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To do this, start with lower Energy settings . This will minimize the initial warping as you stabilize
the work piece . Always alternate sides during the welding process – several welds in a row on
one side can exaggerate the warping, while alternating welds will pull the part back and forth
eliminating most warping . After the smaller stabilizing welds have been placed you can turn up
the energy and make the larger welds - alternating sides as done with the lower Energy welds .
Pulse Arc Welding: Weld Cleaning
For many applications the weld joint will require very little preparation . Keep the weld area clean
and free from debris . Remember that finger oils, etc . will cause blackening around the weld spot .
This blackening can easily be wiped away with a clean rag or taken off with a glass brush (one is
included with your Orion system), sand blaster or steam cleaner .
During the welding process small amounts of metal will be vaporized from the weld joint and can
be deposited elsewhere on the work piece . Typically, this thin film of metal will look black and can
easily be cleaned off with a glass brush, ultrasonic cleaner, etc .
If the welds themselves look black or discolored, it may be an indication of oxidation and can
come as a result of too little or too much argon gas flow . If the part is too hot, some metals will
readily react with oxygen to form oxide layers . If gas flow is insufficient the weld spot may be
poorly covered and oxygen may be present during the weld . On the other hand, if the protective
gas flow is too high, the gas may exit the stylus nozzle in a turbulent state . When the gas flow is
turbulent it will “grab” oxygen and other atmospheric gases and bring them inside the protective
argon gas shield . This will also lead to the molten weld puddle being exposed to oxygen .
PROTECTIVE GAS RULES OF THUMB
1 . 5 - 10 PSI is a good shielding gas rate
2 . The shorter the electrode is, the less gas flow is necessary
3 . Gas flow may need to be increased if the electrode is lengthened .
Any discolorations that shows in titanium is an indication of poor shield gas coverage . For this
reason it may be helpful to practice on titanium to make sure your gas flow is correct . Adjust
your gas to ensure no discoloration in a small titanium weld spot . This will give you confidence of
proper argon shielding for other materials .
CHAPTER 7: METALS
Weldability of Common Metals
One very important aspect of Pulse Arc welding is a working knowledge of material properties .
This knowledge will help you understand why various metals will react differently during the
welding process . Shown below is a table of properties of some common metals . These metals
have been arranged by melting temperature for convenience . Each of the properties listed below
will have an effect of the weldability of the metals .
