Take Control With The Weld-Pro

ACCESSORY SCREEN

 

POWER SUPPLY

 


PARAMETERS CONTROLLED:

The Process Welding “WELD PRO” weld controller makes quick and easy work of changing from job to job with multiple devices. CAPABILITIES:

Control welding power supply, lathe or other motion device, AVC, wire feeder and aux gas from one location with either Modbus or
0 - 10V / analog signals!

• Pre-gas
• Initial Current
• Upslope
• Welding Current
• Pulsation Parameters
• Final Current
• Post-Gas
• Wire Start Delay
• Wire Speed
• Burnback Time
• Arc Gap Setting
• Arc Voltage
• AVC Start Delay
• Lathe Speed
• Lathe Start Delay

Dual Arc 82 Micro-Arc Power Supply

Process Welding Systems - Plasma and Tig Welding Solutions

DUAL PROCESS CAPABILITY FROM 0.1 TO 80.0 AMPS

MICRO PLASMA MICRO-TIG

SIMPLE PROGRAMMING AND PROGRAM STORAGE

 

 

 

 

————————————————————————

Pictured above: Dual Arc 82 Welding Power Supply on top, DA-WR Water cooler underneath (required for Plasma Welding Only) The system is 19.5” (50 cm) square

————————————————————————

The Most Capable Low Amperage Welding Systems Available

Micro -Tig System Capability:

  • •  Precision in Micro-TIG welding
  • •  Ultra low current capability (0.1 amp)
  • •  No arc wander at low amperages
  • •  Soft TIG arc start will not damage small or delicate parts
  • •  Reduced heat input thru built-in arc pulsation
  • •  Accurate, repeatable welds
  • •  Panel programmable start current, upslope, weld current, and final weld current levels
  • Manual and Automatic welding ability

————————————————————————

Micro—Plasma System Capability:

  • •  Micro-Plasma weld process ability offers all of the benefits of the plasma welding process (see page 2)
  • •  No Restriction to TIG or Plasma, it offers both!
  • •  Modular system can be purchased as a TIG system and later upgraded to include Plasma too
  • •  Short duration weld capability starting at 0.1 seconds
  • •  Built in computer control
  • •  Manual and Automatic welding ability

In either GTAW or PAW configuration, the Dual Arc 82 can be configured for manual or automatic welding and offers all connectivity required for automation of welding processes.

————————————————————————

TIG WELDING ADVANTAGES

  • •  Well-known and understood process
  • •  Readily available, low cost consumable parts
  • •  Excellent gas shielding for smaller parts
  • •  Electrode can be extended for improved weld joint access
  • •  “Soft” TIG arc can offer benefits for certain applications
  • •  More forgiving of part fit-up problems in certain applications————————————————————————

PLASMA WELDING ADVANTAGES

  • •  Protected electrode allows for more welds before electrode contamination
  • •  Arc gap distance not as critical as in TIG
  • •  “Gentle” arc transfer
  • •  Stable, stiffer arc reduces arc wander
  • •  No high-frequency arc starting noise
  • •  Extremely short duration welds possible for spot welding of wires, needles and micro components
  • •  Higher weld speeds in specific applications

 

Applications

And Many More

Valves, metal seals, diaphragms, pressure transducers, sensors, implant devices, relay cans capacitor cans, Micro switches, motors, electronic devices, enclosures, explosive detonators, airbag components, air seals, tube/ fitting assemblies, vacuum tubes, electrocautery tools, metal meshes, pacemakers, thermocouples, tube closure, surgical instruments, dental instruments, wires, aspiration needles, injection needles, surgical baskets, catheter metal capsules, guidewires, light bulb filaments, and more.

Read More

Standardization of Welding Procedures

Weld Engineering has recently directed manufacturing engineering to adopt weld standardization into the production work cell. Weld standardization is a consistent and uniform approach to a given welding application. Standardization is divided into two critical components that include Process and Producibility. It is important to recognize that process control should remain independent of the theoretical approach utilized for a given welding application. The first step is to clone every element of each workstation in order to achieve the same process identity throughout production. The second component of standardization is Producibility. Producibility is simply the pursuit of a weld applications procedural limit. With each material there exists a weldability range in which a satisfactory weld can be produced. The candidate material or application is welded at a variety of speeds and parameters. Observations are documented as the window of Producibility is pushed to its maximum limit. This continues until some aspect of acceptance criteria is no longer satisfied. It is at this point that the low, middle, and upper control limits of the process are established. Standardization substantiates a company’s commitment to further product quality and establishes a basis for comparing quantity and quality. Qualification by similarity is one of the many benefits of standardization. Process Welding Systems Welding Positioner's are second to none. Call us today and ask about them and how best to improve the quality of your product production.

