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TIP TIG Welding is always better quality than TIG and 100 to 500%
superior quality than TIG - MIG - FCAW.
Written by Ed Craig www.weldreality.com.
MIG Equipment Facts. Part
decades of WELD sales influence.
Ed. I am reading pulsed MIG literature from the different weld equipment manufacturers.
The different wave forms and pulsed MIG arcs sound fascinating and of course many
welding / application promises are made. My question is this. How much should
I rely on the pulsed MIG data that I am reading?
Answer: If you were reading about pulsed MIG MIG equipment made before 2006, the
information on the weld equipment may be as reliable as what you get on a used
car lot, or as reliable as the above headlines provided in 2006 by the world's
largest newspaper, USA Today.
A WELD EQUIPMENT MANUFACTURER CANNOT MAKE IT'S SOPHISTICATED, ELECTRONIC
MIG EQUIPMENT, WELD COMMON APPLICATIONS BETTER THAN IT'S LOWER COST, MORE DURABLE
CV MIG EQUIPMENT, THE EQUIPMENT MANUFACTURER MAY CREATE A SALES MARKETING STRATEGY
IN WHICH THEY CONFUSE THE POTENTIAL MIG WELD EQUIPMENT CUSTOMERS WITH BOVINE FECAL
EXAMINE THE UNIQUE LANGUAGE THIS GENERATION OF WELD EQUIPMENT
DESIGNERS AND MARKETING PERSONNEL USE TO DESCRIBE THEIR ELECTRONIC MIG EQUIPMENT.
Folks, for only $12999, this unique, new
pulsed MIG power source provides;
FOZZY DE-WOOZZY PULSED.
 SOFT AND HARD PULSED.
 TRIPLE PULSE ON PULSE.
 AC ON TOP OF DC PULSED.
DYNAMIC RESPONSE PULSED.
 ETHERNET CONTROLLED PULSED.
 4 MILLION WAVEFORMS.
 PALM PILOT
PULSED CONTROL, (IN THREE DIFFERENT COLORS).
 REMOTE CONTROL FOR THE PULSED
A little weld reality. The
optimum spray fillet on the right, was made from a simple, two control, CV, $2500,
MIG power source. The inferior pulsed weld on the left, was made with the same
wire feed rate and a $12,000 pulsed power source.
Point from Ed's MIG process Control Training CD program
only problem with a CV. $2000 - $3000 MIG power source, is minimal profits are generated
for both the weld equipment manufacturers and the weld distributors.
have to have a sense of humor if you weld carbon steels and you spent more
than $3000 for that Pulsed MIG power source.
WELD BENEFITS OF ELECTRONIC BELLS AND WHISTLES ON PULSED MIG EQUIPMENT CAN SOUND
IMPRESSIVE TO WELD SHOP MANAGEMENT AND PERSONNEL THAT HAVE NO OWNERSHIP OF THE
EQUIPMENT ON THE WELD SHOP FLOOR.
Twenty pus years after its introduction, we are now seeing one or two reasonably
priced pulsed power sources that can provide minimal yet unnecessary weld benefits
for carbon steels and stainless MIG applications.
Note: In the future, there are three applications that will see real world weld benefits from pulsed, automated weld cladding, automated 5G pipe welds and aluminum applications
I checked the pulsed equipment sold in the USA and I still find that the most
expensive pulsed equipment available to weld carbon and alloy steels still offers minimal
benefits in contrast to the MIG equipment that costs 300% less
A PRIMARY PROBLEM FOR MANY WELD DECISION MAKERS IS SORTING OUT WHICH MIG EQUIPMENT
PROVIDES WELD BENEFITS AND WHICH EQUIPMENT DOES NOT.
For those managers, engineers and technicians that would rather optimize MIG and
flux cored weld quality and productivity from low cost MIG equipment, all you
need is the information in Ed's weld books and process control CD training resources.
the best MIG power source for all position E71T-1 gas shielded, flux cored
contrast to Inverters, multi-process MIG machines and pulsed MIG equipment,
a regular, low cost, CV, MIG power source will always provide superior, all
position,"gas shielded flux cored welds".
A WISE MANAGER LEARNS FROM THE
WITHOUT QUESTION, THE WORST MIG EQUIPMENT SOLD
IN AMERICA CAME FROM PANASONIC AND MOTOMAN: A
friend of mine is in charge of Robots at one the largest Honda supply plants in
the USA. He had over 200 robots all struggling with Panasonic induced weld issues. He will attest that the < 2004 Panasonic pulsed MIG weld equipment
represented some of the most illogical, inconsistent, erratic weld equipment he
has ever had to work with.
In the many plants that I was asked to resolve
robot weld issues, I used to squirm when I saw the Panasonic pulsed MIG equipment,
as I knew that in many cases the weld issues in the plants would not be optimized till the weld equipment was replaced.
the Panasonic MIG equipment is popular on Panasonic robots sold in North America,
I thought I would spend some time evaluating what the Panasonic Pana Star AA2
- AA11- 350 and the HM 500 power sources had to offer. The following is a description
of a verbal event that took place at an AWS weld show. The conversation is not
word for word, however it represents the true content of the discussion.
Panasonic sales rep provides his sales pitch at the AWS show, "Ed
this dip pulsed power source is really unique. The power source provides
"artificial intelligence". He continues.
"This power source
is constantly analyzing the pulsed arc output weld data and making weld parameter
corrections for the arc. In contrast to most other MIG equipment, this pulsed
power source provides superior control of the weld penetration". The
just out of college sales rep continues, "Ed, you may not be aware that with
the earth quakes in Japan, " weld penetration in that country is now a prime
issue". The Panasonic sales rep was in his twenties and keen
to provide me with weld advice and startling revelations about Japanese weld penetration
issues. If you are new to this web site please keep in mind, I have worked with
the MIG process for 40 plus years and with the pulsed process close to 25 years.
When I first started evaluating pulsed equipment the Panasonic rep was approx.
three years old, this did did not stop this rep from trying to educate me on the
subject of welding.
The Panasonic rep then told me "that one of the
things that effects pulsed weld penetration is when the pulsed arc length changes,
as the arc length is shortened the pulsed drop may not be allowed to form without
a short circuit interruption, this therefore effects the pulsed arc stability
and consistency of the weld fusion attained" This poor sales rep did not
realize that the problem he described had been a major issue with his equipment
since it was introduced into the USA. He also did not realize that his artificial
intelligent weld equipment that sat proudly on display at the weld show would
reveal that it still could not provide a consistent pulsed weld arc especially
on small weld cycle times. <
2005: WHY WOULD ANY WELD SHOP ACCEPT A MIG WELD
POWER SOURCE THAT;
YOU HAVE SPENT MORE THAN 20 MINUTES AT THIS SITE YOU
KNOW THE ANSWERS. IF YOU DON'T KNOW THE ANSWER, HE'S ON THE RIGHT.
the last four decades in ten different countries I have set up more than a thousand
different MIG weld applications with focus always on attaining optimum, constant
weld fusion and weld profiles that would always be called optimum. The MIG welds
I have always produced would be made with traditional, MIG equipment that typically
would cost 25% of the price of the Panasonic pulsed equipment.
PANASONIC AND THE POOR WELD GRAPH: This
oscilloscope chart shows voltage (red) and weld current
(black) fluctuations taken by a frustrated Canadian weld engineer. He was frustrated
because his Panasonic MIG equipment lacked the ability to produce two parts with
the same weld appearance and fusion. The pulsed equipment was a Panasonic AA 11-
Note on the chart. The dramatic swings of unstable prime weld parameters,
with both volts and amps frequently hitting zero, this was too common an occurrence
with many pulsed power sources built up to 2006.
MIG welds I produced in 1965 and the MIG welds I produce forty years later with
traditional, low cost, stable CV. MIG equipment, could pass any FILLET weld code requirement.
For over ninety nine percent of conventional manual and robot MIG welds
on carbon steel applications > 4 mm, you simply do not require an intelligent
power source that provides a so called special ~~~Wave Form or unique Ripples~~~. The traditional
MIG equipment I have always utilized, was not electronically "intelligent",
however when I provided weld process control training
to weld decision makers, you could assume that at the weld process control
course completion the welding operators were "process
intelligent" and trained to make optimum welds with out playing with
controls and using unsophisticated MIG equipment.
PANASONIC VERSUS LOW COST CV MIG EQUIPMENT:
traditional MIG equipment I have utilized for decades did have an unusual 50 year
old electrical attribute common to all CV equipment. During the weld the CV MIG
power source instantly responds and makes a controlled current correction for
the wire stick-out changes, (arc length variations).
with the left weld output oscilloscope, the traditional, lower cost CV, weld parameter stability
when using the same weld wire and similar weld parameters as indicated in the
RIGHT picture from the Panasonic AA 11 -350
purchasing your next power source,
spend a little time on the subject of weld
asked for his opinion on weld fusion, and spray versus pulsed, Albert might
have said the following.
energy attainable from CV spray transfer is of course logical for consistent
and constant weld fusion. Wheras the inconsistent weld energy from the peak to back ground current of a pulsed power source will of course on certain applications lead to inconsistent weld fusion.".
2006 ARC LENGTH SENSITIVITY FACT: In contrast to the pulsed mode in which one
weld droplet per pulse cascades hopefully undisturbed across an arc gap, the traditional
MIG spray weld transfer is "less sensitive to arc length variations"
The simple reason for this is the spray transfer stream and does not require the
formation of individual weld droplets to achieve optimum weld transfer.
