Pulsed Mig

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Hi, Everyone,                   Been reading a little about pulsed mig or even pulse on pulse mig, Are they really an improvement over standard mig or just a way of selling you a new "later" welding set. Would like to hear your veiws on both steel and aluminium welding using these machines,  Best regards and many thanks  Gordon.Oop's just realised this has probably been asked be fore,  Sorry  Gordon.Last edited by gordon stephenson; 10-21-2008 at 10:05 AM.
Reply:I use it and love it.  Pulsed mig has the properties of Mig and Tig.  The puddle is fluid and has the control of mig.  On aluminum, its the balls too.Do a search on pulsed spray and you will find examples of steel and aluminum.NO its not a new gimmick, its a process of its own.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Its great for controlling distortion on thinner materials and materials that are sensitive to heat input (stainless, nickels, etc), and the end result is often of much higher quality than short arc.For a home user, I think its completely pointless to have.  But if I were doing high production aluminum work, especially where appearance is paramount, I would get one in a heartbeat.  When set up properly, the bead appearance on with pulsed MIG on aluminum is the cats ***, and is easy as pie to run.  I'm surprised more automotive companies don't use it for things like catch cans, fuel cells, etc that are produced in mass runs.  The time savings over TIG is phenomenal.
Reply:Cheers David, Thanks for your info, Been using my Kemppi Miniarc 180 lately and it is great, Very light,quite powerful and in auto mode only one knob to twiddle, I don't know why but it always gets a lot of small balls of spatter up inside the nozzle and even has arcing marks between the shroud and the brass conector that the tip screws into, the insulator inside the shroud is new, I would only expect this to happen if the nozzle was touching the work while welding.Any idea's.  Thanks again david,       best regards  Gordon.
Reply:Pulsed spray transfer MIG provides better penetration/fusion, improved bead smoothness/appearance, and reduced spatter as compared to short arc, and it allows spray transfer at much lower heat inputs than traditional spray, thus allowing it to operate in all positions.
Reply:Hello All. Am I correct in thinking I would need quite a high power machine to get into the pulsed spray mode, My Garage/workshop ony has a 240V single phase supply at about 35amps, Regards  Gordon.
Reply:Originally Posted by gordon stephensonCheers David, Thanks for your info, Been using my Kemppi Miniarc 180 lately and it is great, Very light,quite powerful and in auto mode only one knob to twiddle, I don't know why but it always gets a lot of small balls of spatter up inside the nozzle and even has arcing marks between the shroud and the brass conector that the tip screws into, the insulator inside the shroud is new, I would only expect this to happen if the nozzle was touching the work while welding.Any idea's.  Thanks again david,       best regards  Gordon.
Reply:We will be doing some pulsed spray tomorrow.  Today my son welded some 1/2" or 5/8 plate fillets.  We had it on 500 ipm  with .035 and 92% argon/8% Co2.  It was too hot, I turned it down to 425.  About 160 AVERAGE amps and 28.5 volts.The amperage switches between about 25 and 400.  It sounds like a bee.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Here is an attempt at a video my son and I tried.  Its good for the sound....[ame]http://www.youtube.com/watch?v=R7V5OCnL48o[/ame]Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Dave beat me to it, this is another attempt albeit not as nice as Dave's. This was taken last Thursday at about 11pm. I am welding on the hull of a ferry made from aluminum.This is pulsed spray, don't know if ya can really hear it, the trailblazer kinda drowns out the sound. but this is this first video I had put on youtube or even the internet so I wanna try to post it Nice vid Dave, I cant get it to turn out right when I try to tape from inside a helmet.BTW, I am fat bastard but that is a life preserver I am wearing, I'm not that tubby      Yup
Reply:NICE WORK David and BurnitIm waiting for my camera to charge so I can post a pic from an atempt  spray vert up from this weekend. weld it like you own it
Reply:Hello farmersamm, Everyone,                                         The spatter balls I mentioned earlier are strange, not like normal spatter that would be adhered to the nozzle etc, But the metal balls look as if they have almost been attracted by magnetism and are not bonded  to the nozzle or tip, Will use spatter spray or dip more often.Thank you  Gordon.
Reply:Heres some spray vert up on 3/8" plates    Gap  1/4"        butt joint w/ 45 degree bevel and 1/4 back plate.Not quite there yet but getting close.  No pulse    Im trying to get the toes just right with the last pass, the face, needs to be a bit smoothertoo.I wanna go to Davids and use the pulse.     Cert says I cant use it though.  Last edited by lewray; 10-22-2008 at 08:27 PM. weld it like you own it
Reply:Making my final 3G pass with mig, I turned the machine down.  Ya can't do that with spray.  Ta hell with the rest of em, I give you an A+ for doing that, I never even attempted it with spray.David Anyone is welcome to come and play with my stuff.Last edited by David R; 10-23-2008 at 06:48 AM.Real world weldin.  When I grow up I want to be a tig weldor.