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Fundamentals of the MIG/MAG welding process

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11.18

909.1550.1-08

16 

Fundamentals of the MIG/MAG welding process

16.1  Principle of the MIG/MAG welding 

process

The wire feed rollers feed the wire electrode from the 

reel to the contact tip. An arc is created between the wire 

electrode and the workpiece. The wire electrode thus 

becomes the arc carrier. The arc melts the workpiece 

point by point and forms the weld pool. The wire elec-

trode melts and drips into the weld pool, thus forming the 

filler metal. The inert gas flows from the gas nozzle and 

protects the arc and weld pool from atmospheric gases.

Wire feed rollers

Shielding gas

Arc

Power source

Workpiece

Welding seam

Contact tip

Gas nozzle

Wire electrode

Abb. 15:  MIG/MAG welding processes

There are two types of metal inert gas welding, which are 

differentiated by the type of inert gas used: metal inert 

gas welding (MIG) and metal active gas welding (MAG).

Welding
process

Shielding gas

inert

active

MIG

Helium (He) Argon (Ar) 

mixture of Ar/He

MAG-C

Carbon dioxide 

100 % CO2

MAG-M

Mixtures of Ar/

CO2 Ar/O2

Tab. 7:  MIG/MAG welding processes

The welding processes are further differentiated by arc 

type. This means that there are differences in the form of 

the arc, short circuit tendency and metal transfer mode.
Selection of the type of arc is only possible to a limited 

extent e. g. when short arc welding. Short arc welding 

is possible using all metal shielding gas welding proc-

esses by the selection of the suitable current intensity 

and the associated arc voltage, although the short circuit 

frequency and drop size are very different, according to 

the shielding gas being used.

16.2  Arc types
Short arc

This type of arc is particularly suitable for welding thin 

sheets, in root layers and for welding in restricted loca-

tions  because  of  its  relatively  "cold"  melt  flow.  In  this 

case, the welding takes place with a very short arc, at 

low arc voltage and at low current intensity. Due to the 

surface tension of the melt pool, the drop is drawn into 

the molten metal and the arc is reignited. This recurring 

cycle creates a continuous alternation between the short 

circuit and the arcing period.

The transition from short to spray arc is de-

pendent upon the gas mixture and the wire 

diameter.

Transition arc

The transition arc is used for medium plate thickness 

and for vertical down welding. The material transfer tales 

place both in short circuit and in free flow. This produc

-

es a reduced short circuit index and a slightly "hotter" 

molten pool than in the short arc. Transition arc welding 

has a higher melting rate than short arc, and is therefore 

more economical. 

Long arc

Long arcs are typically used for welding under carbon 

dioxide and under high CO2 containing gas mixtures in 

the upper performance range. Long arc welding is not 

really suitable for welding in tight spaces. Larger drops 

fall into the molten pool largely by gravity. This some-

times involves short circuits which, at the point of the 

short circuit, can produce spatter when the arc ignites 

again, because of the upslope.

Spray arc

Due to the thinness of the melt pool, spray arc welding 

is not suitable for welding in tight spaces. It is used for 

welding in the higher power range using inert gases or 

gas mixtures with high argon content. The spray arc has 

a very fine drop, short-circuit free material transfer.

i

Содержание X 350

Страница 1: ...Lorch Schweißtechnik GmbH Im Anwänder 24 26 71549 Auenwald Germany Telefon 49 7191 503 0 Telefax 49 7191 503 199 Internet www lorch eu E Mail info lorch eu 909 1550 1 08 Operation Manual X Series EN ...

Страница 2: ...cluding all its parts is protected by copyright Any use or modification outside the strict limits of the copyright law without the permission of Lorch Schweißtechnik GmbH is prohibited and liable to prosecution This particularly applies to reproductions translations microfilming and storage and processing in electronic systems Technical modifications Our machines are in a constant state of further...

Страница 3: ...IG welding process MIG MAG 13 12 4 Call up the secondary parameters 14 12 5 Special functions 15 12 6 Remote control optional 16 13 Graphs 18 13 1 Electrode 18 13 2 TIG 18 13 3 Up 18 14 Messages 19 14 1 Status messages 19 14 2 Error messages 19 15 Welding basics 20 15 1 Stick electrode welding 20 15 2 TIG welding 20 16 Fundamentals of the MIG MAG welding process 22 16 1 Principle of the MIG MAG we...

