Mig Welding Parameters Chart Pdf
Margit Szermer
The following basic MIG welding settings are for welding steel with solid wire. Joint design, position and other factors affect results and settings. When good results are achieved, record the parameters.
Good weld: Notice the good penetration into the base material, flat bead profile, appropriate bead width, and good tie-in at the toes of the weld (the edges where the weld metal meets the base metal).
Hello all! I program and operate a Panasonic vr006 welding robot with a genesis workcell. I am programming several new parts and one in particular is giving me some trouble. The part is made from T1 steel, and the robot is running .045 LA-100 welding wire with 75-25% argon.
The welds are rolling over, they are smaller than they are supposed to be (5/16) weld, and they just look horrific. My current settings are 6x6 weave, 3.0 weaving frequency, 260 amps, 29.0 volts, and .35 m/s travel speed. The component being welded is T1 steel and it is welding 5/8 to 5/16 material in a fillet position. What am I doing wrong?
As far as programming goes I have been doing VERY well, but i'm having so much trouble with how to set the voltage, travel speed, and amperage.... I know how I would set my welder if I was doing this by hand but the robot weld settings are throwing me for a loop.
Note - the above is using the welder setup as " Separate " or "Individual" or A/V. , where current and voltage can be adjusted separately ,
Other setups used are " mono " or " synergic" or A/% where you adjust current and voltage is auto adjusted per welders imbedded e- prom. Programs.
Thank you so much! Current project got put on hold but I had to start programming on a different component and this chart came in very handy! Will these settings still be the same if I do need to continue the weave for seam tracking?
Also the welding unit on this machine has a switch with 3 different settings, C02, Mag/Mig, or DIP Pulse. A few of the parts that are already programmed use the DIP Pulse setting, and other than forcing me to put earplugs in due to the annoying sound I have no clue what it is actually supposed to do? What is DIP Pulse and when is it applicable to use?
Hi ,
** I'm not familiar with Panasonic seam tracking , if it's any thing like some others you still need to run test weaves to setup the tracking correction parameter files.
**Regards , the three switch settings -
*Co2 - this will configure the welder power unit to use Co2 shielding gas ,[[reactance is modified to reduce splatter plus fine tunning of setup for voltage (heat) & current (amps / wire speed) for shielding gas being used ]]
*Mig/Mag - this is the configuration for running mixed gas , Argon & Co2 in different % mixes ie. Argon 80% Co2 20% plus other exotic gases when required. [[as above]]
*DIP - Pulse - this [[ as above]] setup up for mixed gas high in ,ie. Argon 95% with the view to running Panasonics version of Pulse / Spray , this is probably the reason you have LA100 wire. ( Google Dip-Pulse welding)
There are reasons for running all three types of welding procedures for different applications, read through the welding book I posted for you.
**You can have welding Characteristic files for all three , however, I'm not sure of your controller/interface ,this would decide as to weather you would need to change this switch when using the differing file types or your welder interface has the robot controller switching from the pendant ie, when a Robot is fully interfaced to its welder some manual features on the welder are over ridden and controlled only from the robot.
You should be able to ask your Robot Agent regards this or run a test weld and switch it whilst welding, just program a large stick out (1 inch) in case it flashes back to the tip.
Hope this helps .
Pcarbines, thank you so much for providing such useful information. The weld size has been a consistent 5/16 all day long But I have another problem. The current part im programming is a beam that sort of resembles a nike symbol, and I was having trouble around the radius. My solution was to do linear weave welds along the straights, and after the linear weld it begins a circular weaving weld around the radius but the management didn't like the starting and stopping due to the radius being a high stress area. I have tried removing the "CJO" command at the end of the linear weld to keep it going but I get an error. To my knowledge it is not possible to do linear weave and circular weave in the same weld on this particular robot, am I wrong? Seam tracking just doesn't seem to be enough to hold the weld into the joint. I *think* it is a G1 controller, my teach pendant looks like this:
Hi , I'm not familiar with Panasonic machines , however , are the components varying enough that you must use real-time seam tracking ?
Or are you simply over laying a simple harmonic weave on your taught path?
If the robot is travelling in Linear and is then asked to recalculate its path for circular , then their could very well be a small correction in the weave path.
Try using a triangular weave , ( if not seam tracking) these can be setup with far more control.
