Ador Welding Ltd: e-Weldone Newsletter

SYNERGIC MIG-MAG WELDING - INCREASE
PRODUCTIVITY & REDUCE LABOR COSTS

Introduction:

MIG/MAG welding outfits consist of three main units (i) Power source (ii) Wire feeder and (iii) Torch. A welder using conventional MIG/MAG welding system needs to be skilled in setting weld parameters for a particular job. In this welding system, he has to set many welding parameters like voltage, wire speed as per shielding gas, burn-back time and post-flow time before he starts welding.

A power source for GMAW process is constant voltage type; voltage is set and controlled by the power source, where as the welding current at any set voltage is dependant on the wire speed which in turn depends mainly on the following parameters

Wire diameter
The material of wire being used
The type of shielding gas used and
Welding position & joint

From all these variables, one can understand that it requires a lot of skill to set the proper welding speed for any set voltage.

What is a synergic MIG-MAG system?

A synergy exists when different parameters cooperate advantageously for achieving a desired final output; it is similar to teamwork that produces an overall better result than all people working independently.Use of advanced controllers which use micro-controllers has made it possible to set the wire speed and other parameters like burn back time, post flow time etc. with a single point control. The MIG/MAG welding system in which welding parameters are set using such a controller is called Synergic MIG-MAG system. All the welding data with respect to voltage and variables like wire speed, burn-back time, post-flow time etc. are stored in the controller’s memory. Through the controllers one has to enter parameters for –

Wire diameters
Wire material
Shielding gas

Once completed set the voltage required (required for penetration & melting of weld metal) and start welding. During welding a welder needs to adjust only voltage; the wire speed and other parameters get adjusted automatically. If fine tuning of wire speed is required during welding, then it is also possible to adjust the wire speed independently.
In advanced synergic MIG/MAG systems, even voltage does not require to be set; in this case user has to enter few more known parameters like thickness of welding plates, type of joint and position of welding, etc.

Advantages of Synergic controlled MIG-MAG systems:

Any welder can set and store the welding parameters, resulting in saving in labor costs. (Welding parameter through synergic control can be set by remote control also)
One touch control; set voltage and start welding
In these controllers, it is possible to store the weld parameters required for any particular job; settings can be re-called for repetitive operation
It is also possible to lock the set parameters, so that unauthorized person can not disturb these parameters (password protected)
Welding is spatter free; this is particularly useful while welding alloy steels and non ferrous steels
Arc length is steady and consistent because of the advanced controller
Down slope at end of welding avoids crater formation
Digital panel enables accurate setting and monitoring of parameters
Suitable for connection to robots and other automation systems

Conclusion:

With the advantages of this new advanced welding system, the productivity and quality is improved in following ways:

Labor time is reduced in setting the weld parameters
Consistency in operation for set parameters in repetitive work
Lesser dependency on welder skill to set the parameters

Ador Welding Ltd. range of Synergic MIG/ MAG welding machines

AWL has the following MIG/MAG machines with Synergic controllers with program storage and parameter locking facility.
(A) Diode based Synergic MIG/MAG machines