Post on 21-Apr-2018
FUNDAMENTALS OF THE PMC AND LSC PROCESS
Ing. Bernhard Wiesinger Fronius International Froniusplatz 1 4600 Wels
FEEL THE DIFFERENCE – THE NEW PROCESSES
2 Fronius International GmbH / Intelligent Revolution / 20.08.3013
STANDARD
/ Familiar Fronius quality of the short and spray arc
/ Optimized for the most common material/ schielding gas combinations
LSC – Low Spatter Control / New Function „Penetration Stabilization“
especially in the spray arc with stickout changes; Function can be switched on and off!
/ LSC Root Characteristic lines: High arc pressure for better a root formation in confined spaces
/ LSC Universal Characteristic lines: Control of the short-circuit break up due to a smoother re-ignition and fast control
PULSE
/ Familiar Fronius quality of the globular arc
/ Optimized for the most common material/ schielding gas combinations
PMC – Pulse Multi Control / Increased process stability through precise control
/ Optimized pulse characteristics and improved ignition
/ Better stability with reduced energy per unit length (Welding speed and arc length)
/ Penetration stabilization for a more consistent weld penetration
/ SFI, Syn. Pulse
for more consistent weld penetration
PRINCIPLE PULSED ARC
Arc length changes can appear during welding due to surface variations, increased travel speed
3 Fronius International GmbH / Martin Willinger / Fundamentals of the PMC Process Sales Meeting NA 2014 / Aug. 2014 - v01
I/U
PMC - PULSE MULTI CONTROL OVERVIEW
4 Fronius International GmbH / first name last name / Titel of presentation / xx.xx.20xx - v02
Increased Arc Stability Due to the Speed Net communication an High arc stability is generated which allows high travel speeds with minimum to 0 weld defects and an easy operation. HIGH ARC STABILITY = HIGH WELDING PERFORMANCE
Consistence Penetration The penetration stabilizer maintains consistence penetration even if the CTWD changes. Helpful for mechanized welding especially at tight areas and hard to reach positions.
Easy Operation Parameters like the Arc Length Stabilizer helps the welder to set up the perfect weld parameter for every weld joint.
Universal Usability
PMC can be used on several filler metal alloys e.g. Low and High alloy steels, Aluminum and it´s alloys,…. as well for several wire diameters and shielding gas compositions.
More fine tune parameters
PRINCIPLE PMC ARC + ARC LENGTH STABILIZER
PMC adds dedicated short circuits to increase travel speed, penetration and arc stability.
5 Fronius International GmbH / Martin Willinger / Fundamentals of the PMC Process Sales Meeting NA 2014 / Aug. 2014 - v01
I/U
PULSE VS PMC USING ARC LENGTH STABILIZER
6 Fronius International GmbH / Martin Willinger / Fundamentals of the PMC Process Sales Meeting NA 2014 / Aug. 2014 - v01
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PRINCIPLE: PENETRATION STABILIZER “ON” / When changing the contact tube distance (CTWD) a
constant current behavior (CC) can only be obtained by a wire feed adjustment
/ The maximum feed change is determined by the setting of the Penetration Stabilizer
/ Example: Macro: “P-Stab” = 5 m/min Pos.2: CTWD = 20mm Pos 1.: CTWD = 10mm vd = 23 m/min vd = 18 m/min Penetration = 3.9mm Penetration = 4.1 mm
PGM2851 / „Steel dynamic PMC“ / G3Si1 ø1,0mm / 82% Ar 18%CO2 / CTWD 10mm bis 20mm / Schweißgeschw.100cm/min
1 2 1 2
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LSC SHORT DESCRIPTION
/ LSC stands for Low Spatter Control
/ LSC is based on a short circuited transfer mode which is modified to:
minimize spatter increase arc stability increase weld quality decrease training time increase of deposition rate maintaining consistence penetration
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FUNDAMENTALS OF SHORT CIRCUIT ARC
/ Regular short circuit transfer: less control, less forgiven and more spatter.
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FUNDAMENTALS OF LSC UNIVERSAL (Adv.)
Lap Joints
/ Smooth arc characteristic / Minimum spatter / Excellent wetting
Tee Joints
/ High arc stability / Low Spatter / High deposition rates
Fill & Cap on Pipes & Plates
/ High deposition rates / Good penetration due to
Penetration Stabilizer
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1st Step / Main current forms droplet / The end of the wire melts and forms
a big size droplet.
2nd Step / The big size droplet touches the weld
puddle and bridged the gap / The current reduces to a minimum to
avoid any spatter or harsh arc behavior.
FUNDAMENTALS OF LSC ROOT (Adv.)
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3rd Step / The current increases and pinches
the droplet.
4th Step / The droplet transfer happens at
minimum current. / Gap is completely bridged. / The low current avoids burn thru and
wire sticking thru the weld puddle
FUNDAMENTALS OF LSC ROOT (Adv.)
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5th Step / The current increases to a high peak
and pushes thru the weld puddle. / Excellent root reinforcement is
resulting
FUNDAMENTALS OF LSC ROOT (Adv.)
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TPS 400i LSC ADVANCED
LSC Advanced with hardware switch in the current path
/ Power source with LSC advanced module
/ Hardware switch in the current path
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ROOT PASS WELDING PROCESSES IN COMPARISON VERTICAL UP AND VERTICAL DOWN
/ U:16,65 / I:140,7 / Vs:25cm/min / E: 0,55kJ/mm / wfs: 3,6m/min
/ Position: Down / Wire Ø: 1,2mm / Gas: Ar+ 18%CO2 / Gas flow: 12l/min
Short Arc Vertical Down
/ U:9,3V / I:123 / Vs: 5,5cm/min / E: 1,24kJ/mm
/ Position: Up / Filler Ø: 2,0mm / Gas: Argon / Gas flow: 10l/min
TIG (GTAW)
/ U:22,82V / I:83,44 / Vs: 9cm/min / E: 1,26kJ/mm
/ Position: Up / Electrode Ø: 2,5mm
Stick (MMA) (rutil/E6013)
/ U:15,68 / I:101,7 / Vs: 12cm/min / E: 0,80kJ/mm / wfs: 2,5m/min
/ Position: Up / Wire Ø: 1,2mm / Gas: Ar+ 18%CO2 / Gas flow: 12l/min
Short Arc Vertical Up
/ U:14,69 / I:145,8 / Vs: 25cm/min / E: 0,51kJ/mm / wfs: 3,6m/min / Position: Down / Wire Ø: 1,2mm / Gas: Ar+ 18%CO2 / Gas flow: 10l/min
LSC Adv. Vertical Down
APPLICATIONS
/ Thin sheet application / Vertical up welding / Root welding / Automotive (high speed welding)
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