In the pulsed
mode, as the pulsed arc length shortens, the wire tip to work distance decreases
and the pulsed weld drop will be eventually be disrupted as its in contact with
both the positive wire and negative weld. This short circuit arc disruption can
reduce the consistency of both the pulsed weld droplet transfer and weld fusion
potential. Remember also this process spends fifty percent of it's time in a low
back ground current of less than 80 amps. In contrast with traditional spray transfer,
an arc length reduction has minimal impact on the delivery of the more consistent
energy, spray transfer weld stream. With carbon steel welds particularly on metals
> 5 mm when you want optimum and consistent weld fusion you figure out what
process you should be using.
2006 NOTE: WITH CARBON STEELS AND HIGH DEPOSITION MIG WELDS DEPOSITED OVER
12 LB/HR, VIEW THE GREATER CONSISTENCY OF THE WELD TRANSFER AS EVIDENT IN THE
SPRAY WELD SURFACE ON LEFT, VERSUS A 2006 PULSED WELD SHOWN ON RIGHT. PART OF
THIS PROBLEM IS WITH THE PULSED WE HAVE THE INCONSISTENCY OF THE TRANSFER AND
INSUFFICIENT CURRENT FOR THE WELD MASS:
energy and configuration of a traditional MIG spray transfer plasma can also be
superior to the pulsed MIG plasma reference the potential weld fusion profiles
(side wall fusion) attained.
I did not get into a MIG arc plasma physics
characteristic comparison with the Panasonic rep, as I know it would have been
time wasted, any way he was to busy giving me welding advice.
I however I did ask the Panasonic rep a simple question
on the pulsed wire feed range. I said "does your intelligent power source
provide a practical measurable benefit like extending the traditional MIG spray
transfer wire feed range so that we can weld faster with a robot"?
The Panasonic rep instantly developed the infamous
"weld glazed look", paused a few seconds, then
replied. He stated he was not qualified to provide an answer. This was the first
real thing he said to me after thirty minutes of verbal diarrhea.
2006 and 2007 you too may be lucky enough to have discussions with some rep that
wants to discus the attributes of pulsed MIG equipment artificial intelligence,
yet it's likely this same individual will not know the weld deposition rate of
a spray MIG weld made with an 045 wire at set at 450 ipm. The
Panasonic pulsed verbiage again proves that when it comes to welding, "seeing
the actual weld, is always mightier than the salesman's word".
A few years earlier, at my first introduction to the Panasonic
pulsed power source. I had a two hour lesson from another Panasonic rep that must
have had least twelve months weld experience. This rep told me what he thought
was the unique electronic benefits in his companies pulsed power source. In that
time period the Panasonic power source was designed (or
was it marketing strategy} to minimize the so called "ripple weld current
output". Now keep in mind in that time for 30 plus years I had MIG welded
with traditional CV weld equipment, yet with all the trillions of ripples
I must have produced I have never produced a bad MIG weld or a weld with spatter
issues. So you can imagine my surprise when I heard from Panasonic about the bad
influence of the Panasonic "ripple output" .
TO ~~~RIPPLE~~~ OR NOT TO RIPPLE A PANASONIC WELD QUESTION?
COMPARED THE RIPLESS PANASONIC POWER SOURCE WITH THE MILLER DELTAWELD. At
the time of the Panasonic ripless power out put, I compared the rippless Panasonic
power against a Miller DeltaWeld, which was a traditional, lower cost CV power source.
the way as this Panasonic was talking about ripples anyone could have put an oscilloscope
on the Panasonic power source and see something that was much more of a concern than ripples.
The Panasonic power source voltage (red) and current (black) was all over the
place. The bottom line the standard, lower cost CV Miller power source (as shown above) proved
to provide superior arc stability, more consistent weld energy and welds on >
0.125 that have a superior appearance.
years later at another AWS show, I noted that the latest and greatest Panasonic
Power source was using an 0.045 (1.2 mm) wire.
I asked the welder doing
the Panasonic demo to set the wire at the traditional high spray transfer setting
of 500 in./min. I noted while he was welding that the resulting pulsed arc plasma
zone was narrow, agitated and the plasma was intense. The resulting pulsed weld
had a poor convex profile that likely would have resulted in inconsistent side
wall fusion. The bottom line. For the last two decades, when welding carbon steels
I have been trying to find real world, practical, measurable welding benefits
from the complex costly Panasonic power source and from other similar pulsed equipment,
here today in 2005. I am still looking.
OF PULSED WAVE FORMS LATER AND THE SOPHISTICATED ELECTRONIC POWER SOURCES THAT
MAKE THOUSANDS OF WELD DECISIONS PER SECOND AND WHAT DOES THE WELDING INDUSTRY
END UP WITH FOR STEEL WELDS?
DE WUZZZY / RIPPLESS / POWER
THE WAVES / DIP-DE - PULSE / ARTIFICIALLY INTELLIGENT, REMOTE CONTROLLED, COMPUTERIZED
PULSED WELDING EQUIPMENT.
I CRINGE AT THE THOUGHT OF WHAT THE FUTURE HOLDS
FOR AN INDUSTRY THAT BELIEVES IN SO MUCH GIBBERISH,
from Brian. Aug 2005.
Have you heard that it's impossible to modify Panasonic robot settings to program
weld parameters in WFS? (Something you can do with Motoman or ABB robots, for
example.) Further, since even their newer tach-drive units they don't have any
WFS readout or setting, you still can't calibrate the robot in WFS (without a
separate device). I've exchanged a number of very in-depth e-mails with Panasonic
on these two closely-related issues during the last 10 months. Currently Panasonic
seems incapable of grasping the facts that calibrating in AMPS inherently introduces
inaccuracy and cell-to-cell variations that strongly inhibit establishing a continuous
improvement effort in high-level optimizing of parameters. Programming in AMPS
lies to the programmer about what he's adjusting, masks the whole balance of joint-fill-volume
vs. travel speed, and makes it more difficult to teach MIG process troubleshooting
and process improvement to anyone.
Going far beyond my professional
duty in attempting to assist Panasonic, I have presented several arguments of
ironclad logic which clearly point out why WFS calibration would be far more accurate,
than AMPS calibration. So far, they still don't get it. And
with Panasonic being so devoid of in-depth process expertise in North America,
I'm certainly not holding my breath. So far, the only weld engineers I've met
who like PFA welding systems are either self-proclaimed welding experts with no
degree in the field, or OSU welding engineers who typically wet behind the ears
and are incompetent in weld process expertise. Best
Ed's CD Process Control Training Program
Reply. If you have time to
waste and want unnecessary weld complexity in your world, consider a Panasonic
robot cell. Brian
I brought up the WF and amp issue with Panasonic in the early nineties, unfortunately, when it comes to MIG weld process controls the people I dealt with at Panasonic
were sadly lacking on the subject.
may be interested in a recent experience I had with Panasonic. In January 2006
I was asked to reset the Panasonic robot programs for a company in PA. The Panasonic
robots were approx. 12 months old. At this company the touch sensing and through
the arc tracking was not working correctly and as usual the pulsed process was
not suited to the steel application. I switched the pulsed power source over to
the spray transfer mode and with the Panasonic 500 pulsed equipment. To attain
270 amps I had to set 370 amps in the Panasonic robot pendant. By the way I figured
for every hour it took for the programmer to make changes with the Panasonic weld
and robot data, I could have done the same thing in 15 minutes with an ABB robot.
There is only one way to control a MIG weld and that is through control of the
TO FURTHER SCREW UP A CONFUSED WELD INDUSTRY MAKE IT MORE COMPLEX
AND PANASONIC WAS UP TO THE TASK?
it's sophisticated pulsed MIG equipment, Panasonic is proud to claim it provides
"Four Million Wave Forms". A MIG Weld Reality. Irrespective of the pulsed or traditional MIG transfer weld
modes utilized, once the wire size is selected, optimum welds can be made on every
carbon steel, alloy steel and stainless application with "Four simple weld settings".
"Pana Star AA2" Panasonic
increases the power source CPU'S for faster arc response from this artificial
intelligent power source. Panasonic claims this Fuzzy logic, MIG power source
offers electronic wonders. The weld reality, is the welds this power source produces
are inferior to short circuit or spray transfer welds made from a traditional
CV. MIG power source that costs 50 to 70% less.
weld logic and European weld
logic are simply not the same.
weld shops considering the purchase of a robot, remember at the end of the day
it's not about the robot or
MIG weld equipment electronics, it's about the
weld quality and productivity produced.  For
those companies that do low to medium volume, ever changing steel / stainless
weld applications, give serious consideration to the following;
 When you examine each robot manufacture's product don't get caught up with
the bells and whistles and fancy electronic pulsed MIG power source with it's
4 million wave forms. Stay focussed on the MIG power source weld output and communication
with the robot, the weld arc consistency at high and low wire feed rates and don't
forget the equipment durability.
 With the robot program, examine
the length of time required to both program a part and to make weld changes to
 With the robot program, examine the ease in which wire
feed, voltage or pulsed parameter changes are made.
Examine the logic in the robot's weld program and the calibration between pendant
and power source weld data.
Examine the robot's automated tool center point TCP capability and repeatability.
 Examine the robot's touch sense and through the arc tracking capability.
 Examine the robot weld weave program, especially the logic of the
 Examine the accuracy and repeatability of the robot with
 Examine the complexity of programming
the robot to work with secondary equipment such as the positioner, a camera or
torch cleaning stations.
 Examine the robot instruction literature,
the technical support and service capability.
BECAUSE THE ROBOT YOU ARE CONSIDERING SEEMS TO WORK WELL IN AN AUTO PLANT, THAT
THIS IS A LOCATION WHERE THEY THEY MAY RARELY CHANGE THE WELD PROGRAMS AND THIS
IS AN ENVIRONMENT THAT TOO OFTEN HAS MINIMAL WELD EXPECTATIONS.
