erstanding Advanced Inverter and Waveform Controls

Print Article
As compared to a traditional TIG power source, a TIG inverter with advanced controls, such as the Miller Dynasty®
350, offers increased control over the welding arc. This allows the operator to tailor the bead profile, improve arc
starting, increase travel speeds, perform better on thinner materials and thinner sections as well as experience other
production benefits.
A traditional power source uses a transformer to turn high voltage, low amperage primary power into the low
voltage, high amperage power used for welding. An inverter power source takes input power, filters it to DC, and,
using fast solid-state switches, increases its frequency up to 20,000 to 100,000 Hz, and then transforms it into
useable welding power with an advanced level of control over the arc.
With inverter technology comes the capability for high speed pulsing in DC mode. In AC mode, an inverter offers
waveform shaping with more control for optimal results. We’ll take a look at some of the benefits behind these
additional capabilities and how you can put them to use.

DC Pulsing
Pulsing refers to switching from a peak amperage to a lower background amperage. This process is useful on
ferrous metals whenever welding heat input must be minimized or penetration has to be accurately and repetitively
controlled. For out-of-position welding, pulsing may prevent weld metal sagging or drop through. In addition, thin
metals can be welded with less distortion.
“On thin stainless, a lot of times you use a pulse just as a way
to strengthen the arc. Instead of having the tendency to want to
spread out, pulsing focuses the arc,” says Bob Haye, Bob
Haye’s Precision Welding, who specializes in welding needs for
the aircraft and defense industries.
High speed pulsing can also lead to faster travel speeds. When
H.L. Lyons, a refrigerator door fabricator in Louisville, Ken.,
switched from conventional to inverter TIG technology, they cut
welding time in half, reduced finishing time by a third and
allowed each welder to finish almost twice as many products
per shift.
Traditional technology usually allows for 1 to 10 PPS. A
common range for an inverter is 100-500 PPS, which provides
increased penetration, arc stability and travel speeds. More
advanced inverter power sources, such as the Miller Dynasty
350 and 700, can pulse at 5,000 PPS, which further enhances Inverters with advanced controls allow users to
stability, increases travel speed and is beneficial in automated tailor the arc to their needs.
applications.
Some inverter power sources allow the user to set the
percentage of time spent at peak and background amperage to further control heat input and improve weld bead
appearance. Increasing peak-on time increases puddle fluidity and helps to fine-tune penetration. A good starting
point is to set peak time to 50-60 percent of each cycle. This can then be adjusted to suit your particular application.
A few inverters allow you to set the background amperage, which affects heat input into the part and helps
determine the size of the weld puddle and arc, especially during the background portion of the pulse cycle at low
PPS settings. At low pulse frequencies, the background amperage should be high enough to keep the puddle from
solidifying; it should shrink in diameter but not solidify. For stainless and carbon steel, a good starting point is 20-30
percent of peak amperage.
 AC Output—Welding Aluminum and Magnesium
Advancements in electronics allowed for the development of the
squarewave, which solved the problem of the sine wave arc
extinguishing itself. The development of inverter technology took AC
control even further, refining the squarewave to a nearly instantaneous
transition between polarities, eliminating the need for HF arc stabilization
when welding with AC and allowing precise control of AC balance, output
frequency and independent EN and EP amplitude control.

AC Output Frequency
Conventional technology limits AC frequency to 50 or 60 HZ, the same
as single-phase input power. Inverter technology, however, allows output
frequency to be adjusted anywhere from 20 to 400 Hz. Increasing AC
frequency provides a more focused arc with increased directional control
and a narrower bead and cleaning area. A lower frequency softens the
arc and results in a wider weld puddle and bead.
An arc cone at 400 Hz is much tighter and more focused at the exact
spot the electrode is pointing than an arc cone operating at 60 Hz. The
“I’ve tried the triangular wave and result is significantly improved arc stability and increased penetration,
found a setting that was just able to ideal for fillet welds and other fit ups requiring deep, precise penetration.
weld phenomenally on thin material,”
said Neal Vesco, of Vesco Metal Craft, AC Balance Control
shown here working on a quad rugby AC Balance Control adjusts the balance between penetration (EN) and
chair. cleaning action (EP). Inverter-based TIG welders allow the operator to
set the amount of EN from 30 to 99 percent for greater control and fine-
tuning of the cleaning action.
More cleaning action is not necessarily better. To produce a good
weld, you need only a .1-in. etched zone surrounding the weld,
although different joint configurations may have different
requirements. Using the least amount of cleaning action (setting the
balance at the highest practical EN) necessary helps maintain the
tungsten point, reduces balling and provides for deeper, narrower
penetration.
Insufficient cleaning action results in a “scummy” weld puddle. If the
puddle looks like it has black pepper flakes floating on it, add more
cleaning action to “blast” away oxides and other impurities. Too much
cleaning action can lead the tungsten tip to ball and reduce
penetration. A good starting point is 75% EN. Fine tune it from there.

