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LSC - Is based on the dip transfer method utilising short circuits.
/ On equal parameters welding parts, wire and gases it can be expected that the reduction for LSC spatter quantity when compared to standard will be in the region of 75% less, therefore this has positive implications for wire wastage and cleaning/dressing of welds and HAZ.
Other prerequisites of LSC are that it lends itself particularly well to vertical up fillets with penetration stabilisation and for a given equal comparison (conventional MAG and FCAW) will require less shielding gas (up to 50%) and input approximately 10-15% less kj/mm.
LSC root - Fundamentally is easy to control gives excellent root reinforcement through high arc pressure, all with minimal spatter.
/ Benefits include utilising the (CMT) short circuit dip transfer technology to boost the current to form a controlled droplet - the wire movement places the droplet down in to the weld pool at which point the current is reduced to a minimal amount to reduce spatter and inconsistent arc behavior. Whilst in contact the current enters a boost phase and pinches off the droplet already formed then reducing to a minimal current again. At this point the root gap is bridged but because of the low current this has the added benefit of avoiding burn through. Immediately, the a peak is instigated in the current which with the increase in arc pressure ’pushes’ the still molten root puddle through to form the excellent root penetration reinforcement. The dynamic of the amount of reinforcement can be positively or negatively adjusted by the welding operative (-10 +10).
PMC - Adds dedicated short circuits to increase travel speed, penetration and arc stability.
Consistent penetration can be set and adjusted via the ‘Penetration Stabilisation’ parameter which leads to a constant current behavior. Benefits are in tight or hard to reach areas the wire ’stickout’ may change when the contact tube (shroud) is moved further away (or towards) the welding job, this would lead to current change for the given parameter.
Therefore, because the software (Fronius Speed Net 100mb/sec) is constantly monitoring the arc state when a distance change occurs (moving torch away or closer) while welding whether manual or via automation the dynamics of the ‘wire feed speed’ are instantly adjusted to keep the arc length constant regardless. This in turn maintains high arc stability for constant high welding performance.
Within PMC an additional parameter correction ’Pulse Correction’ can be utilised. While in the pulse welding phase the energy of the pulse droplet can be regulated (-10 +10), this will have a direct influence on the droplet ’pinch affect’ and frequency Hz of pulses.
SyncroPulse - Overlays two pulse parameters (high and low) to give maximum control of heat input coupled with excellent aesthetics of the finished weld seam.
Maximum control of the welding parameter is achieved because of operator control over;
/ Duty cycle between high and low pulsing phases (10-90%)
/ Frequency between pulses per second (0.5-3.0Hz)
/ Deviation of the wire dynamics (0.1-6.0m/min)
/ Independent Arc length corrections in high and low (-10 +10)
PCS - Utilises a concentrated short arc with increased pressure and combines spray supported with pulse arc.
Benefits are a constantly stable arc with high pressure, therefore leading to consistent deep penetration in situations where conventional could fail to get to full root edge depth.
Weld start will blend from pulsed arc into spray on up-slope and weld end will blend from spray to down slope back into pulsed arc giving excellent characteristics.
CMT - Utilises the short arc dip transfer weld and incorporates additional dynamics into the wire feed to enable very minimal current and heat transfer of molten wire.
/ The principle of the CMT process is to use the short arc with absolutely minimal current, therefore this leads to very low energy input to the weld which has the added benefit of spatter free welds and also enables material thickness from 0.30 to be welded and brazed. The CMT process uses mechanical hardware which in addition to conventional feed wire forward motion has an additional AC wire drive motor (located at the torch end) which cycles through a forward and reversing motion of the wire, the frequency of which can be up to 130Hz.
The forward motion delivers and ’places’ (whilst in dip transfer) the molten droplet after a boost current has formed the pinch effect into the weld pool, at this point the current is reduced to a minimal amount - at the same time the wire is started on its reversal half cycle leaving the droplet behind through a combination of surface tension and less resistance to the wire end. The volume of the droplet and pinch effect shape will be dictated by the Fronius algorithms which are specifically and individually designed for many various materials. As the wire starts it reversal half cycle again the currents enter another boost phase to start the process all over. The CMT process has revolutionised welding process abilities and compatibilities of materials in that it has made it possible to weld galvanised steel to aluminium which previously would have been thought of as impossible by the MIG MAG process.