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System 1:
Orion Pulse 250i, pulse arc and resistance welder
The Orion Pulse 250i has an advanced settings screen that allows operators to choose which capacitor banks to use for the welds and how much voltage to apply for how long. This customization makes it possible to alter the discharge curve to become more favorable for harder to weld metals such as aluminum.
For sample 1 the primary weld is set to use all banks at 26.5v energy and 40ms length. The ignition is set to standard + and no agitation is used. Using all the banks helps to flatten out the discharge curve and helps avoid digging holes in the aluminum during the weld. A row of overlapping spots would be the most effective in this situation and if possible it would be best to weld the opposite side as well.
Sample 2 can be welded with the primary weld set to all banks at 30v energy and 40ms length. The alloy formed when the two metals fuse creates a somewhat brittle bond and the welds can be broken much easier than with the aluminum to aluminum samples.
Sample 3 is welded using all banks at 35.5v energy and 12ms length. The tip of the electrode is slightly blunted for these samples since the sharper tip has a propensity for digging holes in the thicker metal.
The settings outlined above are a good place to start and yield acceptable results but as you experiment further with the product you will be able to dial in the settings for even better results.
Summary:
The Orion Pulse 250i is able to successfully perform these sample welds. The touch screen user interface and highly adjustable waveforms make it ideal for quickly finding the correct settings for welding aluminum and other difficult to weld metals. The Orion 250s would also be able to perform the welds but lacks some of the waveform customizability of the Orion Pulse 250i.
Let us know if you have any questions.
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Email: sales@SunstoneWelders.com
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