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Overview
Index
Details 1
Waveform
Description
Optimization 2
Synergic Welding
UltimArc Control
Applications 3-4
1F / PA Lap Semi-automatic
1F / PA Lap Robotic
Set-up 5-9
Connection Diagram
Sense Leads
Work Leads
Troubleshooting
Glossary 10
Icons
Technical Terms
Procedure Notes
Customer Assistance Policy
TE12.010
AC Aluminum Pulse Details 1
Process Description
AC Aluminum Pulse (GMAW) brings features that cannot be
realized with standard DC pulse MIG welding. The AC pulse
process reduces the heat input by focusing the energy away Burnthrough
from the base plate and switching the polarity of the arc.
HEAT INPUT
Productivity increases with improved deposition rates using e
ng
AC Aluminum Pulse (GMAW) waveform technology are
Ra
available exclusively on the Power Wave Advanced Module. Ar
c
im
This is possible because the negative polarity arc redirects Ut
the heat away from the workpiece, reducing the chance of
burnthrough. The UltimArc and synergic precision controls
give the user full control over heat input, penetration while
improving cleaning action, and allowing for faster travel WFS
speeds on thin material. MIN MAX
Waveform
Peak 1
Propels droplet toward the
weld pool. Positive Background
2 Completes droplet transfer
and begins the creation of the
next droplet.
Negative Background
Reduces heat input by
redirecting current flow
towards the electrode. 3
AC Aluminum Pulse Optimization 2
Synergic Welding
1
V
- + Adjust WFS to the desired setting.
Refer to the Application section for
the recommended settings.
+ 2
2
Based on WFS a preprogrammed
- nominal voltage is selected.
Synergic Graph 3
Adjusting voltage increases or
decreases the arc length, allowing
AC Aluminum Pulse waveforms are - + the user to fine tune arc
synergic weld modes. Based on the Min. Max. characteristics.
wire feed speedu , set by the operator, V
a p re - p ro g r a m m e d v o l t a g e i s
automatically selectedv . Fine tune Synergic Voltage Display A note on Trim.
t h e a rc l e n g t h u s i n g Vo l t a g e Lincoln Electric developed Trim as a
Above ideal Voltage
adjustmentw . (Upper bar displayed) means to simplify the complexities of Arc
Length control in advanced welding
application set-up, such as Pulse. Now,
Lincoln Electric Synergic Weld modes
At ideal Voltage improve the ease of set-up by
(No bar displayed)
preselecting an ideal voltage based on
the selected WFS. The user can then fine
tune their Voltage setting based on their
Below ideal Voltage
personal preference and can easily see
(Lower bar displayed) whether they are above or below the
nominal setting.
UltimArc Control
Standard Pulse
The UltimArc control fine tunes the
heat input into the plate. 0 -10 +10
-10
AC Aluminum Pulse Applications 3
1F / PA Lap Automatic
o o
0 - 10 Use a 0-10o push angle.
1F
Use a 35o work angle.
> 2mm
Position the electrode approximately one
FRONT SIDE electrode diameter outside the joint favoring
35
o the bottom leg.
For less than 2mm applications position
the electrode directly in the joint or slightly
< 2mm
favoring the top edge. May require decreased
SIDE SIDE work angle.
100Ar
1F / PA Lap Semi-Automatic
o o
0 - 10 Use a 0-10o push angle.
1F
Use a 35o work angle.
> 2mm
Position the electrode approximately one
FRONT SIDE electrode diameter outside the joint favoring
35
o the bottom leg.
For less than 2mm applications position
the electrode directly in the joint or slightly
< 2mm
favoring the top edge. May require decreased
SIDE SIDE work angle.
100Ar
Connection Diagram
S500
S350
AC Aluminum Pulse Set-Up 6
Sense Leads
A work sense lead (optional) is highly DO NOT connect either sense lead to a
An electrode sense lead is required. This
recommended for total welding cable
is a standard connection in an Arclink welding stud as this may result in erratic
lengths >50 ft. and should be connected
cable. arc or increased spatter.
directly to the workpiece.
For best performance, connect the work The work sense lead should be DO NOT route sense lead cable close to
sense lead close to the welding arc. separated away from welding cables to high current welding cables as this may
minimize interference. distort the sense lead signal.
Work Leads
B
C
Connect the work lead to the work stud The total length of the welding current Route cables (A,B) close together to
on the module and directly to the work loop (A+B+C) should be minimized to further reduce cable inductance.
piece. Maintain the shortest connection reduce inductance.
length possible.
For configurations with excessive Lincoln Electric coaxial cables Test cable inductance levels using the
inductance, use Lincoln Electric combine the positive and negative Power Wave Manager software
patented coaxial welding cables. welding leads into one cable to minimize exclusively from Lincoln Electric.
cable inductance.