IN A JOB
SHOP, CONSIDERATION SHOULD BE REQUIRED FOR THE SPEED AND SIMPLICITY REQUIRED TO
PROGRAM DIFFERENT PARTS. ALSO THE ROBOT TOUCH SENSE AND WELD TRACKING CAPABILITY
IS A CRITICAL FEATURE FOR MANY APPLICATIONS.
NOTE: IT TYPICALLY TAKES 30 TO 50% MORE TIME TO PROGRAM A JAPANESE ROBOT THAN IT DOES TO PROGRAM AN ABB SWEDISH ROBOT.
FIRST CHOICE FOR WELDING ROBOTS. I PREFER THE
SWEDISH SOFT WARE LOGIC AND PERFORMANCE OF "ABB ROBOTS" .
- UNION CARBIDE OF OLD HAD OUTSTANDING MIG WELD EQUIPMENT.
VI 252 A LOGICAL, DURABLE, CV MIG POWER SOURCE
1980s. The Linde VI 252 was and still is a gem. This is a power source familiar
to many small to medium weld shops. This is the MIG unit that you would expect
to last for at least two decades. It had an excellent slope out put, providing
great short circuit and spray welds. This power source was considered a medium
size MIG unit, providing 250 to 300 amps. The wire feed permanent MAG motor was
and still is a work horse
and it's two over sized drive rolls is better than most four drive roll units
sold in 2008.
WHO CAN GET PAST WELD EQUIPMENT SALESMANSHIP AND PROVIDE THEIR EMPLOYEES WITH
WELD PROCESS TRAINING CAN PURCHASE TRADITIONAL, LOW COST MIG EQUIPMENT AND PRODUCE
CARBON STEEL / STAINLESS MIG WELDS THAT WILL MEET THE MOST STRINGENT, GLOBAL WELD
Mail from email@example.com
MY GOD ITS REFRESHING TO HEAR SOMEONE TALK STRAIGHT ABOUT MY FAVORITE
SUBJECT. I USED TO FABRICATE RACE CAR CHASSIS AND IN MY QUEST FOR THE ULTIMATE
MIG MACHINE I SELECTED THE MILLER MAXTRON AND THE INVISION.
I HAVE BEEN DISAPPOINTED WITH BOTH POWER SOURCES AND COULD NEVER GET ANYTHING
NICE GOING ON IN THE PULSED MODES.MY OLD MILLERS WERE SO UNBREAKABLE AND ALWAYS
PROVIDED GREAT WELDS. ALL YOU HAVE SAID ABOUT THE NEW ELECTRONIC, MIG EQUIPMENT
JUNK, I HAVE EXPERIENCED.
REGARDS AND KEEP UP THE GREAT WORK. NICK.
would not have poor weld equipment if we had good weld management.
THE NINETEEN EIGHTIES, THE WORLD'S MOST SUCCESSFUL AUTO / TRUCK FRAME MANUFACTURER
WAS COMPANY LOCATED IN MILWAUKEE, THE COMPANY WAS CALLED "A.O. SMITH".
OUT MAKING CAR FRAMES FOR CADILAC IN 1904. IN 1990s A.O.SMITH WAS THE ONLY GLOBAL
CORPORATION TO ESTABLISH ROBOT MULTI-PLANT WELD BEST PRACTICES AND ALSO PROVIDE
EFFECTIVE ROBOT PROCESS CONTROLS. THE AO SMITH DAILY ROBOT WELD REWORK FOR THE
CAR AND TRUCK FRAMES WAS MINUSCULE AND IN CONTRAST TO MANY ROBOT COMPANIES WELDING
IN 2008, THEIR ROBOT MIG PRODUCTION WAS BOTH OPTIMUM AND CONSISTENT.
North America during the mid 1990's, A.O.Smith had more than 1200 ABB robots which
were utilized mostly with Miller Delta Weld 450 equipment and 0.045 (1.2 mm) MIG
wires. The majority of the welds produced were made with the spray transfer mode
at weld deposition rates that averaged 11 - 14 lb/hr. Note:
IN 2011. THE MILLER DELTA WELD IS STILL THE WORLD'S BEST
CV POWER SOURCE.
WELDING FRAMES FOR 93 YEARS, AROUND 1997 SMITH WAS PURCHASED BY TOWER AUTOMOTIVE.
I HAVE BEEN IN MANY TOWER PLANTS AND MY EXPERIENCES LED ME TO SINCERELY BELIEVE
THAT THE "HANDS OFF, TOWER CORPORATE ENGINEERS AND MANAGERS" NEVER FULLY COMPREHENDED
OR APPRECIATED THE WELD TECHNICAL AND PROCESS EXPERTISE THAT A.O. SMITH UTILIZED.
Today thanks to typical hands off management that
you will find at companies like Tower Automotive and the lawyers we call politicians
in Washington, through no fault of their own, American workers are fast loosing
their future ability to earn a decent pay check.
IT'S SAD IN THIS APATHETIC MANUFACTURING
ENVIRONMENT THAT AN AMERICAN MANUFACTURING GIANT LIKE TOWER ADDS TO AMERICA'S
FUTURE POTENTIAL EMPLOYMENT ISSUES THROUGH POOR MANAGEMENT.
A PROUD 90 YEAR OLD COMPANY AND IN LESS THAN 90 MONTHS BROUGHT THEM TO CHAPTER
MUCH FOR WELD MANUFACTURING EVOLUTION: IT'S 2008 AND THERE IS NOT ONE AUTO / TRUCK
FRAME PLANT, OR BIG THREE PART SUPPLIER IN NORTH AMERICA THAT HAS COME CLOSE TO
ATTAINING THE SAME OPTIMUM DAILY ROBOT WELD PRODUCTION AND QUALITY ACHIEVED BY
A.O.SMITH IN 1988.
BEST WELD PRACTICES: 50 PLUS YEARS
AFTER THE DEVELOPMENT OF MIG EQUIPMENT, THERE IS LESS THAN A HANDFUL OF COMPANIES
IN NORTH AMERICA THAT HAVE IMPLEMENTED MULTI-PLANT MANUAL / ROBOT BEST MIG WELD
WELD COSTS: I BELIEVE THERE ARE LESS THAN 100 COMPANIES IN NORTH AMERICA THAT
ACTUALLY KNOW THE REAL COST OF A MIG
WELD PRODUCED ON THEIR WELDED PARTS.
THAT'S REQUIRED FOR MANUAL BEST WELD PRACTICES, WELD COST CONTROLS AND ROBOT PROCESS
CONTROLS IS FOR MANUFACTURING MANAGEMENT AND ENGINEERS TO TAKE RESPONSIBILITY
FOR THE WELD DECISIONS AND EQUIPMENT IN THEIR PLANTS. TRY THIS BOOK.
PROCESS OWNERSHIP DOES NOT START WITH:
Robot management and engineers who are not responsible for the processes they
Managers and engineers who cannot build steel parts and hold 1 mm tolerances.
 Designers who don't understand the weld process limitations on their
 Engineers who produce poor weld fixtures.
engineers and technicians who don't seek the necessary MIG process control education
Lets face it, you don't have to look too far
today in a manufacturing plant to find a management or engineers that lacks weld
equipment or weld process control "depth". . and in any auto / truck
plant, it would not take more than two minutes to find an individual that believes
they are an expert on a subject as they have 12 months experience.
has been around for fifty plus years, it has two weld controls. If you are a manger
or engineer who cannot understand those controls, you now know what you have to
A World's Best MIG power source. The Miller Delta Weld.
2005: When you evaluate the best pulsed MIG equipment for welding carbon steel
and stainless welds, you should compare the weld results with the much lower cost,
optimum, CV MIG power source.
many different manufacturing plants in different countries, for close to two decades,
I religiously recommended the purchase of the world's best traditional MIG power
source, the Miller Delta Weld 450. I took the Delta Weld equipment to Thailand
to MIG and flux cored weld 270 ksi armored plate on USA made army tanks. While
Miller equipment was not sold in Spain, I encouraged a Spanish auto parts supply
company, Viza (Citroen seats) to purchase Miller equipment for it's new robot
lines. I recommended the Delta Weld equipment for hundreds of manual / robot applications
across the USA and Canada.
The Delta Weld provided an optimum slope parameter
output for both short circuit and spray transfer modes. This durable, extremely
well built power source also provided excellent arc starting characteristics.
MIG arc starts used to be a common issue especially with Lincoln's MIG equipment.
The bottom line the Delta Weld was a durable, cost affective work horse for manual
MIG welding and a logical power source for robot steel welds.
ELECTRONIC ENGINEERS AT WELD EQUIPMENT MANUFACTURES WHO TYPICALLY KNOW LITTLE
ABOUT ARC PHYSICS AND WELD REQUIREMENTS, OR OPTIMUM WELD DATA CAN SCREW UP GOOD
MIG WELDING EQUIPMENT.
MILLER, PLEASE TRY NOT TO screw up thAT Delta Weld. Around
1998 or 1999, some individual at Miller, possibly a new electronic engineer
or an inexperienced product manager, decided some cost cutting changes could be made
to this power source. The Delta Weld changes had a negative impact on the slope
output effecting the weld equipment performance. I believe that the person who
made the changes probably did not know what the optimum current / wire feed relationship
is for the common MIG wires and weld transfer modes, or what the ideal weld current,
wire feed relationship is for welding a simple 1/4 fillet with an 0.045 wire. Anyway who
ever got their hands on the Delta Weld took a weld giant and created a mundane
product readily available at the competition.
MILLER ENGINEER SCREWED THIS DELTA WELD.