Welding Positioners

 

Costs of an Automated Welding System.

Basic parameters:

Operator and skilled welder salaries vary somewhat according to geographic locations. The basic assumptions used in the calculations below are as follows:
Work hours per year: 2000 (40 hours/week x  50 weeks/years)
Manual welder Costs
Average welder pay:     $16/hour (range from $14/hour - $18/hour)
Actual welder cost to employer:       $24/hour equals $48,000/year
(
1.5 X hourly rate for overhead, vacation, holidays, sick time, Social Security, unemployment taxes, insurance, etc.)

Operator Costs
Average operator pay:       $10/hour (range from $8/hour - $12/hour)
Actual cost to employer:  $15/hour equals 30,000/year
(1.5 X hourly rate for overhead)

The table below gives a simple example of calculations for return or investment based on equipment and labor costs alone. For a full analysis of actual costs the following must also be considered;

• Actual equipment cost • Labor rates • Production welding speeds possible • Supervisor cough • Personal management • Quality control costs • Reject and scrap cost • Customer relations •

Number of systems required for the call output.

8x

4x

1x

Individual system cost
Total equipment system investment

$5,000
$40,000

$32,000
$128,000

$200,000
$200,000

Individual welder cost/year
Individual operator cost/year
Labor cost/year for equal volume of output.
(One 8 hour shift)

$48,000

 

$384,000

 

$30,000

$120,000

 

$30,000

$120,000

Labor and equipment cost for a 12 month
period with one eight hour shift

$424,000

$248,000

$230,000

Labor and equipment cost for a 12 month
period with one eight hour shift

$808,000

$368,000

$260,000

Carbon Steel – Welding

 

Carbon steel is steel where the main interstitial alloying constituent is carbon in the range of 0.12-2.0%. The American Iron and Steel Institute (AISI) defines carbon steel as the following: "Steel is considered to be carbon steel when no minimum content is specified or required for chromiumcobaltmolybdenumnickelniobiumtitaniumtungstenvanadium or zirconium, or any other element to be added to obtain a desired alloying effect; when the specified minimum for copper does not exceed 0.40 percent; or when the maximum content specified for any of the following elements does not exceed the percentages noted: manganese 1.65, silicon 0.60, copper 0.60."

 

 Mild and low carbon steel

Mild steel, also called plain-carbon steel, is the most common form of steel because its price is relatively low while it provides material properties that are acceptable for many applications, more so than iron. Low carbon steel contains approximately 0.05–0.3% carbon[1] and mild steel contains 0.3–0.6%[1] carbon; making it malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap and malleable; surface hardness can be increased through carburizing.[3]

Higher carbon steels

Carbon steels which can successfully undergo heat-treatment have a carbon content in the range of 0.30–1.70% by weight. Trace impurities of various other elements can have a significant effect on the quality of the resulting steel. Trace amounts of sulfur in particular make the steel red-short, that is, brittle and crumbly at working temperatures. Low alloy carbon steel, such as A36 grade, contains about 0.05% sulfur and melts around 1426–1538 °C (2599–2800 °F).[8] Manganese is often added to improve the hardenability of low carbon steels. These additions turn the material into a low alloy steel by some definitions, but AISI's definition of carbon steel allows up to 1.65% manganese by weight.

 

Medium carbon steel

Approximately 0.30–0.59% carbon content.[1] Balances ductility and strength and has good wear resistance; used for large parts, forging and automotive components.[9]

High carbon steel

Approximately 0.6–0.99% carbon content.[1] Very strong, used for springs and high-strength wires.[10]

Ultra-high carbon steel

Approximately 1.0–2.0% carbon content.[1] Steels that can be tempered to great hardness. Used for special purposes like (non-industrial-purpose) knives, axles or punches. Most steels with more than 1.2% carbon content are made using powder metallurgy. Note that steel with a carbon content above 2.0% is considered cast iron.