Страница 4: ... Machine elements 4 5 6 7 8 8 9 2 3 1 Abb 1 Machine elements 2 Explanation of symbols 2 1 Meaning of the symbols in the opera tion manual Danger of physical injury or death If the danger warnings are disregarded this can cause slight or severe injuries or even death Danger of property damage Disregarding danger warnings can cause damage to workpieces tools and equip ment General note Designates us...

Страница 5: ... Service and repair work may only be carried out by a trained electrician Ensure that there is good direct contact for the ground cable immediately beside the weld point Do not pass the welding current through chains ball bearings steel cables grounding conductors etc as it could cause these to fuse Secure yourself and the welding machine when work ing in elevated or inclined areas The machine sho...

Страница 6: ...te the following Due to their high power consumption welding ma chines can cause problems in the public power grid The mains connection is therefore subject to require ments with regard to the maximum permissible sys tem impedance The maximum permissible system impedance Zmax of the interface to the power grid mains connection is indicated in the technical data If in doubt please contact your powe...

Страница 7: ...d the transportation belt into the welding ma chine and plastic slides See sequence of the num bering in the picture 11 2 Fastening accessories belt 5 14 12 Abb 3 Accessories belt 5 Accessories belt with fastener 12 Plastic slides 14 Closure   Thread the accessories belt into the handle and plas tic slides See sequence of the numbering in the pic ture   Plug the belt fasteners together ...

Страница 8: ...ecting the electrode welding cable   Connect the electrode welding cable to the minus or plus socket 8 and secure the cable by rotating it clockwise The polarity of the electrode depends on the type of electrode and the welding proc ess Please follow the manufacturer s in structions on the electrode packaging for this purpose 11 4 TIG welding process For TIG welding you require a TIG valve torch...

Страница 9: ...r on a current generator   Plug the mains plug into the appropriate socket The mains voltage and tolerance as well as the fuse protection must correspond to the technical specifications see Technical Specifications 11 5 MIG welding process A wire feed case optional is required for MIG welding The operations required may differ depend ing on the version and the configuration of the wire feed case...

Страница 10: ...Plus 30 Selection button Up Arc Force Pulsesis used to select uphand seam welding arc dynamics and or pulsing 31 Selection button Hotstart Regular is used to se lect Hotstart increased start current or regular start current 32 The Regular LED lights up with regular start cur rent without Hotstart 33 The Hotstart LED lights up when Hotstart is se lected 34 The Fault LED lights up continuously and t...

Страница 11: ...Electrode CEL LED lights up if you select CEL electrode operating mode Electrodes with coating containing cellulose suitable for down wards welding The Electrode CEL LED starts flashing when gouging operating mode is selected 50 The Electrode basic rutile CEL gouging selec tion button is used to select the electrode operating modes basic rutile CEL If the button is pushed for longer than 2 seconds...

Страница 12: ...utton 50 Control Pro or 58 BasicPlus re peatedly until the desired electrode operating function is selected 9 9 The electrode basic rutile or CEL symbol LED 47 48 or 49 lights up   Press button 31 in order to switch on the Hotstart or regular function Control Pro   Press button 30 in order to switch the Up Arc Force and Pulse function on or off Control Pro   Use control knob 56 to set the de...

Страница 13: ...ift the electrode a little 9 9 The arc burns between the workpiece and the elec trode Upslope A short circuit current of 60 A is used for igniting during the TIG welding process The upslope takes place with 115 A s until the set welding current is reached Guideline values for the current intensity and the gas quantity Tungsten electrode diameter mm Current in tensity A Gas quantity l min 1 0 3 40 ...

Страница 14: ...ing cur rent correction value 100 0 200 X X Up second cur rent correction value 100 0 200 X X Up duty cycle correction value 100 0 200 X X Second current I2 of welding current I1 50 1 200 X X X Parameter Code Default value Setting range Mode Basic Plus Control Pro Electrode TIG MIG Pulse frequency 3 0 Hz 0 2 to 2000 Hz Repre sentation 0 2 to 2 0t X X X Pulse duty cycle of welding current I1 50 1 9...

Страница 15: ... Up duty cycle uPU secondary pa rameters   Exit the secondary parameters by pressing the Menu button 55 The average welding current is displayed and set in the 7 segment display Welding currents I1 and I2 deviate from the set val ue depending on the secondary parameter settings uPF uP1 uP2 and uPU The setting range of the average welding current is 30 to 200 A Switching Pulses on off Control Pro...

