PULSED MIG WELDERS

What is a pulse MIG welder? 

​Pulse MIG Welders have revolutionised the welding industry, providing enhanced control and efficiency compared to traditional MIG welders.  Pulsed MIG welders offer a unique welding technique that uses a pulsing current to produce a more precise and controlled weld.

So, what exactly makes Pulse MIG welders stand out?  Well, unlike regular MIG welders that use a constant current, pulse MIG welders alternate between a high peak current and a low background current. This pulsing action allows welders to weld at lower average amperages, resulting in reduced heat input and lower distortion on the workpiece. Additionally, the pulsing current helps to minimize spatter and ensure better penetration, leading to higher-quality welds.

Pulsed MIG welders are particularly useful when welding thin materials or projects requiring precise control. The pulsing action enables welders to make smoother and more controlled welds, contributing to a clean and aesthetically pleasing finish. Moreover, this welding technique is also beneficial when working with alloys prone to distortion or heat damage.

That not to say Pulsed MIG Welding isn't suitable for welding steels because it is the advantages of pulsed steel welding mean you can weld up to 40% faster than Dip Transfer MIG Welding with greatly reduced spatter!

Pulsed Welding V Dip Transfer Welding: Key Differences

Did you know the welding technique can change the quality and speed of the work? With new welding tech, pros have many options. Pulsed welding and dip transfer welding are two main ones. They have different benefits for various jobs.

Pulsed welding sends material in small dropule from the welding wire in the torch to the weld pool. This makes the welds clean and cuts down on spatter. Dip transfer welding, however, makes a short circuit. This means the welding wire has to dip into the weld pool all the time to short circuit. (this is why its sometimes called short circuit welding) This action of dipping into the pool is quite aggressive and so naturally it can produce more spatter than spray or Pulsed MIG Welding

Let's look at the main differences between pulsed and dip transfer welding. Knowing these will help you pick the best MIG Welder and welding Mode for your welding task.

Dip or Short Circuit Mode

In welding, the dip or short circuit mode is a popular method. It happens when the wire in the welding gun touches the workpiece, creating a short circuit. This is often used in MIG (Metal Inert Gas) welding, where the wire is the electrode.

When using dip or short circuit mode, the welding wire touches the metal many times a second. This makes a small, solid weld quickly. It works well on both thick and thin metals in any position because it uses less heat.

Benefits of dip or short circuit mode:

• Works on many metals and thicknesses
• Can be used in any position
• Makes a small weld pool, which helps avoid distortion

But, dip or short circuit mode has its downsides. It has a slow wire feed speed, which means less welding can be done. It also creates a lot of spatter, which can lower the weld quality. Thick materials are hard because they don't get enough heat.

Example of "cold lapping" during dip or short circuit mode:

Imagine trying to weld a thick metal with dip or short circuit mode. Because there's not enough heat, the weld might not go deep into the metal. This can cause a "cold lap," which is a visible flaw.

Dip or short circuit mode is versatile and easy to use. But, it has its limits. Welders should think about these when choosing a welding method. Knowing the pros and cons helps make the right choice for each project.

Pulsed Arc Mode

Pulsed arc mode is a top-notch welding method. It blends the best of other welding types but cuts down on their downsides. It uses the latest tech to control how material moves between the electrode and the weld puddle. This way, it doesn't make spatter like some other methods and can weld over a wider range with less heat.

This mode gives welders full control over the welding process. It helps make high-quality welds with few flaws. By turning the arc on and off, it uses less heat. This means less distortion, less chance of burn-through, and better weld quality.

It's great for welding thin materials because it lowers the risk of warping. It also works well in all positions, like vertical and overhead. This makes it useful for more jobs.

Advantages of Pulsed Arc Mode:

• Controlled droplet form of material transfer
• Lower heat input
• Expanded welding range
• Reduced spatter
• Improved weld quality
• Less distortion and warping
• Suitable for thin materials and various welding positions

Pulsed arc mode is getting more popular in many industries. It's great for making high-quality welds. It's used a lot in car making, aerospace, building, and making big structures.

Key Takeaways:

• Pulsed welding and dip transfer welding are two popular techniques in metalwork.
• Pulsed welding involves controlled droplet transfer, while dip transfer welding creates a short circuit for droplet transfer.
• Pulsed welding offers precise heat control and cleaner welds, while dip transfer welding is known for its ease of use and suitability for thicker materials.
• The choice between the two techniques depends on the specific application and material being welded.
• Advancements in welding technology continue to improve the efficiency and effectiveness of both techniques.

At BWS we have had extensive experience with Pulsed MIG Welders for nearly 30 years!  Our team of qualified engineers have had factory training enabling them to service and repair all makes and types of Pulsed MIG Welders available on the market today.  Our in-house electronics repair team ensures fast and efficient repair of any inverter-based welder, especially Pulsed MIG Welders.  Buying from BWS means you can have the confidence that if you have any questions, require support or just need your machine servicing, we are here for you!

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