Heat-reduced welding with defined penetration.

With the mechanically supported droplet detachment technique – patented by our long-standing technology partner – SKS Welding Systems respond to the demands of the market. In perfect interaction with the innovative Frontpull Weld Package, robust welding components enable the new microMIG process. This process provides a spatter-free material transfer at a defined heat input. The result is a process that, on the one hand, can be set to a considerably reduced heat and, on the other hand, reliably ensures the required penetration.

The microMIG process is implemented without the use of expensive additional equipment as the Frontpull Weld Package uses standard components. This makes the microMIG process not only available for new welding machines, but also for existing systems of the LSQ/Q80 series by simply retrofitting the required Frontpull equipment.

Process description: microMIG

With conventional spatter and heat-reduced welding processes, the deposition rate is directly linked to the frequency. This means, a higher deposition rate also requires a higher frequency – which has a negative impact on the wear and tear and service life of the motor, liner and contact tip. The microMIG technology is based on a completely different concept. Here, sequences of the pulse process are placed between the mechanical droplet detachments. The higher the desired deposition rate, the higher are the pulse sequences. A higher deposition rate thus reduces the frequency of the wire movement.

microMIG - How it works:

A pulse sequence [3] (specific number of pulses) is used to create the weld puddle and indirectly set the wire feed speed (deposition rate). The last pulse is used to create a droplet of molten wire at the wire end. Next, the wire is fed until contact with the workpiece with low current [2] and the droplet melts into the puddle. Upon contact [5] the turning direction of the wire feeder is reversed and the wire is retracted for a defined time [4] with low current. After re-ignition of the arc, the turning direction is reversed again (forward) and the pulse sequence restarts after a short waiting period [1].

The microMIG process was implemented using standard components. These components have been used in the industry worldwide for thousands of times. A wire buffer is not required. The related consumables (liner, drive rolls, center guides) are available for aluminum wires with a diameter ranging from 0.8 to 1.6 mm.

Process description: microMIG-cc

Mechanical droplet detachment without pulses in between
An active arc builts up between the forward-fed wire material and the workpiece. A relatively high current (base current) initiates the melting of the wire electrode – a droplet emerges. This droplet is fed into the weld bath. When contacting the weld bath, a short circuit resolves the arc. After that, the direction of the wire feeding changes backwards. The wire material is retracted from the weld bath. With this mechanically supported retraction of the wire, the droplet is directly transferred into the weld bath. The contact and thus the short circuit dissolves – the arc reignites. After ending the retraction of the wire material, the preset arc length is restored, the feeding direction is reversed again, and the process starts to repeat.