Страница 16: ...g by pressing the control knob 56 Standby mode idle state   Press the control knob 56 and the button 55 simulta neously for at least 3 seconds 9 9 The connecting sockets are de energized All LEDs are turned off OFF is displayed in the 7 segment display 41   Press the control knob 56 and the button 55 simulta neously for at least 3 seconds to exit standby mode See also chapter Remote control So...

Страница 17: ...he control knob 56 Â Â Confirm the secondary parameter by pressing the control knob 56 Â Â Set the value OFF by rotating the control knob 56 Â Â Confirm the setting by pressing the control knob 56 Â Â Exit the secondary parameters by pressing the Menu button 55 If the Remote control secondary parameter is set to On Code FrA On the welding machine behaves as follows Standby mode is activated when t...

Страница 18: ...nt routing diagram bPU Pulse duty cycle FPU Pulse frequency I Power I1 Welding current I2 Second current ISt Start current Iz Ignition current t Time tIu Upslope tSt Start current time Abb 13 TIG current routing diagram 13 2 TIG I Power I1 Welding current I2 Second current t Time uP1 Up welding current uP2 Up second current uPF Up frequency uPU Up duty cycle Abb 14 Up current routing diagram 13 3 ...

Страница 19: ...ult current to protective earth con ductor Connect the welding earth lead E06 Overvoltage secondary Initial voltage too high Inform Service E07 EEPROM Communication with EEPROM defec tive Switch machine off and on again ex ecute master reset E09 Voltage detection Voltage measuring system faulty Inform Service E12 Power section Power section start up faulty Inform Service E13 Temperature sensor Tem...

Страница 20: ...rch The arc burns be tween the tungsten electrode and the workpiece in an inert shielding gas atmosphere Thus the tungsten elec trode acts as an arc carrier The arc melts the workpiece point by point and forms the weld pool The shielding gas escapes through the gas nozzle This gas protects the tungsten electrode the arc and the molten pool against the surrounding air This prevents undesired oxidat...

Страница 21: ...he point depends on the welding current When AC welding it is sufficient to sharpen the edge of the electrode slightly After a short time a round to slightly convex form is built If the electrode tip is polluted due to dipping into the weld pool or touching the filler wire the respective part of the electrode must be completely ground off Restore the original pointed shape Grind in longitudinal di...

Страница 22: ...p size are very different according to the shielding gas being used 16 2 Arc types Short arc This type of arc is particularly suitable for welding thin sheets in root layers and for welding in restricted loca tions because of its relatively cold melt flow In this case the welding takes place with a very short arc at low arc voltage and at low current intensity Due to the surface tension of the mel...

Страница 23: ...erials or if the melt pool is very thin because the voltage is too high Weld direction pushing Welding direction dragging Abb 16 Torch position Avoid larger oscillating movements in order to prevent the melt pool from building up in front of the arc This can lead to incomplete fusion due to the forward melt pool Except in the vertical up position you should oscillate laterally only as far necessar...

Страница 24: ... at maximum welding current 35 Current consumption I1 for ED 100 A 16 0 Current consumption I1 for ED 60 A 20 7 Current consumption I1 max A 27 5 Maximum effective mains current I 1eff A 16 3 Power consumption S1 for ED 100 kVA 11 1 Power consumption S1 for ED 60 kVA 14 3 Power consumption S1 max kVA 19 1 Weldable electrodes mm 1 5 8 0 Technical data1 Units X 350 X 350 VRD RU MIG welding Welding r...

Страница 25: ...nce problems or need re pairs contact a dealer authorised by Lorch Never make repairs or technical changes yourself In this case the manufacturer s warranty is no longer valid 19 Disposal Only for EU countries Do not dispose of electric tools together with household waste material In observance of European Directive 2002 96 EC on waste electrical and electronic equipment and its imple mentation in...

Страница 26: ...ts list Список деталей 1 3 31 10 2018 Ersatzteilliste spare parts list Список деталей 990 4110 0 04 9501927 X 350 Control Pro X 4 17 18 19 5 25 26 27 24 6 7 8 9 21 38 42 40 34 31 30 39 37 32 43 45 29 23 22 10 46 44 20 12 14 28 36 16 15 35 41 13 11 3 2 1 22 1 Zeichnung graph Рисунок X 350 Control Pro ...

Страница 27: ... вентилятора G28 100mm 10 604 2803 0 Lüftergitter G28 150mm Fan grill G28 150mm Решетка вентилятора G28 150mm 11 604 3741 0 Handgriffrohr Alu 351mm LORCH Profil handle tube Alu 351mm LORCH Profil Рукоятка Alu 351mm LORCH Profil 12 606 2027 0 Aufkleber Netzstecker ziehen 30mm blau sticker pull mains plug 30 mm blue Наклейка Вытащить вилку 30mm синяя 13 606 3083 0 Aufkleber X sw Oc sticker X sw Oc Н...

