Power Sources

Power Management Technology Eliminates Problems Caused by Dirty Power

Dirty power can impact weld quality in many ways. Here is one way to help avoid the problems caused by dirty power and improve productivity, efficiency and weld quality.
Power Sources: Articles

Using Metal-Cored Wire with Pulsed MIG to Weld Galvanized Steel

The potential for burn-through and porosity that can occur due to the material’s thinness and zinc coating pose risks for quality and productivity in automotive manufacturing. Determining the internal porosity of a part is typically a two-step process: an initial X-ray of the weld, followed by image analysis using contrast analysis to quantify the amount of porosity as a percentage.
High strength galvanized steel is an excellent material to help automotive manufacturers build lighter-weight vehicles, but it can present some challenges that make it difficult to weld.

Industry Standards Are Evolving Faster Than Ever

Fuel economy mandates are dictating significant design changes to new vehicles and trailers. To comply with these changes, shops must learn new techniques while training technicians to weld aluminum in addition to steel. To reduce the already expensive overhead costs auto body and repair facilities endure, it is critical that the welding machine provides versatility and timesaving features.
For auto body shops or tractor repair facilities to effectively keep up with the new demands being driven by fuel economy mandates and remain profitable, they must invest in easy to use equipment that is capable of welding both steel and aluminum.

Blueprint for the Future

Pulsed MIG welding is effective in welding higher-strength steels and galvanized steels. Synergic pulsed MIG welding systems that communicate completely between the power source, feeder and gun are popular in welding materials such as aluminum. With a standard Pulsed MIG system that is not synergic, a welding operator must manually change other settings when changing the wire feed speed. With a synergic system, changes in wire feed speed automatically adjust other settings for a constant welding arc, greater control and better weld quality. 
Fabricators must continually explore new technologies that will grow along with their operations to help them stay competitive, profitable, productive, and ahead of the curve so they are prepared for the demands of the future. 

How Multiprocess Welders Address Heavy Fabrication Challenges

For operations that have a need for multiple welding processes such as TIG, MIG and Stick in various applications, multiprocess machines offer versatility and can have significant benefits for quality, productivity and efficiency in industries that include construction, shipbuilding and heavy fabrication.
The combination of new engineering with improved and reliable current technology for single source TIG, MIG and/or Stick welding and carbon arc gouging can really increase the operating profitability of jobsites and fabrication shops.

The Pride of the Pipeline

Manual welding with a PipeWorx 400 multiprocess power source that does RMD and Pulsed MIG welding. Changeover is quick because there is no need to manually switch polarity or cables and hoses between processes. Welders can also trigger through pre-set programs while at the welding joint to eliminate walking back and resetting the machine.
By changing welding processes, this oil and gas production equipment manufacturer cut more than 200 man-hours out of each product to thrive during the shale gas boom.


Power Sources: Industry News

Miller Announces Sweepstakes

The grand prize in the "New Year – New Build" Sweepstakes includes a Millermatic 211 MIG welder (left) and Spectrum 375 X-TREME plasma cutter (right) with an XT30 torch and storage case.
Their "New Year – New Build" Sweepstakes will award new welding equipment and gear to 23 winners over a 90-day period.


Power Sources: Products

Take Welding to the Next Level

The Continuum 350 features two new welding processes. Versa-Pulse is a fast, low-heat and low-spatter process that delivers faster travel speeds for semi-automatic and automated welding applications, also resulting in increased productivity. This process is ideal for welding on thin materials (up to 1/4 in), such as sheet metal and tube applications, and offers a greater wire feed speed range than short circuit or Regulated Metal Deposition processes. A High-Deposition MIG process offers higher deposition rates and lower heat input than standard spray transfer, resulting in faster welding, increased productivity and better quality. The process works well for welding thicker materials and on larger welds (6 mm to 8 mm).
The Continuum 350 from Miller Electric provides a competitive edge through exceptional arc performance, unique processes and programs, and standard weld data gathering.

Welder/Generator for Critical Repair and Maintenance Applications

The 600 amp Big Blue 600 Air Pak features a powerful EPA Tier 4 Final–compliant Deutz engine rated at 65.7 hp and an Ingersoll Rand screw-type air compressor that is ideal for gouging. It can operate a full range of pneumatic tools, supplying up to 60 cfm of air at 100 psi with a 100 percent duty cycle. It also features improved arc characteristics, digital weld meters and display, and three-phase power available anytime — even while welding.
The 4 in electronic engine display allows users to precisely monitor fuel level, engine hours, coolant temperature, oil pressure, battery voltage, air pressure, and engine rpm — all in one convenient location. The display also tracks oil change intervals and displays engine diagnostics for quick and easy servicing.
The single-operator Big Blue 600 Air Pak from Miller Electric is ideal for welding, carbon arc gouging, auxiliary power, or running an air compressor in rail, mining, construction and fabrication work.

Automated Welding Redefined

The new TPS/i Robotics welding power source from Fronius is specially tailored to the demands of robot-aided welding. Its integrated and fully synchronized system components enable robots to weld faster than ever before, with a higher degree of repeatability, enhanced weld seam quality and minimal spatter. (view one)
The new TPS/i Robotics welding power source from Fronius is specially tailored to the demands of robot-aided welding, with integrated and fully synchronized system components that enable robots to weld faster with a higher degree of repeatability.