The demand for production keeps increasing while fewer people are entering the welding trade than retiring from it. This makes increasing productivity the #1 goal for many fab shops today.

Welding automation has been a hot topic lately, but for a good reason. It's a way to help your welders produce more while eliminating or minimising weld defects and rework.

Welding automation helps improve weld quality and productivity. That's a win-win across the board. However, welding automation systems are often specialised for specific applications, requiring a thoughtful approach when picking the right systems for your shop.

What Is Automated Welding?

Welding automation can be full or partial. For most shops, semi-automated and mechanised welding systems provide the most benefits. Empowering your welders with tools like welding tractors, positioners, or orbital welding systems helps them produce more and repeatedly achieve exceptional weld quality.

For the most part, automated welding systems ensure maximum accuracy and repeatability of the welding process. However, automation is also highly beneficial for one-off jobs because it can drastically improve weld quality and conformity to welding standards and customer specifications.

Benefits of Automated Welding.

• Higher productivity per operator
• Improved weld quality and precision
• Significant reduction of welder fatigue
• Reduced or eliminated rework and scrap costs
• Lower welding costs
• More efficient use of shielding/cutting/welding gas and consumable electrodes
• Improved shop capacity
• Ability to take on complex jobs not suitable for manual welding
• Decreased labour costs per produced part as one operator produces more
• Improved profitability

Welding Automation Systems And Their Applications.

You'll hardly find a welding product today that doesn't require at least some form of mechanisation/automation during production. Pipes, tubes, pressure vessels, heat exchangers, sheet metal fabrication, ships, aeroplanes, cars, bridges, structural members of buildings, wall and deck panels, and many other welding jobs require some form of automation.

While you could do it all manually, the production would be too expensive and time-consuming.

If an automated system reduces rework, it also reduces the business bottlenecks, allowing a streamlined production process.

What happens if the weld on a pressure vessel has a defect? The inspector, welder, metallurgist, engineer, and even salespeople must get involved more than necessary. The true cost of a weld defect is hard to estimate, but project delays can drag on, especially with new work coming into the shop. That's why getting it right the first time is better for everyone, and automated systems help you do just that!

Welding Positioners.

Welding positioners can turn and tilt the welded part, automating the part rotation and movement during the welding process. When combined with manual or automated welding, positioners can significantly improve weld uniformity.

Positioner capacity can range from 50 kg to hundreds of tons. Besides welding, they are used for nondestructive testing, cutting, cladding, grinding, weld polishing, and other allied processes.

The most suitable application for welding positioners and turntables is pipe welding or anything round. With precise rotation speed control and a stationary welding head, you can get a perfect heat input and an outstanding weld every time, part after part. It also makes it easier to quote parts as you can quickly develop the feel for how long it takes to weld with it.

Welding positioners are also highly beneficial for cobot integrations. Cobots are a transformative technology that can significantly boost productivity and quality. But, pairing a cobot with a positioner can additionally improve results. For example, ProArc PT-150P is a system designed for cobot application, integrating cobots with the rotational power of positioners. Imagine welding structural supports on a cylinder and having to manually rotate the part each time. That leaves lots of room for error. Instead, use the ProArc PT-150 to harness the power of the cobot fully for all cylindrical welding tasks.

Welding Rotators and Turning Rolls.

Turning rolls and welding rotators are perfect for weld automation on heavy pressure vessels, smaller tanks, and pipes. It's dangerous and counterproductive to rotate large pressure vessels manually or using a forklift or similar equipment. The fastest and safest way is using turning rolls. They have multiple PU roller wheels that come in contact with the vessel's sides and rotate it for welding or NDT.

Welding rotators can also be used for spraying as they allow controlled rotation. So, you can treat the vessel uniformly and safely access its entire surface.

Column and Boom Welding Machines.

Column and boom welding manipulators are the cornerstone of welding automation. They quite literally hold the welding head static or travel along the joint instead of you doing it manually.

It's the welder's job to use the column and boom equipment to produce sound welds, but eliminating the manual welding action drastically boosts productivity and quality.

You can use the manipulator to hold the welding head while the positioner rotates the welded piece or use a travelling beam to move the welding head over a stationary part. Large vessels and towers are usually welded using rotators and a manipulator. The vessel is rotated while the welding manipulator holds the welding head, producing a uniform weld along the circumference.

These systems can also be used for weld cladding to overlay pipes and other equipment with corrosion-resistant alloys.

We have a large selection of various welding manipulators that can be fitted to almost any industrial application.

Welding Tractors and Carriages.

Welding tractors carry the welding torch/head along the tracks you install to follow the joint. Tractors and carriages are the best solution for highly accurate welding and cutting of large components like storage tanks, ship hulls, and large structural steel members.

These systems are also portable, making them a perfect choice for automating welding/cutting tasks on site.

Tracks can be linear or curved to fully accommodate the weld/cut path. These systems can have excellent traction on horizontal, vertical, concave, and convex components, making them highly versatile. If you plan to weld large components made from thick steel, consider automating the process with welding tractors. Advanced tractors, like the Gullco motorised systems, also give you control over the oscillation speed, width, and dwells. We stock many Gullco systems, including the Gullco KAT, for easy welding and cutting.

Orbital Welding Equipment.

Orbital welding systems dramatically improve productivity, quality, and weld uniformity compared to manual pipe welding. Even the best manual pipe welder can't consistently match the quality of orbital welding equipment.

However, the biggest benefit is just how easy it is to weld pipes with orbital welding equipment. Not only does it require far less skill, but it puts significantly less strain on the operator. Manual pipe and tube welding can be very exhausting as you hold your body in awkward and uncomfortable positions for hours on end. Orbital welding makes the job much less tiring, letting you produce perfect welds all day long.

Orbital welding applications range from petrochemical to food and pharmaceutical. If the job involves significant amounts of pipe welding, orbital is almost always the way to go.

If you are welding extra large diameter pipes, you can use a welding tractor with a circular track system to achieve a similar setup as with the orbital welding equipment.

Welding Lathes.

Like orbital welding, welding lathes produce circumferential welds on pipes. However, the working principle is different. The welding lathe rotates the pipe while the welding head is stationary. You can use a single or multiple welding torches, making these systems versatile for small to medium-sized cylindrical parts.

Welding lathes are used for vacuum vessels, nuclear, defence, aerospace, and many other industries where weld precision is critical. We have an extensive line of welding lathes that can fit almost any application, including lathes from ProArc.

Seam Welders.

Longitudinal arc seam welders are designed to make seam welds on storage tanks and pipes. They can produce welds with almost absolute precision and eliminate rework. Repairing a weld defect on equipment with thick walls can be very costly, making seam welders an indispensable tool for shops considering offering seam welding services.

We also provide resistance seam welders that work differently than arc welding equipment. For example, the PEI PFT resistance welder for seam welding has circular electrodes that clamp and roll two sheet metals between them, causing them to fuse due to the resistance of the current flow. They are a perfect choice for automating the production of gas tanks, vessel pipes, tubes, air-tight equipment, and other products made from sheet metal.

Westermans International - Your Trusted Source For High-Quality Welding Equipment.

Westermans International has a large stock of used and new welding and cutting equipment for automated and manual applications. Everything from plasma and gas profile cutting systems to submerged arc welders, positioners, manipulators, and welding power sources. We provide individual, modular, and bespoke automatic welding solutions to help you fix specific production challenges.

Whether you want to buy or sell your welding/cutting equipment, Westermans is here for you! Contact us today, and we'll help you choose the most suitable welding automation equipment for your application.

Westermans Is Taking Over The Agency For PEI Resistance Welding Solutions In The UK And Ireland.

If you were a Sureweld customer or are interested in resistance welding equipment, we have big news to share! Westermans International is taking over the agency for PEI resistance welding products from Sureweld, as of the end of January 2024.

We shared 35 years of history with Sureweld and have built a massive wealth of expertise supplying PEI welding equipment as their authorised re-sale partner.

Richard Papworth, Sureweld owner of over 40 years is retiring, and the business will be closing its doors. But, since we shared so many years with Sureweld and their team, we've come to an agreement to take over the PEI agency for resistance welding equipment and care for their previous customers. Going forward, Westermans International will supply resistance welders directly and provide support to past and future clients in the UK and Ireland. You will have backup and service from Westermans International, PEI, and experienced Sureweld technicians, ensuring a smooth transition if you are a previous Sureweld customer.

