AC Aluminum Pulse (GMAW) Weld Process Guide

Transcription

1 AC Aluminum Pulse (GMAW) Weld Prcess Guide Overview AC Aluminum Pulse fr superir quality welding*. Increases travel speed up t % Increases depsitin up t 75% Decreases burnthrugh Imprves gap bridging Index Details Wavefrm Descriptin Optimizatin Synergic Welding UltimArc Cntrl Applicatins 1F / PA Lap Semiautmatic 1F / PA Lap Rbtic Setup Cnnectin Diagram Sense Leads Wrk Leads Trubleshting Glssary Icns Technical Terms Prcedure Ntes Custmer Assistance Plicy *Based n a side by side cmparisn f AC Aluminum Pulse and Pulse. TE12.010

2 AC Aluminum Pulse Details 1 Prcess Descriptin AC Aluminum Pulse (GMAW) brings features that cannt be realized with standard DC pulse MIG welding. The AC pulse prcess reduces the heat input by fcusing the energy away frm the base plate and switching the plarity f the arc. Prductivity increases with imprved depsitin rates using AC Aluminum Pulse (GMAW) wavefrm technlgy are available exclusively n the Pwer Wave Advanced Mdule. This is pssible because the negative plarity arc redirects the heat away frm the wrkpiece, reducing the chance f burnthrugh. The UltimArc and synergic precisin cntrls give the user full cntrl ver heat input, penetratin while imprving cleaning actin, and allwing fr faster travel speeds n thin material. HEAT INPUT MIN Burnthrugh UtimArc Range WFS MAX With this technlgy, it is nw easier t weld thin aluminum and bridge gaps. Precise cntrl f the heat input is achieved with the UltimArc cntrl using AC Aluminum Pulse (GMAW). UltimArc adjusts the amunt f DC negative time during the backgrund t allw less heat t be transferred t the wrkpiece. Wavefrm Peak Prpels drplet tward the weld pl. 1 2 Psitive Backgrund Cmpletes drplet transfer and begins the creatin f the next drplet. Negative Backgrund Reduces heat input by redirecting current flw twards the electrde. 3

3 AC Aluminum Pulse Optimizatin 2 Synergic Welding 2 1 Adjust WFS t the desired setting. Refer t the Applicatin sectin fr the recmmended settings. Synergic Graph AC Aluminum Pulse wavefrms are synergic weld mdes. Based n the wire feed speedu, set by the peratr, a preprgrammed vltage is autmatically selectedv. Fine tune the arc length using ltage adjustmentw. 2 3 Min. Max. Synergic ltage Display Abve ideal ltage (Upper bar displayed) At ideal ltage (N bar displayed) Belw ideal ltage (Lwer bar displayed) Based n WFS a preprgrammed nminal vltage is selected. Adjusting vltage increases r decreases the arc length, allwing the user t fine tune arc characteristics. A nte n Trim. Lincln Electric develped Trim as a means t simplify the cmplexities f Arc Length cntrl in advanced welding applicatin setup, such as Pulse. Nw, Lincln Electric Synergic Weld mdes imprve the ease f setup by preselecting an ideal vltage based n the selected WFS. The user can then fine tune their ltage setting based n their persnal preference and can easily see whether they are abve r belw the nminal setting. UltimArc Cntrl The UltimArc cntrl fine tunes the heat input int the plate. Standard Pulse Increasing () the setting prvides mre heat int the weld puddle resulting in a mre fcused arc. Decreasing() the setting reduces heat directed int the puddle resulting in a less fcused arc. AC Pulse

4 AC Aluminum Pulse Applicatins 3 1F / PA Lap Autmatic 1F 0 10 FRONT >2mm < 2mm Use a 010 push angle. Use a wrk angle. Psitin the electrde apprximately ne electrde diameter utside the jint favring the bttm leg. Fr less than 2mm applicatins psitin the electrde directly in the jint r slightly favring the tp edge. May require decreased wrk angle. 100Ar 1/2 in. 43 mm (ga) ( 0.9mm) 2.5 (12) in/min in/min 20 A * /64 (1.2mm) /16 (1.6mm) (0.9mm) 2.5 (12) /64 (1.2mm) 2.5 (12) /16 (1.6mm) * Optimal vltage may vary based n cable and trch cnfiguratin

