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‘Using the adaptive arc length control
brings all kinds of benefits.’
Picture 5: The upper row of pictures shows normal
MAG process without WisePenetration, and lower row
shows how WisePenetration affects the weld. Stickout
lengths from left: 25mm, 30 mm, and 35 mm.
and do not operate reliably in all welding
conditions.
Kemppi offers the unique
WisePenetration function for cases where
it is difficult to keep a constant stickout
length. This function makes it easy
to keep the welding parameters (I, U)
within the WPS limits. This guarantees
the desired penetration and improves the
weld quality.
WisePenetration offers constant
welding current with stick-out length
within the limits defined in welding
procedure specification (WPS). When
welding with stick-out lengths within
the permitted limits, WisePenetration
operates like conventional MIG/MAG
process and lets welding current fluctuate
with the stick-out length. However, if
stick-out length increases above the
permitted level, WisePenetration takes
the control and ensures that the current
remains constant.
Picture 5 shows how WisePenetration
keeps the penetration constant while the
standard process loses its penetration
when stick-out length rises above normal
limits.
The WiseFusion focused arc
function offers many benefits
In position welding (other than flat or
horizontal vertical), the most common
problem is how to control the welding arc
and the molten weld pool.
This issue is emphasised in MIG/
MAG pulse arc and spray arc welding.
For example, it is very difficult to find
the correct pulse welding parameters
when welding aluminium in horizontal
overhead position. To meet the needs
of all position welding, Kemppi has
developed the WiseFusion function,
which keeps arc length more constant and
prevents the arc from becoming longer as
the stick-out length changes.
Picture 7: 960 MPa grade steel weld.
Plate thickness is 6 mm. I-groove welded
with a single pass from one side. Welding
energy is only 0.58 kJ/mm.
The principle of operation is based
on controlled regulation of pulse or
spray arc current and voltage waveform.
This produces a welding arc that is more
focused and has higher energy density
than in normal pulse or spray arc welding.
Another benefit of WiseFusion is
that a focused arc allows greater welding
speeds. The greater welding speed and
higher energy density mean less heat
input compared to standard pulse or
spray arc, and low heat input is a critical
factor with certain materials.
Using the adaptive arc length
control brings all kinds of benefits, such
as excellent weld pool control in all
positions, narrow and energy-dense arc,
and no need to fine tune the arc length.
WiseFusion is very easy to use.
Welding parameters are always right, so
you don’t need to adjust them. You can
use faster welding speeds and get deeper
penetration and stiffer, more focused
arc. Low heat input and narrow grooves
make it also a very productive and costefficient
welding function.
Picture 6: On the left you can see a weld made with
pulsed MIG and WiseFusion function. The weld on
the right is made with pulsed MIG without fine tuning
the arc. The wire feed rate is 4.6 m/min.
26 Kemppi ProNews 2011