Craig Westerman, Sales Director, said that taking over the PEI agency was an easy decision. "We are very familiar with their machines, share the same values, and have trust in PEI's ability to deliver exceptional quality resistance welding equipment. It's great to work directly with such a strong European manufacturer".

Who We Are - Westermans International

We buy, sell, and rent new and used welding equipment, and our stock includes top-of-the-line brands. We are proud of providing equipment with high-quality standards and bespoke solutions to our clients globally for over 50 years. Westermans International is located in Groby, Leicestershire, UK, with our 30,000 sq. ft facility of modern offices, warehouses, and workshops.

We are a family-owned and run business with a highly passionate team about welding, especially welding and cutting power sources, positioners, fume extractors, and specialised welding equipment. If it welds or assists in the process, we want to know more about it!

PEI-Point SRL - High Standards And Reliability

PEI-Point SRL is a renowned Italian manufacturer with a long history in the international market. We've worked with their equipment for a long time and have seen first-hand the value their machines bring to small and large shops and manufacturers.

PEI is a proven, reliable brand with high standards and strong company values, like sourcing most of their resources locally. So, taking over the PEI agency was an easy decision for us. We understand their machines, share the same values, and believe in their ability to deliver exceptional quality spot, seam, and projection welders.

We are looking forward to supplying automotive, appliance, aerospace, and manufacturing industries in the UK and Ireland. Every resistance welding machine delivered to a small shop or a large production facility improves productivity, makes the job easier, and helps businesses meet goals and serve their local or global clients and communities.

Resistance Welding Equipment

Resistance welding plays a major role in the production of many everyday items. The best example is the automotive industry, where resistance welding equipment is used to fuse auto body parts during the production process and repairs.

This welding method uses the resistance of the current flow through the base metals to heat, melt, and fuse the two metal parts under the pressure applied by the electrodes. It's the most straightforward autogenous welding process that's extremely fast and reliable.

Once the base metal is placed between the two electrodes, the resistance welding power source releases a current that flows through the electrodes in a closed circuit. But, the electricity also flows through the welded metal, which is where the magic happens. Electrodes are made from copper alloys, so the current flows through them without much resistance. However, carbon steel and many other materials have high resistance to electrical flow, which causes extreme heat and melting of the material. At the same time, electrodes clamp and apply pressure at the point of contact, causing the two materials to fuse in a spot or a seam weld.

However, while this process sounds simple in theory, the power source must output current with high accuracy. Too low of a current density wouldn't produce a desirable weld quality, while too high of a density would cause molten metal to be expelled from the weld. Likewise, timing the electrode pressure action for efficient cooling and weld fusion is an important step for maximum productivity of resistance welding processes. In addition, optimal current duration is vital to prevent excessive heating of the electrode faces, which could reduce their service life. This is why it's paramount to use high-quality brands to maximise your productivity and ROI.

The three primary types of resistance welding are spot, seam, and projection resistance welding, and we supply PEI equipment for all three.

Spot Welding Equipment

Spot welding machines create welds between or on overlapping sheet metal, and their weld cross section is circular. There are several spot welding machine types:

• Rocker arm spot welders are free-standing machines with heavy bodies for stability and have electrodes with a large reach. The arm depth is adjustable, and the electrodes can rotate to weld at an angle if necessary. They are designed for versatile applications like fabrication or large part repairs. But, they require you to bring the part to the welder since these aren't movable machines. 
• Linear action spot welders are designed to apply pressure in a straight line, unlike rocker arm welders with a pivoting arm. See examples of these machines.
• Bench-top spot welders are designed for smaller shops, especially if the operator is to be seated during use. These spot welders are smaller in size but provide a lot of welding power, with up to 35 kva current output. 
• Suspended spot welders are movable with a built-in transformer. Portable spot welders have the significant advantage of allowing you to weld workpieces too large for handling. They can also be complemented with balancers and watercoolers to suit all industrial needs.
• Hand-held light-duty spot welders are ideal for auto body repairs where the size and manoeuvrability of a spot welder are vital.
• Fastspotter single-sided spot welder is a unique solution for jobs where it's impractical or impossible to access the workpiece from both sides. You can use PEI's Fastspotter to spot or seam weld the joint from one side only.
• Single-side twin spot welders create two spot welds from a single side. They can also be grouped in a multi-single-sided spot welding configuration for higher productivity and efficiency. Twin spot welders can be suspended from a gantry or boom for applications where the parts are too large for handling.

Pedal vs. Pneumatic Spot Welding Machines

Some pillar spot welding machines use a mechanical foot pedal that works like a treadle-type machine. Basically, pedal-operated spot welders like the PEI BSM 221 allow manual clamping force application. So, the harder you press the pedal, the more force is applied with the electrodes.

Pneumatic spot welding machines like the PEI BSP 226 use electro-pneumatic control to apply precise pressure as defined by the air pressure control unit.

PEI spot welding equipment can be configured in many ways using various electrode shapes and sizes and machine settings. With the correct spot welder selection and adjustment, PEI's products can spot weld most applications with exceptional results.

Projection Welding Equipment

Projection welding machines are similar to spot welders, but they don't produce the same end result. With projection welding, the workpiece has "projections" formed during the production process, and these projections are used as points for weld localisation. So, when the welding machine's electrodes clamp the parts, the prefabricated projections on the workpiece are where the current concentrates and creates welds.

PEI manufactures dedicated single-phase AC or three-phase MFDC projection welders, but some of their spot welders dual as spot/projection welding machines too.

Seam Welding Equipment

Seam welders have the same working principle as spot/projection welders, but they produce continuous welds instead of welds in one spot. Since the contact area between two electrodes must be constant, seam welders have circular electrodes. The sheet metal is fed between the wheel electrodes, which apply pressure and electricity, melting and fusing the two metals with a seam joint.

PEI seam welders can be longitudinal or transversal. The best design depends on your application and the type of welded product. Longitudinal seam welders can let you weld with the material coming out of the machine or going into it. Transversal seam welders have the advantage of the material passing on the sides of the machine, giving you more working space.

Resistance Welding Applications

Resistance welding applications are all around us. The car you drive, appliances in your kitchen, furniture in your living room, machines and equipment in production, hospitals, warehouses, and stores. Likewise, aerospace, defence, transportation, and shipbuilding rely on resistance welding when an economical, fast, and efficient method of joining thin metal sheets is needed.

You can apply resistance welding to almost all metals, including high-strength and ultra-high-strength steel, stainless steel, aluminium, magnesium, titanium, nickel, and copper. This is the most widely applied joining method for thin metal sheets. It's far more economical and faster than riveting, mechanical fastening, and screwing. So, whenever the disassembly for maintenance isn't required, or it makes more economic sense, resistance welding is a better option than other metal joining methods.

Westermans - Your Partner For High-Quality Welding Equipment

Westermans International continues to deliver the best welding brands and equipment for all your welding needs. Our PEI agency addition will help us supply the highest quality resistance welding equipment from a reliable manufacturer with exceptional standards. We are proud to continue providing PEI-Point SRL to all UK and Ireland customers and maintaining support for all past and future clients.

Whether you want to buy or sell welding equipment, Westermans International is here for you. Contact our team, and we'll help you choose suitable machines, depending on your application.

Common problems in sub arc welding can affect weld quality, penetration and overall performance.

Firstly, what is Submerged arc welding?

Here are some sub arc welding troubleshooting tips:

1. Insufficient Penetration:

• Low current or voltage settings.
• Excessive travel speed.
• Inadequate joint preparation.

• Increase current or voltage to achieve sufficient heat input.
• Adjust travel speed to allow for proper penetration.
• Ensure proper joint preparation, including bevel angle and root gap.

2. Excessive Penetration:

• High current or voltage settings.
• Slow travel speed.
• Excessive joint preparation.

• Reduce current or voltage to control heat input.
• Increase travel speed.
• Adjust joint preparation to avoid excessive penetration.

3. Weld Bead Irregularities:

• Uneven flux distribution.
• Incorrect wire feed or arc voltage settings.
• Poor wire alignment.

• Ensure proper flux distribution by checking the flux hopper and feed system.
• Adjust wire feed and arc voltage settings for a stable arc.
• Verify that the wire is properly aligned and centred.

4. Porosity in Weld Bead:

• Contaminated flux.
• Moisture in the flux.
• Insufficient preheating.

