Welding Tips and Tricks

Hi Jody,
Not much out there on pulsed mig that shows fillet weld penetration and macros. Can't find anything that shows pulsed macros. I'd certainly be interested to see it. There's a talk about how pulse gives better fusion but not much proof.
Cheers from down under!

We use pulse mig at work. It's a specific set up (means to an end) but the set up seems to lack the punch one might expect. That could well be the crappy wire we use. I know you can't do a quick filler run with the settings we use as you can do with conventional mig.

That's what concerns me. If you're getting fast freeze does that mean at the expense of peno? I would like that answered before I consider upgrading my old school transformer 250 mig. I'm keen on technology but peno is more important to me.

Ooooooo....this thread is calling my name.

Oscar wrote:Ooooooo....this thread is calling my name.

Lol ProPulse incoming!!

I agree, I’m using pulse mig as often as I can, I love it. Anything over 1/8” get pulsed. So much more control, cleaner...I haven’t yet gotten around to doing cut/etch, can’t seem to get my hands on some naval jelly. But am for sure planning to.


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JayWal wrote:

Oscar wrote:Ooooooo....this thread is calling my name.

Lol ProPulse incoming!!

lol, good one! I should make a gif using a clip from an old black & white war movie, but instead of a warhead it's a flying Pro Pulse MIG!

We have done macros with the process for our wpqs. That said it does not look the same as conventional, but doesn't mean you aren't getting penetration in a different way.

LtBadd wrote:

c3361546f27245850f759bb6ffe3b5dc.gif

I found this one with a B-2 Stealth Bomber....They even look like red HTP Pro Pulse MIG's! Take cover!

Oscar wrote:

LtBadd wrote:

The attachment c3361546f27245850f759bb6ffe3b5dc.gif is no longer available

I found this one with a B-2 Stealth Bomber....They even look like red HTP Pro Pulse MIG's! Take cover!

Aw, you guys.
Smart-ass is what I bring to this relationship. If you take that away from me I got nuthin!

I recon if HTP were available in oz they would really shake the market up.

LOL.....well I got some test pieces cut out of 6.4mm steel, about 35mm wide x 100mm long, and did some trial runs to get used to the whole 12mm-15mm CTWD since it is a spray-based process and the arc length is rather long. I should have some time tomorrow to weld them up and hopefully etch them.

In the meantime, enjoy a video of one of the trial runs I did on scrap.

GTv1VCFKki8

Oh yer, that's it.
I'm goin down the LWS right now and talk to them about whips and dirty tips

Found a really interesting scientific investigation into various mig processes (pulse, synergic etc) which also includes macro inspection of fillet weld in the 200-250 amp range. Really interesting. Macros show excellent penetration for pulse mig, not so much for synergic mig.

Lots of big words for an Aussie joker but here it is:
https://lutpub.lut.fi/bitstream/handle/ ... sAllowed=y

Go to page 80 and look at the pretty pics ifn you strugl wit big woids.

Yeah I’m gonna need at least a week of half hour potty breaks to read through that one.

Looks interesting, thanks!


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I haven't forgotten about this, just been swamped at work! And I got stuck testing out some metal-core wire

Looking forward to it Oscar

Almost there. I ran the pulsed-spray beads (finally), and just waiting on Naval Jelly to take it's sweet time. Granted this is not the be-all-end-all as my own technique is a factor since I'm a hobbyist and really don't weld all that much unless I want to experiment different processes to learn/use up my free-time.

Well the results speak for themselves. Same amperage (175A) on the machine synergic settings. Could have sworn I was aiming the wire [and thus arc] right at the root of the joint, but the fusion depth profile shows it was off a little bit. Either way, the pulse-spray penetration/fusion profile looks better on pulsed-spray, but the short-circuit fusion profile doesn't look all that bad to me either.

Welding Parameters/Info:



Right-click here and open Image in new tab, since it's a large file size.


Small version of pic:

Thanks Oscar,
Very interesting. Which are pulsed, the fillets on top?

Coldman wrote:Thanks Oscar,
Very interesting. Which are pulsed, the fillets on top?

Yup. So there you have it. Fusion profile and travel speed like pure spray-arc, but with some resemblance of weld puddle control like short-circuit MIG so it can be used in out-of-position welds when dialed in correctly.

Thanks you've been a big help and confirmed my thoughts.
Been looking around for a suitable power source. Very poor choice here in the backside of the world. So far the only machine I've found that is single phase, 240v, 250amp pulse mig is the Bossweld and I'm not going there.
If I was out your way I'd have plenty of choice. Sux.

Coldman wrote:Thanks you've been a big help and confirmed my thoughts.
Been looking around for a suitable power source. Very poor choice here in the backside of the world. So far the only machine I've found that is single phase, 240v, 250amp pulse mig is the Bossweld and I'm not going there.
If I was out your way I'd have plenty of choice. Sux.

BOC mig and EWM migs are pulse.
BOC have the basic 250a pulse mig. can't remember what EWM has in the 250a range but i've used the 180a before.
i have not found many USA migs with pulse. seams to be more of a euro thing.

Have heard good things about this company
https://weldingstore.tokentools.com.au/ ... ig-welder/

Also, cebora, weldmax, Olympic from wa welding supplies,