Heat treatment

The purpose of heat treating carbon steel is to change the mechanical properties of steel, usually ductility, hardness, yield strength, or impact resistance. Note that the electrical and thermal conductivity are only slightly altered. As with most strengthening techniques for steel, Young's modulus (elasticity) is unaffected. All treatments of steel trade ductility for increased strength and vise versa. Iron has a higher solubility for carbon in the austenite phase; therefore all heat treatments, except spheroidizing and process annealing, start by heating the steel to a temperature at which the austenitic phase can exist. The steel is then quenched (heat drawn out) at a high rate causing cementite to precipitate and finally the remaining pure iron to solidify. The rate at which the steel is cooled through the eutectoid temperature affects the rate at which carbon diffuses out of austenite and forms cementite. Generally speaking, cooling swiftly will leave iron carbide finely dispersed and produce a fine grained pearlite (until the martensite critical temperature is reached) and cooling slowly will give a coarser pearlite. Cooling a hypoeutectoid steel (less than 0.77 wt% C) results in a lamellar-pearlitic structure of iron carbide layers with _-ferrite (pure iron) between. If it is hypereutectoid steel (more than 0.77 wt% C) then the structure is full pearlite with small grains (larger than the pearlite lamella) of cementite scattered throughout. The relative amounts of constituents are found using the lever rule. The following is a list of the types of heat treatments possible:

There Are Differences in Welding

Difference Between MIG and TIG Welding

The Basic difference between MIG and TIG welding is that one uses consumable wire electrode (MIG) and other (TIG) uses non-consumable tungsten electrode. In MIG welding process, electric arc is produced between a consumable wire electrodes and workpiece metals. And in TIG welding process, electric arc is produced between a non-consumable tungsten electrode and workpiece metals. The heat generated by the arc is used to melt the metals and forms weld. Here we will discuss all the major differences among MIG and TIG Welding.
Difference Between MIG and TIG Welding

Difference Between MIG and TIG Welding

Here we have learnt all the major difference between MIG and TIG welding. If you have any questions regarding this article than comment us at Process Welding Systems.

S.no
MIG Welding
TIG welding
1.
MIG stands for Metal Inert Gas Welding. It is also known as Gas Metal Arc Welding (GMAW), Metal Active Gas Welding (MAG).

TIG stands for Tungsten Inert Gas Welding. It is also known as Gas Tungsten Arc Welding (GTAW).
2.
It is a welding process in which electric arc is formed in between a consumable wire Electrode and workpiece metal(s).

It is a process in which an electric arc is formed in between a non-consumable tungsten electrode and workpiece metal(s)
3.
The type of electrode used is consumable wire electrodes.

The type of electrode used is non-consumable tungsten electrode.
4.
Most commonly it uses constant voltage, direct current power source for the welding. It can also use constant current system and alternating current.

It uses constant current welding power supply for the welding.
5.
The materials which it can weld are aluminum, non-ferrous materials and steels.

It is most commonly used to weld stainless steels and non-ferrous metals like aluminum, magnesium and copper alloys.
6.
High skilled operator is not required to perform MIG welding process.

High skilled operator is required to perform TIG welding process.
7.
It has high weld deposition rate.

It has low weld deposition rate as compared with MIG welding.
8.
No filler metal is required. The feed electrode wire melts and acts as filler metal.

It may require filler metal from outside in some cases if needed.
9.
It can weld thick metal sheets up to 40 mm.

It can weld thin metal sheets up to 5 mm.
10.
It produces less quality of weld as compared with TIG.

It produces high quality of weld because it affords greater control over weld area.
11.
It uses continuous wire feed.

It does not uses continuous wire feed.
12.
The equipment used in MIG welding process is a welding gun, a welding power supply, a feed wire unit, a welding electrode wire and a shielding gas supply.

The equipment used in TIG welding process is welding torch, non-consumable tungsten electrode, a constant-current welding power supply and a shielding gas source.
13.
It is a faster welding process.

It is a slower welding process.
14.
In this welding process, the use of filler metal is compulsory.

But in this welding process the filler metals may or may not be used. There is no compulsion of using filler metals, it is used when required.
15.
 It cannot work in any position.
It can be worked in any position.

TIG Welding – Beginners Guide

We are always interested in our customer’s welding product needs. To maintain it’s growth pattern PWS has developed a variety of products and many of the products we offer are of a “value added” nature. PWS is able to assist customers in improving their production processes through equipment to enhance or improve welding quality.