• Use dry and uncontaminated flux.
• Store flux in a dry environment to prevent moisture absorption.
• Increase preheating if necessary, especially for thick materials.

5. Incomplete Fusion:

• Insufficient heat input.
• Inadequate flux coverage.
• Poor joint fit-up.

• Increase current or voltage for better heat input.
• Ensure proper flux coverage to protect the arc and molten pool.
• Improve joint fit-up for better fusion.

6. Flux Inclusion in Weld Bead:

• Improper flux application.
• Flux contaminated with foreign materials.
• Incorrect welding parameters.

• Ensure even and consistent flux application.
• Use clean and uncontaminated flux.
• Adjust welding parameters to prevent flux entrapment.

7. Arc Instabilities or Arc Blow:

• Magnetic interference.
• Incorrect electrode polarity.
• Insufficient or excessive flux coverage.

• Address magnetic interference by repositioning the workpiece or using magnetic field controls.
• Verify and use the correct electrode polarity.
• Adjust flux coverage to stabilize the arc.

8. Uneven Weld Bead:

• Uneven joint fit-up.
• Inconsistent wire feed.
• Irregular flux distribution.

• Improve joint fit-up for uniform welding.
• Ensure consistent wire feed and adjust as needed.
• Verify and correct flux distribution for a uniform weld.

Responsive Engineering quoted “The ESAB submerged arc welding system attached to the Bode column and boom manipulator, has allowed us to carry out high deposition rate welding during the latter part of jetty construction sections, increasing our skill levels in the process whilst rapidly recouping its initial cost,”

When it comes to TIG welding, the right equipment can make all the difference in the world. Whether you're an experienced welder or just starting out, selecting which TIG welder to use is a crucial decision. With various brands, models, and features on the market, it's easy to feel overwhelmed. This comprehensive buying guide will help you navigate the process, ensuring you choose the TIG welder that best suits your needs.

Understanding TIG Welding.

TIG (Tungsten Inert Gas) welding is known for its precision and versatility, making it the go-to choice for many professionals. It's ideal for welding thin materials; producing clean welds and suitable for a wide range of metals. These include both aluminium and stainless steel. With the right equipment, you can also achieve strong, aesthetic welds on thicker materials.

Key Considerations When Choosing Which TIG Welder.

1. Type of TIG Welder: AC or DC?

• AC/DC vs DC TIG Welder: If you plan to weld a variety of materials, an AC/DC TIG welder is your best bet. This type can handle both alternating current (AC) for welding aluminium, and direct current (DC) for steel, stainless steel, and other metals.

2. Which TIG Welder Brand

• Miller TIG Welders: Miller is a renowned brand in the welding industry, known for producing high-quality equipment. Consider their TIG welders for reliability and performance. Models include the Syncrowave and Dynasty.
• Lincoln TIG Welders: Known for their robust construction and superior performance, Lincoln Electric offer a range of TIG welders for industrial applications. These include the Precision TIG (AC/DC) and the Invertec, a DC TIG welder.
• Fronius TIG Welders: Often considered the "Rolls Royce" of the welding industry, Fronius TIG welders are worth the investment. Excelling in precision applications and demanding environments. Their Magicwave offers a premium AC/DC TIG welding solution. While the Transtig is a consistent overachiever for DC applications.

3. Power Output

• Ensure that the welder's power output meets your specific welding requirements. The thicker the material, the higher the amperage requirements. A rule of thumb for steel is 1 amp of output power per .001" material thickness (suitable for most work). Miller also have a great weld settings calculator if you need a guide to get you started!

4. Portability and Size

• Consider where and how you'll use the TIG welder. If you need portability, look for compact and lightweight inverter TIG welders. These are great for light-duty, on-site repairs or welding jobs. For industrial welding applications, consider a robust set up with a cart and foot pedal. This will make them portable enough to move around the shop, while keeping ease of use a priority.

5. Duty Cycle

• The duty cycle indicates how long the welder can operate without overheating. A higher duty cycle is better for prolonged welding tasks and heavy duty applications.

6. Which TIG Welder for Ease of Use

• Look for features like user-friendly controls, digital displays, and clear instructions. A welding machine that's easy to use will reduce the learning curve, as well as increase output.

7. TIG Welder Price

• Your budget is a crucial factor. While it's tempting to opt for the cheapest option, consider your long-term welding needs. Invest wisely to avoid regrets and the potential of having to upgrade at a later date. This will help to future-proof your business.

8. Extra Features

• Some welders come with advanced features. These include things like pulse settings, pre-flow and post-flow timers, and foot controls. Determine which features are essential for your work now, or in the future if your budget allows.

Safety Precautions

Safety should be a top priority when TIG welding, so you need to ensure your TIG welder has the necessary safety features. These include overheat protection and water cooling, as well as an effective gas shielding system. You should also have appropriate PPE (personal protective equipment) like welding gloves and eye protection. Finally, ensure the area is well ventilated to avoid the dangers of welding fume. This may include an air fed mask if working outdoors, or a welding fume extractor if indoors.

Which TIG Welder Is Best for You?

The 'best' TIG welder varies from person to person. It depends on your specific welding applications, budget, and preferences. To make an informed choice, answer these questions:

• What types of materials will you be welding?
• Do you need both AC and DC capabilities?
• What is your budget?
• Will you be moving the welder frequently, or will it stay in one location?

Our Recommendations When Choosing Which TIG Welder is Best.

Below, we have summarised some of our favourite machines for popular TIG welding applications:

Portable TIG Welder.

If you're looking for portability, a great choice is the GYS TIG 220 DC machine. Coming in at a light 12kg (machine only), it's ideal for on-site work. Optimised for DC TIG, pulsed DC TIG, as well as spot welding functions, it's versatile too! Plus, it comes new with a 2 year warranty and a fantastic back-up service from GYS for repairs and servicing.

Shop here.

TIG Welder for Aluminium.

If you're TIG welding thin aluminium (2-3mm), then take a look at the Miller Dynasty. They have the advantage of advanced inverter technology, with features associated with a high-end power source. All in a compact footprint!

Shop the Miller Dynasty range.

For thicknesses of 10mm plus, then the Fronius Magicwave is a great choice. Perfect for industrial TIG welding, it's robust design and simple operating system makes it ideal for demanding environments. Being a digitised power source, if offers superb control and superior performance, as well as perfect root fusion. Making it the go-to choice for critical TIG welding applications.

Shop Fronius Magicwaves.

TIG Welder for Beginners.

If you're just starting your TIG welding journey, it may be a case of trial and error to find a machine you're comfortable with. If you have some jobs in mind that you'd like to use the TIG welder for, use Miller's welding calculator mentioned earlier. This will give you an idea of the characteristics a suitable machine will need. We would advise to stick to well known manufacturers, with good after-sales support. If you can find a used machine in good working order, you could trial it and see how you get on. If it's not for you, re-sell it and get another one until you're happy!

Which TIG Welder? Final Thoughts

Choosing the right TIG welder is a critical decision for any welding professional. By understanding your specific needs and considering the factors mentioned in this comprehensive guide, you can make an informed choice. Whether you're looking for an AC DC TIG welder or a DC TIG welder, remember that investing in quality equipment will pay off in the long run.

In conclusion, the key to choosing the right TIG welder is understanding your unique needs and priorities. Whether you're tackling aluminium, stainless steel, or other metals, this buying guide will help you make an informed decision. Prioritise quality, safety, and the specific features that matter most to you, and you'll be well on your way to finding the perfect TIG welder for your business. Happy welding!

Pulse MIG welding is a modified spray transfer MIG process that allows exceptional heat input control, better operating characteristics, and higher weld quality than standard MIG.

Are you experiencing distortion, burn-through, or negative material property changes when welding exotic metals like aluminium, stainless steel, and high-strength steel? The vast majority of these issues stem from excessive heat input. The solution? — Pulsed welding processes, like pulsed MIG or TIG.

However, pulsed MIG does so much more than preventing heat-related issues. Read on to discover how pulse MIG welding works, its applications, and how your business can benefit from its advantages over conventional MIG welding.

What Is Pulse MIG Welding and How It Works

Pulse MIG is a modification of the spray transfer MIG welding process. By alternating between the high (peak) and low (background) current, pulse MIG reduces the average heat input into the metal. In addition, pulse MIG times the peak current just right for maximum efficiency and deposition rate.