AC Aluminum Pulse Set-Up 7
Troubleshooting
Erratic Arc ! ! -
Action
+ -
Check
V
Volts
?
Gas Coverage
Fine Spatter - ! !
Action
o
Check ?
V
Contact Tip
Volts Travel Speed
Wire Feed ? to Work
Speed Push Angle Gas Coverage Distance
Large Spatter ! ! - -
Action
+ - -
o
Check ?
Contact Tip
? Surface to Work Travel Speed
Gas Coverage Contaminates Distance Tip Push Angle
Porosity ! - ! - - -
Action
o
Check ? + Increase
V -
Wire Feed Volts
Decrease
Speed UltimArc Push Angle
Concave Bead
- ! - ! - - Inspect
& Replace
Action ! Important
AC Aluminum Pulse Set-Up 8
Troubleshooting
o
Check ? + Increase
V -
Decrease
Contact Tip
Wire Feed Volts to Work
Travel Speed
Speed UltimArc Distance Push Angle
Inspect
! ! & Replace
+ + +
- - +
Convex Bead
Action ! Important
o
Check ?
V
Wire Feed Volts
Travel Speed
Speed UltimArc Push Angle
! ! -
+ + -
Poor Penetration -
Action
o
Check ?
V
Wire Feed Volts
Travel Speed
Speed UltimArc Push Angle
- ! !
+ +
Burnthrough - -
Action
o
Check ?
V
Wire Feed Volts Travel Speed
Speed UltimArc Push Angle
! !
+
Under Cut - - - -
Action
Check
Wire Feed
Travel Speed
Speed UltimArc Weave
Gap Bridging ! !
Action
- - + +
AC Aluminum Pulse Set-Up 9
Troubleshooting
Check + Increase
-
Decrease
Wire Feed
Speed Double Back
Wire Type on Crater
Inspect
! ! & Replace
- +
Cracking
Action ! Important
Check
V
Contact Tip
Volts to Work Travel Speed Surface
Gas Flow Distance Contaminates
Soot
! - ! - -
Action
Check
t1
Wire Feed
Speed Gas Pre-flow Burnback Run-in Speed
! !
+ +
Cold Starting -
Action
Check
V
Volts Travel Speed Electrode
Weave Sense Lead
! !
+
Noodle Welding - -
Action
NOTES: Aluminum is more susceptable to some issues which can be easily fixed with the right tools.
Arc Wandering - tends to be more prevalent with 5000 series wires. This can be minimized by introducing a Spring Loaded Tip which provides a constent
contact point for the current path.
Soot - is undesirable from an appearance standpoint, but can not be completely eliminated. It is important to remember that black soot around the weld
bead is acceptable. If soot is present on the weld bead the operator should verify all set-up and procedures. Voltage and gas coverage are two main
culprints of this problem.
Erratic Arc Behavior - can be caused from various components in the weld system. It is important to clean gun liners, change contact tips, and check wire
tension. Drive rolls should not be overtightened causing the wire to deform as it exits the feeder.
Torch Calibration - Some push pull systems require the operator to verify wire feed speed calibration. Following the torch manufacturers calibration
recommendations can prevent major feeeding issues.
AC Aluminum Pulse Glossary 10
Icons
V A T Contact Tip
Material Wire Feed
to Work
Wire Type Gas Thickness Speed Travel Speed Volts Amps Trim Arc Length Control Knob
Distance
Electrode Work Heat Input Heat Input Arc Focus Arc Focus
Weld Stud Torch Sense Lead Sense Lead Work Clamp Torch Nozzle (Low) (Broad) (Narrow) UltimArc
(High)
Technical Terms
Procedure Notes
All listed procedures are starting points and may The result of welding at higher travel speeds is a At faster travel speeds, the bead-shape can
require some adjustment depending on the specific tendency to produce more spatter, less become very convex (or ropy), and the weld will not
application. penetration, more undercut, and a less desirable wet well. There is a point at which the arc is set so
bead shape. Depending on the limitations / short that the arc will become unstable and
Torch angle, electrode placement, contamination, requirements of the actual application, slower stubbing will occur. This forms a limitation of just
mill scale, joint fit up, and joint consistency are travel speeds and higher arc voltages may be how fast the travel speed can be raised.
factors that may require special consideration required.
depending on the specific application. It is ultimately the responsibility of the end user to
As the travel speed increases in fast follow ensure the proper weld deposition rate, bead
At higher travel speeds, joint fit up, wire placement, applications (1/4 to 14 Gauge), a tighter and arc profile, and structural integrity of a given weld
and contamination all become factors that are length must be maintained so that the puddle application.
more significant. properly follows the arc. Operators typically
reduce the arc length control (Trim) to achieve this.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains
the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication
methods and service requirements.
Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated
information.