100c User Manual
56
ch.11
For all welds, the size and thickness of the metal will play a significant role in the energy settings
that you choose. Orion recommends that users start at a low energy, and work upwards until an
appropriate energy setting is found.
WILL I CONTAMINATE MY BASE MATERIAL WITH THE TUNGSTEN ELECTRODE?
ere is a possibility of tungsten contamination when the Orion user forces the welding electrode
into the weld material. However, with proper practice using the pulse-arc welding stylus
contamination is very unlikely.
DO I NEED TO USE ARGON TO WELD?
Argon is necessary to produce a clean and repeatable pulse-arc weld. Without protective argon,
oxygen may combine with the weld metal to produce brittle and porous welds. In Tack Mode,
however, protective argon is not necessary. Other protective gases can also be used, such as
pure nitrogen. However Orion recommends high purity argon. is can be purchased at your local
welding supply shop.
HOW DO I CONTROL WELD SPOT SIZE AND WELD DEPTH?
Simplified answer: Energy adjusts your spot size while your weld time controls penetration.
In reality both of these factors (energy and time) influence both welding characteristics (spot
size and weld depth). However, the above rule-of-thumb will allow good and intuitive control of
your welding parameters. It is also important to keep your tungsten electrode sharp to maintain
precise control over the characteristics of the weld spot size and weld depth.
HOW MUCH HEAT IS ADDED TO MY WORKPIECE?
e Orion is capable of extremely fine welds. In low energy settings, small amounts of energy are
added and cause virtually no heat to be added to the workpiece. During small welds involving little
energy it is possible to hold the work-piece in hand. For applications that require higher energy,
the Orion is capable of adding up to 100 Joules (Ws) of energy to a weld. Until the user is familiar
with the welding characteristics of the Orion, we recommend holding all parts with the pulse-arc
attachments (e.g. alligator clip) and not with your fingers.
WHAT IS THE SMALLEST AND LARGEST SPOT SIZE ACHIEVABLE?
e answer to this question depends greatly on the material being welded. However, spot sizes of
down to 0.75 mm and up to 3.5 mm are typical and simple to implement.
HOW DEEP CAN MY PULSEARC WELD PENETRATE?
Depends on the material being welded, however, spot depth of down to 1 mm can be achieved.
HOW LONG WILL ELECTRODES LAST?
Under normal use electrodes will last for approximately 8,000 welds. To ensure that you get the
most life out of your electrodes use argon gas for pulse-arc welding and maintain a sharpened
electrode tip during the welding process.
ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WHEN PULSEARC WELDING?
Pulse-arc joint preparation is very similar to that of general “tungsten inert gas” – TIG welding.
Some different types of weld preparation include the simple “I” seam (but joint), X, Y and V joints
(named for the way they look). e “I” seam may require no filler material, while the X, Y and V
require filler material and may require successive layers of material to be added to the joint. For
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