Pulse MIG provides perfect surface finish

Quality welding of ever thinner exotic metal alloys can be achieved by switching over from the TIG to a cooler pulsed-MIG process that uses self-calibrating arc control.

Quality welding of ever thinner exotic metal alloys is one of the challenges of today and many companies see the point in switching over from the TIG to the MIG welding process which is 6-10 times faster.

Precise control of a shorter, controlled arc combined with a harmonized pulse current makes colder welding of the sheet metals possible and ensures perfect penetration.

The digital Migatronic Flex welding machines with self-calibrating arc control are now being used by many of Europe's leading automotive manufacturers for welding of sheet metal in both aluminium and high tensile steels.

The Flex 4000 is the first welding machine with Migatronic's revolutionary Quattro Pulse.

The Quattro Pulse is controlled via the software and produces optimal droplet pinch-off of the wire on the rear flank of the pulse peak and results in a shorter arc and a colder weld pool.

Digital connection of several pulses with varying energy will allow the Quattro Pulse to create perfect penetration at a relatively lower average current.

Especially at low current intensities in thin materials the full effect will be achieved with a minimum of heat input to the work piece.

Thus the material will keep its mechanical properties and there will be a minimum of tempering and deformation.

The Migatronic Flex 4000 is programmed with a Smartcard that stores welding know-how and synergic welding programs, standard, edited or tailor-made settings for fixed welding procedures, specific jobs and/or for the individual welder.

Via the integrated card reader the requested welding program is transferred directly to the data bank of the welding machine.

As standard the Flex 4000 is supplied with a Smartcard with a typical selection of MIG/MAG programs from Migatronic's dynamic program data bank.

The data bank is continuously updated in co-operation with product developers and suppliers of materials, welding consumables and gases.

Special programs can be designed for direct use for a WPS and are available for MIG brazing, Superduplex and special gases etc.

MIG brazing of, for instance, galvanised sheet metal in high tensile steels is being increasingly used in the automotive industry, and the procedure for MIG brazing the new GM Opel Vectra C with fully galvanised body has been determined and documented by Migatronic.

In the Migatronic brazing process the welder uses a special wire of copper and silicon with a fusion temperature of 960-1000degC, which is approx.

600deg under the temperature in traditional MIG/MAG welding.

The Flex 4000 has achieved excellent results in a comprehensive field test: the welding machine is perfect not only for welding sheet metal but also for extending the limits for the welding jobs that can be MIG brazed.

Every conceivable user-friendly intelligence is incorporated in the Flex 4000 welding machine, so justifying the Migatronic slogan 'Switch on, press and weld': self-calibration of the arc and key parameters such as current, voltage, gas flow etc., individual hot start, undreamt-of programming options and self-adjusting frequency, allowing the machine automatic adjustment to the changed stickout that constantly occurs in manual welding.

(This was Manufacturingtalk's Top Story on 27 January 2003).

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