The Orion mPulse is a pulse arc welder designed for beginners or small shops, offering a balance of features and affordability. It is part of the Orion family of micro welders from Sunstone Engineering LLC, known for their precision and control in welding applications.
Function Description
The Orion mPulse is used for pulse arc welding, a process where high-temperature plasma quickly melts metal into a molten pool. During the weld, a small amount of shielding gas is released through the weld stylus to prevent oxygen from entering the molten pool, which helps avoid brittle, porous, and burnt-looking metal oxides. The device is designed to provide an unobstructed working view before welding and to protect the operator's eyes during the welding process through a darkening lens system or microscope with an LCD filter shutter.
Important Technical Specifications
- Weld Technology Type: Pulse Arc
- Weld Modes: 1
- Pre-Programmed Metal Settings: 0
- Customizable Save Setting: 0
- Display: 4.4" Touchscreen
- Energy Range: 3-30 Joules (Ws)
- Weld Spot Diameter: 1.0-1.25mm
- Footprint: 5.5"x5.25"x3.625" (13.79x13.34x9.21cm)
- Weight: 2 lbs. 6 oz. (1.07kg)
- Pulse Frequency: 0.5 Hz
- Microscope Magnification: 5X (>IR 16/>UV 16)
- Darkening Shutter Visibility: Shade 3 to Shade 12
- Power Supply: Internal switching power supply accepting both 120 and 240VAC.
- Electrode Compatibility: Accommodates 0.5mm and 1.0mm electrodes.
Usage Features
The Orion mPulse offers a user-friendly touchscreen interface for controlling welding parameters.
- Weld Energy Level: The device displays the current weld energy level in Joules (Ws) on the top right corner of the touchscreen. This value indicates the amount of energy ready to be released through the electrode.
- Energy Bar: Users can rapidly adjust the weld energy level by sliding a finger horizontally across the Energy Bar on the touchscreen.
- Plus and Minus Buttons: For precision adjustments, the Plus and Minus buttons allow users to alter the Weld Energy Level by one Joule per tap.
- Play/Pause Button: The welder operates in "Play" mode and will not operate in "Pause" mode. Tapping this button toggles between the two modes.
- Microscope System: If purchased, the microscope arm can be mounted in several ways (clamp to table, bolt through table, screw to vertical surface). It features an adjustment knob for focusing on the welding stylus and a tension adjustment for arm movement. The LCD Filter Shutter System provides eye protection by automatically darkening during a weld, with a visibility range of Shade 3 to Shade 12.
- Darkening Lens System: An alternative to the microscope, this system also darkens automatically during a weld and has an adjustable shade dial for lighter or darker views.
- Welding Stylus: The stylus is connected to the welder and holds the tungsten electrode. It can be angled for optimal welding and its position fine-tuned for focus through the microscope or darkening lens.
- Shielding Gas Setup: The device uses 99.996% pure argon (Argon 4.6) as a shielding gas to prevent oxidation. The gas regulator should be securely attached to a pressurized gas tank, and the flow rate adjusted between 7-10 liters per second.
- Workpiece Grounding: An alligator clip connects the workpiece to the grounding port on the welder, ensuring proper circuit completion for a weld.
- Welding Process: To make a weld, users select the desired energy level on the touchscreen, ensure eye protection is in place, attach the alligator clip to the workpiece, and then lightly touch the electrode to the workpiece. The welder will automatically retract the electrode slightly after the weld to form a desirable weld spot.
Maintenance Features
- Electrode Care:
- Workpiece Electrode Pressure: Users are advised to touch the workpiece with very light pressure to prevent material from sticking to the electrode and causing contamination.
- Sharpening: For most applications, a sharp electrode tip is recommended to improve arc initiation and focus the arc. Electrodes should be sharpened using a diamond disk on a rotary tool at a 10-degree angle, spinning the electrode with the thumb and middle finger. Sunstone recommends sharpening the electrode anytime a new workpiece is being welded.
- Flattening/Blunting: For highly conductive metals like silver and copper, especially at energy levels above 20 Ws, blunting the electrode tip (at a 90-degree angle against the diamond disk) is recommended to prevent sticking to the weld surface.
- Shielding Gas Management: Always turn off the shielding gas at the main valve when finished to conserve supply and prevent potential suffocation hazards from gas leaks in enclosed spaces.
- Cable Management: Tubes and cables can be routed through a removable guide on the microscope arm for a tidy setup.
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