5 AC Aluminum Pulse Applicatins 4 1F / PA Lap SemiAutmatic 1F 0 10 FRONT >2mm < 2mm Use a 010 push angle. Use a wrk angle. Psitin the electrde apprximately ne electrde diameter utside the jint favring the bttm leg. Fr less than 2mm applicatins psitin the electrde directly in the jint r slightly favring the tp edge. May require decreased wrk angle. 100Ar 1/2 in. 43 (0.9mm) mm (ga) 2.5 (12) in/min A * /64 (1.2mm) /16 (1.6mm) (0.9mm) 2.5 (12) /64 (1.2mm) /16 (1.6mm) * Optimal vltage may vary based n cable and trch cnfiguratin.

6 AC Aluminum Pulse SetUp 5 Cnnectin Diagram S0 S500

7 AC Aluminum Pulse SetUp 6 Sense Leads An electrde sense lead is required. This is a standard cnnectin in an Arclink cable. A wrk sense lead (ptinal) is highly recmmended fr ttal welding cable lengths >50 ft. and shuld be cnnected directly t the wrkpiece. DO NOT cnnect either sense lead t a welding stud as this may result in erratic arc r increased spatter. Fr best perfrmance, cnnect the wrk sense lead clse t the welding arc. The wrk sense lead shuld be separated away frm welding cables t minimize interference. DO NOT rute sense lead cable clse t high current welding cables as this may distrt the sense lead signal. Wrk Leads B A C Cnnect the wrk lead t the wrk stud n the mdule and directly t the wrk piece. Maintain the shrtest cnnectin length pssible. The ttal length f the welding current lp (ABC) shuld be minimized t reduce inductance. Rute cables (A,B) clse tgether t further reduce cable inductance. Fr cnfiguratins with excessive inductance, use Lincln Electric patented caxial welding cables. Lincln Electric caxial cables cmbine the psitive and negative welding leads int ne cable t minimize cable inductance. Test cable inductance levels using the Pwer Wave Manager sftware exclusively frm Lincln Electric.

8 AC Aluminum Pulse SetUp 7 Trubleshting Erratic Arc Prper Feeding Spring Laded Tip* (5000 Series) Surface Cntaminates lts Tip Electrde Sense Lead * The use f a spring laded tip is recmmended fr semiautmatic welding applicatins using 5000 series electrde. lts Gas Cverage Fine Spatter Large Spatter lts Gas Cverage Cntact Tip t Wrk Distance Prsity Gas Cverage Surface Cntaminates Cntact Tip t Wrk Distance Tip Cncave Bead lts Increase Decrease Inspect & Replace Imprtant

9 AC Aluminum Pulse SetUp 8 Trubleshting Cnvex Bead lts Cntact Tip t Wrk Distance Increase Decrease Inspect & Replace Imprtant Pr Penetratin lts Burnthrugh lts Under Cut lts Gap Bridging Weave

10 AC Aluminum Pulse SetUp 9 Trubleshting Increase Cracking Wire Type Duble Back n Crater Decrease Inspect & Replace Imprtant St Gas Flw lts Cntact Tip t Wrk Distance Surface Cntaminates Cld Starting t1 Gas Preflw Burnback Runin Ndle Welding lts Weave Electrde Sense Lead NOTES: Aluminum is mre susceptable t sme issues which can be easily fixed with the right tls. Arc Wandering tends t be mre prevalent with 5000 series wires. This can be minimized by intrducing a Spring Laded Tip which prvides a cnstent cntact pint fr the current path. St is undesirable frm an appearance standpint, but can nt be cmpletely eliminated. It is imprtant t remember that black st arund the weld bead is acceptable. If st is present n the weld bead the peratr shuld verify all setup and prcedures. ltage and gas cverage are tw main culprints f this prblem. Erratic Arc Behavir can be caused frm varius cmpnents in the weld system. It is imprtant t clean gun liners, change cntact tips, and check wire tensin. Drive rlls shuld nt be vertightened causing the wire t defrm as it exits the feeder. Trch Calibratin Sme push pull systems require the peratr t verify wire feed speed calibratin. Fllwing the trch manufacturers calibratin recmmendatins can prevent majr feeeding issues.

