Welding is a tricky endeavor as it demands years of practice and patience to reach an expert level. One of the most common techniques that novice welders misunderstand is pulse welding which levels them down from the pro welders. I’ll try to clear your misconception about pulse welding as a novice welder to help you become a wizard welder in this article.
What is pulse welding do you know? If not, then don’t worry, I will tell you there. It is a technique of constantly changing the amperage of a welding machine from high to low and high to low, unlike different welding procedures. The purpose of this technique’s development is to avoid the typical drawbacks of welding.
The primary benefit of pulsed welding is that you will weld high heat catchy and thin metals without tarnishing them, which is the disadvantage of high amps setting. However, it doesn’t mean you can’t weld thick metals and alloys that demand deep penetration by this procedure.
Pulse welding: An Overview
Pulse welding is opposite to traditional welding techniques. In this procedure, current or amperage fluctuates means the value changes according to the condition and demand. Tungsten inert gas (TIG) welding is one of the oldest welding techniques on the planet. As we have mentioned before, pulse welding is the opposite of older welding techniques, so let’s compare it with TIG welding.
If you are a welder, then you certainly know how TIG welders work. It works when you put the amperage at maximum level and manage the output through a foot pedal. Moreover, it indicates that a TIG welder is excellent if you have to weld thick metals in a short period. However, this functionality of the TIG welder doesn’t make it fit for welding thin metals as it will deform these metals.
Pressing the foot pedal in TIG welding will significantly exceed or lower the heat emerging from the electrode. The TIG torch’s output depends on the pressing down direction of a foot pedal. You can utilize a foot pedal in pulse welding similar to TIG welding. But the difference is when you press the foot pedal in the pulse welder, it will generate a waveform in the TIG torch rather than a steady amperage.
Common terms of pulse welding
Some common terms related to the use of welding are as follows:
Basically, in pulse welding, the pulse duty is the feature that regulates the top amperage level and low amperage level. However, 50% of the time, it adjusts amperage at the top-notch level and minimal amperage for the rest of the 50% time. It doesn’t indicate you will not be able to set %age time according to your low and high levels preferences.
The number of times an amperage of the welders hit a peak and low in season is pulse frequency. So let’s say if a welder goes from high to low and then back to high amperage ten times per second, then it indicates a pulse frequency of 50.
Experienced welders often suggest setting the pulse frequency above 30 and below 4 for errorless work. The reason is frequencies between 4 and 30 are uncomfortable to handle. Besides, less pulse frequency is ideal for welding thin metals, and a high pulse frequency is excellent for thick metal welding.
It is the trick that pulses welding offers to avoid the deformation of base metals. In general, the slope-down strategy is a countdown timer that comes into work when you push the trigger. Moreover, the time in the countdown indicates the minimum time required for finishing up the current time gradually. Therefore, you can weld thin metals without the fear of burning them, which is remarkable.
Difference between pre-gas flow and post-gas flow?
Pre-gas flow is the supply of shielding gas along with an electric arc to save the weld from environmental contamination during the making of the weld. However, in pulse welding, shielding gas continues to flow, unlike TIG welding, which allows the newly created weld to get into a solid form. Moreover, the post-gas flow makes the welds stronger and oxidation-free.
What is the benefit of using pulse welding?
The benefits of pulse welding over traditional welding procedures aren’t limited at all. These are:
- Firstly, pulse welding is inexpensive, and you will spend less gas and wire
- Secondly, it will marginally boost your productivity as it offers higher deposition rates
- Thirdly, It’s a safer welding procedure as it creates a bit of molten metal splash.
- Fourthly, it is ideal for welding thin metals, which requires less amperage
- Finally, it delivers finer and stronger welds which are noteworthy
When should you use it?
You can take advantage of the pulse welding technique when you want to compete to avoid atmospheric contamination of welds. The reason is that the post flow of shielding gases allows the molten weld to condense quickly. In this way, it can’t get oxides and hence results in smoother and firmer welds.
Moreover, if you want to enhance your safety by reducing the spatter, then you can also aid from pulse welding. As it offers less heat for welding thin metals, that’s why little splash will produce, which indicates better safety. Besides, it can also increase your welding productivity through higher deposition rates.