During 1999, I provided weld management consulting and
training services to a company called Omniquip. This company made SkyTraks. At
the time Sky Trak used Lincoln MIG equipment. I ordered 4 Miller Delta
Weld power sources for the companies weld training facility.
the Delta Welds would last for one to two decades without equipment or process
issues. In a six month period the new revised Miller equipment at Omniquip resulted in;
[a] Numerous "wire feed" electronic issues
with 3 of the 4 new power sources. [b] In contrast to the traditional
Delta Weld power source, the >1999 Delta Weld power sources, weld voltage and
current per/wire feed rate (slope output) had been altered. The result was a negative
influence on weld fusion potential and on the power source performance.
[c] For low current MIG applications, the Delta Weld power source when using "a
low energy argon mix" now no longer provided low current, consistent arc
Note: A primary weld concern with MIG welding equipment is attaining sufficient
weld energy for the wire feed rate delivered. For example the slope output (volt
amp curve) is designed to provide a specific current for a given voltage. Also
the slope of the curve will determine the amount of weld current change per volt
important is the volt / amp wire feed relationship? For
example, with a traditional, effective CV power source, when using an 0.035 wire
at 210 ipm, delivering 3.3 lb / hr, the power source would put out approximately
140 amps and require 17 welding volts. This weld parameter combination provided
both optimum weld voltage and current for the short circuit wire feed rate selected.
If a power source designer changes the slope, lets say the required short circuit
weld voltage for that wire feed position is now 19 volts. As a result of the extra
voltage, the short circuit weld droplet size is now larger, more globular and
the short circuit weld transfer would be more erratic with excess spatter.
seems in their quest to add electronic bells and whistles, some MIG power source
designers forgot about the fundamental arc / slope and wire feed relationship
of MIG weld transfer. When
a power source designer makes negative changes to a power source that for decades
has been perfect, one has to ask what is the weld equipment manufacturers motive?
[a] Is it weld process ignorance?
[b] Is the need to reduce the weld equipment cost?
[c] Is it
the need to add electronic bells and whistles to justify a future power source
You don't try to change Coke and
if they had any sense Miller management would not allow it's designers or product
managers to screw around with their number one power source, the Delta Weld.
Miller Weld Power Source Manager told me he
"plays" with MIG weld
address the Delta Weld issues at the Omniquip(Sky
Trak) plant, I had to deal with the Miller product manager for MIG equipment.
The Miller product manager came to the Wisconsin plant to review the problems
with his companies revised Delta Weld equipment. I went through the problems and also went through
the wire feed range, pointing out the weld parameter, current / wire feed relationship
issues snd the differences between this equipment and the superior older Delta equipment.
talking to the Miller MIG product manager about the slope performance and
the necessary relationship between the wire feed and parameter setting, I noted the Miller manager had a glazed look. That glazed look is one I have seen many times on my wifes face when I talked to her about welding.
Miller MIG power source product manager's response to my complaints was, "he had no problems
with the revised Delta Weld power source, and reference the weld parameter / wire feed differences, he could not understand my concerns as when he makes welds he just "plays
around" with the weld controls till he finds a weld setting he likes.
the responsible Miller power source designer check the revised Delta Weld parameter
output with the original unit?
Did the engineers who built the new revised
Delta Weld equipment check the revised performance with all the common available
argon mixes before sending the equipment out to welding shops?
Did the Miller management believe it was important to hire a MIG product manager who did not understand the MIG process, a man who had to "play
around" with the two simple controls on the MIG weld equipment
When did the Miller management believe that they should build it and weld shops should test it.
2003 MILLER DELTA WELD 450 / 452 UPDATE. DUE TO THE POOR PERFORMANCE OF KOBELCO MIG EQUIPMENT THAT'S USUALLY FOUND ON MOTORMAN
ROBOTS, IN OCT 2003, I HAD TO GET ONE OF MY CLIENTS TO SWITCH OVER FROM THE KOBELCO
350 MIG EQUIPMENT TO A MILLER, DELTA WELD 452. THIS POWER SOURCE HAS THE BUILT
IN ROBOT INTERFACE. THE 452 PROVIDED EXCELLENT WELD PERFORMANCE ON THIS APPLICATION.
SOMEONE AT MILLER MUST HAVE BEEN TAKING NOTES. THE DELTA WELD IS BACK ON IT'S
Miller. Invision 456MP.Electronics and Weld Mediocrity.
If you have nearly $6000 to waste on poor performance
and a poor slope out put, take a look at the Miller Invision 456MP. However If
you wanted to save well over $3000 you would bring in a Miller CP 302. Then spend
a few $ on my books and Cd process control training resources, and then attain
the process control expertise necessary to produce superior weld quality and productivity.
Auto Axcess 450
think this next e-mail tells a great story about Miller and bells and whistles: E.Mail
The following is my experience and my frustration since owning 7 Miller Auto Axcess
450 machines for almost 1 year. My Magna boss believes my job is to get the GM robot
welded parts out of the door without weld quality or production issues, however
with all the Miller issues I have had to put up with, I feel like less like a
robot technician and more like an unpaid Miller Weld Equipment Technician. What
happened to the good old days when you switched the Miller DeltaWeld on and got
through the shift without welding issues?
We were told by Miller that their Accupulse would weld faster than traditional CV equipment
and produce less spatter.
2) We set most
of the welds in "Accupulse mode" initially, a few welds used Short Circuit
we had gaps. The Accupulse welds were on parts that had good fit. While we used
optimum weld parameters and Miller's recommendations for the welds, we could not
keep the arc stable enough while running production. Almost half the welds coming
off the cell had ropey, unstable bead appearance, while the other 50% of the welds
were perfect with small amounts of spatter. I was only traveling about 30 IPM
when using Accupulse.
We also had high tip burn back issues when using Accupulse.
I could not get more than 2-3 hours of production without an arc fault due to
a burn back. We had lots of evidence of micro arcing on the weld wire.
4) To try and help stabilize the process and also
to reduce the tip burn backs, Miller sent us custom Accupulse programs 2 times.
They attempted to limit the peak current at the arc start to prevent the micro
arcing and tip burn backs. This never worked properly and I still had the problems.
I have updated core system software in the machines 3 times since I own them.
6) Finally I was forced to turn off Accupulse due to excessive production
downtime and excessive weld repair on welds that went unstable.
When running in the traditional CV mode we were able to get the travel speeds
thirty percent faster 40 IPM than the Accupulse mode.
turning off the Accupulse mode completely, we were still having what we felt were
excessive robot cell stoppages due to Arc Faults and burn backs.
were getting intermittent "Wire Stuck Alarms" when we did not have wire
a) Miller's response to this was that there was
a timing issue between the robot and the welder causing erroneous nuisance alarms.
It may occur if the tip of the wire scrapes on the part after a weld was complete,
even though the robot was not stuck and on the way to its next weld or its home
position. Miller told me to disable this alarm to avoid nuisance occurrences.
10) We continued having excessive amount of "Arc Shortage Alarms"
on the Motorman XRC robots. The Arc Shortage alarms are things coming in from
the welder after getting a legitimate arc ignition. The welder was logging an
excessive amount of wire feed speed errors for no apparent reason. Each time the
welder felt it had a wire feed speed error; it would send an alarm to the Motoman
XRC causing the Arc Shortage alarms. a) Miller ended up turning off the Wire
Speed Error alarms in the machine because they felt these alarms were nuisance
only causing excessive faults on the robots.
11) Miller was requested
for an on site visit to investigate the root cause of our problems.
While on site, they cold booted all of the welders to clear out any alarm occurrences.
They then verified that the most recent version of "Code" was in the
12) On a few machines I had the Inductance set to 60 on a 0-100
scale. Miller's default inductance setting is 30. I did this on short circuit
welds to get a better wetting action and better bead appearance. Miller decided
to set all the welders at an inductance of 30. They felt that a 60 inductance
may have been too high causing harsh arc starts. After turning the machines down
to 30 inductance, we had to change the arc start conditions in the robots and
reduce the start voltage. I had higher than normal starting voltages when using
60 inductance to prevent machine gun type starts.
13) Millers approach
to its numerous equipment issues was to bring in a new pulsed power source, the
Auto Axcess 300. My application is on 1.8mm and below down to 1.0mm. We are using
0.035 wire with a 92-8 Ar-C02 gas mixture. a)
Miller told me that the Auto Axcess 450 machines have a peak short circuit starting
current of around 700 amps. They felt that this was much too high for an 0.035
wire causing the micro-arcing conditions.
b) The Auto Axcess 300 machines
have a peak short circuit starting current of around 500 amps which they felt
would be better for welds done less than 200 amps using 0.035 wire.
Miller turned down the run-in settings to 50 IPM from the 250 IPM I had set. They
wanted the wire to run-in much slower while attempting to strike the arc. I started
at 100 IPM when we first bought them and tried various settings between 100 and
275 IPM with no real changes noticed.
d) Miller also set the wire retracts
at the end of the weld to 100 IPM for 0.2 sec. This is done at each arc off automatically
by the welder to ensure the wire is not touching the part at the next arc strike.
