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Welding's Wave of the Future
 The use of high-performance metals in a broader variety of applications has helped drive the need for an equally sophisticated welding alternative, in industries ranging from heavy equipment manufacturing and industrial fabrication to automotive and robotic applications. George Blankenship, Vice President, Equipment and Process Development, The Lincoln Electric Company, explains, "Our goal was to build one power source that captures the technology of all the best power sources on the market today, in one package." He says the company's latest machine provides "one multi-process power source with built-in intelligence, allowing users the flexibility to complete all of their GMAW welding applications with only one machine." Previously, switching welding modes would have required the use of several different power sources or the time-consuming task of resetting all of the machine's parameters for new welding procedures. While some machines offered limited control of some variables, they did not allow modification of the waveshape. Now, Waveform Control Technology™ makes it easy to download complete new machine dynamics from a computer to the machine's internal memory system. Performance benefits of the waveform-controlled inverters include positive arc starting, exceptionally smooth arc welding performance, and multi-process welding output (CC/CV and pulse.) Another performance benefit of machines such as Lincoln's Power Wave® units is their adaptive control capabilities. While most pulse machines do not consider the differences between material types, these power sources maintain arc consistency even when longer stick-outs are required, such as when vertical welding in tight corners. The machine literally "juggles" multiple variables simultaneously to produce the ideal arc for the situation. The consistent repeatability that this degree of control produces makes machines such as Lincoln's STT® II and Power Wave 455 ideal for use in robotic arc welding applications. The technology allows for more advanced seam tracking and precise control of weld penetration. The machine's software eliminates the need for an additional wire feed control box, which is traditionally needed for robotic welding. Yet this versatile technology also applies to small fabricating shops that want the flexibility of using one power source for all their GMAW welding needs.
Machines that control the waveform enable the operator to achieve unequaled performance with many different
metals, on a wide variety of applications. The built-in "intelligence" of the machine enhances the operator's
skill level, taking charge of the welding output while the operator concentrates on achieving good welds.
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As a result of switching to this new inverter-based technology, companies have documented higher productivity
rates, generated by the ease of welding and lower material costs that come from improved weld consistency.
Precise control of arc dynamics allows it to be used as either a fast-follow process at high speeds or a
high-deposition fast-fill process. Waveform control provides an extremely stable arc that easily handles
out-of-position welds. It results in less cold casting (lack of fusion) than short arc welding, and requires
lower heat input than spray arc welding at a given wire feed speed. Additional benefits of the technology
include a cleaner shop environment because of reduced welding fume and spatter, and lower training costs for
workers. Typically, a high percentage of argon gas is used with this process.
Power sources that allow the selection of different waveforms have the ability to weld with several different
processes on a wide variety of materials. One of Lincoln Electric's Power Wave machines, for example,
incorporates more than 60 welding programs that include GMAW, pulsed GMAW, FCAW, SMAW, and even air arc
gouging. Programs are optimized for mild and low alloy steel, stainless steels, aluminum, and silicon bronze.
Other programs are also available for high-performance metals such as nickel alloys and copper-based alloys, and
custom waveforms can be developed to address very special applications.
