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Considerations for Switching to Pulsed MIG and Pulsed TIG Welding in Thin Gauge Aluminum Applications

Tuesday, February 28th, 2012

Pulsed welding equipment has been around for a long time. However, technical advancements have made pulsed welding equipment much easier to use and, consequently, better for training operators to make quality welds. Some of the new Pulsed MIG and Pulsed TIG welding technologies provide excellent welding performance on thin gauge aluminum.

Upgrading to modern Pulsed MIG or Pulsed TIG inverter technology could potentially help you increase productivity, improve weld quality, reduce weld costs, and boost operator efficiency. That being said, you will need to study your particular application in detail to determine which, if any, of these processes is appropriate for you. Remember, pulse welding is not the answer to all aluminum welding-related problems.

Read the whole article here.

Manufacturer Succeeds on Aluminum with Pulsed MIG Welding

Monday, August 15th, 2011

Check out one of our latest case studies on Greenheck Fan, a Wisconsin manufacturer who has experienced a number of welding efficiencies by relying on Pulsed MIG for welding aluminum:

As customer demand drove the company to shift much of its product to be fabricated of aluminum (lightweight, aesthetic versatility), Greenheck addressed the need to optimize its aluminum welding applications while maintaining the ability to weld mild, stainless and galvanized steels effectively. The solution: an advanced Pulsed MIG welding system (Miller’s Invision™ MPa Plus System) that not only improved weld quality, but due to built-in efficiencies, also helped the company streamline its welding operations. Improvements include:

  1. Improved welding of thinner aluminum (reduced burn-through, blistering, reduced distortion).
  2. Improved productivity (faster travel speeds).
  3. Improved starts and stops to the weld (ensures quality).
  4. Standardizing on a larger diameter wire (greater deposition, lower cost per pound, simplification of inventory and equipment outlay).
  5. Dual wire feeder makes it fast and easy to switch between types of filler metal.
  6. Improved weld aesthetics compared to conventional MIG welding on aluminum.

Read the whole story here. Check out videos from our visit with Greenheck below.

Advantages of Pulsed MIG welding on aluminum:

Simplified Welding Operation at Greenheck Fan:

Miller’s Introduces New XMT® 450 MPa Multiprocess Welder

Tuesday, June 21st, 2011

Miller is excited to announce today the introduction of the new XMT® 450 MPa multiprocess welder. This new machine offers one of the industry’s most powerful and consistent options for Pulsed MIG welding. It features increased power and duty cycle ideal for heavy carbon arc gouging and large diameter welding applications. It is also optimized for MIG, Stick, TIG, and Flux Cored welding processes.

This powerful new inverter-based power source features the reliability and arc performance of the XMT 350 MPa but with more amperage, exceptional power efficiency and additional programs for Pulsed MIG welding with up to .052- and 1/16-inch wires.

For more information:

To view the product page, please click here.

To read the entire news release, please click here.

 

Case Study: Bollinger Shipyards and the AlumaFeed System

Friday, June 3rd, 2011

You’ll be hearing a lot from us over the next few months on aluminum. One of the first things we’d like to share with you is this great snapshot of the aluminum welding needs at Bollinger Shipyards in Lockport, La.

Read the whole story here. After the excerpt, see what the folks at Bollinger Shipyards had to say about Miller’s AlumaFeed™ System.

Aluminum is increasingly specified in marine applications because it’s lighter without sacrificing strength and functionality. This makes ships faster, saves on fuel, and provides them with excellent anti-corrosive properties. It does, however, present difficulties: distortion, cleanliness, aesthetics, burn through and difficult wire feeding, to name a few.

To best meet these challenges, Bollinger overhauled its entire aluminum welding facility to include a new bulk gas delivery system, wall-mounted booms for wire feeders, and new AlumaFeed™ synergic aluminum welding systems from Miller Electric Mfg. Co. The system is designed to simplify and improve MIG and Pulsed MIG aluminum welding applications and has proven a good fit at Bollinger.

Improvements include: Hours saved in productivity, thanks to the synergic controls; reduced distortion and burn through, thanks to the Pulsed MIG capabilities; the aesthetics of a TIG weld with the production speeds of MIG welding; less bird nesting, thanks to advanced wire feeding technology; switch to a larger diameter wire, which allows for faster travel speeds.