The pulsed MIG arc alternates between the two phases:

1. The hot phase, where the molten drop of filler wire is deposited into the joint.
2. The "cooler" phase, which keeps the arc going but doesn't deposit the filler metal.

The second phase lets the puddle cool slightly, which prevents burn-through, distortion, and many negative material property changes.

Double Pulse MIG Welding

Double-pulsed MIG welding, sometimes called dual-pulse or pulse-on-pulse, adds a second pulse to the standard pulsed MIG mode. The first pulse acts as a regular pulsed MIG, while the second pulse significantly reduces the current output, additionally decreasing the heat input and timing the weld puddle cooling action. As a result, you get the benefit of standard pulsed MIG, but the second pulse cools the puddle to achieve a TIG-like "stack-of-dimes" weld appearance.

The first pulse (with its own high and low current) deposits the metal during its peak current. Since the first pulse has a background current phase, you get all the benefits of a single pulse. However, the second pulse turns the first pulse off without extinguishing the arc. This is achieved by a significant current output reduction while keeping the arc on. So, when the first pulse finishes its metal deposition, the second pulse lets the weld cool before the first pulse continues depositing metal, resulting in a stack-of-dimes appearance.

Pulse MIG Welding vs. Conventional MIG Transfer Modes

Most MIG welding applications use a short-circuit transfer mode. But, almost all MIG power sources can be configured to run globular and spray transfer modes as well. However, pulsed MIG requires a power source designed for pulsing the spray transfer output. So, standard MIG machines cannot provide the benefit of pulsed MIG power sources.

Pulsed MIG welding is better in almost every way than conventional MIG transfer modes. While each transfer mode has pros and cons, pulse welders amplify their advantages and eliminate most negatives.

Short circuit MIG works by feeding the wire into the weld joint, where it physically touches the grounded metal (work clamp attached to it) and closes the circuit. Due to electrical flow resistance, the wire melts and deposits into the joint at the point of contact. Short circuit transfer works well for thinner metals. But its disadvantages are a low deposition rate and high spatter. Since the wire practically explodes at the point of contact, a lot of spatter is produced.

Globular MIG transfer is rarely used due to extreme spatter. It works similarly to short circuit but with more filler wire. A lot of filler metal is lost to spatter, making globular transfer inefficient.

Spray MIG transfer sprays the molten filler wire as a stream of tiny metal droplets. Since the wire never physically touches the joint, it never shorts and doesn't cause spatter. Spray arc transfer offers exceptional deposition rates, deep weld fusion, and works great for thick metals. But, the weld puddle becomes too liquid with spray transfer, making out-of-position welding difficult. In addition, spray transfer is too hot for thin metals, which can lead to burn-through and excessive distortion.

Pulsed MIG is a modified spray arc transfer mode where the current drops and rises at a high frequency. Basically, pulsed MIG offers the same benefits as standard spray transfer. But, it doesn't run as hot and the puddle is not as liquid, making it easy to weld in all positions and join thin and thick metals alike.

Pulse MIG Welding vs. TIG Welding

The TIG welding process produces the highest welding quality and aesthetic appearance of all arc welding processes. But, it's challenging to master and has a low deposition rate and travel speed.

Pulsed MIG offers similar weld quality, but with a significantly higher deposition rate and travel speed. In addition, double-pulsed MIG can mimic the TIG-like weld appearance, making it an excellent choice where visual weld quality is paramount.

Benefits of Pulse MIG Welding

Many businesses have improved their productivity and bottom line thanks to pulsed MIG advantages. This welding process is especially beneficial when welding sensitive materials like stainless steel and aluminium.

Heat Input Reduction

Not only does pulsed MIG prevent warping and burn-through on thin materials, but it can help you avoid losing favorable metal characteristics by controlling heat input.

For example, stainless steel can lose corrosion resistance if the heat affected zone (HAZ) is overheated. If austenitic stainless steels are held at critical temperatures (427 to 871°C) for too long, chromium carbides can precipitate. As a result, the chromium content can deplete at grain boundaries, leading to intergranural corrosion. Pulsed MIG is an excellent welding process to avoid excessive heat input and to keep the stainless steel corrosion-resistant post-welding.

The heat reduction of pulsed MIG is also beneficial for welding nickel alloys, aluminium, high-strength steels (HSS), and ultra-high-strength steels (UHSS).

Significantly Less Spatter

Pulsed MIG can improve your productivity by reducing the amount of post-welding work, like spatter removal. Short-circuit MIG creates a lot of spatter that often needs to be chipped off or ground off with an angle grinder. This non-value-adding activity reduces the operator's efficiency. So, pulsed MIG saves time and improves shop productivity by eliminating spatter in welding.

Reduced Welding Fumes Production

Since the pulsed MIG reduces the average energy output, less welding wire is vaporized. As a result, the production of welding fumes is reduced. While pulsed MIG cannot be used on its own as an effective fume engineering control, it helps lessen the effects of welding fumes.

Wire Savings with Pulse MIG Welding

Pulsed MIG welding cuts the costs of filler metal wires in three ways:

1. Less spatter means more wire is deposited into the joint instead of ending up as a spatter that must be removed from the welded metal surface.
2. You can have a wider operating range of a wire when using pulsed MIG machines. So, instead of stocking multiple wire diameters, you can stock just one or two wires for various applications. Buying a large spool of one-diameter wire is less costly than buying multiple smaller spools of different diameters.
3. Saving time on wire changeovers improves your productivity and bottom line.

Improved Weld Aesthetics

Standard pulsed MIG makes better-looking welds than short-circuit MIG, flux-cored, or stick welding processes. In addition, double-pulsed MIG can produce welds similar to TIG in appearance, making it an excellent choice for applications where perfect weld looks are crucial.

Works In All Positions

Unlike regular spray transfer, you can use pulsed MIG to weld in all positions. Thanks to its low current phase, the puddle cools slightly and gains the necessary rigidness not to fall down due to gravity.

Pulse MIG Welding Applications

Aluminium Pulse MIG Welding

Aluminium welding is the primary pulsed MIG application because it allows high deposition rates without the fear of burn-through. Typically, aluminium MIG welding is performed in the standard spray transfer mode because short circuit is too cold for aluminium.

Since aluminium is an excellent heat conductor, it needs a high heat input. But, aluminium also has a low melting point. So, it's challenging to find the sweet spot to avoid burning through, especially when welding thin aluminium. So, using pulsed MIG gives you the best of both worlds. The peak current melts the aluminium, while the background current prevents burn-though and warping.

Welding Sensitive Alloys

Pulsed MIG is often used in auto body collision repair. Some car manufacturers mandate pulsed MIG welding to prevent heat from negatively affecting the car body parts. The automotive industry uses aluminium and highly specialized advanced high-strength (AHSS) and ultra-high-strength steels (UHSS) to lighten the vehicles and meet emissions regulations. But, these materials are sensitive to heat. Excessive heat input can drastically increase hardness, cause distortion, and significantly increase the probability of cracking.

Stainless steel and nickel-based alloys are also sensitive to heat input and benefit from pulsed MIG. This is especially true on thin sections and visible welds where weld appearance is essential.

Filling Holes and Large Grooves

Thanks to highly efficient wire use and high deposition rates, pulsed MIG allows you to quickly fill large grooves. And low heat input prevents the weld root from burning through.

Out Of Position Welding

HVAC, pipe welding, construction jobs, or other applications where a welding operator finds themselves under the weld puddle benefits from pulsed MIG. Since the background current lets the puddle cool slightly, it gains rigidity and resists the gravitational pull.

Which Pulse MIG Welders Are The Best

Pulse MIG welders are challenging to manufacture because the internal circuitry must meet many demands to produce a good MIG weld. Since pulse output quality depends on the programming to adapt to different welding wires, material types, and shielding gasses, it's paramount to choose a welder from a reputable brand. Some of the best pulsed MIG welding brands are Fronius, Lincoln Electric, Miller, ESAB, and GYS. In addition, synergic MIG welding pulse machines are the best choice for ease of use. Synergic MIG auto-sets most settings for you, making pulsed MIG accessible and quick to implement.

Besides the power source, it's vital to choose a high-quality wire feeder for stable pulsed MIG. Since this process is highly reliant on wire feeding accuracy, any slippage may negatively impact the end result.

