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Modern, ultra-lightweight places demands on welding technology that simply cannot be met with traditional
shielding gas welding processes. Variants of the robust arc welding process need to be developed which feed very
little heat into the material but which still guarantee strong connections. The coldArc is a variant of the MIG/MAG
process that meets these demands. In this process, all interventions in the process flow are carried out directly in
the power source without mechanical intervention in the wire feed, which means that standard welding torches can
be used and the process can also be used to produce excellent manual welding results.
1
Introduction
Phase 2
Short-circuit
Phase 3
Short-circuit resolution
and renewed burning phase
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Phase 1
Arc burning
Phase 3
Short-circuit resolution
and renewed burning phase
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Development work with the aim of achieving a lowenergy process without mechanical intervention in the
wire feed process, resulted in a process variant in
which all necessary interventions in the process take
place in the power source alone. This variant of the
MIG/MAG process, known as coldArc, is also a short
arc process, and is called such due to the cyclical
change between the arc and short circuit phases. As
the electrical output during the re-ignition process is a
critical criterion for successfully welding thin sheets,
active intervention is carried out in the outline of the
power intake for the overall process, however, in other
words during the arc phase, in the short circuit phase
and especially when re-igniting the arc, Figure 2, the
voltage outline remains the same as in the normal
short arc process.
Phase 2
Short-circuit
5.
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Figure 3
Sequence of the material transfer in the coldArc process taken from high-speed pictures, 8,000 B/s.
The copper-based wires have a melting point of
around 1000 C. In comparison to the same type of
MAG welding, the heat loading of the surface layers is
already therefore considerably reduced. These are
even more protected if MIG brazing is carried out
using zinc-based solder with melting intervals of
around just 450 C. The use of these wires is only
possible however, if the short circuit current is strictly
limited and the general heating feeding is also
reduced considerably. The vaporisation temperature
of the zinc/aluminium alloys used for arc brazing is
just under 900 C, in other words still below the
melting temperature of copper alloys.
PS
coldArc arc
Output on
re-ignition
on re-ignition.
For some time now, different welding techniques have
been used on surface-coated metal sheets, in other
words, using copper-based filler material for arc
brazing. This helps to preserve the zinc layer, but
difficulties can arise if there is a larger air gap. With
the coldArc process, on the other hand, even larger
air gaps can be bridged with the filler material.
Figure 5 shows 0.8 mm thick zinc-plated steel metal
sheets which have been brazed manually with air
gaps of as large as 4 mm in the vertical down position
using 1.0 mm CuSi3 wire with a moderate current of
50 A and a voltage of 13.5 V coldArc.
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wires;
Top: Overview picture
Bottom left: Detailed picture
Bottom right: Car door
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Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Literature
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