These activities serve to broaden the product and services offering and make the company less dependent on outside sources for development. The acceptance of new equipment has been researched and appears to be welcomed consideration to the current customer base. Continual product development will ensure balanced growth and recognition as a source of expertise in welding equipment and processes.


SERVICES INCLUDE:
 Design services for precision welding systems (manual load/unload or semi-automatic)
 Integration of welding system accessories & site installation assistance
 Experienced staff for custom design & manufacture of tooling, fixtures & specialty torch nozzles
 Free weld application review & process recommendation

TECHNICAL SUPPORT:
 Troubleshooting, maintenance & repair of equipment
 Weld training – skills development
 Weld development – material evaluation, joint design, weld parameter development
 Comprehensive consumable inventory stock of replacement parts for plasma power supplies, accessories & plasma welding torches

CUSTOM PRODUCTS AND ACCESSORIES:
Special gas shields – MIG, TIG & Plasma
Torch slides – X, Y, Z


TIG Welding – Beginners Guide

TIG welding is probably he most complicated type of welding there is, and for a beginner the shear number of variable can be a bit confusing. Below is a break down on all the different areas with some “numbers” to help you get started.

TIG Welding – Beginners Guide – Gas

Now you may think talking about gas before the welder is odd, but bear in mind that if you are on a budget then the gas is going to represent a significant outlay.

Unlike MIG welding TIG welding can only use pure argon (or other specialist gases), so using food grade CO2 for example is not possible.

TIG Welding – Beginners Guide – Welders

Make sure that the welder actually comes with a proper TIG torch, as some Arc Welders can be used for TIG welding but do not come supplied with a TIG torch as pictured below.

A TIG Torch

TIG Welding – Beginners Guide – The Tungsten

The tungsten is the electrode that sticks out of the front of the torch. Confusingly there are various different types, that are better suited to different applications. Your welder may come supplied (as mine did) with an unsuitable tungsten electrode. Most people suggest a 2% thoriated tungsten, but this is radioactive, so perhaps go for a 1-2% lanthanated electrode which I believe performs similarly

You should sharpen your tungsten before first use. 

OK so hopefully that covers the gear now a little on technique.

TIG Welding – Beginners Guide – Holding the Tig Torch  

To avoid damaging the electrode, you will need to hold it around 2 – 3mm from the working surface. With a welding mask on this is no mean feat, and will take a great deal of practice to get the hang of. The torch should be held in a way that is very comfortable;

Index Finger on Top
Or like a pencil

Gloves should be used or you will get sun burn from the UV radiation emitted from the arc. If you are working on a large item, it may heat up meaning you will need something heat proof to rest your hand on.

The torch should be held with the electrode as upright as  possible, whilst still allowing you to see what you are doing.

TIG Welding – Beginners Guide – Setting the Amperage

On the most basic of TIG welders there will be an amperage control, too little amperage and you will not melt the metal, too much and you make a hole.

It is recommended around 65 amps for 16 gauge steel  (1.63mm). So a bit more for thicker stuff, and a bit less for thinner stuff, remember that the maximum amperage you can use will be limited by the diameter of the tungsten you are using. 1.6mm tungsten will go up to around 90 amps, if you intend to use more amps then get a thicker electrode.

The better the conductivity of the metal the higher your amperage will have to be, aluminum requires a higher amperage that steel for the same thickness.

TIG Welding – Beginners Guide -Gas Flow Rate

During welding set gas flow around 7 – 8 liters per minute.


PROCESS WELDING SYSTEMS AUTOMATED WELDING SYSTEMS TAKE YOU TO THE NEXT LEVEL:

Our automated system helps  you increase welding quality, improve welding productivity, enhance the working environment and decrease manufacturing cost.

Special Purpose Machines (SPM) with simple timer and contractor control to complex designs using CNC controllers, servo motors, pneumatics, hydraulics as requirement.

Process Welding Systems’ design, manufacture and sell complete weld automation stations for mass production with automated welding of various components , equipments, overlay metal build up, hard-facing and metal spray applications .

See our CUSTOM AUTOMATED LATHE

Let Us Know More About You

We are always interested in our customer’s welding product needs. To maintain it’s growth pattern PWS has developed a variety of products and many of the products we offer are of a “value added” nature. PWS is able to assist customers in improving their production processes through equipment to enhance or improve welding quality.