Westermans - Your Partner In The Ever Evolving Welding Industry

If you are looking to buy or sell a pulsed MIG welding system, Westermans is here for you. We stay on top of the changes in the welding industry and are always ready to support your equipment needs. Contact us today, and our expert team will help you choose a suitable pulsed MIG welder or other equipment you may need.

Introduction to Orbital Welding Applications:

Automated orbital welding systems are among the core technologies that enable the modern world to function. The preciseness, consistency, and productivity of orbital welding ensures smooth operations in many industries. From pharmaceutical to aerospace, and semiconductor industry, orbital welding applications play a huge role.

We couldn't have modern aircraft or smartphones, as chip manufacturing relies on orbital welding. So, the device you are using to read our blog would be more challenging to make without orbital welding. Providing the necessary weld integrity for semiconductor stainless steel processing lines. Oh, and the price of oil and gas would probably be higher if we excluded this vital welding process from the industry.

No other welding technology can match the orbital welding quality for tube and pipe welding applications. So, let's dive into orbital welding and see how it benefits almost every major industry in the world.

What Is Orbital Welding?

Orbital welding is an automated welding method where the torch rotates around the static tube or pipe. The 360-degree rotation provides a consistent weld speed, tip-to-joint distance, and weld quality.

Orbital welding was designed to remove human error. As well as providing repeatable weld results for greatest efficiency, safety, and joint quality. You can use many arc welding processes with this automation method. However, orbital welding mostly uses the TIG welding process, which is the focus of this article. You can learn more about how orbital welding works in our separate guide.

Orbital Welding Applications.

TIG orbital welding provides the cleanest welds, thanks to it's focused arc and non-consumable tungsten electrode. Most critical orbital welding applications rely on TIG welding. This is because it allows perfect accuracy and exceptional heat input control. As well as it's main draw; virtually contamination-free welds. So, if you are unsure when to use orbital welding, the answer is whenever you need to join tubes and pipes for costly equipment and critical lines.

Thanks to TIG versatility, orbital welding applications include almost all metals. You can join aluminium, magnesium, titanium, stainless steel, and exotic alloys. Achieving near-perfect welds on each!

Food, Dairy, And Beverage.

The food, dairy, and beverage industries are heavily regulated to improve food safety and quality. Which includes the welds joining the pipes, tubes, fittings, and equipment. The sanitary pipe welds must have consistent, full penetration, and their surface must be smooth and without crevices. This prevents bacterial growth and meet the strict sanitary stainless welding requirements.

The majority of food, dairy, and beverage production requires stainless steel tube welding. This material is highly resistant to corrosion and contamination. But, it's also prone to carbon precipitation if overheated during the welding process. This could lead to the loss of corrosion resistance.

The precision of computer-controlled TIG orbital welding systems ensures consistent and accurate tungsten rotation around the pipe/tube. Preventing excessive heat input and ensuring the continuation of corrosion resistance.

Semiconductor Industry.

Semiconductor production relies on miles of stainless steel processing lines. These transport highly toxic and corrosive gasses necessary for chip production. These tubes must not distort from heat input or lose corrosion resistance. Plus, the greatest weld purity and integrity are non-negotiable.

The orbital TIG welding process has been the industry's standard since the early 1980s. Today, it's the most reliable way to meet the needed weld quality and flexibility. As well as the ever-increasing stringent requirements of the semiconductor industry. Usually, a closed weld head is used to provide maximum weld shielding and cutting oxidation of the bead. Contractors working in the semiconductor industry often use Magnatech, Orbitalum, and AMI orbital welders. This is due to their high-quality software, precision, and reliability.

Oil and Gas Pipe Welding.

While some contractors still use manual stick, MIG, and TIG welding in offshore drilling operations. Or for joining pipelines that transport crude oil and gas, automated orbital welding offers higher productivity and safety.

Everything from the tubular construction of oil platforms, to stainless steel pipes on the sea floor. As well as pipelines transporting the crude product, benefits from orbital TIG welding. Offshore rigs, crude transport pipelines, and tubes and pipes in petrochemical plants must be welded with absolute integrity. A single weld inspection failure prolongs the time to pipeline completion. Thus creating a bottleneck, since you can only lay pipes one after another. But, it's even worse when the welds fail in service due to corrosive chemicals that flow through these pipes. Such pipeline failures can cause devastating environmental and capital damage.

Automated orbital pipe welding with TIG applies to pipelines in the oil and gas industry. The process provides exceptional precision, weld quality, and above all, consistency. All of these factors improve productivity and weld inspection pass rates. The oil and gas industry often uses specially cladded pipes and exotic, custom-formulated alloys. Both need stringent adherence to weld procedures, and orbital TIG welders can meet these demands. Orbital TIG welding heads for pipeline welding, like the AMI Model 15, are both rugged and precise, even in adverse outdoor conditions. So, while the TIG welding process is sophisticated, we can use it in rough work environments with the right equipment.

Pharmaceutical And Biotechnology

Thanks to the ever-advancing medical field and exceptional medical professionals worldwide, we've eradicated some of the most debilitating diseases like polio. The fight against cancer and other health maladies continues. But year on year, R&D engineers, scientists, and medical professionals are making inroads. Improving the successful treatments for the worst health problems every year. Still, pharmaceuticals and innovative medical devices must be produced in facilities fabricated to the highest standards.

The large-scale production of fluids, tablets, capsules, and vaccines includes hazardous chemicals. Processing, storing, and distributing, where the safety of the produced medicine is of utmost importance. Safety of working personnel is also a huge priority every step of the way. A weld cannot be responsible for a contaminated batch because lives could are at risk. This is why sterile tube welding in the pharmaceutical industry is one of the most regulated jobs on the planet.

These high-purity industries have the most demanding requirements for pipe and tube cleanliness. Which includes standards for high-purity fusion pipe welding. This is especially important for CIP (Clean in Place) and sterile WFI (Water For Injection) systems. Sanitary tube and sanitary pipe welding in these industries rely on orbital TIG welding to meet stringent codes and standards. Orbital welding is the most reliable method to produce accurate and smooth welds without crevices. As well as reducing loss of corrosion resistance, or contamination that can compromise the medicine safety. Orbital TIG welding helps to save lives, by allowing us to create complex, functional, and safe medicine production systems. Welding these systems by hand would be almost impossible!.

Aerospace Orbital Welding Applications.

Have you ever heard the saying that flying is safer than driving a car? It's true. Research by Harvard University shows that flying in the US, Europe, and Australia has a 1 in 1.2 million chance of a flight accident. While the chance of a fatal car crash is 1 in 5000! Today, flying is safer than ever, and according to MIT, flight safety increases year after year. Of course, this is thanks to the brilliant engineers. Innovating and improving the airplane navigation, engine, and flight systems. But, orbital TIG welding plays a significant part in turning engineering ingenuity into reality.

Airplanes can have thousands of critical fuel and hydraulic control lines, and are the main orbital welding applications in the aerospace industry. These are exposed to highly complex cyclical loads and thermal stresses. Joining these tubes requires absolute process control, because any mishap can lead to a compromised joint. If this burst, it would present a major safety hazard. The welded joint must not negatively impact the alloy's characteristics, contribute to corrosion, develop cracks, or distort. The heat input control is paramount, and computer-controlled orbital TIG welders are up to the task. The aerospace industry was the first to introduce orbital welding. It still relies on its near-perfect welding characteristics to create powerful, safe, and awe-striking airplanes. Including the likes of Boeings and Airbuses.

Power Generation

Fossil fuel and nuclear power generation plants rely on orbital TIG welding to meet stringent weld requirements. A single weld failure at a critical point could pose a significant safety hazard. Creating a high capital loss in these facilities. But to make matters worse, the tubes in power generation plants are often tightly packed. Meaning limited space for construction and welding.

TIG orbital welding systems are the industry's standard for boiler tube welding and constructing heat exchangers. Other orbital welding applications in this sector include economisers, superheaters, reheaters, and tube lines. Thanks to their weld head's compact size, versatility and accuracy. As well as adaptability and exceptional weld quality, orbital TIG welders provide excellent joint integrity. Meeting the demanding needs of power generation.

Orbital Welding Applications in Shipbuilding

Large cruise and naval ships can be hundreds of meters long and tens of meters high! For example, the largest UK Navy aircraft carrier, the HMS Queen Elizabeth Class, is 280 meters long and 73 meters high! Likewise, cargo ships or vessels that transport crude oil can be of enormous dimensions. Such ships can take years to produce, with substantial time devoted to welding the hull plates and piping systems.

