WAVE PULSE MIG Process

Work thickness vs. gap tolerance!

DC WAVE PULSE and AC WAVE PULSE bridge the gap between aluminum work thickness ranges of conventional Pulse MIG welding and TIG welding.

WAVE PULSE MIG Process

Variable frequency adjustment!

WAVE PULSE MIG Process

Lowers risk of porosity!

WAVE PULSE has a profound effect on reducing porosity (blowholes) due to the degassing effect created by agitating the weld puddle at various low frequencies.

WAVE PULSE MIG Process

Minimizes crack susceptibility!

Low frequency pulsing offers a significant reduction in grain size. This is proven to be very effective in reducing crack susceptibility, especially in aluminum alloys.

DC WAVE PULSE MIG

TIG bead appearance at MIG welding speed!

OTC innovated this unique low frequency DC Pulse MIG technology almost 3 decades ago to satisfy the growing demands of aluminum fabricators requiring the highest quality aluminum MIG welds.

Newer generation machines incorporate Digital Inverter control to further enhance performance.

AC WAVE PULSE MIG

TIG bead appearance even on thin aluminum!

Very similar to DC WAVE PULSE MIG, but the electrode negative (EN) half cycle of AC WAVE PULSE generates more heat in the wire causing a faster wire melting rate.

Less heat in the plate avoids burn-through of thin aluminum.

AC WAVE PULSE MIG

Bridges the gap even on thin aluminum!

Increasing electrode negative (EN) ratio reduces heat input in the plate as much as 30~40% at the same wire feed speed.

Adequate bead size is maintained while controlling penetration on thin plate lowering the risk of burn-through and distortion.

AC WAVE PULSE MIG

Ultimate penetration and heat input control!

Increasing electrode negative (EN) ratio reduces amperage at the same wire feed speed. (below left)

Conversely, increasing (EN) ratio allows higher wire feed speeds at the same amperage. (below right)

4-Mode MIG Versatility

The DW300 welding modes can be changed during automated welding for ultimate penetration and heat input control.

STANDARD ALUMINUM MIG WELDING FEATURES

Perfect arc start and arc end every time!

All D-Series MIG machines have pre-set conditions according to welding wire type and diameter. Knowing this information, ideal arc start conditions are determined by time between weld end and the next re-start to ensure instantaneous arc starts.

STANDARD ALUMINUM MIG WELDING FEATURES

Perfect arc start and arc end every time!

Conventional MIG welding machines often leave a ball on the end of the wire when the arc is turned off causing the wire to burn back into the contact tip during subsequent arc starts. OTC eliminates the balling of aluminum wire to create a perfect arc start every time.

STANDARD ALUMINUM MIG WELDING FEATURES

Perfect arc start and arc end every time!

Starting an aluminum MIG weld with the wire bird-nested like the example below would often create an immediate burn-back to the contact tip with most MIG welding systems.

This illustration is presented only as an extreme example of the incredible arc starting capabilities of OTC aluminum MIG welding systems and is not a recommended practice.

STANDARD ALUMINUM MIG WELDING FEATURES

If you can gas shield it - you can weld it!

OTC MIG systems effortlessly handle extreme narrow groove welds. Even with a 3 inch wire stick-out this aluminum weld can be performed as easily as a normal fillet weld.

STANDARD ALUMINUM MIG WELDING FEATURES

Perfect welds in 5 simple steps!

AC + DC HYBRID TIG

Highly focused arc control

Combining AC and DC output provides increased penetration compared to conventional AC only TIG welding of aluminum. The DC cycle reduces tungsten erosion allowing a rather sharp point to be maintained improving arc focus.

AC + DC HYBRID TIG

Adjustable frequency improves arc concentration

Similar to the effect of combining AC and DC output, higher switching frequency between EN and EP provides deeper penetration, excellent bead width control, and reduces overall heat input in the plate.

SYNCHRO MIG

Excellent for welding dissimilar thicknesses!

By synchronizing WAVE PULSE frequency with robot weaving frequency and amplitude, heat input into the base metals can be precisely controlled.

SYNCHRO TIG

Excellent for welding dissimilar thicknesses!

Conventional methods can risk cold starting due to a section of the wire blowing off during the arc start and not properly melted. Retract starting combined with digital inverter MIG welding machine functions eliminates this risk.