Getting the most from your GMAW power source

The Deltaweld 350 welding power source with Intellx Pro feeder includes EZ-Set technology, which simplifies parameter setup based on material thickness. This removes complexity and helps decrease time spent on setup and welder training.

Operator factor—the percentage of a welder's working day that is spent welding—is tied to the ability to maintain a high percentage of arc-on time through a shift. If an operator is busy adjusting their settings, welds aren't being made. It's that simple.

Determining the correct weld settings for a job has gone high-tech in a number of different ways over the past few years. The simplest incarnation of this is the availability of weld setting calculator apps for smart phones. Rather than pulling out a paper chart, it's now possible to answer a few simple questions on your phone to arrive at the correct weld parameters, electrode/wire type, as well as getting other information on techniques and process information for GTAW, GMAW, and SMAW.

Newer equipment, however, takes the weld setting calculator out of the equation altogether. With a few button pushes, weld presets allow operators to get to an acceptable range for welding. Another recent addition to new power source feature sets is a "synergic" function, where arc length or voltage adjusts automatically when wire speed is changed. This simplifies equipment setup for a particular wire, gas, and material combination.

For those looking for a welding power source for their home shop rather than for steady production work, technology is available that sets optimal parameters automatically based on material thickness and wire/rod/tungsten diameter. This way, the welder can focus on proper technique rather than settings.

The challenge in today's industrial space is that most shops have welders of various skill levels handling machines with a number of advanced features. At times, this can make it harder to set up equipment.

Preset technology simplifies this. For welders who don't know where to set wire feed speed or voltage but know the material thickness, this technology will help them set their parameters. In Miller Electric Mfg. LLC's version of this technology, a welder operating a power source that contains EZ-Set functionality will select a program that contains the EZ-Set feature. They then can adjust the wire feed speed knob on the display screen until it shows the desired material thickness.

However, in the industrial space, these presets are more of a guideline to be used as a starting point. They are not supposed to be prescriptive because some points along the synergic line may not be desirable welding parameters. This can include a globular mode of transfer in the middle of the range on a synergic GMAW program. Alternately, EZ-Set could recommend a spray parameter for 3/8-in. material when the shop runs a short-circuit parameter, so the welder may need to adjust to meet shop requirements. With most systems, the presets can be turned off to adjust to unique configurations.

Ensuring operators use the correct settings on more advanced machines is achieved by setting "memory slots" on the machine with different settings based on the parts welded in the shop. For instance, with the Continuum series of power sources, up to 98 memory slots are available, making it possible to set up different parameters in each of those memory slots. This can be an effective way to manage a very complicated assembly. Most power sources typically have between two and eight memory slots that are easily accessible from the user interface. In most shops, that is sufficient.

Memory settings can be particularly useful for keeping inexperienced welders in a prescribed operating window. For instance, using locks and limits will lock a welder into that prescribed operating window, which can be set by the weld engineer or manager to ensure operators stay within a welding procedure specification.

The computing power of newer welding machines means that whether a shop is working in GMAW, GTAW, or SMAW, technology is available to help simplify basic setups and, in multiprocess power sources, ensure welders can switch to the correct process automatically. Each creates efficiencies that can increase arc-on time and keep operators focused on what matters—quality part production.

Jason Bonnell is product manager, industrial equipment manufacturing, Miller Electric Mfg. LLC, 1635 W. Spencer St., Appleton, WI 54912, 920-734-9821, [email protected], www.millerwelds.com.