Amplitude Control
Independent amplitude control, available only on some inverters,
allows the EN and EP amperage values to be set independently.
Independent control of the EN and EP portions of the AC cycle allows
the operator to direct more or less energy into the work piece, as well
as take heat off the tungsten.
For example, when welding a thick piece of aluminum, the operator
can put 250 amps of EN into the work and only 60 amps of EP into Too much cleaning action can lead to the
the tungsten. This provides faster travel speeds, faster feed of filler tungsten tip balling.
rods, deeper penetration, and the potential to eliminate pre-heating.
Some companies cut production time by up to two-thirds using this
technology.
Independently increasing EN amperage while maintaining or reducing EP amperage also narrows the arc cone, lets
the operator use a smaller diameter electrode to make narrower welds and may allow the use of straight argon in
place of argon/helium.
Waveforms
Some inverters also bring control over the waveform itself to meet a specific requirement or operator preference.
Some of the waveforms include:

 Advanced Squarewave, which gives fast transitions for a responsive, dynamic and focused arc for better
directional control.
 Soft Squarewave, which provides a smoother, softer arc with a more fluid puddle than the squarewave.
 Sine wave, which gives the soft-arc feel of a conventional power source, while using square transitions to
eliminate the need for continuous HF.
 Triangular wave, which combines the effect of peak amperage while reducing overall heat input. Leads to quick
puddle formation and, because of lowered heat input, reduced weld distortion, especially on thin material.

Achieving maximum productivity often depends on the inverter’s ability to produce a weld bead profile and
characteristics that meet the application needs without over-welding, under-welding, excessive post-welding
grinding or weld repair. In critical or high-volume applications, only advanced AC controls provide this benefit.
"With the Dynasty [an inverter based AC/DC TIG power
source by Miller Electric], you can weld much quicker,"
says Derek Grundler, production manager of A1A Dock
Products, Hollywood, Florida. "And when you strike an
arc, it draws a puddle at least twice as fast as
conventional TIG."
Grundler found that the inverter-based TIG source
increased production by 18 percent, provided a payback
time of two weeks per machine and improved weld bead
consistency. Neal Vesco of Vesco Metal Craft, leading
manufacturer of rugby wheelchairs, found production
increased by approximately 30% by switching to an
inverter based TIG power source, finding the triangular
Two arcs one at 150 HZ and one at 40 HZ. Note the wave especially useful on thin aluminum. Both Grundler
and Vesco also noted an improvement in bead
thinner weld bead at the higher frequency and the
appearance.
wider one at the lower frequency.
"We only have a 1/8-in. white line (etched zone) around
the weld," says Grundler. Describing how the new system eliminated post-weld cleanup requirements and protected
the aluminum finish. "With conventional TIG, no matter what you do, you're going to get a 1/4-in. white line around
the weld."

Riding the right wave in aluminum welding

AC GTAW waveform controls, options optimize arc performance
THE FABRICATOR APRIL 2009
MAY 19, 2009
BY: JOHN LUCK
Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, often is thought of as the most difficult
welding process to master. Fortunately for welders, several technological advances have occurred, forcing many to
rethink their assumptions.
Alternating current (AC) GTAW is no longer just a way to blast through oxides to weld the aluminum underneath. AC
GTAW inverters—through new arc controls and waveform options—have made it easier for operators to tailor arc
characteristics, weld puddle behavior, weld bead profile, penetration, and appearance. Such controls include those
for:

 AC waveform shaping.
 Independent control of amperage values during the electrode negative (EN) and electrode positive (EP)
portions of the AC cycle.
 Adjustable AC output frequency.
 Extended balance control.

Selecting an AC Waveform
Today's AC GTAW inverters let the operator choose from four different waveforms: advanced square wave, soft
square wave, sine wave, and triangular wave (see Figure 1). Each wave changes the arc and puddle characteristics
as well as the penetration profile.
Advanced square wave. The advanced square wave waveform offers fast transitions between EN and EP for a
responsive, dynamic, and focused arc with better directional control. It forms a fast-freezing puddle with deep
penetration and fast travel speeds.

Soft square wave. Soft square wave provides a smooth, soft, "buttery" arc with a fluid puddle and good wetting
action. The puddle is more fluid than with advanced square wave and more controllable than with sine wave.
Sine wave. The sine wave offers a soft arc with the feel of a conventional power source. It provides good wetting
action and actually sounds quieter than other waves. Its fast transition through the zero amperage point also
eliminates the need for continuous high frequency.
Triangular wave. The triangular wave offers peak amperage while reducing overall heat input into the weld. This
leads to quick puddle formation, low weld distortion, and fast travel speeds. It is especially good for welding thin
aluminum.

