MIG/MAG welding processes

We deliver progress: innovative welding processes from EWM

As a technology leader, we have been involved in research and development for decades, making welding easier, more cost-effective and especially more reliable. In doing so, we examine and analyse the complex interplay of individual components and parameters, thus optimising the entire welding process.

coldArc/coldArc puls

Perfect welding and brazing

coldArc:

Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing, plus root welding with excellent gap bridging capabilities.

coldArc puls:

The optimum enhancement for the higher power range, with focused heat input exactly where the heat is required.

  • Less distortion and reduced discolouration thanks to minimised heat input
  • Considerably reduced spatter thanks to virtually power-free material transfer
  • Impressive process stability even with long hose packages without additional sensor leads
  • Commercial torch systems, as the material is transferred without drive in the torch, causing no wear and tear
  • Easy welding of root passes in all panel thicknesses and in all positions
  • Perfect gap bridging even with inconsistent gap widths
  • Excellent wetting of surfaces when brazing thin metal sheets
  • Minimal finishing work, ideal for visible seams thanks to low-spatter process
  • Unalloyed, low-alloy and high-alloy steels and also dissimilar joints of even the thinnest metal sheets
  • Brazing of CrNi sheets with CuAI8/AIBz8
  • Brazing and welding of coated metal sheets, e.g. CuSi, AlSi and Zn
  • Root welding of non-alloyed and low-alloy steels and high-tensile fine-grained steels
  • Visible CrNi seams within the thin metal sheet range

coldArc weld seam

Minimised
heat input

Ideal
for butt welds, overlap welds, and edge welds through effective use of
positional welding

Up to
99 %
less spatter
for less discolouration and scaling by minimising the
heat-affected zone

coldArc seam pattern

coldArc/coldArc puls

  • Heat, where heat is needed, with coldArc puls
  • Root welding with coldArc: full control of droplet transfer, minimised risk of lack of fusion
  • Pass build-up and final passes with coldArc puls
  • Performance enhancement for thick metal sheets with coldArc puls
  • Perfect welding with transitional areas with coldArc puls
  • Press torch trigger to switch between coldArc and coldArc puls for secure overlaying of tack points.
  • Turn on superPuls to switch between coldArc and coldArc puls automatically for straightforward modelling of the molten metal.
  • When superPuls is turned on, the machine switches automatically between coldArc and coldArc puls for outstanding and straightforward welding in the vertical up position, without using the "Christmas tree technique".
Vertical-up weld with PF

Unique gap bridging for root passes

  • coldArc delivers perfect gap bridging, even with alternating gap widths
  • No sagging of the molten metal
  • Secure sidewall fusion even with misaligned edges
  • Total elimination of "wire stab"
  • Root passes for all material thicknesses in all positions
  • Pass build-up and final passes with coldArc puls
Perfect gap bridging
Reliable sidewall fusion

forceArc puls

forceArc puls® is a MIG/MAG welding process with a heat-minimised pulsed arc. Easy to handle and suitable for welding non-, low- and high-alloy materials throughout the entire power range.
It is characterised by outstanding gap bridging, even in the high output range and enables controlled welding with an air gap that fluctuates by up to 4 mm.
forceArc puls® – for the best steel and stainless-steel welding of all time with unbelievable cost reductions!

Advantages:

Faster welding speed

  • Symmetrical seam formation and the greatest possible seam thickness (throat thickness) on fillet welds.
  • Outstanding wetting
  • Deeper, more concentrated penetration with reliable root fusion
Virtually spatter-free
  • Finishing work minimised
  • Even for panels with scaling or very impure surfaces
Healthier
  • Minimal stress for the welder while working
  • Fewer welding fumes
  • Pleasant, quiet arc sound
  • Easy to guide (excellent wetting)
Micrograph of throat thickness

Up to
30%
total savings*
by reducing materials
and energy consumption
and shortening production times

Up to
15%
lower heat input*
for less distortion, discolouration, and finishing work

Up to
20%
greater throat thickness*,
deep, concentrated penetrationwith reliable root fusion for symmetrical seam
formation

*compared to pulsed arc

Welding of stainless steel

forceArc puls® when welding high-alloy (CrNi) steels, compared to forceArc® and pulsed arc

Weld seam comparison

The forceArc puls welding process® has up to 15 % lower heat input in the upper power range compared to pulse. This results in less discolouration and less distortion in the component.

