Traditional vs Pulse Synergic MIG Welding

By Ralph Large

Traditional vs Pulse Synergic MIG Welding

So ubiquitous is welding that people rarely stop to consider how influential it’s been in builds ranging from the tallest skyscraper to the smallest circuit boards. Put in the most simplistic terms, welding is the process of using heat and/or pressure to securely join two pieces of metal. So far so simple, but there are numerous types of welding that each have their own strengths and weaknesses depending on the job at hand. Here, we’ll shine a light on Pulsed Synergic MIG (Metal, Inert Gas) welding and outline the benefits and advantages of using this method over other more traditional forms.

How does traditional welding differ from Pulse Synergic MIG Welding?

Think of the difference between traditional Arc welding and Pulse Synergic MIG welding as a timeline of innovation that goes something like this.

1.      Arc Welding

Arc welding is first on the timeline of modern welding (we won’t go as far back as the Ancient Egyptians, no one needs that!). First used following the discovery of the electrical arc in 1800, it’s one of the oldest and most traditional forms of welding. It doesn’t require many different materials and the tools used are relatively simple. It can also be very efficient when used correctly but is a highly skilled type of welding that takes years to master in order to ensure consistent, sturdy welds. It’s better suited to bigger builds and thicker materials.

2.      MIG/MAG Welding

MIG (Metal, Inert Gas) and MAG (Metal Active Gas) comes later down the line and was first commercially available in 1948. This type of welding allowed for fast welding of non-ferrous materials but did require a relatively large spend on gas. It uses an arc between an electrode wire and a weld pool.

3.      Pulsed Welding

Pulsed welding wasn’t commercially available until the 1980s so is relatively new to the market. It’s most commonly used to lower the average current and achieve effective spray transfer. As the name suggests, the current used is pulsed which allows for maximum efficiency. It’s a huge upgrade on the most traditional forms of welding but does require specialised knowledge to execute well. The effectiveness of the machine is largely defined by operator knowledge and skill as it’s down to them to set the machine parameters correctly. Pulsed MIG is at its most effective in a production environment.

4.      Pulsed Synergic MIG Welding

Last but by no means least comes Pulsed Synergic MIG welding. In this welding method, as above, specific pulses are used for optimum efficiency for certain materials and wire diameters but there’s a major difference – the machine is largely automated which means it’s suitable for use with a far wider section of welders.

Three essential characteristics of a synergic operation:

  1. Pulse parameters are automatically selected
  2. Pulse frequency is determined dependent on wire feed rate
  3. Electronic control allows for ease of use and a professional finish

This means that the user need only enter the simplest of details to find the correct pulse efficacy.

What are the key advantages of using Pulsed Synergic MIG welding vs more traditional arc welding?

As the most modern and innovative form of welding available on today’s market, it follows that Pulsed Synergic MIG welding is packed with advantages and upgrades. Here are a few of the most notable:

●        Greater productivity

These newer machines are easier to use than the more traditional forms of welding, this means less training for welders and more time on the job. It also offers higher deposition rates for a better finish.

 ●        Savings on consumables

These machines offer a wider operating range and can extend the range of each wire meaning users who would ordinarily need to stock up on a wide range of wire diameters for different applications can simply use one wire for each. This results in savings for higher volume purchases.

 ●        Great weld quality

Pulsed Synergic MIG welding leads to a more stable arc and welding with no spatter. Not only does this make for a better finish and a great quality weld but can also reduce clean up and grinding time.

●        Energy saving

The new technology  allows for less heat input. It’s also highly efficient and has a range of sleep and hibernation functions which will provide energy when needed but look to conserve it when it’s not. Not only is this a positive step for the planet but it can save money on energy bills too.

If you’re interested to know how a Pulsed Synergic MIG welder could aid your business then contact our sales team here we’ll endeavour to help.

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