Synergistic Welding Machine

GMAW: Pulsing Improves Quality and Increases Profitability.

Pulsed MIG is a welding process that offers a contactless transfer method between the electrode and the weld pool. This means the electrode never comes into contact with the weld pool. The process is achieved by rapidly modulating the welding machine’s electrical output and is designed to provide a clean weld with lower heat input compared to spray or globular transfer methods.

The pulsed MIG process works by forming a droplet of molten metal at the tip of the electrode with each pulse. Then, the correct amount of current is applied to propel this droplet along the arc and into the weld pool. The transfer of droplets occurs at a rate of one droplet per pulse.

To better understand this process, let’s examine the waveform. Unlike the constant voltage (CV) mode, where the current is represented by a straight line, the pulsed MIG current cools the process by interrupting the current. It can be said that this “cooling” period enables better welding of thin materials, controls distortion, and allows for operation at low wire feed speeds.

During the process, the current reaches a peak when the droplet forms. Then, during the background current phase, the current is reduced to lower the total heat input. The height and width of the peak are critical for proper heat transfer.