Welding Success Factors for the Perfect Weld Seam

Related Vendors

EWM GmbH

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

In welding, high process reliability is essential, as unstable processes promote spatter, porosity, and binding defects. This way, no high-quality weld seam can be produced. The following conditions should be met for the perfect seam.

Every welding task is different. This fact makes the welding process so complex because many individually varying factors must be considered. These include the selection of the right welding filler and shielding gas, the necessary component preheating and layering sequence, as well as the adjustable welding parameters such as current, wire feed, and corrections. The welding speed and the respective torch guidance also play an important role. To master this complexity, device manufacturers are increasingly enhancing the user-friendliness of their products. Although it is still up to the welder to guide the arc correctly, they now receive essential support in setting up the equipment to achieve a stable welding process.

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Stable Arc Thanks to Stored Characteristic Curve

An example of enhanced user comfort is provided by EWM with the XQ series for MIG/MAG welding. The major advantage: The software of the devices contains stored characteristic curves for various welding tasks. The user only needs to select the right welding process, specify the material, the shielding gas, and the wire diameter, and can then start directly. On the selected working characteristic curve, the desired performance can be adjusted. The stored characteristic curves always regulate the arc with optimal stability to optimally apply the respective process for the result. This applies to welding in short arc, spray arc, and pulse arc. The highlight: With the available favorite buttons, set working points can be saved and easily recalled at any time with the push of a button. This saves users from frequently setting up preferred welding parameters.

Even when using multiple WPS, this quick selection is helpful. In addition, operators benefit from welding processes such as Force Arc puls – a MIG/MAG welding process with a heat-minimized pulsed arc for welding steel and stainless steel. The process enables higher welding speeds in the high power range due to good wetting and optimal gap bridging. This results in a deep, concentrated penetration and a symmetrical seam—almost spatter-free.

Importance of the Welding Torch for the Welding Result

When it comes to achieving optimal seam quality, it usually involves the right selection and setting of the power source, but additionally, the correct choice of welding torch is crucial. Because only with high-quality equipment can perfectly coordinated processes be transformed into high-quality seams. This especially includes the use of a high-quality welding torch. They are characterized by long durability and low consumption of wear parts. This is particularly important as components such as the contact tip, gas nozzle, gas distributor, and nozzle holder are subjected to significant stress during the welding process.

Above all, the contact tips significantly determine the quality of the arc, as they transmit the welding current to the wire electrode. With unilateral wear, the tip becomes increasingly clogged. A worn contact tip can lead to micro-arcs and short circuits. If the contact tip overheats, wear is further accelerated. It is therefore important to regularly check for wear and replace them as needed or replace them with higher-quality contact tips. It is worthwhile to use quality products from the outset. The high process stability and low wear of the components demonstrate that high-quality torches not only deliver the best weld quality but also provide economic advantages.

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