The New Pulsed MIG is a state-of-the-art form of welding. It’s a non-contact transfer technique between the electrode and the weld puddle.
What’s in its name?
The process works by shaping a droplet of molten metal at the end of the electrode for every pulse. The appropriate amount of current is mixed to push that droplet across the arc and into the weld puddle. The transfer of droplets happens through the arc, a droplet per “pulse.” Hence, the name.
Advantages of Pulsed MIG
- It doesn’t produce spatter unlike short circuit.
- It doesn’t limit welding positions.
- Its wire use is more efficient than standard ones.
- You can say goodbye to burn-through thanks to its lower heat input.
- It’s one of the best welding processes for various applications and metal types.
Modern Pulsed MIG technology and Thin Aluminum
Here are the reasons why pulsed MIG is ideal for welding thin aluminum.
- You can control heat input. The pulse of top current supplies the good fusion with spray transfer, while the low background current cools off the weld puddle and allows it to slightly freeze.
- You can control bead profile. You can do this by using “arc control” which adjusts the width of the arc cone, allowing you to customize the bead profile. A narrow bead can help provide good fusion at a joint’s root, while a wider one can help tie in the joint’s sides. If your bead has the right size, there’s no need for over-welding and post-weld grinding.
- It offers fine travel speeds. Shifting from AC TIG to pulsed MIG can increase travel speeds by around 30% and cut heating input by over 55%.
- It starts well. Pulsed MIG technology now supplies more energy at the beginning of the weld compared to the standard MIG. This helps establish good fusion and then lowers energy to the normal limit for maximum welding features.
- It ends well. New pulsed MIG tech also does a good job ending the weld by ramping down to a cooler welding variable to fill in the crater. It also has the ability to modify the amount of ramping to make up for the different heat dissipation characteristics of carbon steel, stainless steel, and of course, aluminum.
All this information makes it worthy to check out this new technology. However, if you need to weld thicker aluminum or you’d rather wait for this modern technology to fully develop, you can check my favorite MIG welders for personal use instead.