Other advantages:
  • Minimised energy per unit length
  • Reduces distortion, discolouration and tension
  • Less finishing work (straightening, sanding, cleaning)
  • Less melting loss of alloy elements, producing greater corrosion resistance

Comparison of throat thickness with forceArc puls®, forceArc®, and pulsed arc

Comparison of throat thickness

forceArc puls® forms a symmetrical fillet weld. This is the requirement for achieving the maximum throat thickness for a given deposition rate.
Up to 20 % greater throat thickness possible compared to pulsed arc.

Looking at things from a different perspective, this means welding speeds up to 20 % faster can be achieved compared to a pulsed arc process with an identical throat thickness.

Pulse
Vs = 45 cm/min, a=4,8 mm
forceArc puls®
Vs = 60 cm/min, a=5.1 mm

Welding of steel

forceArc puls grinds comparison
 

Your benefits

  • Virtually spatter-free
  • Excellent seam appearance
  • Few undercuts, optimum wetting on edges
  • Insensitive to contaminated and scaled surfaces
  • Symmetric weld seam

forceArc

Efficient and cost-effective welding

Heat-reduced, directionally stable and powerful arc with deep penetration for the higher performance range. Unalloyed, low-alloy and high-alloy steels as well as high tensile fine-grained steels.

Deeper penetration for
reduced throat thickness
or cross-section

Fast stabilisation
of changes in stickout length

Particularly advantageous for
very narrow gaps and fillet welds

Welding with forceArc.
  • Smaller included angle due to deep penetration and directionally stable arc
  • Fewer passes
  • Less distortion thanks to heat-reduced, concentrated arc
  • Excellent root and sidewall fusion
  • Perfect welding even with very long stick-outs
  • Reduced undercuts
  • Virtually spatter-free
  • Particularly advantageous for dynamic fillet welds, for example
  • Components under load, like weight-bearing parts of bridges
  • Wagon building and steel construction
  • Unalloyed, low-alloy and high-alloy steels and high-tensile fine-grained steels
  • Manual and automated applications
  • Welded fillet welds exhibit deeper penetration
Comparison of forceArc standard spray arc

Process comparison of forceArc®/standard spray arc through TWI

Butt welds with
narrow preparation angles of
30° and 40°
fulfil the requirements of
EN ISO 15614-1:2004


Low seam volume shortens
welding time by 50 %
compared to the standard spray arc process

Fulfilment of the
requirements of
EN ISO 156141:2004
for fillet welds with
mitred profile without
undercut

Seam pattern deep penetration

forceArc/forceArc puls

  • Combination of forceArc puls, forceArc and coldArc
  • Root pass with coldArc, intermediate passes with forceArc and final passes with forceArc puls
  • Saves a welding pass with a smaller included angle
  • Perfect ignition and crater fill time with forceArc puls, welding with forceArc
  • Less material distortion due to reduced heat input
  • Lower intermediate pass temperature and minimised joint modification
  • Particularly advantageous e.g. when welding
 fine-grained steels
  • Angular shrinkage reduced in fillet welds
Combination coldArc, forceArc, and forceArc puls

Sheet metal: S 235; 20 mm
Gas: M21 - ArC - 18
Wire: 1.2 mm G4Si1
Runs: 4
Position: PC
Preparation angle: 10°
Welded on one side, without backing bar

Combination of coldArc, forceArc, and forceArc puls

Efficient and cost-effective welding

  • Overall cost savings of up to 60 %
  • Minimal seam preparation
  • Fewer passes
  • Less welding consumables and shielding gas consumption
  • Faster welding time
  • Particularly advantageous with dynamically loaded components
Efficient and cost-effective welding

Sheet metal: S 355; 30 mm
Gas: M21 - ArC - 18
Wire: 1.2 mm G4Si1
Runs: 11
Position: PB / PA
Preparation angle: 25°

Welded on one side, without weld pool backing with forceArc

rootArc/rootArc puls

The arc with optimum control of the weld pool

rootArc:

Short arc with perfect weld modelling capabilities for effortless gap bridging and positional welding

rootArc puls:

The perfect enhancement for focused heat input for the higher performance range.