Miller Auto Axcess 450 has another core problem that I feel is definitely worth
mentioning. If you use multiple processes on the machine as I am sure many users
do, there is a software problem that causes harsh arc strikes, which will add
to the tip burn back problems. Essentially the problem is this; if you are doing
a pulse weld, and the next weld after that is a CV weld, the machine strikes the
arc in its last known process (which was pulse) and then switches to its new process
(which is CV). This switching cannot be preset in any fashion currently. Miller
asked me to actually try and do an Arc On in mid air during an air cut so the
next weld could have the proper schedule preselected. You can imagine the problems
in doing this. While the robot is moving, a "Hot" weld wire would be
enabled, and feed wire out at the run-in settings; it would have to see an Arc
Off prior to the timer for the Arc Fail alarms, and then you would have to retract
the wire before the next weld. I told Miller this was an unacceptable situation
and that I need a way to ensure the next weld is set properly without having to
do this. Miller is currently working on a fix for this in their next release of
"Code" which has not yet been released. At this time there are also
no factory preset programs for 0.035 Metal Core wires for CV, Pulse, Accupulse,
or RMD. I have asked them to provide me with those as soon as possible because
I am using 0.035 Metal Core wires. I am currently using Accupulse on a few welds
but had to select an 0.045 program and had to turn the Trim and Arc Control settings
way down on the machine to get the Arc Length down to a reasonable level. Much
of the development on these machines is done way after the product launch at the
customer's request. I feel that they should have had many of these things available,
and most of the other bugs worked out prior to releasing this welder to the consumers.
We are going to monitor the progress of the machines and continue to compare the
Auto Axcess 450 to the Auto Axcess 300. I will continue to monitor the progress
and see what happens. I don't appreciate being a test facility for the Miller
products. If new MIG welding power sources were designed and tested correctly,
why is it that the major weld equipment manufactures such as Miller, Lincoln Panasonic
etc. seem to be weekly revising the electronic circuit boards and programs in
their MIG welding equipment?
From Ed. Greg has the patience of a saint. I believe his company should have replaced
the MIG equipment and taken Miller to court. Scroll down to see that years later
the Miller Axcess fiasco continues.
TO CUT DOWN ON WELD SHOP FRUSTRATION? DON'T BUY ELECTRONIC MIG EQUIPMENT TILL
YOU TEST THE HELL OUT OF IT AND MAKE SURE THAT THE MODEL YOU PURCHASE HAS BEEN
AVAILABLE FOR AT LEAST 3 YEARS.
21-2007: E-Mail to Ed Craig.
I am a robot technician at a plant that manufactures lawn mowers. We normally
weld in the 170-230 Amp range. We had been using Miller DeltaWeld 452's on all
of our robot cells. The decision was made to replace these welders with the new
"high-tech" Miller AutoAxcess 350 which
has MIG, Pulse, and Miller's own "accupulse" processes. Since changing
to these new welders we have to change a lot of contact tips, mostly due to poor
arc starts. Miller reps have been back several times but we are still not seeing
the benefits from pulse welding that they promised. Any ideas.
As you and I are not electronic engineers, you should consider setting your companies
lawyers on Miller for selling equipment that does not function correctly.
Perhaps your managers and engineers could read some of the info at this site before
making important and costly MIG weld equipment and process decisions.
E-mail to Ed.
we have the Miller Axcess 450 in our our plant. Our latest Miller MIG equipment
fiasco. The gas solenoid just
quit working after welding a few parts. We could manually purge gas, weld 1-2
more parts and it would happen again. We originally thought it was in the Wire
Feeder or the Feeder Cable, but swapping them out did not fix the problem. We
replaced the Motor PC board inside the welder which actually turns the gas valve
on and off and still had the problem. Finally in the end we exchanged the entire
welder and the problem went away. We only own 7 of these welders and 1 is a spare
for emergencies. Of the seven, four have required us to replace PC Boards, these
units have not in service one year.
Ed. What's that old song that has a line, "when will
they ever learn"?
having the same Miller Axcess problems in Spain 2008.
April 2008 MILLER AXCESS PROBLEMS. A note from Ed. This month I visited the west coast of Spain to
assist an auto plant that makes BMW car seats. The
plant had great success with their ABB robots and Miller Delta Weld equipment
which I had recommended to them five years ago. The plant in 2008 ordered the
Miller Axcess for it's robot cells and arc start contact tip issues started to
occur. Sometimes 13 contact tips a shift were being changed. I believe that Miller
has known about this problem for at least three or four years and still has not
fixed the problem. My client wants to get rid of the new Miller Axcess, however
Miller adds to the problem by no longer making the Delta Weld equipment available
with a robot interface. By the way what a useless toy the Miller Palm pilot is,
its another tool that will ensure people waste the day "playing" around
with useless bells and whistles.
Aug. 2008. Ed in my Canadian company, we weld auto parts and use the Accu-Pulse,
Miller Axcess, 450 amp mig unit with Motoman robots. Too frequently we get holes
in the end of the welds on the thin parts, and the weld end craters are extra
long. It seems like every afternoon I play around, (yes, I play around) with the
torch angles and wire , stick out, but still have not been able to solve the problem.
The bottom line is I get lots of complaints from the weld reworks guys. Do you
have any suggestions? Regards. Zhu. Weld Tech. Canada
Zhu, The crater and control of the weld end data has been an on going problem
for years with this equipment. I have devised unique programming and process solutions
for these issues. You will find them in package 4 of my robot process control
Just to show you how long this Miller BS has been going on, take note of this email in 2013.
Jan 2103: Ed. We have had arc end weld issues with 2 Miller Auto Axcess 450 D.I's in a dual arm Motoman cell since the insallation. It seems the Auto-Axcess Sharp-Start routine is causing small explosions at the weld ends. These explosions can be heard and seen as little balls of molten metal shoot out of the cell at the arc ends and some times cause micro crater cracks little "snowman" looking eruptions that have to be ground off and manually repaired. We needed assistance se we called in the Miller rep.
When the regional Miller rep came to our plant he first blamed the weld wire. Then he blamed the gas mix, the gas flow rate, the weld voltage, wire feed speed and the wire stick-out. He then blamed the raw materials we were welding and then followed with we should change all the weld schedules from DC Spray Mig to AccuPulse. With nothing working for this joker, he finally he decided that thee smooth drive rolls on the metal-cored wire was the problem. More to the point, I asked repeatedly if he could turn off the Sharp-Start and auto burnback "features" he said we would have to talk with the Miller Engineer responsible for the Auto Axcess line.
Do you know what we need to do to disable these "special features" so I can use normal crater fill and burnback techniques? By the way we weld only 3/4" Hot-Rolled plate and its a railroad application. All the robot welds are in the 2F position, 3/8" single pass fillet.
The gas and voltage lets us burn through the mill scale pretty well and we have used these parameters for years in manual welding with regular CV equipment.
Thanks In Advance. Jeff Christensen. Mfg. Eng. Progress Rail Services.
the hell has the weld current gone
Invision, XMT or Accupulse.
happens when you use
the regular short circuit or spray transfer MIG modes with this equipment? Inverters,
pulsed and multipurpose CC/CV MIG equipment typically provide a steeper slope
than traditional CV equipment, restricting the typical weld current output. The
current reduction from this equipment can result in sluggish welds (poor weld
fusion) or welders welding in the globular mode when they should be in spray transfer.
If using this equipment with low energy argon - oxy or argon < 9% CO2 mixes,
these gas mixes as you know require low weld voltages and will further lower the
potential weld current output.
ESAB Aristo 450. This multipurpose
pulsed inverter provides two different features worth evaluating. The
power source has a built in water circulator for water cooled guns. It also has
if you feel you need one, an "arc data monitor" The
Bottom line. This MIG power source provides good weld characteristics, however
for 99% of your welds you will never need most of the bells and whistles found
on this costly equipment.
MANUAL OR ROBOT WELD POWER SOURCES DO NOT REQUIRE
"ARC DATA MONITORS". WELD SHOPS HOWEVER DO REQUIRE WELD PERSONNEL WHO
HAVE WELD PROCESS EXPERTISE AND
WELD MANAGEMENT WHO BELIEVE IN EQUIPMENT OWNERSHIP, BEST WELD PRACTICES AND WELD
ABB Robots and ESAB Arcitec Weld Issues.
Welds on Ford 6061 Aluminum Car Seats.
2000, I was requested by an engineer at VAW a tier one supplier to analyze the
welding performance of their ABB robot and ESAB Arcitec welding equipment. This
plant produces extruded aluminum parts. The aluminum welded car seats were for
Ford. The car seats and parts required small welds which were made on thin gage
the installation of the robot cells, continuous production of optimum weld quality
parts has been impossible due to the issues documented in this report. Weld
reject rates averaged sixty percent and the robot down time per hour averaged
20 to 30 minutes. To see the rest of the story, click
the land of Lincoln. The
LINCOLN POWER WAVE ISSUES. It's only fitting that my last weld consulting job in the year 2000, would be working
with Lincoln pulsed MIG equipment at a GM plant in Ohio.
The job was simple. A new multi-million dollar production line set up to
automatically MIG weld torque converters. The weld problems generated on the lines
created, a 4 - 8 % leak rate from the 1000 MIG welded parts produced daily,
What I found interesting about the costly, high volume installation that had
two weld production lines using six Lincoln Power Wave power sources, the lines
were not yet in the full production mode, yet the plant engineers informed me
that four of the six Lincoln pulsed power sources had already been replaced. Two
days into my visit, after switching the erratic pulsed mode off, I used a different
wire size and set the torque converters welds to spray transfer mode. The weld
reject figure was reduced to "0%" and as a bonus I gave the GM plant
25 % more production. If
the lower cost, traditional, more durable Lincoln CV 400 power sources had been
purchased, the weld problems would not have occurred and several GM engineers
would today would have more respect for Lincoln and it's red welding equipment.
By the way when making those changes on the converter lines, not one GM manager
showed any interest.
E-mail sent to Ed Oct. 2002.
in the US in an automotive parts plant that manufactures components for
a Japanese company. We continuously have problems with internal weld porosity.
The porosity is not visible from the outside of the weld but when you grind the
surface away the welds are full of it.
We are MIG welding the galvanealed
materials and we have exhausted all efforts to eliminate the porosity. We use
a Lincoln Power Wave 450 and have had Lincoln come in and try different pulsed
Wave Forms but they could not solve our problem. We have tried different wires
and use 90 argon 10% CO2. I believe that the galvanealed coating is contaminating
the weld, however it's a customer spec and cannot be changed. Any suggestions?