Modern ships have many piping systems, including engine cooling, steam, and fire protection. As well as bilge, water, and fuel systems. These piping systems are challenging to weld, due to stringent quality requirements and constricted spaces. The welder's safety can often get jeopardised due to welding in cramped areas. Where the welding fumes can quickly displace the breathable air. Plus, these piping systems must be accessible for weld repairs while at sea. Emergency contingencies can require prompt welding repairs to save people on board. But quality construction prevents such events from happening in the first place.

Orbital TIG welding can join small and large diameter tubes and pipes in cramped areas, with near-perfect weld quality. The shipbuilding industry employs orbital TIG to pass safety and welding quality codes and regulations. Some vessels can have their own nuclear power generators, complicating the construction and amplifying safety hazards. These ships can require welding titanium, high nickel, and many specialised alloys. Orbital TIG welding easily achieves exceptional welds on these materials.

Westermans - Meet Your Orbital Welding Needs

Whether you are looking to buy, rent, or sell your orbital power sources and weld heads, Westermans is here for you. Contact us today, and our experts will help you choose suitable orbital welding machines. High-end brands like AMI, Magnatech, Orbitalum, Fronius and ESAB, are available from stock today.

TIG welding, also known as Gas Tungsten Arc Welding (GTAW), is a highly versatile and efficient welding process. It's proven to be ideal for pipe applications, with its precise control and ability to produce high-quality welds. TIG pipe welding offers several more advantages over other welding techniques.

In this article, we will take a closer look at the benefits of TIG welding for pipe applications. Including why it is the preferred choice for many professionals in the industry. From its ability to create clean, precise welds, to its suitability for a wide range of materials. TIG pipe welding offers unmatched performance and reliability. Whether you are working with stainless steel, aluminium, or other alloys, TIG welding ensures superior strength and durability. Join us as we delve into the advantages of TIG welding for pipe applications. Discover why it continues to be the go-to method for achieving flawless welds in various industries.

Understanding TIG Pipe Welding Applications.

Pipes play a crucial role in various industries, including oil and gas, construction, and manufacturing. They transport fluids, gases, and other materials, making them an integral part of many systems. The welding process used in pipe applications is of utmost importance. It determines the strength, durability, and integrity of the pipes. TIG welding has become the preferred method for joining pipes in these industries. This is due to it's precise control and ability to create clean, high-quality welds.

TIG welding involves the use of a tungsten electrode and a shielding gas to protect the weld pool from contamination. The tungsten electrode, which does not melt during the process, provides heat to the base metal. While the shielding gas prevents oxidation and ensures a clean weld. This combination of heat control and shielding makes TIG welding an ideal choice for pipe applications. When the integrity of the welds is paramount.

TIG welding also offers the advantage of being a manual or automated process. This allows welders to have complete control over the welding parameters depending on the application. This level of control is especially important in pipe applications, where precision is crucial to ensure leak-free joints and optimal performance. With TIG pipe welding, welders can adjust the heat input, welding speed, and electrode position. Helping to achieve the desired results, resulting in strong and reliable welds.

The Advantages of TIG Welding for Pipe Applications

Increased Precision and Control when TIG Pipe Welding.

One of the main advantages of TIG pipe welding is increased precision and control. The nature of TIG welding allows welders to have complete control over the welding process. Ensuring accurate and consistent results. This is particularly important when working with pipes that need precise alignment and fit.

With TIG welding, welders can adjust the heat input and welding parameters to match the requirements of the application. This level of control allows for the creation of clean, precise welds that meet the highest quality standards. Whether it's a small-diameter pipe or a large-diameter pipeline, TIG pipe welding ensures that the joints are strong and leak-free. Making them able to withstand the demands of the application.

Superior Weld Quality and Aesthetics.

TIG welding is renowned for producing high-quality welds with excellent aesthetics. The precise control, coupled with the use of a tungsten electrode and a shielding gas, results in clean and visually appealing welds. This is important in pipe applications where the appearance of the welds can be a significant factor. As well as their visual appeal, TIG welds also offer superior strength and durability.

The process allows for thorough fusion of the base metals. This creates a strong bond able to withstand the stresses and pressures experienced in pipe applications. This ensures that the welded joints remain intact. While also preventing leaks and ensuring the long-term performance of the pipes.

Minimised Heat Distortion and Warping.

Heat distortion and warping are common challenges in welding, particularly in pipe applications. The heat generated during the welding process can cause the base metal to expand and contract. This leads to defects like distortion and warping, resulting in misaligned joints and compromised structural integrity. All contribute to increased repair and maintenance costs.

TIG welding helps cut heat distortion and warping due to its low heat input and precise control. The focused heat provided by the tungsten allows for localised heating, reducing the heat affected zone. Reducing distortion and warping, ensuring that the pipes maintain their shape and alignment.

Versatility for Various Pipe Materials and Thicknesses.

Another significant advantage of TIG welding for pipe applications is its versatility. The TIG process is suitable for various materials and thicknesses. These include stainless steel, aluminium, and carbon steel, as well as exotic alloys. This makes it suitable for diverse pipe applications across different industries.

Furthermore, TIG welding can handle both thin and thick pipe walls with ease. The precise control allows welders to adjust parameters like heat input and welding speed, to match the thickness of the pipes. This versatility ensures that TIG welding can be used for a wide range of pipe applications. From thin-walled pipes used in HVAC systems, to thick-walled pipes used in oil and gas pipelines.

TIG Pipe Welding: Critical Applications

In critical pipe applications where safety and reliability are of utmost importance, TIG welding shines. Industries such as nuclear power, aerospace, and pharmaceuticals are great examples. Needing welds that meet stringent quality and safety standards. TIG welding is the preferred choice for these high-stakes applications. Due to it's ability to produce clean, defect-free welds.

The regulated heat input and precise control of TIG pipe welding ensures that welds meet the required specifications. Whilst enabling them to withstand the extreme conditions and pressures they're exposed to. Whether it's a nuclear reactor pipe or a pharmaceutical processing pipeline. TIG welding provides the reliability and performance necessary for critical applications.

TIG Pipe Welding Techniques

While TIG welding offers several advantages for pipe applications, it is essential to understand and use the proper welding techniques to achieve optimal results. Certain considerations and techniques must be taken into account when TIG welding pipe. This will optimise the integrity and strength of the welds.

One crucial technique is the proper preparation of the pipe joints before welding. Like ensuring clean, smooth surfaces free, from contaminants that can compromise the weld quality. Proper fit-up and alignment of the pipe joints are also critical. Making sure that welds are strong and leak-free.

Another important technique for TIG welding pipe applications is the use of proper welding parameters. Things like selecting the appropriate welding current and electrode size. As well as shielding gas flow rate based on the pipe material and thickness. Welders must also maintain a consistent travel speed and control. While the tungsten electrode's angle and position to achieve optimal results. This is where automation and orbital welding can be very beneficial.

Safety Considerations for TIG Welding in Pipe Applications

Safety should always be a top priority when performing TIG welding in pipe applications. Welders must take necessary precautions to protect themselves and others from potential hazards. This includes wearing personal protective equipment (PPE) like welding helmets, gloves, and clothing.

Proper ventilation is also crucial in all situations. Welders should ensure that the workspace is well ventilated to prevent the accumulation of harmful fumes and gases. Additionally, proper grounding and electrical safety measures should be followed. This will prevent potential electrical accidents.

TIG Pipe Welding: Conclusion

TIG welding offers a multitude of advantages for pipe welding applications. Helping to make it the preferred choice for professionals in various industries. From increased precision and control, to superior weld quality and aesthetics. TIG welding ensures strong, durable, and aesthetic welds. It's ability to cut heat distortion and warping, as well as it's versatility for various pipe materials and thicknesses are also benefits. Further solidifying it's position as the go-to method for achieving flawless welds.

Whether you're working in critical pipe applications or everyday pipe installations. TIG welding pipe provides the performance, reliability, and safety required for successful welds. By understanding the proper techniques and considering safety measures, welders can harness the full potential of TIG welding. Achieving optimal results in their pipe welding applications. Experience the unmatched quality and durability TIG welding pipe offers for your needs.

