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APPLICATION

Tandem MIG

TM

Low cost and profitability are key
business objectives, whether the
product offering is a wheel, a
water tank, or a truck frame. It
used to be thought that on the
road to lower cost, quality had to
be sacrificed. That’s no longer
true with Tandem MIG welding. 

The following factors affect 
pricing per welded part:

Capital Equipment

Overhead 

Labor cost

Part production rates

Lincoln Tandem MIG welding 
systems are designed to produce
quality welds at welding speeds
well above accepted single 
wire processes. The unique 
engineered output control of the
Tandem MIG dual wire process 
is designed to overcome the 
barriers limiting the travel speed
capabilities of conventional single
wire GMAW processes. 

INCREASED TRAVEL SPEEDS

• The combined contribution of two separate welding arcs in one weld pool

provides the control to overcome the lack of follow tendencies of single 
arc processes.

INCREASED DEPOSITION

• Two small diameter Tandem MIG wire electrodes provide higher melt-off

rates per current drawn when compared to a single larger diameter wire 
electrode at similar current draws.

IMPROVED THROUGHPUT

• Higher travel speeds and higher deposition rates reduce part welding 

time cycles.

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NX-3.70 10/05

© Copyright 2005 The Lincoln Electric Company. All rights reserved.

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High-Speed and High-Deposition Welding

W A V E F O R M   C O N T R O L   T E C H N O L O G Y

T M

Increased deposition

on thicker materials

reduces welding time

and distortion.

Fast travel speeds on thin

lap welds increase the

number of parts per day.

Summary of Contents for Tandem MIG AD1202-1

Page 1: ...e wire GMAW processes INCREASED TRAVEL SPEEDS The combined contribution of two separate welding arcs in one weld pool provides the control to overcome the lack of follow tendencies of single arc proce...

Page 2: ...would be The two welding arcs that are generated in the Tandem MIG process are electrically isolated from one another and are controlled independently The welding arcs work together generally separate...

Page 3: ...ol follow speed The trail arc should be kept directly in line with the lead arc and focused on the center of the weld pool The trail wire melting rate typically represents approximately 40 of the proc...

Page 4: ...rage systems trash hauling containers and similar components are welded with 2 035 diameter electrodes to produce welds at travel speeds ranging from 80 100 ipm Larger 4 6 mm fillet welds common to st...

Page 5: ...e and multi pass beveled butt welds used in industries fabricating ship hulls earth moving equipment structural platforms pressure vessels beams and similar heavy plate weldments are performed at depo...

Page 6: ...require the use of larger wire diameters or higher wire feed speeds Both choices will cause an increase in current draw The added current draw creates added penetration that must be managed With a sin...

Page 7: ...ld porosity The elevated welding currents create weld pool turbulence that can cause root porosity or porosity just below the surface of the weld bead Solution Tandem MIG The two wire electrode config...

Page 8: ...rocess the two smaller diameter electrodes produce a lower heat input and improved weld pool control when compared to a larger single electrode process attempting to perform similar welds When compare...

Page 9: ...T R O L T E C H N O L O G Y T M Comparing High Deposition Tandem MIG To Single Wire GMAW Process Deposition Rate Comparison 40 20 30 Single Wire GMAW Lbs Hr Tandem MIG 1 4 Horizontal Fillet 10 Weld Me...

Page 10: ...the total wire feed In the case where a larger wire diameter is used as a lead for added penetration the lead should represent approximately 60 or more of the total deposition The lead arc can be ope...

Page 11: ...e added penetration but may produce added spatter The lower CO2 will produce less spatter 3 95 5 Ar O2 is recommended for high speed welding of thin gage material under 3mm The mixture will provide im...

Page 12: ...ceNet Communication Cables drops 20 in S23383 4 S23383 4 2 F DeviceNet Communication Cables trunk line 19 5 ft S23383 2 S23383 2 1 G Communication cables Power source to wire feeders 25 ft K1785 25 K1...

Page 13: ...4 0 25 14 14 L 4 0 25 14 14 2 F Fanuc RJ3iB robot and controller Arc tool software 6 4 or above 100 or 120 Series RJ3iB Controller 100 or 120 Series RJ3iB Controller 1 Dual channel DeviceNet board S23...

Page 14: ...tor driving the feeder mechanism in a sheet metal frame The logic for controlling the wire feeder resides in a PC board inside the robotic power source Tandem MIG High Speed and High Deposition Weldin...

Page 15: ...num and nickel alloys Custom control of the arc for each wire type and size provide consistent welds time after time These Power Waves are designed to be part of a modular multi process welding system...

Page 16: ...f arc welding processes Advancements in power electronics digital communications and Waveform Control Technology are the foundation for many of the improvements NEXTWELD brings you a series of Process...

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