Pulse MIG welding is a revolutionary precision welding process that has transformed the fabrication industry. This form of welding has allowed companies to reduce the need for costly and time-consuming manual welding processes. The ability to quickly weld components with high accuracy has resulted in a dramatic reduction in the cost of production and increase in efficiency.
According to a survey, approximately 80% of all welders in the United States are using some form of pulse MIG welding. The annual cost savings from using pulse MIG welding is estimated to exceed $5 billion a year.
In this article, we’ll look at what pulse MIG welding is, its advantages, and why it is so popular.
What is Pulse MIG Welding?Pulse MIG welding is a specialized form of metal inert gas (MIG) welding. It is also known as “pulsed arc welding” because it combines short bursts (or “pulses”) of welding current with intervals of no current.
The process is used to weld aluminum, stainless steel and most other non-ferrous metals with precision.
Pulse MIG Welding AdvantagesPulse MIG welding offers several advantages over standard MIG welding.
- More consistent welds.
- Less splatter and spatter build-up on the adjacent welding surface.
- Better control over weld penetration.
- Narrower heat-affected zone (HAZ), which helps to limit distortion on the workpiece.
- Faster weld speeds due to less spatter.
- Less need for post-weld clean up.
How Pulse MIG Welding WorksPulse MIG welding uses a combination of a short burst of intense current (the “peak”) and a low background current. The peak of the pulse, which is usually set by the welder, is often between 60 and 100 amps.
The background current is set at a much lower level, between 10 and 25 amps, depending on the size of the weld. The welder controls the pulse rate, which is the number of pulses per second.
This allows the operator to match the welding speed on the workpiece. Higher pulse rates result in faster weld speeds. The welder can also control the background current, and even adjust it on the fly as needed. The key to pulse welding is that the peak current is limited to a much lower level than with a standard MIG weld. This prevents the weld pool from becoming too large and reducing the strength of the weld. It also helps to prevent the edges of the weld from becoming glossy and distorted.