What is a Pulse MIG? A how & why guide to Pulse MIG welding
What is Pulse MIG Welding?
Pulse MIG offers fast, high quality, low spatter and consistently great looking welds, with better thermal control vs. conventional MIG welders.
Pulse MIG is best known as a great process for welding aluminum, however it is also an excellent process for welding with stainless-steel and bronze wires. In many cases, Pulse MIG can achieve results that are comparable to TIG welding, but with speed and productivity that is superior to TIG.
In technical terms, Pulse MIG is a highly-controlled spray-transfer MIG process. Unlike the traditional 'short-circuit' MIG process, the filler metal is transferred from the wire to the weld pool, without the wire contacting the weld pool. The current alternates, or pulses, between a high peak current and a low background current at a frequency of up to several hundred times per second. With each pulse, the peak current pinches off a droplet of wire and propels it to the weld joint, while the background current maintains the arc at a low enough power level so that a short circuit cannot occur.
Why use PulseMIG?
Among other benefits, Pulse MIG is best known (or desired) because it offers;
Lower heat = minimal distortion, reduced burn-through
Reduced spatter: Spatter is significantly reduced, or even eliminated = Minimal cleanup
Visually appealing welds = Added value to the finished product
Higher deposition rates = Increased efficiency & faster travel speeds
Tighter weld pool control = Ideal for out-of-position welding
Reduced welding fumes = Safer & cleaner work environment
What metals can you weld with Pulse MIG?
Pulse MIG is ideal for metals and applications where controlling heat is difficult when using a standard MIG process, and/or where high weld quality and appearance is desired.
Pulse MIG welding Aluminum
Aluminum is a high thermal conductor (which means that heat is quickly transferred away from the weld pool), with a relatively low melting temperature. Pulse MIG process allows the operator much greater thermal control to apply enough heat for a successful weld, whilst avoiding distortion or burn-through.
Pulse MIG welding with Bronze wires (MIG brazing)
Bronze wires are typically applied at a temperate that is lower than the melting point of the parent material - where the materials are essentially "stuck" rather than welded together - and are commonly used on thin materials (eg car body panels) where low temperature welding is essential to avoid distortion. Also commonly used on galvanised or zinc-coated steels (up to 2 mm thickness) because the weld metal does not rust and the lower application temperature prevents disturbance (evaporation) of the zinc coating. The ability to control and reduce heat makes pulse an ideal process for brazing wires.
Pulse MIG welding with Stainless Steel
Because stainless-steel is a poor thermal conductor, heat is typically 'trapped' close to the weld zone. This can result in expansion/distortion and rust contamination due to concentrated carbon in the weld zone. The weld pool is comparitively sluggish with poor wetting/flow into parent metal. The pulse process allows stainless wires to be applied at lower temperatures to minimize distortion and imperfections. Pulse MIG is especially beneficial for welding thin stainless material where it is often extremely difficult, if not impossible, to avoid warpage/distortion with conventional MIG process.
In all these applications, Pulse allows successful welding at lower temperatures with much better control of the weld pool.
Pulse MIG welding mild steel
Mild-steel does not present the same "thermal challenges" as other metals like aluminum or stainless, and therefore pulse does not necessarily offer the same advantages. For this reason, conventional MIG (rather than pulse MIG) is still the best process for welding mild steel in many applications - especially in the material thickness range that is achievable with single-phase machines.
Pulse MIG can offer some productivity advantages for welding heavy steel, however this requires a high "peak" current which is available only from three-phase pulse machines.
For this reason single-phase pulse machines like the Weldclass Ultra 220MP don't offer a pulse mode for mild steel - although the 220MP does offer excellent results when welding mild steel in non-pulse modes, including welding of thin materials down to 0.5mm , thanks to the ATC (Advanced Thermal Control) technology.
What is Double-Pulse MIG?
Also known as dual-pulse or pulse-on-pulse (PoP), this adds an additional pulse 'wave', where the current alternates (or cycles) between the main current level and a secondary current level. This effectively multiplies the benefits of single-pulse, with even better thermal control, weld quality and appearance.
Pulse MIG vs TIG Welding
TIG is traditionally the go-to process there is a need to weld materials to a higher standard (quality and/or appearance) than conventional MIG. Aluminum and stainless-steel are commonly welded with TIG, as these materials are often used on projects where the finish of the final product is critical - for example; boats & marine, architectural fixtures, food handling equipment, etc.
The disadvantage of TIG is that it is a comparatively slow & inefficient process, which increases cost and processing time.
Enter Pulse MIG! Essentially, Pulse MIG offers;
Weld quality and finish comparable or very close to TIG in many applications
Superior speed and efficiency vs TIG
Compared to TIG, it typically requires less skill and is easier to learn, which reduces training time
While the TIG process will always have its place, Pulse MIG is certainly replacing TIG as the logical choice for many applications, especially production work.
Pulse MIG Weld Cycle, Settings & Adjustments
If you're new to Pulse MIG, one of your questions is likely going to be; What are the different parameters and adjustments involved with MIG pulse welding?
