Puls Controlled Spray Arc

Controlled concentrated - dynamic

Name of Speaker
Company
Division
Street
City

Puls Controlled Spray Arc

Fronius 01/2009

Impulsed- vs. spray arc

Advantages of the impulsed arc:

Reduction of spatter
Exact, one puls / one drop
Controllable penetration
Controllable wetting behaveour
Disadvantages of the impulsed arc:
High voltage / this effects:
Wide arc focus
High tendency of undercut
Loud sound of the process

Advantages of the spray arc:

Reduction of spatter
Deep / wide penetration
Good wetting behaviour
Clean surface of the welding seam
Disadvantages of the spray arc:
Limited power range
High welding energy
Weld pool is difficult to control (much effort is
required)
Big heat development / arc-radiation
Puls Controlled Spray Arc
Fronius 01/2009

Arc types

Puls Controlled Spray Arc

Fronius 01/2009

How is the PCS arc generated?

c
e ar
t
a
i
d
rme
Inte
t ar c
c
i
u
c
r
d ar
i
e
c
s
l
t
r
Pu
Sho

c
y ar
a
r
p
S
ar c
y
a
r
Sp

ed
ulat
d
o
e-m
c
Puls pray ar
s

The PCS characteristic line overlaps the short- and intermedial arc with the impulse drop
release.
With increasing welding parameters in the spray arc area the influence of the
impulse is reduced.
Puls Controlled Spray Arc
Fronius 01/2009

Advantages of the PCS arc

z

Focussed arc

Low process voltage enables narrow arc focus

Arc pressure is carried into the work piece what effects deep and concentrated
penetration
High arc pressure > arc doesnt burn on but in the weld pool

Left picture:
Conventional arc burns over the weld
pool
Right picture:
PCS arc burns in the weld pool

Advantages for the welding staff:

reduced light- and warmth radiation arc burns in the weld pool
low welding parameters easier reach of the root edge
Puls Controlled Spray Arc
Fronius 01/2009

PCS Concentrated arc

z

Applications on fillet welds

Optimal reach of the root edge

Optimal combination with TIME welding in the multilayer welding seam
construction
Deep penetration can be calculated as additional seam volume.

Time cap pass

PCS root pass

Puls Controlled Spray Arc
Fronius 01/2009

PCS Concentrated arc

z

Application on butt welds

Controlling of the arc-concentration in the depth

Easier reach of the root edge

Conventional arc:

PCS - arc:

irregular or not reached

root edge.

Through high arc pressure in the

depth the root edge can be
reached.
Puls Controlled Spray Arc
Fronius 01/2009

PCS Concentrated arc

z
z

The suffocation of the arc, which is very short, is prevented by the dynamic regulation.
fast / active arc regulation gives you a constantly stable arc pressure / penetration
deepness

Traditional arc regulation:

-Welding current
-Voltage
-Wire feed speed
Adjusted together
= slow / time intensive

PCS arc regulation:

-Base current
-Pulse current
-Pulse frequence
Adjusted independently
= fast / flexible

Voltage/Current Diagram

Voltage U

Arc area

Current I

Puls Controlled Spray Arc

Fronius 01/2009

Advantages PCS start and end

z
z
z
z
z

Welding start low power area impulsed arc

Slope on the main parameter PCS
Main parameter dynamic regulated spray arc
Downslope to the welding end parameter - PCS
Welding end low power area impulsed arc

Welding start
impulsed arc

PCS welding area

Welding end
impulsed arc

Perfect start

Pulse supported spray arc

Perfect end

Up - Slope pulse-influence
decreases

DownSlope puls-influence
increases

Puls Controlled Spray Arc

Fronius 01/2009

Application areas
Standard / Pulse / PCS / TIME - arc

G3Si1 / ER70S wire material 1,0mm / 1,2mm

Process

Standard

Impulse

PCS

TIME

Kind of arc

Short- / intermedial
arc

Impulsed arc

Pulse controlled
spray arc

High performancearc

Advantages

Low energy / heat

input

Controlled energy
/ heat input

Concentrate deep
penetration

High depositionrate

Disadvantages

Physic. arc area

Wide arc focus /

noisy

Limited work area

Long stick out

(experience)

Recommended
application
areas

Thin sheet area

until 3mm
Root pass

0,5 8mm parent material

0,5 15mm /
root pass welding

From 3mm fillet

and but weld joint

Puls Controlled Spray Arc

Fronius 01/2009

Gases
18% CO2
82% Ar

100% CO2
Penetration

wide
very good

Pores

Very little

Arc stability

Spattering

8% CO2
92% Ar

4% O2
96% Ar

good

small
deep, good

small
normal

little

sensitive

Very sensitive

Bad
good
No pulse possible

Very good

Very good

Very much

Very little

Hardly any

little

Form of the
penetration

Comparison of gases 21.9.08 Stefan Hglinger / Schrghuber Manfred

constant: StickOut 20mm, vd wire 12,5m/min, vs welding speed. 70cm/min, torch position 5 push, MAG 65 d=1,2mm
Variable: sheelding gas 12l/min
Puls Controlled Spray Arc
Fronius 01/2009

Effect of the gas on the arc

CO2
8% CO2
92% Ar
Narrow arc range
Deeper, concentrated
fusion penetration

100% CO2

Wider arc range

Wider fusion penetration

Pore creation possible

Low risk of pore

creation

CO2: Good thermal conductor / wide spread of arc

Ar: Bad thermal conductor / concentraded arc

Puls Controlled Spray Arc

Fronius 01/2009

Welding programs PCS

Version: 15.05.2009
PGM Nr.

