base current
4 Pulse time
5 Base current time
6 Downslope
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SKS Welding Systems
KF Pulse Process
Wire feed speed
1 Pulse voltage
2 Field charactaristic
3 Base current
4 Pulse time
5 Base current time
6 Downslope
Wire feeding speed
+ increasing deposition rate and weld current
- decreasing deposition rate and weld current
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SKS Welding Systems
KF Pulse Process
Pulse voltage
(max. voltage during pulse time)
need for cable length (resistance) correction
longer arc length
+ uncontrolled droplet detachment
required current cannot be reached
- droplet cannot detached before short circuit
short circuits and spatter occurs
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SKS Welding Systems
KF Pulse Process
Field characteristic
(current limit during pulse time// 100%= 520A)
generate in combination with pulse time the pinch power for
droplet dissolution
+ arc length increased
more heat input; undercut can occur
- droplet cannot pinch
short circuits and spatter occurs
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SKS Welding Systems
KF Pulse Process
Base current/ - correction
(min. current during base time)
usable to fine tuning heat input
+ increase heat input
(max. level depends on wire diameter)
- decrease heat input
(lowest level 24A)
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SKS Welding Systems
KF Pulse Process
Pulse time
(duration of pulse phase)
generate together with pulse current the pinch power for droplet
dissolution
+ more droplets occur
more heat input
- droplet cannot detach
short circuit and spatter occurs
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SKS Welding Systems
KF Pulse Process
Base current time / -correction
(setting arc length)
+ decreasing arc length (shorter arc)
(tBase will increase; Pulse frequency -)
- increasing arc length (longer arc)
(tBase will decrease; Pulse frequency +)
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SKS Welding Systems
KF Pulse Process
Downslope
(current fall down from pulse current to base current)
+ increase speed
droplet cannot pinch
- decreasing speed
more heat input; undercut can occur
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SKS Welding Systems
KF Pulse Process
KF Dynamics
automatic arc length control
Arc length can increase at long weld seam because of a
heat effected change of the resistance.
By using the KF Dynamics the weld system can
compensate this effect automatically.
higher setting effect faster reaction
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SKS Welding Systems
KF Pulse Process
Short circuit routine
In case of a shortage during the weld, a special
short circuit routine will maintain the arc.
This procedure allows to setup a very short
arc length without having a lot of spatter,
reduce heat input and undercut.
Short circuit
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SKS Welding Systems
KF Pulse Process
Application
examples:
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November 26, 2019