From Ed: Galvanealed coating rarely causes weld issues. Galvanized causes extensive
weld issues. You need more weld energy. Get of the pulsed. Increase the CO2 content
to 20 %. Use smaller weld wires 0.035, (greater current density). Use low end spray data when possible.
decades Lincoln lived on its SMAW weld equipment and consumable reputation. Lincoln
MIG welding equipment was rarely sophisticated, however it was usually durable,
low cost and typically always provided a few process performance irritations.
From my personal perspective, the Lincoln MIG equipment of the last two decades
was inferior to Miller, Linde (ESAB US) and Hobart MIG equipment.
The Lincoln ~~~~~Power Wave ~~~~ 455 / STT.
This power source combines surface tension transfer (STT) with the pulsed Power
Wave characteristics. In other words two unique sets of bells and whistles for
the price of one. I have got to admit, I am fascinated by the hype that surrounds
the PowerWave, but not facinated by the performance. This
is a MIG package that along with the wire feeder can sell for more than $12.000,
or the price of a decent car.
STT? If your company MIG welds carbon steels,
low alloy or stainless steels, and you don't weld a "root
pass on a pipe, with the pipe in the fixed position, then instead of spending
$12.000.00 on the Lincoln Power Wave / STT you could purchase a traditional 300
amp, CV power source from Lincoln or Miller, equipment that is 25% of the cost,
easier to operate and much more durable.
of what that salesman tells you, when used for welding steel parts,
the traditional lower cost, CV weld equipment in combination with a little weld
process expertise can produce the same weld quality and productivity as the $12.000.00
Lincoln Power Wave unit.
Power Wave~~~At the AWS welding show, while
visiting the Lincoln booth, I watched with amusement as a Lincoln rep, with his
computer attached to the Power Wave told the welding crowd, (these were mostly
guys who typically had not learnt how to control the fifty year old, two control,
CV power source) "that if they do not like the "Power Wave Waveform
Output" then we at Lincoln can use this computer with its unique software
change the pulsed waveform features to suit your specific welding application".
from Ed: First lets get
the "designer software"
that can change a MIG waveform
put put, BS out of the
way. If a weld equipment manufacturer provides you with a "pre-programmed"
pulsed power source set to weld carbon, stainless or aluminum applications, as
you will likely not be welding metals that fell of the side of a space ship, the
preset pulsed weld program should therefore be set to deliver optimum pulsed parameters
for a specific gas mix and electrode type and size.
all pulsed welds can be made with 4 weld settings, it's logical to assume that
any preprogrammed pulsed weld data from a pulsed power source manufacturer, should
be close to optimum.
the preprogrammed weld programs in the pulsed MIG equipment are not optimum, the
weld equipment manufacturer should replace the individuals responsible for setting
the substandard pulsed weld programs.
The bottom line, if welds on the
world's common steel MIG applications could be improved through playing around
with computer programs, the reality is that data should be part of the preprogrammed
guess many things have changed at Lincoln during its electronic renaissance, especially
when they found out that MIG equipment profits are greatly enhanced when electronic
bells and whistles are added to the MIG power source and wire feeders.
to Ed. Nov. 8 2003.
Ed. I find that in
you are right on the mark. I have silently read much of what you have publishedhere without response and sometimes I bite my tongue when the "salesman"
(as you would say) in me would love to send off a scalding e-mail.
my company does manufacture the Lincoln Power Wave 455 and many times, I have
seen first hand benefits to welding companies. I do not try and "sell"
a Power Wave 455 to people that do not need a Power Wave 455, which is one way
that I tend to agree with you. Many of my competitors in Detroit are pushing their
"bells and whistles" on to people to weld simple carbon steel applications
that can be tackled with a traditional CV 300 unit quite easily. One more thing,
to dispel any thought in your head about the manufacture of L-50 (and L-56) MIG
wires. These wires always have and always will be manufactured in Cleveland. Yes,
we make MIG wire in Taiwan, England, Mexico etc. but these wires are not branded
as L-50 (L-56) nor are they manufactured to the same standard as L-50 (L-56).
In order to compete with all of the foreign MIG wires out there, we created
"budget" brands that cost less to manufacture and therefore, cost less.
Keep it real Ed, I look forward to meeting you down the road.
with held FROM A Technical Representative at the Lincoln Electric Company - Detroit.
Craig. First allow me to say that I truly enjoy visiting your website. There are
always a multitude of informative articles to view. I am writing in regard to
a specific article you wrote that I just viewed today (5/10/07) entitled "The
Lincoln Power Wave, is Not Required For This Job". But first allow me to
say that I agree with your position on Pulsed Spray GMAW equipment and the common
misapplication of it. As a AWS CWI/CWE that provides training to manufacturers
throughout the region, I have run across many instances where manufacturers have
been sold the most innovative technology at a stifling price only to find out
after considerable cost in rework ,rejects and unacceptable welds that they could
have had superior quality in finished product by using conventional Spray-Transfer
Having welded to ASME pressure vessel code for years using conventional
GMAW-Spray Transfer and conventional DCEN GTAW along with AC GTAW, I have difficulty
in supporting the pulsed technology trend, and even more difficulty understanding
why the blue and red suppliers alike are not doing a better job of explaining
the technology. Wouldn't have anything to do with increased weld equipment prices
or sales commission rates would it?
Name Withheld, May 2007.
Lincoln Pulsed MIG Power Wave and Ford Axle Cracks:
you want to make your weld manufacturing life more expensive, more complex and
less meaningful than it needs to be, you could always have listened to a salesman
and purchased the Pulsed Lincoln
for your robot application.
-2000: My weld task appeared simple. American Axle a tier one manufacturer
located in Michigan ordered two ABB robot systems to weld truck axles. The company
I worked for supplied the robots, we were also responsible for setting up the
robot cells that would provide one million axles annually.
When the robot cells were complete, as part of the contract, we were required
to provide a few hundred welded axles as part of the robot cell run off, little
did I know about the cracking issues that were about to occur. For the rest of
the story click here.
two pictures above are the Lincoln STT wire feeder and STT power source. Lincoln's
price on the STT package with a few extras should be around $11,000 to $12,000.
Lincoln advertises that on gage applications you can eliminate weld spatter and
two, 300 amp traditional MIG equipment packages on the right are from Lincoln
and Miller. These power sources sell for with the wire feeders for approx $2700.
The majority of gage applications in the industrial world can be welded (spatter
free) utilizing the lower cost CV equipment. Also in 2006, you can use $3000 pulsed
MIG equipment, that can easily out perform the STT power source on most common
gages steel applications > 20 gage.
With a little MIG weld process
expertise, low cost CV equipment will
get the job done to your satisfaction. Its up to you, if you have money to burn
you know where the fire is. If you weld parts less than 0.080 and you simply cannot
have miniscule weld spatter, then yes evaluate STT and the electronically modified
short circuit weld transfer modes like RMD and CMT, with the low cost (< $4000)
pulsed MIG equipment now sold by Miller (350P).
Ed we run a Lincoln CV 600. We are running an 0.035 (1 mm) wire
at 650 ipm and 28 - 30 volts. We use 90 argon 10 CO2 and are drawing about 200
amps. According to your books we should go into spray at >200 amps at >420
inch/min, what's happening?
Answer. You have lost your current. If you note, on this power source you will
find a process switch that can be set at three settings.
 UPPER SETTING:
 Middle SETTING SAW - CV,
 LOWER SETTING. Self
If you use either the stick (SMAW) setting you will
have selected a steeper slope which restricts the weld current. Use the SAW -
CV setting and you should be drawing 240 - 250 amps, which is correct for that
wire feed rate. Of course the power source could also require repair, or you need
to replace a fuse
a weld equipment manufacturer's rep informs you that their sophisticated MIG power
source has "unlimited weld parameter adjustment potential", please remember
this simply allows your workers to spend even more time "playing around"
with typically useless, unnecessary weld parameters and controls".
MIG WELD EQUIPMENT BECOMES MORE SOPHISTICATED, THE POWER SOURCE MANUFACTURERS
APPARENTLY DO NOT SEEM TO CONCERNED THAT THE WELDING EQUIPMENT IS ALSO BECOMING
MORE COMPLEX, COSTLY TO REPAIR AND IS LESS DURABLE FOR THEIR CUSTOMERS.
question: Ed. We have a Lincoln PowerWave and are having what Lincoln calls
a "Birds Nest" problem. This is an intermittent problem but when they
do occur, at various locations in the weld paths, they begin with an Arc 18 arc
failure alarm, followed by the wire continuing to feed momentarily, doubling over
on itself inside the weld gun conduit and jamming up the guide. We checked our
lost arc detect interval in our weld system setup; it is set at the factory 0.25
was not sure what the problem was so they have been having us swap out components
in an elimination process to isolate the cause. First we replaced the wire feeder
cable. Then we replaced the wire feed unit itself. Now they think we should have
our Power Wave looked at, since the problem persists. Do you have any suggestions
on what can be causing this problem and how we should best deal with it? The snarls
never used to happen;
it is a recent thing in the last couple of months. Sincerely.
For a weld
power source that has more weld issues than an Enron balance sheet you know what
my answer to this problem would be.
you really want a power source that will control you, or would you rather have
your weld personnel have the unusual ability to control the power source?
