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Advanced Processes Now Available in Engine-Driven Welder/Generator

Friday, February 20th, 2015

BigBlue_158x102The new Big Blue® 800 Duo Pro with FieldPro™ Smart Feeder compatibility improves productivity and efficiency in field welding applications. The multiprocess system can run conventional Stick, TIG, FCAW and MIG welding — and now advanced Regulated Metal Deposition (RMD®) and Pulsed MIG processes with the addition of the FieldPro Smart Feeder.

These advanced processes help to reduce weld failures and can eliminate backing gas on some stainless and chrome-moly pipe welding applications.

Learn More


Revved up Aluminum Boat Ride Built with Pulsed MIG Power from Miller

Wednesday, February 6th, 2013

The super boats from Smoky Mountain Jet Boats cruise in as little as four-inches of water and can stop on a dime. The all aluminum watercraft are built with modern welding technology from Miller.

Learn about the technology from Miller that  make these boats possible and climb aboard for a jet boat ride on a Smoky Mountain lake.


New Miller XR™-Pistol-Pro Gun Designed for Aluminum MIG and Pulsed MIG Welding

Friday, September 14th, 2012

Miller introduces the new XR™-Pistol-Pro Gun built for aluminum MIG and Pulsed MIG welding in heavy industrial applications. The XR-Pistol-Pro Gun is a push-pull gun designed specifically for use with aluminum wire and other soft alloys where wire feeding consistency is critical such as truck and trailer manufacturing, shipbuilding, emergency and recreational vehicle manufacturing, and general fabrication. Read more about the XR-Pistol-Pro Gun here.

Miller Introduces new Invision 450 MPa

Thursday, March 8th, 2012

The new Invision 450 MPa MIG/Pulsed MIG welding inverter is the big brother to the popular Invision 352 MPa. Optimized for use on thicker materials and larger diameter wires, the Invision 450 MPa offers manufacturers and fabricators 450 amps of Pulsed MIG welding power at 100 percent duty cycle. Additional features include:

  • Longer welding times with larger wire diameters for increased productivity, thanks to higher amperage and duty cycle
  • Dual wire feeder capability so you can always have two wires ready as particular jobs change, saving time and money with less set-up.
  • Additional Pulsed MIG programs for .052- and 1/16-inch wires and all the great programs found in the Invision 352 MPa
  • Simple interface and controls for operators
  • Improved Pulsed MIG welding arc with ability to weld on wider range of thicknesses
  • Synergic “one knob” controls that automatically adjust pulse parameters to match wire feed speed
  • Improved energy efficiency over older and non-inverter welding equipment

The new Invision 450 MPa is designed for extremely easy use: the operator selects the wire diameter, wire type, gas being used and wire feed speed and they are ready to weld. The machine features standard built-in programs for steel, metal-cored, aluminum, stainless steel, nickel, silicon bronze and copper nickel wires. Advanced arc controls provide a more robust, stable Pulsed MIG arc at very low arc length, which reduces heat input and provides the ability to weld on a wider range of material thicknesses.

The system is optimized when connected to a 74 MPa Plus wire feeder.  Additional benefits include:

  • Operation is simplified with synergic Pulsed MIG controls, which give the operator “one knob” control over pulse adjustments by adjusting wire feed speed.
  • The system also offers Profile Pulse™, a feature that gives a cosmetic bead appearance similar to TIG welding.
  • Consistent, versatile and dependable aluminum welding is possible with the 74 MPa Plus wire feeder, using Alumination™ technology that also allows for the use of extended-reach push-pull guns.

The Invision 450 MPa also offers 115 volts of auxiliary power for added flexibility when matching the system with a water cooler or using hand tools.

For more information, visit the product page.

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.


No Turning Back: Pipe Welding System Kicks it up a Notch

Wednesday, April 27th, 2011

Fabricating and MetalWorking recently ran an article on Shinn Mechanical of Kent, WA and its use of Miller’s PipeWorx welding system. An excerpt from the article:

Shop operators here complete joints three to four times faster than shops that rely solely on stick and TIG technology. How? They use a pipe-specific multi-process welding system from Miller Electric Mfg. Co. (Appleton, WI) called PipeWorx™ that was recommended by Jim Hedberg, a representative from Pacific Welding Supply (Tacoma, WA).

The PipeWorx system uses Pro-Pulse™ pulsed MIG and RMD™ (regulated metal deposition) processes, as well as stick, TIG and flux cored processes that have been optimized specifically for pipe fabrication. The system also provides traditional MIG processes. Switching between processes requires only the push of one button, with no need to manually switch polarity, cables or hoses, thus increasing productivity and eliminating a potential source of errors.

You can read the whole article here. You can also watch a video of the guys from Shinn discussing RMD and Pro-Pulse here.



Wondering If Advanced Pulsed-MIG Is Right For You?

Thursday, July 15th, 2010

For Ultra Machine and Fabrication (Shelby, N.C.), investing in advanced Pulsed MIG technology was a critical step in positioning the company to win a major contract to provide over 74,000 components for M-ATVs to an Israeli defense firm.

The vehicles are similar to the MRAP (mine resistant ambush protected) vehicles used by the U.S. military, and require the utmost quality from their welds in order to be effective at protecting their occupants from road-side attacks and improvised explosive devices.

The contract called for Ultra to be able to weld MIL-A 46100 ballistic steel in all positions with a 307 stainless steel filler metal, and using the Accu-Pulse™ Pulsed MIG technology in Miller’s Axcess® “multi-MIG” systems, the company was able to produce those components with only 23 defects — a rate of .03 percent.

Click here to read the full story about the challenges Ultra Machine and Fabrication faced in meeting the welding demands for the M-ATV contract and how the Axcess’ Accu-Pulse technology helped the company successfully complete the project and positioned it to win more in the future.

New Aluminum MIG Push-Pull Feeders

Wednesday, June 9th, 2010

Building on the proven reliability and performance of our XR Control aluminum MIG push-pull wire feeder, Miller introduces two new models, the XR-S Control and XR-D Control, designed to meet the specific needs of basic and more advanced aluminum MIG applications.

Featuring adjustable run-in, jog & purge, a digital wire feed speed display and the option of using pre- and post-flow, the XR-S Control feeder meets the needs of basic aluminum MIG push-pull applications without all the bells and whistles that aren’t needed & that might lead to inconsistencies between operators.

Taking things a step further, the XR-D Control features point-of-use remote voltage control, digital voltage display, programmable pre- and post-flow, and adjustable start and crater settings.

Check out the XR-S & XR-D news release for more information about the features and benefits of these new products as well as the applications and industries they are designed to serve.