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OrionWelders.com
ch.11
CAN I BUILDUP OR ADD MATERIAL TO A WELD LOCATION?
Yes, the Orion is very versatile. In Pulse Arc Mode, filler wire can be used to add metal to a weld
location. In Tack Mode, filler wire or sheet filler can be permanently affixed to a location. Wire
sizes up to and greater than 1mm in diameter can be added. However, the user should select wire
diameters that match the size of the feature being welded. Users should also select wire with
similar material to that of their workpiece. For example: when re-tipping a gold ring, 0.25mm
gold filler wire is an excellent choice. If filling a large gap in a steel workpiece, 1mm steel wire may
be more suitable. e Orion has the energy and versatility to weld both of these, and many more
applications with ease.
CAN THE ORION WELD SILVER?
Yes, the Orion has been specifically designed with the more difficult-to-weld materials in mind.
Silver requires appreciable energy for a sustained period of time. e Orion has enough energy
and capacity to make quick work of your silver applications.
CAN I WELD DIFFERENT DISSIMILAR METALS TOGETHER?
Yes, in many instances different metals can be welded easily together with the Orion. In pulse-arc
welding the weld spot location becomes a new alloy of the two primary metals (this new alloy will
adopt new properties that may be better or worse than the primary materials).
Dissimilar metals can also be joined in Tack / Fusion Mode. Again, weld strength and properties
will depend on alloy properties.
HOW DO I DETERMINE THE BEST ENERGY SETTINGS FOR MY APPLICATION?
In Arc Mode, metals will weld according to thermal conductivity and melting point. For example,
a metal with lower thermal conductivity (e.g. stainless steel, titanium, cobalt alloys) will weld
easily because the weld heat stays concentrated in the spot. erefore, less energy is required
to weld one of these metals than other metals of the same thickness that have a higher thermal
conductivity.
Metals with higher thermal conductivity (e.g. copper, silver, gold) will require more energy to
create the same spot because much of the heat is conducted away quickly.
e melting temperature of the metal is also very important when determining the necessary
energy setting for a weld. Knowing the approximate, or relative, melting temperature of your
working metal will enable you to estimate the amount of energy required to create a spot. High
melting temperature translates to a large amount of energy required. Low melting temperature
translates into a smaller amount of energy required to make the weld.
In Tack Mode, energy is important but there are two other important factors that need to be
remembered. ese factors are electrical conductivity and contact pressure. In Tack Mode the
Orion is a full-fledged resistance welder. is means that the Orion uses a metal’s electrical
resistance to create the weld heat. Metals that conduct electricity well (e.g. copper) are more
difficult to weld in Tack Mode and require special Tack attachments to obtain a proper weld.
e second important factor when in Tack Mode is the weld contact pressure. e weld contact
pressure can be controlled by how much force you apply to the two pieces that are being welded
together. e harder you push the pieces together the lower you make the electrical contact
resistance between them and the lower the created heat. Conversely, light pressure will result in
high contact resistance and high heat.
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