Pulsed Mig Questions.

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I've been researching pulsed mig online and I still can't get a full grip on what it's purpose is.I've read some conflicting things about it.  What Ive gleaned, pretty much, is its almost a totally different process than regular mig.  Droplet transfer occurs at a more defined and synchronous rate.  You get good heat at the weld, but less total into part.  The puddle freezes faster.  You can weld thin materials with thicker wire but still weld thicker stuff without changing the spool.I bought an Optima controller cause the price was too good to pass up, but now I'm looking for a real world reason to use it.  Picking up a new tank of 95/5 today, so now I can spray and use the programs in the controller.It also seems, by reading the Miller manual, that the WFS becomes the only control needed when the optima is on and in adaptive mode.  It seems that turning the WFS up and down adjusts the voltage and pulse parameters automatically.  So you crank it up on thick stuff and turn it down on thin.So anyway, with my setup you see listed below, what would you be using pulse mig for?  When would it be advantageous over regular SC and spray mig?Thanks for the help.  I'm just not fully grasping this.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Pulse mig is supposed to be great for mig welding aluminum.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I think the advantage is you can pile more metal in without getting lack of fusion. I've only tried it once for a short time, but it was kinda nasty, just really loud and spattery, maybe they had it set wrong.There's a new process called RMD that really works nice.
Reply:Hello Drf255, 2 quick items: first, you can run a higher heat input average, faster travel speeds, smaller heat-affected zones, and with less loss of control of the weld pool as the high amp/low amp pulsing allows for just enough of a reduction in heat to not cause the puddle to drip-out or take an unwanted profile(mainly beneficial for out-of-position type work), secondly, pulsing provides agitation of the puddle for use on "sluggish" weld metals and helps with control of the puddle and improves undercut issues a lot of the time. I don't have the time to compose this better right now, will try to get back to it and likely others will have chimed in by then. Best regards, Allanaevald
Reply:I use the pulse on steel thinner than 16ga.   Find it works better than no pulse.Been known to use it on poor fit ups also.From the desk of Kevin CaronTrying to be the best me I can!www.kevincaron.comAHP Alpha Tig 200x MillerMatic 251Miller Syncrowave 200
Reply:Hello again Drf255, had a little bit more time, so here goes with a bit more about pulse. The Optima system you have is a very simple pulse system by many of todays more advanced offerings. You can utilize it for pulsing with either a "standard" feeder or a spoolgun, such as when you are working with aluminum. Your mention of being able to increase the wire speed and having other parameters change along with it is often referred to as being "Synergic", in the case of the Optima, this feature is described as "adaptive". When you are using it for steel/stainless steel at higher settings(spray) you will likely see better puddle control and even wetting out of the puddle along it's toes and if you are simply pushing or dragging you should definitely notice less undercut issues and likely a more even bead profile. If you are working with thinner materials and as some have already mentioned, uneven fit-ups and gaps, lowering the voltage and pulsing will provide better control with pulse than with standard CV. For welding aluminum many of the same characteristics apply to bead and profile and additionally pulsing often contributes to better cleaning action of the arc due to the hi/lo current and it's bombardment/agitation of the surface oxides. Beyond the Optima control that you have most all of the commonly known welding machine producers have stepped-up and evolved systems that produce what are commonly referred to as "advanced process technology". This sort of stuff is generally very propietary and thus it is dificult to specifically describe or know how it exactly works. Miller has the "Invision" systems, "Pipe Pro", "RMD"(regulated metal deposition), and "Axcess" I believe. Lincoln has "STT"(surface tension transfer), I am not aware of others of theirs although there certainly could be. Fronius has CMT(cold metal transfer) and certainly others and is said to be the leader in pulsing technology by many. That I am aware of ESAB has pulsing but I don't know any of the acronyms associated with their systems. OTC also has some very advanced systems, I believe they even have a wire process for welding aluminum that incorporates AC current, likely the only one of this type currently. I know there are other European systems but I am not familiar with them. Just a bit on these systems: many of them are able to adjust hi and low current, percentage of time on each type of current, ramp-up and ramp-down of the current changes on both the hi and low currents. Additionally, they often have the ability to advance, stop, and retract wire feeding as a part of the welding process. The wire feeding control provides for almost zero spatter as the wire is retracted before it can "explode" when the current goes from hi to lo. In a conventional feeder that is pulsing the wire speed remains constant and you have to have enough wire to accomodate the hi current but when it goes to the low current the puddle is "over-fed" for lack of a better explanation and this is when spatter is generally produced. There is so much more, but I am not technically educated enough to explain all of it. Anyhow, that's my $.02 for now. Best regards, Allanaevald
Reply:Pulse allows for out-of-position aluminum MIG.With the 350P, I can pretty much dial it in by adjusting the speed (machine does the rest).  The 'arc/cone' is also smaller than when doing full blown spray transfer.On steel, I prefer short arc.  I like seeing the wire hit the puddle.  I have experimented with pulse.  With Miller's settings, on thin material, the wire speed is slower than with short arc.  On thicker material, the wire speed is higher.  So with a single .035 wire, I think I can cover from sheet metal to 1/2".  In reality I never weld on 1/2" and I TIG the thin stuff.To me it sounds like angry bees.  Low spatter.  I use a 1/4" recessed tip for pulse.  As for fine tuning Miller's settings, I typically shorten the arc length (about 70% of recommended).  I also like the arc a bit more focused.   Again, I like short arc more.  To me, with spray it can be difficult to tell where I'm piling up the metal.If you are going to build an aluminum boat and/or trailer, invest in pulse MIG.  If not, save your money.Con Fuse!Miller Dynasty 350Millermatic 350P-Spoolmatic 30AMiller Multimatic 200Hypertherm PowerMax 1000G3Miller Maxstar 200DX
Reply:While it is nice that pulse MIG sets everything for you when you adjust the wire speed, it is really helpful to know and use the other settings.I set the arc length just long enough to avoid spatter. This may be higher or lower than the default setting depending on which wire and shielding gas you are using.Additionally, most pulse MIG machines have "arc control" or some such, which is roughly like inductance or pinch in short-arc MIG. Turning it up gives you a tighter, more forceful arc, good for vertical or overhead welds. Turning it down makes a softer, wetter bead.The default settings are generally pretty close in most cases, but when bead appearance is important or you have a difficult or "abnormal" weld, tweaking the settings can make a real difference. I can't make any suggestions in terms of numbers since I have a Lincoln, not a Miller, but the principles still apply.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:I use pulse mig for aluminium, brass and steel to brass. Works perfect for alu, even with higher currents over 200 amps (we have cebora mig welder where you set one parameter- amps or mat. thickness or wire speed, everything else is automatic). I was trying pulse settings with 82/18 mix on steel, works ok, but normal short-circuit or spray mig is simply better (just avoid globular transfer area). IMO pulse mig is usefull sometimes, but not realy worth the extra money unless you're working with thinner alu.
Reply:82/18 is on the edge of usability for spray or pulsed-spray. Try a mixture with 5 to 10% CO2 and you will get much better results with steel.JohnA few weldersA lot of hammersA whole lot of C-clamps