Square Wave Offset Effect

W A V E F O R M C O N T R O L T E C H N O L O G Y T M

APPLICATION

Making Fillet Welds with Power Wave AC/DC 1000™ System	4/10
	4/10

Welding Guide

Offset is expressed as a percentage between -25% and +25% of the rms2 value that is kept positive or negative. In other words, -25% means the normal positive component of each cycle is held to 25% of the normal rms value and the negative component becomes 75%. In some respects, when offset is adjusted to maximum values, the arc action almost becomes analogous to that of a pulsed arc. Negative values contribute to increasing deposition to levels closely approaching the values obtainable with DC negative welding. See Figure 5.

Figure 6 shows two welds: the same 3/8” (10mm) flat position fillet as Figure 3, but this time made using a setting of 25% balance, (-)10% offset. Note that this results in an additional gain of 12% in travel speed!

This is a net gain of 29% over DC+.

The increased deposits possible using a combination of wave balance and wave offset may raise the question about root penetration. While at present the major welding codes do not allow sizing a fillet weld based on root penetration, some producers of proprietary products do. Figure 7 shows the depth of penetration as compared to DC+ for a number of settings. This shows a variation of only .05” (1.3mm) in penetration, a variation of nine to ten percent. All of the welds were made when the plate was at room temperature and at 54.25Kj heat input.

		Square Wave - Normal Curve
		Square Wave - Negative Offset
Total Amps	50% Positive
Total Amps	0	Total Amps
	0
	50% Negative
	50% Negative

1 CYCLE

1/60 SECOND

Square Wave - Current Offset

Figure 5

Comparison of offset vs normal balanced wave

DC+		SW AC with Offset
		AC 25% Balance
		AC 25% Balance
		(-)10% Offset

	Figure 6

		Square Wave	SW AC	SW AC	SW AC
Mode		Square Wave	SW AC	25% Balanced	25% Balanced
Mode	DC+	Balanced	25% Balanced	(-) 10% Offset	(-) 20% Offset

Penetration-mm	5.53	4.06	4.06	4.02	4.43

Figure 7

Penetration vs. Various Modes

All welds made using 5/32” (4mm) Diameter Electrode

525 Amperes, 31 Volts, 1.25” (31.8mm) ESO

18 ipm (457.2mm/min) Travel Speed

54.25 Kj Heat Input

T h e	f u t u r e	o f	w e l d i n g	i s	h e r e .	®

Making Fillet Welds specifications

Lincoln Electric, a global leader in the welding industry, has been at the forefront of developing innovative solutions for producing high-quality fillet welds. Fillet welds, which are commonly used to join two surfaces at an angle, are critical in various applications ranging from construction to manufacturing. Lincoln Electric’s commitment to quality and efficiency is evident in its advanced technologies, products, and dedicated approach to customer satisfaction.

One of the main features of Lincoln Electric's approach to fillet welding is its range of welding machines designed for different applications. The company offers an array of MIG, TIG, and Stick welding equipment that ensure optimal performance and versatility for any project. From portable welding machines for on-site work to industrial-grade systems for large-scale operations, Lincoln Electric provides solutions that cater to every welding requirement.

Incorporating cutting-edge technologies, Lincoln Electric emphasizes the importance of automation in improving the consistency and quality of fillet welds. Their robotic welding systems are engineered to enhance precision and reduce labor costs while maximizing productivity. These automated systems utilize advanced programming and real-time monitoring, ensuring that every weld meets industry standards.

Another critical aspect of Lincoln Electric's innovation is its emphasis on welding consumables. The company produces a variety of filler metals, including flux-cored wires and solid wires, designed specifically for fillet weld applications. These consumables are formulated to provide excellent penetration, strength, and corrosion resistance, ensuring that the final product can withstand rigorous conditions.

Moreover, Lincoln Electric places a strong focus on training and education. The company offers comprehensive welding training programs that cover all aspects of fillet welding, from fundamental techniques to advanced practices. This commitment to enhancing the skillset of welders ensures that teams can execute high-quality work effectively and efficiently.

Lincoln Electric's dedication to research and development guarantees that they remain at the forefront of welding technology. By continually exploring new materials, techniques, and processes, they guarantee that their solutions not only meet but exceed customer expectations.

In summary, Lincoln Electric excels in the production of fillet welds through advanced welding equipment, automated solutions, high-quality consumables, and robust training programs. Their unwavering commitment to innovation makes them a trusted partner in the welding industry, enabling customers to achieve superior results in their projects. Whether in construction, manufacturing, or any other sector, Lincoln Electric continues to shape the future of welding with its state-of-the-art solutions.

Making Fillet Welds with Power Wave AC/DC 1000™ System

Welding Guide