Page 41 - MetalForming May 2015

Short/ Spray
Spray
Pulse
Modified A
Pulsed Spray* B
Wire-feed speed, in./min.
245
300
245
263/307
263/307
Volts
15.5 (synergic)
21.5 (synergic)
23.7 (synergic)
24.2/26.7
24.2/26.7
Duration
N/A
N/A
N/A
0.35 sec./0.10 sec.
0.75 sec./0.20 sec.
Amps (avg.)
162
212
172
173
188
Travel Speed, in./min.
26
36
36
25
25
*Modified pulsed-spray welding performed using Esab’s Aristo SuperPulse pack- age—an AristoMig 4004i Pulse inverter power source and AristoFeed wire-feed unit.
A
These images show the weld beads associated with the parameters for the modified pulsed-spray processes (A-B) in the table. They demonstrate that fabricators can reduce filler-metal costs by using a larger-diameter weld wire on thinner materials.
transfer, the wire-feed speed was increased to 300 in./min. However, obtaining a weld size similar to the pulse-mode sample—and to not melt through the workpiece material— required a travel speed of approxi- mately 72 in./min., nearly impossi- ble for a welder in a production environment. If the welder were to slow down to a manageable travel speed of 36 in./min., the risk of burn- through becomes high, plus the work- piece material becomes overheated, the weld becomes hard to control and bead appearance is poor.
Conversely, the pulsed- and modi- fied pulsed-spray transfer processes have no problem. Travel speeds remain manageable and heat input is con- trolled to prevent burnthrough.
For fabricators who want to reduce filler-wire inventory, and wire- changeover time and standardize on a single, larger-diameter wire, pulsed and modified spray-arc transfer can provide significant savings. MF
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