  • Optimum reduction of spatter compared to standard short arc
  • Perfect for sheet metal from 1 mm and greater
  • Optimal for repair and maintenance
  • Reduced-energy short arc
  • rootArc puls for welding around transitional areas and for initial and final passes
  • Excellent, heat-reduced welding in vertical-up positions (PF) through rootArc - superPuls
  • Superb root formation and secure sidewall fusion
  • Vertical-up welds without weaving
  • Un-alloyed and low-alloy steels
  • Manual and automated applications
Vertical-down weld front view Vertical-down weld rear view

Effortless gap bridging in the vertical-down weld

  • Stable, firm vertical-down weld without any inclusions of the molten metal
  • Very good gap bridging
  • Heat-reduced, low-spatter arc
  • Superb root formation and secure sidewall fusion
Effortless gap bridging

rootArc/rootArc puls

  • Heat input, if necessary, with rootArc puls
  • Root welding with rootArc: Effortless controlling of the weld pool
  • Pass build-up and final passes with rootArc puls
  • Performance enhancement for thick metal sheets with rootArc puls
  • Switch between rootArc and rootArc puls by pressing the torch trigger for secure overlaying of tack points
  • Effortless mastery of the weld pool by changing between rootArc and rootArc puls when superPuls switched on
  • Quick and easy welding of vertical-up welds by changing between rootArc and rootArc puls when superPuls switched on

Vertical-up welds in the PF position

  • Excellent welding in vertical-up weld positions (PF) with rootArc superPuls
  • Secure formation of the root base
  • Weaving no longer required
  • Smooth bead ripples result in aesthetically pleasing weld seams
Vertical-up weld with PF

Your benefits

  • Reliable short arc welding in all positions
  • Ideally suited for vertical-up welds (PF) without using the laborious "Christmas tree technique"
  • Quick and reliable root welding in TIG quality
  • Effortless welding of vertical-up/down welds and overhead welds
  • Ideal for CO2 and mixed gas
  • Reduced-energy short arc for effortless mastery of gaps
  • Low-spatter, digitally-controlled material transfer
  • Perfect for sheet metal from 1 mm and greater
  • Excellent for butt welds and lap welds

pipeSolution

Powerful arc for rapid, secure welding with and without gap in all positions.

Absolutely reliable root welding

  • For any panel thickness
  • Can be used in any position for sheet metals and pipes
  • No sagging or fall-back of the molten metal
  • Excellent root formation
  • Extremely reliable sidewall fusion
  • Easy to use for positional welding
  • Reliable root passes even without air gap
Root welding on pipes

pipeSolution + pulse

Combined in a single machine

  • Root welding with pipeSolution: stable basis for fill and final passes
  • Passes built up with pulse: reliable sidewall fusion in any position
  • High degree of weld seam reliability and excellent quality
  • Cost-effective alternative to TIG welding
pipeSolution

Low-spatter MAG welding – optimum energy and resource efficiency

  • Inverter technology reduces energy consumption
  • Wage costs reduced thanks to higher welding speed
  • Welding pool backing no longer necessary

pipeTruck - practical orbital solution for automatic welding

  • Tremendous potential for cost reductions
  • Outstanding, reproducible quality
  • High deposition rate
  • Long arc burning times
  • Maximum ease-of-operation
  • Short set-up times
  • For root, fill and final passes, with or without air gap
pipeSolution - alpha Q 551 application diagram
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