I believe I do need the seam tracking (but I could be wrong) as the flanges for the beams are 3\8 to 5\8 thick and there are often variations in the radius of the beams do to the steel often springing back after bending. Also the beams are welded halfway on one side, then the table rotates to allow access to the underside, and it welds the opposite side.
This is done so the beams do not warp (as badly) as they would if one side was welded all in one pass. The beams do distort a small amount while they are being welded but alternating sides was done to keep it to a minimum. The beams look very similar to these (the part that hooks on to the truck, a long straight portion and then a large radius) Perhaps I could accomplish this with touch sensing?
This online tool is programed with all Asahi/America welding equipment and piping systems to give the user easy access to weld parameters, including weld temperatures, bead height, pressure, heat soak times, and cooling times.
Under no circumstances will Asahi/America, Inc. be liable to any person or business entity for any direct, indirect, special, incidental, consequential or other damages based on any use of this website or any other website to which the Asahi/America, Inc. website is linked, including, without limitation, any lost profits, business interruption, or loss of programs or information.
Before you can even start, you have to choose the right process and take care of the mechanical and technical setup. The wire you choose, the shielding gas, and the machine settings all depend on the material.
Second, manufacturers indulge in a little bit of magic to get these numbers to advertise performance. They bevel the edges of the joint to get the thickness down. This way, less current can make the same weld in one pass.
Quality welding equipment makes things easier. For instance, to weld aluminum with a MIG welder, installing a spool gun for trouble-free wire feeding is better. Make sure your bottle of shielding gas is full, and the hookups are clean and tight.
Higher concentrations of helium or argon make for a hotter arc. The whole point of shielding gas is to shield the arc and weld puddle from oxygen. The nature of pressurized gas flow means experimenting and analyzing. In other words, trial and error.
Take this information and these charts not as gospel nor as science. This is simply a place to start. The rest of your craft is up to you. These are only guidelines. Watch your weld puddle and inspect your beads.
The process of thermal plastic welding is based on the precise balance of three key parameters: Temperature/energy, speed and pressure. If these parameters are correctly balanced, the welded area has the same high strength as the base material. Any deviation from the optimum parameter range can lead to weak weld seams. Monitoring and controlling these parameters is therefore crucial in order to achieve consistent and high-quality geomembrane welds. As shown in the diagram below, the geomembrane welding process depends on the combination of the following three parameters in the right balance.
The purpose of this graph is to illustrate the "sweet spot" for the welding parameters to optimize the welding quality. The area in which the red color is most intense indicates the point at which the three welding parameters are most likely to be in the correct ratio or in optimum balance. All three parameters are interdependent and any change to one parameter has an effect on the others. The further one or more of the parameters move out of this ideal range, the weaker the weld seam strength. Different thermoplastics have different welding properties. Therefore, the balance of the three parameters can vary depending on the composition of the thermoplastic.
The squeeze-out (see figure below) is the lateral melt extrusion that occurs during welding and is an important indicator of the welding process. It means that sufficient plasticization of the melt has taken place for a good weld. However, excessive squeezing out may indicate unsuitable welding parameters such as overheating or excessive pressure.
In addition, overheating and excessive squeeze-out at the suture can reduce the antioxidant content or cause morphological changes that make a suture more susceptible to oxidative degradation and stress cracking. Understanding and the significance of the squeeze-out helps in the professional assessment of weld seam quality.
To ensure uniform and reproducible welding, all three welding parameters must be precisely controlled: Temperature/energy, speed and pressure. The closer these parameters are to the ideal settings, the stronger the weld seam will be. The strength of the weld seam should be comparable to the strength of the base material, which can be checked using a tensiometer.
The welding parameters must be adapted to the specific conditions on site, taking into account criteria such as material type, melt flow index (MFI), surface condition and external weather influences. It is therefore recommended that test welds are carried out in advance in accordance with recognized standards, such as B. GRI-19a, GRI-19b, DVS 2225-3 or 4, ASTM D6392 or ASTM D7747. It is also important to know the limits of these standards and to apply project-specific welding parameters if necessary. The latter has become increasingly important in recent years as geomembranes with new compositions have come onto the market.
Welding below the dew point is generally not recommended as it negatively affects the welding quality.