Mode

Wire

GAS

Base

Machine

0942

Pulse

ER70S6

1,0

8% CO2 Ar

S235

TPS 4000

0944

Pulse

ER70S6

1,0

4% O2 Ar

Steel

TPS 5000

1282

Pulse

ER70S6

1,0

18% CO2 Ar

Steel

TPS 4000

0947

Pulse

ER70S6

1,2

8% CO2 Ar

Steel

TPS 5000

0949

Pulse

ER70S6

1,2

4% O2 Ar

Steel

TPS 5000

1283

Pulse

ER70S6

1,2

18% CO2 Ar

Steel

TPS 5000

0988

Pulse

ER70S6

0,9

15% CO2 Ar

Steel

TPS 4000

1004

Pulse

ER70S6

1,3

10% CO2 Ar

Steel

TPS 5000

1080

Pulse

ER70S6

1,2

10% CO2 Ar

Steel

TPS 5000

Update of all digital Fronius MIG/MAG systems is possible every where all time

Fronius Database

Puls Controlled Spray Arc

Fronius 01/2009

PCS Sample
6mm T joint both sides S235JR
Welding - parameter:
VD = 11,0m/min
I = 305A
U = 29,8V
VS = 51 cm/min
Filler - wire: ER 70S / 1,2mm
Shielding-gas: M21 / ArCo2 82/18

Without beveling !

Puls Controlled Spray Arc

Fronius 01/2009

PCS TIME Sample

8mm T - joint both sides S235JR

PCS
Welding - parameter:
VD = 12,0m/min
I = 365A
U = 30,2V
VS = 51 cm/min
Filler wire: ER 70S / 1,2mm
Shielding-gas: M21 / ArCo2 82/18
Without beveling !

+30%
Deposition - rate
+30%
Welding speed

TIME
Welding - parameter:
VD = 15,7m/min
I = 365A
U = 33,1V
VS = 66 cm/min
Filler wire: ER 70S / 1,2mm
Shielding-gas: M21 / ArCo2 82/18
Without beveling !

Puls Controlled Spray Arc

Fronius 01/2009

PCS TIME Sample

10mm T joint both sides S235JR
PCS Welding parameter / root pass:
VD = 11,0m/min
I = 305A
U = 29,8V
VS = 51 cm/min
Filler wire: ER 70S / 1,2mm
No beveling !
TIME Welding parameter / cap layer:
VD = 11,0m/min
I = 305A
U = 29,8V
VS = 51 cm/min

Shielding - gas: Ar/Co2 82/18

Filler wire: ER 70S / 1,2mm

Puls Controlled Spray Arc

Fronius 01/2009

PCS TIME Sample

8mm narrow gap 25 degrees S235JR
PCS Welding parameter:
VD = 12,0m/min
I = 270A
U = 30,0V
VS = 51 cm/min
Filler wire: G3Si1 / 1,2mm

Shielding - gas: Ar/Co2 82/18

Puls Controlled Spray Arc
Fronius 01/2009

Applications PCS
z
z
z
z

z
z
z
z

Narrow welding application

Material: steel
Wire: G3 Si1
Gas: 8%CO2 / 92%Argon

Bild

Sheet thickness (3-12mm)

Material: steel
Wire: G3 Si1
Gas: 8%CO2 / 92%Argon

Bild

Puls Controlled Spray Arc

Fronius 01/2009

Applications PCS

Thin sheet application on Robot

Material: steel
Wire: G3 Si1
Gas: 10%CO2 / 90%Argon

Vs: 300cm/min

z
z
z

Bild

Bild

Puls Controlled Spray Arc

Fronius 01/2009

Applications PCS
z
z
z
z
z
z
z

Wire material: ER70 1.4mm

Basematerial: Steel
Gas:10%CO2 90%Argon
Ws: 10-12,7m/min
Vs: 60-90cm/min
PGM:1004
17.06.2009

Bild

Bild

Puls Controlled Spray Arc

Fronius 01/2009

Summary PCS
z

Concentrated arc

- Through reduced weld voltage

- Through alternative shielding gas mixtures ( Co2 proportion )
z

Deep in the weld pool burning arc

z Dynamic powerful arc
- Through flexible arc regulation
z Optimal addition to the existing production
- Runs on TPS 4000/5000 and TIME 5000 digital

processes

TIME 5000 digital is suitable for all arcs and

material thicknesses

Puls Controlled Spray Arc

Fronius 01/2009

PERFECT WELDING