These activities serve to broaden the product and services offering and make the company less dependent on outside sources for development. The acceptance of new equipment has been researched and appears to be welcomed consideration to the current customer base. Continual product development will ensure balanced growth and recognition as a source of expertise in welding equipment and processes.


SERVICES INCLUDE:
 Design services for precision welding systems (manual load/unload or semi-automatic)
 Integration of welding system accessories & site installation assistance
 Experienced staff for custom design & manufacture of tooling, fixtures & specialty torch nozzles
 Free weld application review & process recommendation

TECHNICAL SUPPORT:
 Troubleshooting, maintenance & repair of equipment
 Weld training – skills development
 Weld development – material evaluation, joint design, weld parameter development
 Comprehensive consumable inventory stock of replacement parts for plasma power supplies, accessories & plasma welding torches

CUSTOM PRODUCTS AND ACCESSORIES:
Special gas shields – MIG, TIG & Plasma
 Torch slides – X, Y, Z
 Special plasma nozzles – custom sizes
 Contract welding
 Tungsten electrode grinders

Plasma Spare Parts

Plasma Welding Parts

At Process Welding Systems we offer spare parts for over a dozen different plasma torches. If it is a plasma welding torch we probably have spare parts for it.

We offer:

  •  Ceramic gas cups, centering pieces, sleeves
  •  Tungsten electrodes, pre-sharpened to customer specifications
  •  Copper welding nozzles of various sizes
  •  Custom length plasma torches
  •  Custom fittings on plasma torches

 

Not only are we your plasma welding experts but we also offer:

  •  Off the shelf plasma power supplies
  •  Custom welding packages
  •  Weld lab assistance for our customers
  •  Fully automated, semi-automated welding systems

We Offer Tungsten Electrodes for Tig and Plasma Welding.

Announcing the sale of high quality, low cost tungsten electrodes for GTAW and PAW welding.  Thoriated, ceriated and lanthanated electrodes are in stock.

Both TIG and Plasma processes require tungsten electrodes to generate the arc for welding. For most applications, 2% Thoriated tungsten has been used as the general purpose electrode material. With this electrode almost all materials can be welded including aluminum.

Over the past few years, several other tungsten electrode types have been formulated that offer specific advantages for certain applications. Cerium has replaced Thorium for a tungsten alloy that offers great arc starting performance with no radioactivity like thorium. Lanthanum has also been added to improve arc starting and offers better performance for certain applications.

Here is a quick reference table with the advantages of each tungsten type;

2% Thoriated Tungsten (color Red)

  •  The standard for most applications, but is slightly radioactive. Works well for DC welding and can be used for AC welding on aluminum for non-critical applications. Has some tendency to split if used for aluminum and the electrode is contaminated.
  • Medium to good wear rates and low current arc starting capabilities
  • Good general purpose electrode

 

 

2% Ceriated Tungsten (color Grey)

  • Electrode is not radioactive and offers excellent DC welding capabilities. Can also be used for AC welding of aluminum.
  • Excellent low wear rates and excellent low current DC capabilities
  • Excellent arc starting properties

 

 

2% Lanthanated Tungsten (color Blue)

  • Electrode is non radioactive and offers excellent DC and AC welding capabilities. Can be used for AC welding of aluminum.
  • Excellent low wear rates and excellent low current DC capabilities
  • Excellent arc starting properties

The proper choice of electrode type can improve welding processes by offering improvements in arc starting and offering longer life between re-sharpening. For very low current applications, the Ceriated and Lanthanated Tungsten Electrode materials can give much better performance.

 

Our Electrodes are ready for purchase over the internet or by purchase order.  Discounts are available on orders of 10 or more boxes. The tungsten electrodes are 7” long and diameter sizes from 0.020 up to 1/8”. Visa, Mastercard and American Express orders are accepted. Contact us for pricing, technical information or free tungsten electrode samples.

 

Process Welding Systems also offers Plasma and Tig welding power supplies, weld programmers, plasma welding torches, welding lathes and positioning devices. Custom automation systems, custom welding systems are designed and built to meet demanding customer specifications with accuracy  and consistent weld quality results. Complimentary sample welding and weld development assistance are standard services.

For further information call or write: Process Welding Systems Inc., 72 Buchanan St., LaVergna, TN 37086. Phone: 615-793-7020, Fax: 615-793-7557, Email: sales@processwelding.com  www.processwelding.com