What is a Pulse MIG? A how & why guide to Pulse MIG welding
What is Pulse MIG Welding?
Pulse MIG offers fast, high quality, low spatter and consistently great looking welds, with better thermal control vs. conventional MIG welders.
Pulse MIG is best known as a great process for welding aluminum, however it is also an excellent process for welding with stainless-steel and bronze wires. In many cases, Pulse MIG can achieve results that are comparable to TIG welding, but with speed and productivity that is superior to TIG.
In technical terms, Pulse MIG is a highly-controlled spray-transfer MIG process. Unlike the traditional 'short-circuit' MIG process, the filler metal is transferred from the wire to the weld pool, without the wire contacting the weld pool. The current alternates, or pulses, between a high peak current and a low background current at a frequency of up to several hundred times per second. With each pulse, the peak current pinches off a droplet of wire and propels it to the weld joint, while the background current maintains the arc at a low enough power level so that a short circuit cannot occur.
Why use PulseMIG?
Among other benefits, Pulse MIG is best known (or desired) because it offers;
Lower heat = minimal distortion, reduced burn-through
Reduced spatter: Spatter is significantly reduced, or even eliminated = Minimal cleanup
Visually appealing welds = Added value to the finished product
Higher deposition rates = Increased efficiency & faster travel speeds
Tighter weld pool control = Ideal for out-of-position welding
Reduced welding fumes = Safer & cleaner work environment
What metals can you weld with Pulse MIG?
Pulse MIG is ideal for metals and applications where controlling heat is difficult when using a standard MIG process, and/or where high weld quality and appearance is desired.
Pulse MIG welding Aluminum
Aluminum is a high thermal conductor (which means that heat is quickly transferred away from the weld pool), with a relatively low melting temperature. Pulse MIG process allows the operator much greater thermal control to apply enough heat for a successful weld, whilst avoiding distortion or burn-through.
Pulse MIG welding with Bronze wires (MIG brazing)
Bronze wires are typically applied at a temperate that is lower than the melting point of the parent material - where the materials are essentially "stuck" rather than welded together - and are commonly used on thin materials (eg car body panels) where low temperature welding is essential to avoid distortion. Also commonly used on galvanised or zinc-coated steels (up to 2 mm thickness) because the weld metal does not rust and the lower application temperature prevents disturbance (evaporation) of the zinc coating. The ability to control and reduce heat makes pulse an ideal process for brazing wires.
Pulse MIG welding with Stainless Steel
Because stainless-steel is a poor thermal conductor, heat is typically 'trapped' close to the weld zone. This can result in expansion/distortion and rust contamination due to concentrated carbon in the weld zone. The weld pool is comparitively sluggish with poor wetting/flow into parent metal. The pulse process allows stainless wires to be applied at lower temperatures to minimize distortion and imperfections. Pulse MIG is especially beneficial for welding thin stainless material where it is often extremely difficult, if not impossible, to avoid warpage/distortion with conventional MIG process.
In all these applications, Pulse allows successful welding at lower temperatures with much better control of the weld pool.
Pulse MIG welding mild steel
Mild-steel does not present the same "thermal challenges" as other metals like aluminum or stainless, and therefore pulse does not necessarily offer the same advantages. For this reason, conventional MIG (rather than pulse MIG) is still the best process for welding mild steel in many applications - especially in the material thickness range that is achievable with single-phase machines.
Pulse MIG can offer some productivity advantages for welding heavy steel, however this requires a high "peak" current which is available only from three-phase pulse machines.
For this reason single-phase pulse machines like the Weldclass Ultra 220MP don't offer a pulse mode for mild steel - although the 220MP does offer excellent results when welding mild steel in non-pulse modes, including welding of thin materials down to 0.5mm , thanks to the ATC (Advanced Thermal Control) technology.
What is Double-Pulse MIG?
Also known as dual-pulse or pulse-on-pulse (PoP), this adds an additional pulse 'wave', where the current alternates (or cycles) between the main current level and a secondary current level. This effectively multiplies the benefits of single-pulse, with even better thermal control, weld quality and appearance.
Pulse MIG vs TIG Welding
TIG is traditionally the go-to process there is a need to weld materials to a higher standard (quality and/or appearance) than conventional MIG. Aluminum and stainless-steel are commonly welded with TIG, as these materials are often used on projects where the finish of the final product is critical - for example; boats & marine, architectural fixtures, food handling equipment, etc.
The disadvantage of TIG is that it is a comparatively slow & inefficient process, which increases cost and processing time.
Enter Pulse MIG! Essentially, Pulse MIG offers;
Weld quality and finish comparable or very close to TIG in many applications
Superior speed and efficiency vs TIG
Compared to TIG, it typically requires less skill and is easier to learn, which reduces training time
While the TIG process will always have its place, Pulse MIG is certainly replacing TIG as the logical choice for many applications, especially production work.
Pulse MIG Weld Cycle, Settings & Adjustments
If you're new to Pulse MIG, one of your questions is likely going to be; What are the different parameters and adjustments involved with MIG pulse welding?
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