GMAW

By Lawrence (*****)

Date 10-17-2019 20:35

Yeah,

GMAWP....

Both Lincoln Powerwave and Miller Continuum have some solid waveform subroutines that can make a very short arc at spray transfer parameters and very brisk travel speeds with .045 solid wire.

My preference is “Rapid Arc” and “Rapid-X” but Miller has some good waveforms as well.

By Jarhead1 (**)

Date 10-18-2019 12:33

Thanks for the info.. All I have is a bunch of old Miller DetaWelds 451-452. To be competitive I will have to invest in a short arc machine. Can't cut it welding high qty pcs with TIG.

By pipewelder_1999 (****)

Date 10-20-2019 11:32

A convention CV power source will work fine. A 1/8" fillet will require a faster travel speed than your typical 1/4" fillet weld at the same wire feed speed. 4 times faster

While high end pulsed machines can achieve the required settings with little to no spatter, a conventional power source may require some fine tuning.

Miller makes a new pulsed power supply that is in the 3-4K range called the Millermatic 255 and I used one last week for pulsed GMAW on aluminum and I like it.

By TimGary (****)

Date 10-21-2019 13:28

No doubt GMAW-P is the way to go.
While, as Lawrence said, .045 wire use is doable, the travel speed required to avoid over-welding is a bit much for some Welders to be able to keep the weld centered in the joint.
.035 wire works a bit better for this, if all or most of the welds are to be 1/8"
If most welds on the assembly are larger, with only a few 1/8" thrown in the mix, stay with .045 wire.

If a steady large qty of these is in the works, the investment in a pulse capable machine will have a short ROI.

Tim

By Jarhead1 (**)

Date 10-21-2019 15:38

Tim,

I have a couple Miller 350P's (pulse machine) that we use with a push/pull gun for aluminum...

I changed out to carbon steel and gave this a try and could not hold 1/8" .030 -.035 wire.

Thanks

By TimGary (****)

Date 10-21-2019 20:27

Try:
- .035 solid wire
- with 90% Ar / 10% CO2
- 10 gage sheet (clean)
- 270 IPM WFS
- 40 Arc Length
- 25 Arc Control
- Straight push ( no whip or oscillation)
- 20 - 25 IPM TS