Lincoln Electric Making Fillet Welds manual Converting to a Power Wave Procedure

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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

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Welding Guide

 

CONVERTING TO A POWER WAVE PROCEDURE

An easy approach to making a conversion to a Power Wave AC/DC 1000™ procedure is to use this table as a general guide and follow these steps:

1.Start with the existing variable voltage DC positive procedure as the reference procedure.

2.Move to AC balanced square wave mode and use the reference travel speed and voltage.

3.Adjust frequency from 30 to 90 Hz. (stop if the current value begins to drop).

4.Shift the AC balance to 25%,

a.Increase voltage 2-3 volts,

b.Increase travel speed 1.2 times reference value.

5.Add 5 to 10% negative (minus) offset,

a.Increase voltage an additional 1-2 volts,

b.Raise travel speed to 1.3 times reference speed.

This will yield a good starting point for converting a DC+ fillet welding procedure. Fine tuning these steps will yield the maximum increase with equal or improved weld appearance.

% Positive

% Offset

Deposition

Arc Volt

Rate

Change

 

 

 

 

 

 

100 DC+

NA

1.0

Reference

 

 

 

 

50

0

1.11

+0

 

 

 

 

25

0

1.20

+3

 

 

 

 

25

-10

1.30

+4

 

 

 

 

0 DC-

NA

1.35

+3

 

 

 

 

Easy Welding Procedure Setup

The Power Wave AC/DC 1000™ system is the easiest system ever produced when it comes to changing from one welding procedure to another.

•No need to move (change) welding cables even when changing polarity or changing from constant current to constant voltage.

•No need to internally reconnect power carrying taps or bus bars, hence, in many instances no need for a maintenance electrician.

•Control all output functions on the control panel.

•Fully supported by Lincoln’s Power Wave Submerged Arc Utilities software where demanding applications require activity reporting or even remote procedure verification (see Nextweld NX3.20 brochure).The heart of the system is the Power Wave AC/DC 1000™ featuring:

•Balanced input line-draw even when welding with AC.

•High 86% electrical efficiency contributes to keeping energy charges low.

•95% power factor assures minimizing excess ampere draw from the supply lines.

•Continuous output rating 1000 amperes assures the system is ready-to-go full time.

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f u t u r e

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Contents Application Understanding Power Wave AC/DC Square Wave Balance Square Wave vs. Sine Wave10% Offset Square Wave Offset EffectSquare Wave Frequency Deposition Rates vs. Frequency Penetration vs. FrequencyPower Wave AC/DC 1000 Deposition Rate Some Fillet Weld Results` Easy Welding Procedure Setup Converting to a Power Wave ProcedurePower Wave AC/DC 1000 System Cost Recapture Analysis

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.
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