THOSE THAT ARE IMPRESSED WITH BELLS AND WHISTLES,
LINCOLN MAY HAVE
PRODUCED WITH THE POWERWAVE, THE ULTIMATE WELDING TOY.
in 2008, the Lincoln Power Wave is one of the biggest selling robot power sources
sold to the North American automotive industry. Many automotive manufacturing
plants believe that costly, sophisticated weld equipment with extensive bells
and whistles will provide the solutions to their hands off management / engineering
welding woes. It's a pity the managers and engineers who select this equipment,
don't spend a few dollars and get a weld process education. It will be even more
of a pity the first time they see the frequent issues from this equipment and
the high repair costs for the Power Wave.
Forms: While on the subject
of pulsed, let me quote from a Lincoln article on the Waveform in the Welding
Journal, Jan 2000 edition. The Lincoln author states, that "the waveform
is the means for determining the performance characteristic of a single molten
droplet of electrode. The area under the waveform determines the amount of energy
applied to that single drop. The Lincoln author continues with this statement
which every weld shop decision maker has been holding his breath for three decades
waiting to here, "superimposed in a selective fashion
over the waveform is the "adaptive" characteristic of synergic pulsed
1980 picture is a slo motion shot of regular, spatter free MIG transfer in the
glob to spray transition zone. Doyou
really believe that all the electronic sophistication mentioned is necessary for
controlled weld metal transfer from the MIG wire tip to the weld?
any low cost MIG power source, built in the last 40 years, set it with spray parameters
and watch it provide controlled, spatter free weld metal transfer.
Still not convinced? For god's sake I could take two
car batteries and create a power source to form a good MIG weld. Also a point
many seem to forget, any traditional >300 amp CV MIG power source manufactured
from 1960 can produce a MIG or flux cored weld to meet the most stringent weld
code requirements anywhere in the industrial world.
~~PULSED WAVES UNDER THE BRIDGE~~. It's
Feb. 2004, I just spent a few days with a bridge manufacturer. This company had
two robot cells for welding bridge decks and frames. On the one side an ABB robot
was utilized with Miller Delta Weld equipment, the other robot cell utilized Fanuc
robots with the Lincoln Power Waves. The robots and MIG equipment was purchased
in the late 1990s. The steel, short length, 6 mm fillet welds made by the the
Miller equipment required minimal weld repairs, the weld repairs that were required
were a usually a result of the part fit.
the robot cell containing the Lincoln Power Wave, the weld rework for two years
had been over
fifty percent. When evaluating the weld performance I came to the following weld
The Fanuc cells were supplied with through arc weld tracking. Due to the inconsistency
and poor performance of this equipment the bridge company had turned the arc tracking
off. To compensate they made the welds much larger and longer than the weld spec
When evaluating the Lincoln power source, I found the Power Wave weld current
variation on a weld 2 inches long, varied from 170 amp to
300 amps, with the same welds you could also note a two volt weld variation.
This parameter instability from the power source, has dramatically impacted what
should have been a simple weld application. This application required through
the arc weld tracking, however it's not logical to try to utilize through the
arc weld tracking when the MIG power source cannot provide relatively stable weld
voltage or current on an application with a constant wire stick out.
The crater control on this unit was very poor, the robot / Power Wave data did
not start to react till more than a second was added and even then the crater
welds with optimum weld data, at best would be described as erratic. On bridge
welds, if you cannot control the weld craters you have to compensate and make
the welds longer.
The weld arc on time on the application in the Fanuc cell accounted for more than
85% of the total cycle time. Due to the lack of effective through arc tracking
and unstable weld conditions twice the amount of weld required was used for the
bridge platform welds. The bottom line this weld equipment has caused the bridge
manufacturer to utilize three shifts to do work that could have been done in less
than 2 shifts. To resolve the weld issue the bridge company will for its next
robot installation make sure it has stable weld equipment (not from Lincoln) and
the robot has an effective through the arc tracking unit.
GM Pontiac MI.Ed
we are a GM plant in MI. I have about 50 Fanuc Robots all using Lincoln Power
Waves pulsed MIG equipment. We weld using an 0.045 (1.2 mm) silicon bronze wire
and argon gas. The 0.045 wire feed rate is 240 inch/min with 24V. The welds are
made on galvanealed thin gage parts. The robots were purchased around 2001 and
2002. In the last 6 months some of the Power Waves have extensive burnt backs
to the contact tip for no logical reason. The burn backs occur any where in the
welds. We have changed liners, the guns and tips. We even changed the power source.
The good Lincoln Power Wave power source we have would also start to do the same
thing when placed in the cell where the burn backs occur. We have had all the
experts in and got no help including Lincoln, what do you think? Dave
As you are using short circuit wire feed rate for the silicon bronze 045 wire
it's a pity your organization did not purchase the much lower cost Lincoln CV
400, you would have saved around $250,000.00 and avoided these power source electronic
problems. Also for those of you new to this site, if you have a moment, try the
search engine in the QA section to see if other people are having similar problems.
You would use the search words (Power Wave).
 I am amazed that Lincoln
or Fanuc did not help you as this appears to be a power source issue, however
I guess your 36 month warranty is up. Yes burn backs can occur frequently if wire
restriction issues occur, as you changed the guns and tips and checked the weld
wire feed ability, that should rule that out.
Are you using an external volt sensing (VS) lead? if so check continuity.
If the volt sense lead is OK, its likely the power source is causing the issues.
Disable the VS lead. I have found that artificial intelligence (looped electronic
feed back of the weld data) with pulsed equipment can be unstable even when the
pulsed equipment is new and that the instability can increase with the aging electronics,
(especially once the 36 month warranty is up). This problem in my simple mind
would be an indication that the power source technology is beyond the capability
of the power source mfg. I believe to disable the VS, a jumper lead has to be
moved in the power source, this is supposed to only take 10 minutes.
If disabling the VS did not work, then in the robot pendant disable both the arc
start and wire burn back functions as these functions have been known to influence
weld performance and produce erratic results. To displace this preset power source
weld data use separate weld schedules at the arc starts / ends.
start. Use one to two volts higher than weld volts.
 Arc end. Use one
to two volts less than weld volts.
 Your 24 weld volts for this application
also sounds too high. For short circuit an actual weld voltage (indicated on the
power source volt meter of 16 to 19 volts would be typical. For pulsed around
 If using a laptop provided weld schedule / program, change
to a standard power source program. Try the 045 standard short circuit mode for
steel / stainless. Its a pity your 36 month warranty is just up, what's that song?
"when will they ever learn"
See Lincoln issues above, and thanks
to Greg Smith at Marada for his contribution. Greg also had to go through many
frustrating issues with his Lincoln Power Wave equipment.
NEXT TIME YOU WANT TO SPEND MONEY ON "WAVE FORMS" I WOULD MAKE SURE IT'S AT THE BEACH. I
have had extensive experience with the Lincoln Power Wave on many robot applications.
I would rather not repeat the experiences. My advice to anyone looking at a Power
Wave, consider instead the $2000 to $4000 traditional Lincoln CV units and use
the thousands of dollars saved for a cool vacation.
PULSED PICTURE IS WORTH A THOUSAND WORDS.The
next two picture are are two 3/16 fillet welds I made on 1/4 stainless steel.
The welds are made with a Lincoln 300 Power MIG. This is single phase, pulsed
MIG power source that retails around $3,700 . This power source has pre-scheduled
pulsed programs for specific wire diameters. This MIG power source was purchased
by a company that welds steel and stainless parts. The MIG wire is an 0.035- 308L
stainless wire. I set the 0.035 (1mm) wire feed at 550 ipm which should be an
optimum pulsed wire feed rate. The power source provided the preset pulsed parameters.
I simply had to set the trim weld voltage to attain the optimum arc length. The
welds were untouched after welding. Take note of the pulsed weld appearance and
also the heat affected zone.
pulsed power source
with pulsed mode switched on.
Lincoln pulsed power source
off the pulsed mode and this 3/16 stainless, traditional spray transfer fillet
weld was made with the same power source, consumables and wire feed rate as the
pulsed weld. As you can see the HAZ is similar, this weld had similar spatter
and similar surface. My point is simple, why pay an additional $1500 for something
you don't need for steel or stainless welds? Why pay for something that adds to
the weld complexity, something that is less durable and more costly to repair?
Oct 2008: : Ed I recently bought a new Lincoln
350MP, for pulse welding 18 ga aluminum. At first my new unit performed OK
then the problem started, while welding 18 gage, my weld would flare up the wire
back into the nozzle. The machine is rated to weld 19 ga. I got the supplier to
exchange my machine for another one, which has the same problem, it flares just
as bad on 1/8th alum. I have a push-pull gun, and the wire feeds fine. I'm running
the machine on 50ft multi-strand cable, two 50 amp breakers. My friend is going
to help me check out the electricity. Lincoln and the supplier have been no help,
I don't have a clue, and I don't know what to do. Adam
Reply: Adam as you are using a push pull gun
with this multi-purpose, Lincoln pulsed on pulsed, chopper technology I rule out
wire feed issues. The fact that you purchased a multi-purpose power source and,
these units are rarely noted for optimum MIG performance especially at low end
or high end parameter ranges.You are welding very thin gage that requiries low,
stable pulsed parameters and Imn sure the 50 foot cable does not help. Your weld
problem sounds like you don't have enough voltage and current available to sustain
a consistent pulsed arc. Low, erratic pulsed parameters would cause the pulsed
arc plasma to collapse causing the arc to wonder or occasionally flare. I have
said many times at this site, that instead of being impressed with bells and whistles
and the wave forms, chopper and pulsed on pulsed marketing verbage, check out
the equipment, especially the recommended low and high end welding range. The
bottom Line when the same problem occurs in two new power sources, you have an
equipment design or part problem. This is Lincoln's problem, not yours. As they
are not likely to recall the equipment, and you have wasted enough of your time
on this issue, send the power source back. The Miller 350P appears to have a good
pulsed low end, give it a try. Ed
YOU PURCHASE MIG EQUIPMENT BELLS AND WHISTLES, DON'T EXPECT REAL WORLD RESULTS:
Lets face it the biggest attribute about some of the Lincoln equipment, may be
the marketing names applied to the specific options and weld transfer modes. Chopper,
pulsed on pulse, wave forms, all sound impressive and I am sure help in the sale
of the in the equipment. The real question is does the technology in question
perform in a consistent stable manner and do the resulting weld transfer modes
provide real world benefit for the application..
a pulsed equipment manufacturer to show his pulsed technology is superior, we
are going to hear some wonderful pulsed equipment gibberish presented in the next
decade. In 2009, expect a tremendous amount of new marketing induced bovine fecal
matter to be presented on how advanced electronics will further influence the
pulsed weld droplet size, shape and energy etc.
in an industry that too frequently has to rely on sales brochures and weld sales
expertise to resolve it's weld issues, there are many welding customers that are
ready to believe the pulsed MIG equipment sales hype. Also lets face weld reality.