Independent Amperage Control

Independent amperage (or amplitude) control allows the EP and EN amperages to be set independently. This
precisely controls heat input into the work and even takes heat off the electrode. The EN portion of the cycle
controls the level of penetration, and the EP portion affects the arc cleaning action.
A current with greater EN than EP creates a narrow bead with deeper penetration and no visible cleaning action,
ideal for fillet welds and automated applications. A current with greater EP than EN gives the operator a wider bead
with less penetration and clearly visible cleaning action, ideal for buildup work (see Figure 2).
For example, when welding a thick piece of aluminum, the operator can pour 350 amps of EN into the weld and only
175 amps of EP into the tungsten. This allows faster travel speeds, faster filler metal deposition, deeper penetration,
and the potential to eliminate preheating. Case studies about GTAW inverters with independent amperage control
suggest that companies can cut production time by as much as two-thirds.
Increasing EN while maintaining or reducing EP also permits the use of a smaller-diameter tungsten. This takes
heat off of the tungsten and more precisely directs it into the weld. Companies have reported that this has allowed
them to purchase thinner-diameter electrodes, which are less expensive than the thicker variety.

Adjustable AC Output Frequency

Adjusting the AC frequency—the number of times per second that the direction of the electrical current completes a
full cycle—gives welders excellent control over bead appearance and penetration profile (see Figure 3). While
conventional GTAW technology limits AC frequency to 50 or 60 hertz (Hz), new GTAW inverters allow frequency to
be adjusted anywhere from 20 to 400 Hz.
Frequencies between 80 and 120 Hz are comfortable to work with, increase control of the arc, and boost travel
speeds. Setting the frequency from 120 to 200 Hz provides an ideal frequency for most aluminum welding. An arc
cone at 400 Hz is even tighter and more focused; improves arc stability; and is ideal for fillet welds or other fit-ups
requiring deep, precise penetration.
Figure 4 provides an example of a weld done at 150 Hz and 40 Hz.
In general, increasing AC frequency provides a more focused arc with increased directional control and a narrower
bead and cleaning area. This improves performance when welding in corners, on root passes, and in fillet welds. A
narrower bead also prevents overwelding, which is a significant waste of time and filler metal.
Turning up the frequency while turning down the balance (see next section) has allowed some manufacturers to
reduce scrap and increase productivity by achieving deeper penetration without putting too much heat into the part.
This achieves the desired bead profile and production speed without warping the part.
A lower frequency softens the arc and results in a wider weld puddle and bead. This removes impurities well and
transfers the maximum amount of energy to the weld piece, which speeds up applications requiring heavy metal
deposition, such as building up a worn part or making a fill pass. A good starting point for such applications is 60 Hz
with adjustments made from there.

Extended Balance Control

AC balance control allows the operator to adjust the balance between the penetration (EN) and cleaning action (EP)
portions of the cycle. Some inverters have adjustable EN as great as 30 percent to 99 percent for control and fine-
tuning of the cleaning action.
For instance, if the operator sets EN at 70 percent, it means that 70 percent of the AC cycle is putting energy into
the work, while 30 percent of the cycle is cleaning.
A good starting point on clean aluminum is between 60 percent and 75 percent. Some companies have even
experimented with AC GTAW on ferrous metal, where a few extra percentage points of cleaning action proved
beneficial.
Extending the EN portion of the cycle narrows the weld bead, achieves greater penetration (good for thick welds),
and may permit increased travel speeds (see Figure 5). It also reduces the size of the etched zone for improved
cosmetics. It reduces balling action, increases tungsten electrode life, and may permit the use of a smaller electrode
to more precisely direct the heat into the weld.
Reducing the EN portion of the cycle widens the weld bead and decreases its penetration (see Figure 6), which
may be beneficial in catching both sides of the joint.
It produces a greater cleaning action to remove heavy oxidation and minimizes penetration, which may help prevent
burn-through on thin materials. Reducing the EN cycle, however, decreases tungsten electrode life and increases
balling action because more heat is being directed into the electrode. This creates a large ball at the end of the
tungsten and causes the arc to lose stability, making it hard to direct the arc weld puddle.
In terms of bead appearance, too much penetration (higher EN) can result in a scummy-looking weld puddle that
may still contain oxides and inclusions. Increasing cleaning action will blast away those contaminants. Ultimately,
operators should practice adjusting balance control on scrap material and find which settings work best for them.