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

 

DC welding has almost always been the preferred choice for producing submerged arc welds. Some of these reasons are:

1.Lowest capital cost for equipment.

2.Greater arc stability than with AC.

3.Virtual elimination of arc striking problems.

4.Power issues (single phase vs. three phase balanced power)

While DC negative may offer the highest deposit rate per ampere, it is seldom used for automatic welding that must meet stringent code requirements. This is because DC negative is more prone to magnetic arc interference (arc blow), porosity resulting from

contaminants, organic and/or inorganic contaminants in or on the steel and greater potential for slag entrapment because of the larger and “colder” weld puddle. DC negative has always been the method of choice for welding off-analysis steel or dirty steel where it is desirable to have minimum dilution. But with Power Wave AC/DC 1000™ technology, this is no longer the best option. The Power Wave AC/DC 1000™ provides the capability of easily using the best welding mode for the job at hand.

Understanding Power Wave AC/DC 1000

To fully understand the potential for possible productivity gains using the Power Wave AC/DC 1000™ system, understanding the major AC components and what they contribute is helpful. The major components consist of:

1.Square wave (vs. a conventional sine wave)

2.Square wave balance

3.Square wave offset

4.Square wave frequency

Figure 1 shows photographs of two 5/16” (8mm) horizontal fillet welds1. One is made using a good DC+ procedure and one using a square wave 25% balanced, (-)10% offset and 30 Hz. Both are excellent fillets but the square wave procedure is forty percent faster! Note that the amperage used is virtually the same, 520 vs. 527 amperes.

DC+

 

 

AC/DC

527 Amps

 

 

520 Amps

 

 

 

 

 

 

 

 

 

Figure 1

 

 

 

 

40% faster travel speeds by using Power Wave AC/DC 1000™ Square Wave procedures over DC+ procedures.

1These welds comply with the geometry requirements for leg and throat dimensions of all AWS codes.

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Lincoln Electric Making Fillet Welds manual Understanding Power Wave AC/DC

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.