If you or your welding team work frequently with heavy industry and equipment manufacturing, you’re probably all too familiar with difficult welding situations that come with high costs. I’m talking about welding thick metals with large joints in a variety of challenging angles and curved surfaces.

Pulsed welding is one of the top methods that experienced welders use to make those projects easier to successfully manage. Today our robotic welding experts will be talking a little bit about what it is and why it’s a great choice for many applications.

 

What is Pulsed Welding?

Pulsed welding is a variation of the spray-arc process. Where the spray-arc process can be an excellent choice for a flat or horizontal position, pulsed welding can be used in any number of angles and directions.

Pulsed welding forms a single droplet at a time by using a fluctuating wave form of the power source. The higher peak current is used to form the molten metal droplet. It is then followed immediately by the lower peak current which causes it to detach and pushes the droplet into the weld puddle.

Benefits of Pulsed Welding for Thick Materials

Pulsed welding is a superior choice for high-deposition joining of thick materials. It’s simple and quick to set up and offers a method that doesn’t require the talent of a veteran welder. In addition to those benefits, other pros include:

  • Cost-effective
  • Lower total average current than with conventional spray arc
  • Proper penetration without as much heat input
  • Low-spatter

With having less spatter and more control of the heat input with pulse, it will drastically reduce the amount of post-weld clean up along with less re-work.

pulsed welding automtion

When Not to Use Pulsed Welding

There are some cases when an alternate method to pulsed welding is preferred. It’s important to identify these conditions and use the best possible techniques and tools every time. The top two times when we recommend not using pulsed welding are with solid steel wires greater than 5/64 inch and applications that require a flux-core wire.

 

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Bancroft’s expertise & technology will improve your welding operations. From simple, stand-alone machines to full robotic welding automation systems. We are a welding equipment builder uniquely qualified to furnish reliable, cost-effective solutions. Plus, we back it up with quality installation, field service, spare parts, & support.

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