13229 pcs puls controlled spray arc en

Puls Controlled Spray Arc Fronius 01/2009

Puls Controlled Spray Arc Controlled concentrated - dynamic

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Fronius 01/2009Puls Controlled Spray Arc

Impulsed- vs. spray arc

Advantages of the impulsed arc:- Reduction of spatter- Exact, one puls / one drop- Controllable penetration- Controllable wetting behaveourDisadvantages 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 seamDisadvantages 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


Arc types


How is the PCS arc generated?

The PCS characteristic line overlaps the short- and intermedial arc with the impulse droprelease.With increasing welding parameters in the spray arc area the influence of theimpulse is reduced.

Short circu

it arc

Spray arc

Spray arc

Pulsed arc

Intermediate

arc

Pulse-mod

ulated

spray arc


Advantages of the PCS arcz 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

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

Left picture:

Conventional arc burns over the weld pool

Right picture:

PCS arc burns in the weld pool


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.

PCS root pass

Time cap pass



z Application on butt welds- Controlling of the arc-concentration in the depth- Easier reach of the root edge

Conventional arc:

irregular or not reached root edge.

PCS - arc:

Through high arc pressure in the depth the root edge can be reached.



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

deepness

Traditional arc regulation:-Welding current-Voltage-Wire feed speedAdjusted together= slow / time intensive

PCS arc regulation:-Base current-Pulse current-Pulse frequenceAdjusted independently= fast / flexible

Voltage/Current Diagram

Current I

V

o

l

t

a

g

e

U

Arc area


Advantages PCS start and end

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

Welding start impulsed arc

Perfect start

Welding end impulsed arc

Perfect end

PCS welding area

Pulse supported spray arc

Up - Slope pulse-influence decreases

DownSlope puls-influence increases


Application areas Standard / Pulse / PCS / TIME - arc

Process Standard Impulse PCS TIMEKind of arc Short- / intermedial

arcImpulsed arc Pulse controlled

spray arcHigh performance- arc

Advantages Low energy / heat input

Controlled energy / heat input

Concentrate deep penetration

High deposition- rate

Disadvantages Physic. arc area Wide arc focus / noisy

Limited work area Long stick out (experience)

Recommended application areas

Thin sheet area until 3mmRoot pass

0,5 8mm parent - material

0,5 15mm / root pass welding

From 3mm fillet and but weld joint

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


Gases100% CO2

18% CO282% Ar

8% CO292% Ar

4% O296% Ar

Penetration widevery good good

smalldeep, good

smallnormal

Pores Very little little sensitive Very sensitive

Arc stability BadNo pulse possible

good Very good Very good

Spattering Very much little Very little Hardly any

Form of the penetration

Comparison of gases 21.9.08 Stefan Hglinger / Schrghuber Manfredconstant: StickOut 20mm, vd wire 12,5m/min, vs welding speed. 70cm/min, torch position 5 push, MAG 65 d=1,2mmVariable: sheelding gas 12l/min


Effect of the gas on the arc

8% CO292% Ar

Narrow arc rangeDeeper, concentrated

fusion penetration

Pore creation possible

CO2100% CO2

Wider arc rangeWider fusion penetration

Low risk of pore creation

CO2: Good thermal conductor / wide spread of arcAr: Bad thermal conductor / concentraded arc


Welding programs PCS Version: 15.05.2009

PGM Nr. Mode Wire GAS Base Machine0942 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


0949 Pulse ER70S6 1,2 4% O2 Ar Steel TPS 5000





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

Fronius Database


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 !


PCS TIME Sample 8mm T - joint both sides S235JR

PCS Welding - parameter:VD = 12,0m/minI = 365AU = 30,2VVS = 51 cm/min

Filler wire: ER 70S / 1,2mmShielding-gas: M21 / ArCo2 82/18Without beveling !

TIME Welding - parameter:VD = 15,7m/minI = 365AU = 33,1VVS = 66 cm/min

Filler wire: ER 70S / 1,2mmShielding-gas: M21 / ArCo2 82/18Without beveling !

+30%Deposition - rate

+30%Welding speed


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

Filler wire: ER 70S / 1,2mmShielding - gas: Ar/Co2 82/18


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


Applications PCS

z Sheet thickness (3-12mm)z Material: steelz Wire: G3 Si1z Gas: 8%CO2 / 92%Argon

Bild

Bild

z Narrow welding applicationz Material: steelz Wire: G3 Si1z Gas: 8%CO2 / 92%Argon


Applications PCS

z Vs: 300cm/min

Bild

Bild

z Thin sheet application on Robotz Material: steelz Wire: G3 Si1z Gas: 10%CO2 / 90%Argon


Applications PCS

Bild

Bild

z Wire material: ER70 1.4mmz Basematerial: Steelz Gas:10%CO2 90%Argonz Ws: 10-12,7m/minz Vs: 60-90cm/minz PGM:1004 z 17.06.2009


Summary PCSz Concentrated arc- Through reduced weld voltage- Through alternative shielding gas mixtures ( Co2 proportion )z Deep in the weld pool burning arcz Dynamic powerful arc- Through flexible arc regulationz Optimal addition to the existing production processes- Runs on TPS 4000/5000 and TIME 5000 digital

TIME 5000 digital is suitable for all arcs and material thicknesses

PERFECT WELDING

Puls Controlled Spray ArcControlled concentrated - dynamicImpulsed- vs. spray arcArc typesHow is the PCS arc generated?Advantages of the PCS arcPCS Concentrated arcPCS Concentrated arcPCS Concentrated arcAdvantages PCS start and endApplication areasStandard / Pulse / PCS / TIME - arcGasesEffect of the gas on the arcWelding programs PCS Version: 15.05.2009 PCS Sample 6mm T joint both sides S235JRPCS TIME Sample 8mm T - joint both sides S235JRPCS TIME Sample 10mm T joint both sides S235JRPCS TIME Sample 8mm narrow gap 25 degrees S235JRApplications PCSApplications PCSApplications PCSSummary PCSFoliennummer 22

13229 pcs puls controlled spray arc en

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