Where Pulse Waveforms Meet Excellence

July 7, 2009

I thought that others might benefit from this Q&A on pulse GMAW welding.


I have a cell that I am working on that has a pulse capable power supply.  It currently runs .035″ solid lincoln wire.

If I was to experiment with pulse, somewhere in the back of my mind I thought you always taught us to go up to .045″.  Is that correct or am I getting confused with some other application?

Thanks, N.

N –

Thanks for the question. You are correct.  This is the reason why various welding “experts” say that going to pulse causes a reduction in penetration that is often a problem. Going up one wire size is the “trick” that puts you back in the same ballpark on penetration, while gaining the benefits that pulse can bring – such as a longer arc length for lower spatter, spatter that is cooler and much less tenacious in adhering, and a different bead profile that often brings advantages.

Basic Variables of the Pulse Waveform

Basic Variables of the Pulse Waveform

Now, once you’re in pulse, then the window of opportunity opens in terms of waveform selection/alteration to optimize your weld characteristics for most advantage. Some say that “a factory waveform is already optimized and pulse is pulse”. That’s the voice of ignorance.  The Pulse-GMAW process is the waveform, which produces specific results. Repeatability of the results hinges on the consistency of that waveform’s reproduction and stability.  Each and every waveform produces a unique balance in target criteria such as travel speed, deposition rate, resistance to burn-through, spatter production, out of position capability, fit-up gap variations, sidewall penetration, bead width/depth, etc.  Sure, the “factory waveform” was optimized, but probably not for your factory or specific application. Odds are that the “canned” waveform does not have the target balance you need to get highly optimized results like fast cycle times, zero rework, and no quality concerns.    Read the rest of this entry »

Advice for Recruiter Client’s Welding Engineer position – #2

March 7, 2009

This is the SECOND in a series of responses from my e-mail archives, which I’m publishing because the Recruiters noted them as helpful advise and perspective on their client’s Welding Engineering search. Most recruiters and even most HR Managers have little experience or exposure to the Welding Engineering segment because it’s so small. It’s my hope that these will help increase understanding of some of the realities, needs, obstacles and rewards in finding and retaining degreed welding engineers.

I read the job description you sent, and Wow. To softly summarize, your Asian-car-company client would be well advised to change their strategy on this position. Why not wisely select a Smart Welding Engineer and let them do their job?

OK, let me take the velvet gloves off for a minute. Don’t take this wrong, but after reading the job description, here’s my very blunt assessment:

“Welding Specialist” is a bad start for the job title. It might be simple ignorance, it could be an inadequate Asian cultural translation, it could be mimicking poor practices in the “Big Three”, or it could be someone’s “clever” idea to save money, but that job description is the role of a BS-degreed Welding Engineer. That’s what they are trained to do: the average BSWE (or equivalent) has 3,000 – 4,000 hours of classroom and hands-on training in the welding processes.  Filling that welding engineer role with anyone else is like taking a CFO position, relabeling it as “Financial Supervisor”, and requiring candidates to have any Bachelor of Arts degree instead of an MBA.  Yeh, a stunning cost-savings idea there.

If they don’t hire a BS-degreed Welding Engineer for this position, it will probably save them $20-40k a year and cost them a minimum $500k (if not several $M) in the first 3 months of startup alone, vs a qualified Smart Welding Engineer. But unfortunately, as that happens, there’s rarely anyone around who’s qualified enough to recognize the losses and missed opportunities and attribute them to targeting and hiring an unqualified person. Even if the “Welding Specialist” knows it, are they likely to be explaining to management that they can’t do their job justice? 

Read the rest of this entry »