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

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PMC - PULSE MULTI CONTROL OVERVIEW

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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

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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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Constant Current 320A WFS variable

LSC PROCESS

TPS 400i LSC ADVANCED

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TPS 400i LSC

TPS 400i LSC Advanced

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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

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COMPARISON INTERMEDIATE ARC „STANDARD“ AND „LSC-ADVANCED“

APPLICATIONS

/ Thin sheet application / Vertical up welding / Root welding / Automotive (high speed welding)

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