Weld distributors have never made much profit selling Lincoln equipment, a product
line which now appears to be available in just about every hardware store in North
believe the high price of the Power Wave is it's greatest feature, and that feature
benefits Lincoln and it's weld distributors more than it will benefit most weld
Be very wary of the JAPANESE Motoman 350 MIG Power Source,
it's a sad excuse
for a a welding piece of equipment
you use Motoman robots, it's unfortunate that you may have purchased the Japanese
built 350 MIG equipment. If you want a poor to mediocre, inconsistent, traditional
globular type short circuit this equipment will provide it.
two separate locations during 2003 I have had issues with this equipment. In Aug.
2003 it was my unfortunate task to optimize a large welding cell that utilized
Moto Man UP6 robots with the 350 welding equipment. One of the new power sources
was so erratic it had to be replaced. On the remaining equipment I found inferior
arc starting characteristics, inconsistent weld transfer and the required voltage
range was excessive resulting in globular type transfer.
in 2003 I assisted one auto supplier of thin parts with his numerous robot weld
issues. The parts were 1.2 mm thick, the weld wire was 035 - 1 mm. The weld mode
selected was short circuit. I noted again with the Motor Man MIG equipment that
at the required low wire feed short circuit settings that the minimum stable weld
voltage required from this equipment was 1 to 3 volts higher than that which would
have been required with the traditional North American CV equipment.
required, higher weld volts from this inferior Japanese MIG equipment caused ERRATIC
"globular transfer" and the additional voltage provided higher weld
energy which added to the "weld burn through potential" on the thin
weld droplets or a stream of weld metal? Do you believe that when you water your
lawn the grass will be greener if the water is pulsed when it leaves the hose?
is an issue for most welds is the weld energy delivered. The bottom line, pulsed
can produce in some instances a lower energy open arc weld mode. Therefore to
justify purchasing pulsed equipment look for a weld application that requires
the heat concerns, such as clad welding or welding aluminum;
Pulsed provides lower weld energy than traditional spray transfer. However if
you are aware of all the wire feed and voltage settings that can produce spray
transfer with the different wire diameters, you can often replicate the pulsed
weld energy with spray transfer and a smaller diameter MIG wire.
Pulsed can provide weld spatter levels to an absolute minimum. If spray transfer
is set correctly the weld spatter amount will be minuscule.
Pulsed is beneficial on alloy electrodes that typically provide poor weld transfer,
electrodes such as alum bronze. A real pulsed benefit.
equipment I Would Not Recommend.
If you have a robot purchase in mind the following power sources are
personally would not recommend in 2008.
The Lincoln Power Wave.
This welding unit "will often take
you where you don't need to go, restrict you where you should not be restricted,
and make you pay a price you don't need to pay. With this power source in your
robot cell it would be wise to make sure you have a spare. For optimum manual
or robot carbon / stainless MIG welds stick with the Lincoln CV 400 amp power
The Lincoln Ideal ArcThis
multi-purpose unit provides mediocre MIG performance.
 The Panasonic HM Units. <2004 units. If Panasonic thinks this is a solution to North American welding problems
they should fire their so called Japanese welding experts. If you purchased Panasonic
pulsed equipment before 2004 god help bless you.
The ABB/ESAB Arcitec. Sold as a
built in with ABB robots. This erratic, poor performance power source introduced
in the nineties must have put Swedish weld manufacturing technology back two decades.
For more information on this "unique" welding equipment you know where
to find me, and I won't be in Stockholm.
Miller Maxtron. It's hard to understand how a company with Miller's
reputation would want to place this machine into any welding shop.
Miller Invision. Inconsistent
performance, sold before it was ready for weld shops.
Thermal Arc MIG equipment. Erratic electronics and poor
/ spray arc characteristics at high / low data. 
Kemppi. I do not
like the performance or durability of their MIG equipment.
TO WELDING REALITY.
Transfer can be so simple. With traditional CV MIG equipment,
an argon mix and two simple weld parameter settings, you can produce weld droplets
as shown in this video, or turn the wire feed rate up and create a weld stream
at higher current and voltages. Its
true that with spray transfer, the weld droplets are not "individually controlled"
but who cares, as long as they transfer into the weld in
a stable manner, inside a suitable plasma. And if you want more or less
MIG energy from CV equipment,
[a] change the wire feed rate,
[b] change the welding voltage,
the wire size or type,
[d] use a different gas mix.
[e] change the wire
open arc transfer such as pulsed MIG and spray transfer, its not that important
on how the weld wire converts to molten metal, what is important is that the molten
metal transfers in a consistent, stable manner. A CV MIG power source has had
this capability since the nineteen sixties. MOST
MIG WELDS ON PARTS > 3 mm WILL PROVIDE MARGINALWELD
correct spray weld parameters, the traditional spray transfer is stable and almost
completely spatter free. Yes traditional spray transfer is hot, but as most MIG
welds have marginal weld fusion this is a weld benefit not a weld detriment.
The primary issue with most spray welds is insufficient side wall fusion,
there fore there is little logic to utilize pulsed and reduce the potential weld
the end of the day, the following may be the best justification why pulsed MIG
will one day soon be the world's number one MIG welding process.
welding distributor if lucky may make 10 to 20% on a traditional $3000, CV. MIG
power source / wire feed equipment package. In contrast on that $6000 to $12,000
pulsed equipment package which produces no more weld productivity and no better
weld quality on most steel welds, that additional profit will certainly be an
incentive for both the weld equipment manufacturer and distributors. And lets
face it, with the short pulsed equipment life, well that's just a bonus to the
MIG equipment manufactures who repair and sell this equipment.
WHEN YOU ARE WELDING ALLOYS AND CODE QUALITY WELDS,
GIVE CONSIDERATION TO TIP TIG,
A PROCESS THAT PROVIDES
THE HIGHEST WELD QUALITY WITH THE LOWEST WELD HEAT.
REGULAR TIG VERSUS TIP TIG ON THIN GAGE APPLICATIONS:
REGULAR TIG: YOU CAN USE REGULAR
TIG, TAKE TOO MUCH TIME, PUT IN TOO MUCH WELD HEAT AND MAKE WELDS LIKE THIS. PLAY THIS VIDEO FIRST
TIP TIG: YOU COULD GET ON WITH YOUR LIFE, REDUCE YOUR WELD COSTS. MAKE HIGH QUALITY TIP TIG WELDS LIKE THIS WITH MUCH LESS HEAT INPUT.
REGULAR TIG: Play this video first: Regular TIG typical manual weld speeds for these welds is 4 to 7 inch/min.
TIG arc on time for this 12 inch weld would be around 2- 3 minutes. Take a look at the irregular weld quality influenced by too many arc start / stops, and take special note of the large heat affected zone that's going to create distortion concerns.
Someone can always do a better TIG weld than this but it will never match the quality and productivity attained with TIP TIG.
TIP TIG: Manual TIP TIG weld travel rate
48 inch/ min as noted on the UTube second counter with this 12 inch length of 3 mm weld made with an arc on time of 15 seconds:
Note the uniform weld quality that comes from the constant wire feed rate and only one arc start / stop. Examine the smooth clean, unoxidized weld surface, the very small HAZ and lack of weld distortion and weld minimal fumes. Think about the savings that will results from less cleaning.
From welding small, long track, 3 mm fillet welds on the deck of an Aircraft Carrier to the small size stainless welds typically found on food and beverage / processing equipment, no other weld process can provide long, small size gage welds with the TIP TIG quality and the lowest possible weld heat input.
When pulsed MIG does not provide the weld quality you want you have to look at TIP TIG.
If you manage a pipe shop or any weld shop that welds code
quality welds then you need to take a look at TIP TIG.
TIP TIG in contrast to TIG is a process that enables much higher wire feed rates and increased weld current that result in faster weld speeds & much lower weld heat input.
IP TIG has a unique patented wire feeder that agitates the weld pool improving weld fusion (especially beneficial for sluggish duplex and stainless alloys) and dramatically reduces weld pore defects.
This TIP TIG pipe weld was made by a Westinghouse. The weld is being made with TIG wire feed rates 250 - 280 inch/min with deposition rates on par with flux cored and pulsed MIG. On this weld the welder achieved a wire feed 250 - 300 % greater than any manual TIG welder could achieve, with a weld quality higher than that attained by any regular TIG welder.
Note: Companies such as Exon, Westinghouse and WSI (Aquilex) lead the way in the USA developing 5G, TIP TIG pipe procedures with manual wire feed rates 250 - 300 % greater than that attained by regular manual TIG welders.
MUCH MORE MIG WELDING EQUIPMENT DATA FOR
WELDING PIPE IN THE MIG AND FLUX CORED