11 AC Aluminum Pulse Glssary 10 Icns Wire Type Gas Material Thickness A T lts Amps Trim Cntact Tip t Wrk Distance Arc Length Cntrl Knb Weld Stud Trch Electrde Sense Lead Wrk Sense Lead Wrk Clamp Trch Nzzle Heat Input (High) Heat Input (Lw) Arc Fcus (Brad) Arc Fcus (Narrw) Stp / Avid Gap Bridging Technical Terms St Burnthrugh Cable Inductance GMAW Prsity RunIn Wrk Angle A black substance which cllects near r n the weld bead. A hle in the base material caused by excessive heat input during welding. Resistance t change in current. Gas metal arc welding including metal inert gas (MIG) and metal active gas (MAG) welding. Gas entrapped in slidifying metal frms spherical r elngated pres in the weld. The angle at which the electrde leads the weld pl relative t the directin f travel. A wire feed speed used t establish an arc. The angle f the electrde, ff perpendicular, relative t the wrk piece surface. Prcedure Ntes All listed prcedures are starting pints and may The result f welding at higher travel speeds is a At faster travel speeds, the beadshape can require sme adjustment depending n the specific tendency t prduce mre spatter, less becme very cnvex (r rpy), and the weld will nt applicatin. penetratin, mre undercut, and a less desirable wet well. There is a pint at which the arc is set s bead shape. Depending n the limitatins / shrt that the arc will becme unstable and Trch angle, electrde placement, cntaminatin, requirements f the actual applicatin, slwer stubbing will ccur. This frms a limitatin f just mill scale, jint fit up, and jint cnsistency are travel speeds and higher arc vltages may be hw fast the travel speed can be raised. factrs that may require special cnsideratin required. depending n the specific applicatin. It is ultimately the respnsibility f the end user t As the travel speed increases in fast fllw ensure the prper weld depsitin rate, bead At higher travel speeds, jint fit up, wire placement, applicatins (1/4 t 14 Gauge), a tighter and arc prfile, and structural integrity f a given weld and cntaminatin all becme factrs that are length must be maintained s that the puddle applicatin. mre significant. prperly fllws the arc. Operatrs typically reduce the arc length cntrl (Trim) t achieve this. Custmer Assistance Plicy The business f The Lincln Electric Cmpany is manufacturing and selling high quality welding equipment, cnsumables, and cutting equipment. Our challenge is t meet the needs f ur custmers and t exceed their expectatins. On ccasin, purchasers may ask Lincln Electric fr infrmatin r advice abut their use f ur prducts. Our emplyees respnd t inquiries t the best f their ability based n infrmatin prvided t them by the custmers and the knwledge they may have cncerning the applicatin. Our emplyees, hwever, are nt in a psitin t verify the infrmatin prvided r t evaluate the engineering requirements fr the particular weldment. Accrdingly, Lincln Electric des nt warrant r guarantee r assume any liability with respect t such infrmatin r advice. Mrever, the prvisin f such infrmatin r advice des nt create, expand, r alter any warranty n ur prducts. Any express r implied warranty that might arise frm the infrmatin r advice, including any implied warranty f merchantability r any warranty f fitness fr any custmers particular purpse is specifically disclaimed. Lincln Electric is a respnsive manufacturer, but the selectin and use f specific prducts sld by Lincln Electric is slely within the cntrl f, and remains the sle respnsibility f the custmer. Many variables beynd the cntrl f Lincln Electric affect the results btained in applying these types f fabricatin methds and service requirements. Subject t Change This infrmatin is accurate t the best f ur knwledge at the time f printing. Please refer t fr any updated infrmatin.