Aluminium is a versatile and widely used metal in various industries. From automotive and aerospace to construction and manufacturing. When it comes to joining aluminium parts, MIG welding is a popular and efficient method. But MIG welding aluminium poses unique challenges compared to other metals. A low melting point, high thermal conductivity, and oxide layer contribute to this.

In this blog, we will explore the world of MIG welding aluminium. Providing valuable insights, tips, and techniques. As well as best practices to help you master the art and achieve high-quality welds.

Understanding the Properties of Aluminium.

With a low melting point and high thermal conductivity, aluminium is difficult to weld. The low melting point increases the chance of defects. Issues like warping, distortion and burn-through can be common. While high thermal conductivity dissipates heat quickly. Making it a challenge to retain heat in a specific area, particularly in thicker material. Precise heat control and proper welding techniques will overcome these challenges. Increasing the heat input and slowing travel speed for example. Ensuring proper fusion and structural integrity of the weld. Other things to consider are oxide formation and material porosity.

Selecting the Right Equipment for MIG Welding Aluminium.

You'll need a MIG welder with specific features for welding aluminium. Adjustable voltage and wire feed speed will ensure precise setting control. The wire feeder will need to be smooth and reliable, opting for a push-pull gun or spool on-gun will help achieve this. A MIG gun with a teflon liner will help to reduce friction with wire feeding. Reducing the chance of jamming and "bird-nesting". The welding wire will need to be aluminium, specifically suited to MIG welding. It should match the alloy composition of the base metal. Or be compatible with the specific aluminium alloy you are welding. These include ER4043 and ER5356 filler wires. Argon is a popular shielding gas as it provides excellent coverage. Nozzles and contact tips have larger internal diameters. This helps to accommodate the softer wire, preventing it from clogging, as well as allowing better flow of the shielding gas. Other consumables include the correct drive rolls for aluminium welding and wire size. As well as wire brushes and cleaning solvents for pre-weld preparation.

MIG Welding Aluminium Pre-Weld Preparation.

Preparing aluminium before welding is essential for removing oxidisation and other contaminants. Start by thoroughly cleaning the aluminium base metal. A wire or stainless steel brush will help to remove things like oil, grease and other substances. You will need to use a specific solvent or chemical cleaner for aluminium to remove the oxide layer. Use with a brush or abrasive pad to gently scrub, making sure to rinse after, checking the oxide has all gone. Other, more advanced steps include using mechanical cleaners for professional/industrial use. As well as proper fit-up of the joint, equipment and gas checking. Always wear appropriate PPE!

Shielding Gas and Wire Selection.

The primary shielding gas used for MIG welding aluminium is pure argon or a mixture of argon and helium. These gases provide excellent coverage and protection for the weld pool. Preventing atmospheric contamination and minimising the formation of defects. Whether you use pure argon or an argon-helium mixture will depend on application and parameters. For appropriate mixtures, we recommend consulting welding reference charts. Or seek guidance for the appropriate shielding gas mixture ratios. ER4043 is the most commonly used filler wire for welding aluminium. It is suitable for welding aluminium alloys in the 3XXX and 6XXX series, such as 3003, 6061, and 6063. ER4043 offers good fluidity, excellent corrosion resistance, and good colour match after anodizing. ER5356 is ideal for welding aluminium alloys in the 5XXX series, such as 5052 and 5083. ER5356 provides higher tensile strength and improved crack resistance compared to ER4043. It is particularly suitable for applications that need higher strength. As well as better performance in high-pressure environments.

Techniques for MIG Welding Aluminium.

Some common aluminium MIG welding techniques include the push/pull methods. Whereby you push, or pull, the MIG gun towards the weld pool. This helps to control the heat input, improving fusion. Use the push technique for thinner aluminium sections, and pull for thick material. Using a tilted torch angle can help direct the heat towards the base metal. Allowing for better penetration while maintaining good arc stability. Back-stepping helps manage heat build-up. The welder moves backward, against the direction of welding after depositing a short section. Controlling distortion, and cutting the effects of thermal conductivity. Pulse welding alternates between high and low currents during the welding process. Controlling heat input, reducing distortion, and improving weld quality. It is useful for welding thin aluminium sections, or when appearance is a critical factor. Weaving is where the MIG gun is moved in a controlled side-to-side motion while welding. It helps distribute heat and widen the weld bead, ensuring proper fusion. It is effective when welding wider joints, or when you need extra reinforcement.

Troubleshooting and Common Challenges.

Some common challenges that may arise while MIG Welding Aluminium include:

1. Burn-Through or Warping. Due to aluminium's lower melting point and higher thermal conductivity, there is a higher risk of burn-through or warping. Especially when welding thin sections. To mitigate this issue, you can:

• Reduce the heat input by adjusting the voltage and wire feed speed.
• Use a smaller diameter filler wire to decrease heat input.
• Use a shorter welding arc length.
• Utilise tack welding or stitch welding techniques to aid heat distribution.

2. Porosity. Aluminium is susceptible to porosity, which manifests as gas pockets in the weld. To reduce porosity:

• Ensure the base metal is clean and free from contaminants, such as oil, grease, or moisture.
• Clean the filler wire with a stainless steel wire brush or wipe it with a clean cloth before welding.
• Use a high-purity shielding gas, such as pure argon. Along with proper flow rates to provide adequate protection.
• Adjust the shielding gas flow rate and positioning of the gas nozzle. This helps to ensure optimal gas coverage over the weld area.

3. Incomplete Fusion or Lack of Penetration. Insufficient fusion or penetration can weaken the weld joint. To address this:

• Increase the heat input by adjusting the voltage, wire feed speed, or using a higher amperage setting.
• Ensure proper fit-up and joint preparation to allow for enough penetration.
• Use weaving techniques to ensure thorough fusion across the joint.
• Consider preheating the base metal to improve weld penetration in thicker sections.

4. Oxide Formation and Contamination. The oxide layer on aluminium surfaces can hinder proper fusion and lead to weld defects. To mitigate oxide-related issues:

• Clean the base metal properly using a wire or stainless steel brush. Appropriate cleaning agents will also help to remove oxide, dirt, and contaminants.
• Use a dedicated stainless steel wire brush for aluminium to prevent cross-contamination.
• Use mechanical cleaning methods like abrasive pads or sanding, for tougher oxide layers.
• Consider using a suitable aluminium-specific cleaning agent to remove oxide effectively.

5. Wire Feeding Issues. Aluminium wire can be softer and more prone to tangling or bird-nesting in the wire feeder. To address this:

• Use a spool gun setup or a push-pull wire feeding system to ensure smoother wire feeding.
• Maintain proper tension on the wire spool and drive rolls to prevent wire slippage.
• Check the contact tip size and condition to ensure it matches the wire diameter. It should also be clean and free from debris.

6. Joint Fit-Up and Alignment. Poor joint fit-up and misalignment can lead to weld defects and compromised strength. Consider the below:

• Ensure accurate joint fit-up and alignment before welding.
• Use clamps or fixtures to hold the parts securely in position during welding.
• Use appropriate joint preparation techniques, such as bevelling or grooving. Ideal for thicker sections or critical applications.

Practice and experimentation with welding parameters is key. Experience will help you troubleshoot specific challenges encountered during aluminium MIG welding. We recommend consulting welding references, as well as seeking guidance from experienced welders. Also conduct test welds to optimise your technique and achieve high-quality aluminium welds.

MIG Welding Aluminium Safety and Health Considerations.

As well as general welding safety, you should consider some aluminium-related hazards too. Aluminium is a good conductor of electricity, so be aware of the potential for electrostatic discharge. Take precautions to prevent accidental contact with electrical components. As well as grounding yourself and the workpiece to avoid static build-up. Aluminium welding involves high heat and sparks, increasing the risk of fire hazards. Make sure there are fire extinguishers nearby, and clear the workplace of flammable material like card and paper. Any flammable items that can't be moved should be covered in a fireproof blanket or use a welding curtain. Take caution around hot workpieces and spatter, as these can ignite flammable material. Standard welding practices like appropriate PPE and eyewear. As well as proper ventilation with a fume extraction filter, should all be employed when welding aluminium. Ensure you have had adequate training on the process and safety aspects. As well as familiarising yourself with the equipment and it's operating manuals for success.

Conclusion.

