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ch.6
To do this, start with lower Energy settings. is will minimize the initial warping as you stabilize
the work piece. Always alternate sides during the welding process – several welds in a row on
one side can exaggerate the warping, while alternating welds will pull the part back and forth
eliminating most warping. After the smaller stabilizing welds have been placed you can turn up
the energy and make the larger welds - alternating sides as done with the lower Energy welds.
Pulse Arc Welding: Weld Cleaning
For many applications the weld joint will require very little preparation. Keep the weld area clean
and free from debris. Remember that finger oils, etc. will cause blackening around the weld spot.
is blackening can easily be wiped away with a clean rag or taken off with a glass brush (one is
included with your Orion system), sand blaster or steam cleaner.
During the welding process small amounts of metal will be vaporized from the weld joint and can
be deposited elsewhere on the work piece. Typically, this thin film of metal will look black and can
easily be cleaned off with a glass brush, ultrasonic cleaner, etc.
If the welds themselves look black or discolored, it may be an indication of oxidation and can
come as a result of too little or too much argon gas flow. If the part is too hot, some metals will
readily react with oxygen to form oxide layers. If gas flow is insufficient the weld spot may be
poorly covered and oxygen may be present during the weld. On the other hand, if the protective
gas flow is too high, the gas may exit the stylus nozzle in a turbulent state. When the gas flow is
turbulent it will “grab” oxygen and other atmospheric gases and bring them inside the protective
argon gas shield. is will also lead to the molten weld puddle being exposed to oxygen.
PROTECTIVE GAS RULES OF THUMB
1. 5 - 10 PSI is a good shielding gas rate
2. e shorter the electrode is, the less gas flow is necessary
3. Gas flow may need to be increased if the electrode is lengthened.
Any discolorations that shows in titanium is an indication of poor shield gas coverage. For this
reason it may be helpful to practice on titanium to make sure your gas flow is correct. Adjust
your gas to ensure no discoloration in a small titanium weld spot. is will give you confidence of
proper argon shielding for other materials.
CHAPTER 7: METALS
Weldability of Common Metals
One very important aspect of Pulse Arc welding is a working knowledge of material properties.
is knowledge will help you understand why various metals will react differently during the
welding process. Shown below is a table of properties of some common metals. ese metals
have been arranged by melting temperature for convenience. Each of the properties listed below
will have an effect of the weldability of the metals.
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