MIG welding aluminium requires a solid understanding of the metal's properties. As well as specialised techniques, and appropriate equipment selection. By following the tips, techniques, and best practices discussed in this blog post, you can enhance your skills. Helping you to achieve exceptional results in aluminium MIG welding projects. Remember, practice and patience are key to mastering the art of MIG welding aluminium. Do this, and you'll unlock its vast potential in various industries!

If you have anything to add, we'd love to hear from you! Share with us in the comments below.

Our machine of the week is a used, ex-TWI, Fronius weld cladding machine.

This Fronius weld cladding machine is a top-of-the-line solution for your cladding and weld overlay needs. With a 1000kg welding positioner, this system can handle large and heavy workpieces with ease. The Fronius TT 450 TIG welding machine is a high-performance machine. It delivers excellent welding results, whether you're working with hot or cold wire welding processes.

Weld Cladding Process.

Weld cladding is a process that involves welding a layer of material onto a base material. Used to enhance its properties and critical strength. It is a process used in various industries, including oil and gas and power generation. As well as offshore and chemical processing. Weld cladding is an effective way to improve the corrosion and wear resistance of the base metal. Plus other properties of materials used in these industries.

Advantages of Using a Weld Cladding Machine.

There are many advantages of weld cladding. Firstly, it provides an extra layer of protection to the base material. Which in turn, increases it's lifespan and reduces maintenance costs. Additionally, weld cladding allows for the use of less expensive base materials. This can lead to significant cost savings. Finally, weld cladding machines can improve the performance of a material. Making it more durable and resistant to wear and tear.

Weld Cladding Machine Applications.

The Fronius weld cladding system is ideal for a wide range of applications, including:

• Corrosion protection. Weld cladding protects materials from corrosion in harsh environments. Such as this found on offshore oil rigs and chemical processing plants.
• Wear resistance. Materials used in high-wear applications benefit from weld cladding. The process increases their durability and reduces the need for frequent replacement.
• Heat resistance. Using a weld cladding machine helps protect base metals from high temperatures. Making it critical in industries such as power generation.
• Repair and maintenance. Weld cladding is a great process to repair damaged or worn components. Helping to extend their lifespan and reducing the need for costly replacements.

Why choose Fronius?

The Fronius weld cladding machine is a must-have for any industry that requires demanding welding results. With its 1000kg welding positioner and Fronius TT 450 TIG welding machine, this system delivers exceptional performance and reliability. Whether you're working with hot or cold wire welding processes, the Fronius weld cladding system is the perfect solution for your cladding needs.

Benefits of buying from Westermans:

• Get a 4 month warranty as standard with this weld cladding system, giving you peace of mind on your purchase.
• Whether you're located in the UAE or Canada, Scotland or Australia. We ship Internationally via our knowledgeable and experienced logistics partners.
• Don't get left out in the cold! You'll get technical support from us for the duration of your ownership of the equipment.

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Introduction: What is an Orbital Welder?

An orbital welder is a specialised welding machine, performing automatic welding of pipes and tubes. It is an effective solution for a precision welding process. It uses a rotating mechanical device that moves the welding head around the circumference of the tube or pipe. Thus producing a consistent and uniform weld for high purity applications. Ideal for use in industries such as semiconductor, biotechnology, aerospace, and pharmaceutical manufacturing.

The orbital welding process eliminates manual intervention and can perform a range of welding processes. Including gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW). It does this with a high level of accuracy, speed, and repeatability. The orbital welding tool affords a high degree of control over the welding process parameters. Things like welding speed, arc length, and heat input; ensuring consistent, high-quality welds.

What are the Benefits of Using an Orbital Welder?

There are several benefits of using an orbital welder, which include:

1. Consistency. Orbital welding machines are precise and produce consistent welds. Thus ensuring the integrity of the joint every time.
2. Efficiency. The automated nature of the orbital welding process saves time and reduces labor costs. Making it the ideal solution for high-volume production.
3. Quality. The advanced technology used in orbital welding produces high-quality welds. With minimal defects, this leads to improved product reliability and longevity.
4. Safety. Orbital welding minimises the risk of accidents and injuries. This is due to reduced manual intervention in the process.
5. Purity. Depending on the application, orbital welding can be used to produce welds with high purity and cleanliness. Making it ideal for use in hygienic industries. These include industries like pharmaceutical and food processing.
6. Versatility. Orbital welders can weld a wide range of materials. Stainless steel, nickel alloys, and carbon steel are all suitable. Making them a versatile option for various welding applications.
7. Documentation. Orbital welders can provide detailed documentation of the welding parameters. Producing a record of the process for quality assurance and regulatory compliance.

The benefits of using an orbital welder include improved consistency and quality. As well as efficiency, safety, and versatility, making it an ideal choice for many industrial welding applications.

How Does an Orbital Welder Work?

An orbital welder works by rotating an electrode and the workpiece around a static pipe or tube. The welding process occurs under an inert gas blanket, which is usually argon or helium. Here are the basic steps of how an orbital welder works:

1. Preparation. Before the welding process begins, the surface of the workpiece and electrode require cleaning. This helps to ensure that there is no contamination.
2. Clamping. The workpiece needs clamping into place, and the electrode then attaches to a rotating arm.
3. Arc Initiation. An arc initiates between the electrode and the workpiece. Creating an intense heat that melts the metal.
4. Welding. As the electrode rotates around the pipe or tube, it maintains a constant distance from the workpiece. This then creates a uniform weld.
5. Cooling. After the weld is complete, the workpiece is cooled slowly. This helps to prevent warping or distortion.

An orbital welder features a computer controller that programmes the welding parameters. These include the diameter of the workpiece, the material, and the welding speed. The controller then sends the required information to the welding head. Which uses both mechanical and electrical components to perform the welding process.

The orbital welding process is precise, producing consistent, high-quality welds with minimal operator intervention. It is used in industries where welding quality and repeatability are critical. Such as aerospace, semiconductor, and pharmaceutical applications.

What are the Different Types of Orbital Welding Machine Available on the Market?

There are several types of orbital welding machines available on the market, each with its unique features and capabilities. Here are the four main types of orbital welding machines:

1. Power Supply Integrated Orbital Welding Machine. This type of machine integrates with the power supply, control panel, and welding head as a single unit. These machines are compact and suitable for welding small to medium-sized pipes.
2. Enclosed Orbital Welding Machine. This type of machine is suitable for welding pipes in a clean environment. It utilises a welding chamber, which provides a clean, inert gas atmosphere to the weld puddle.
3. Portable Orbital Welding Machine. This type of machine is lightweight and easy to carry around. It is usually used for field welding, where the welder needs to move between different locations.
4. Pipe-to-Pipe Orbital Welding Machine. This type of machine is designed for welding two pipes end-to-end, without any gap. The pipe-to-pipe orbital welder uses a welding head that clamps around the pipes, welding them together.

Orbital welding machines also differ based on the technology they use. Some machines use a programming language to program the welding process. Others have a touchscreen interface. Features like remote controls, on-board data logging, or automatic electrode alignment improve the efficiency and accuracy of the welding process. The choice of machine depends on the type of material, the size of the pipes, and the application requirements.

How to Choose Which Orbital Welder is Right for Your Project.

Choosing the right orbital welder for your project is essential. It ensures that the welding process is efficient, cost-effective, and produces high-quality welds. Here are some of the factors to consider when choosing which type of orbital welder is right for your project:

1. Material. The type of material being welded is one of the most important factors to consider. The material will determine the required welding method and welding parameters. As well as the type of welding head needed.
2. Pipe size. The pipe size is another crucial factor to consider when selecting an orbital welder. Different machines are designed to handle different pipe sizes. Therefore it is essential to choose a machine that can handle the size of pipes you need to weld.
3. Environment. The environment in which the welding will take place may also influence the type of orbital welder you choose. If you are working in a confined space or a clean room, you may need an enclosed or portable machine.
4. Frequency of use. Consider how often you will need to use the machine. If you need to perform many welds, you may prefer a machine that is easy to set up and operate.
5. Price. The cost of the welder will also be a factor in your decision. Higher-end machines will come with more features and capabilities. However they may not always be necessary for your specific project.

By considering these factors, you can better determine which type of orbital welder is suitable for your project needs. It is recommended to consult with an orbital welding expert. They will provide guidance on choosing the right machine for your project requirements.

If you're looking to buy or sell an orbital welding machine, contact us today for a hassle-free, professional experience!