Страница 28: ... cable 4x2 5 without plug 3C 1TA 40 C Сетевой кабель 4x2 5 без вилки 3C 1TA 40 C 35 661 8210 9 Kabelbaum AMP14B Minifit 12p 400mm Cable loom AMP14B Minifit 12p 400mm Кабельный жгут AMP14B Mini fit 12p 400mm 36 663 0207 0 Isolierbuchse M7 Ø9 2 H2 5 7 5mm AD25 insulating bush M7 Ø9 2 h2 5 7 5mm AD25 Изоляционная муфта M7 Ø9 2 H2 5 7 5mm AD25 37 665 0519 0 Nebenwiderstand 350A 35mV 0 1mOhm 4 8mm Shun...

Страница 29: ...mm Решетка вентилятора G28 100mm 10 604 2803 0 Lüftergitter G28 150mm Fan grill G28 150mm Решетка вентилятора G28 150mm 11 604 3741 0 Handgriffrohr Alu 351mm LORCH Profil handle tube Alu 351mm LORCH Profil Рукоятка Alu 351mm LORCH Profil 12 606 2027 0 Aufkleber Netzstecker ziehen 30mm blau sticker pull mains plug 30 mm blue Наклейка Вытащить вилку 30mm синяя 13 606 3083 0 Aufkleber X sw Oc sticker...

Страница 30: ...el 4x2 5 ohne Stecker 3C 1TA 40 C Mains cable 4x2 5 without plug 3C 1TA 40 C Сетевой кабель 4x2 5 без вилки 3C 1TA 40 C 35 661 8210 9 Kabelbaum AMP14B Minifit 12p 400mm Cable loom AMP14B Minifit 12p 400mm Кабельный жгут AMP14B Mini fit 12p 400mm 36 663 0207 0 Isolierbuchse M7 Ø9 2 H2 5 7 5mm AD25 insulating bush M7 Ø9 2 h2 5 7 5mm AD25 Изоляционная муфта M7 Ø9 2 H2 5 7 5mm AD25 37 665 0519 0 Neben...

Страница 31: ...hnung graph Рисунок X 350 Basic Plus Lorch Schweißtechnik GmbH Im Anwänder 24 26 71549 Auenwald Germany Tel 49 7191 503 0 Fax 49 7191 503 199 info lorch eu www lorch eu 1 3 31 10 2018 990 4471 2 04 9501927 X 350 Basic Plus Ersatzteilliste spare parts list Список деталей 8 10 46 20 ...

Страница 32: ... G28 150mm Решетка вентилятора G28 150mm 11 604 3741 0 Handgriffrohr Alu 366mm LORCH Profil handle tube Alu 366mm LORCH Profil Рукоятка Alu 366mm LORCH Profil 12 606 2027 0 Aufkleber Netzstecker ziehen 30mm blau sticker pull mains plug 30 mm blue Наклейка Вытащить вилку 30mm синяя 13 606 3083 0 Aufkleber X sw Oc sticker X sw Oc Наклейка X sw Oc 14 608 5001 0 Folientastatur X350 BasicPlus keypad X3...

Страница 33: ...Кабельный жгут AMP14B Mini fit 12p 400mm 36 663 0207 0 Isolierbuchse M7 Ø9 2 H2 5 7 5mm AD25 insulating bush M7 Ø9 2 h2 5 7 5mm AD25 Изоляционная муфта M7 Ø9 2 H2 5 7 5mm AD25 37 665 0519 0 Nebenwiderstand 350A 35mV 0 1mOhm 4 8mm Shunt resistance 350A 35mV 0 1mOhm 4 8mm Шунт 350A 35mV 0 1mOhm 4 8mm 38 665 2216 0 Verschlußkappe AMP 14pol cover cap AMP 14pol Вставная крышка AMP 14pol 39 665 7020 0 E...

Страница 34: ... L1 1 L2 5 L3 7 Q1 L2 LP1 A1 A2 AC AC AC 3 LP5 LP6 LP7 LP8 LP4 2 T1 R1 A9 X2 X5 1 X5 2 X6 1 9 X6 2 10 X6 3 3 X6 4 4 X6 5 5 X6 6 6 X6 7 7 X6 8 8 X4 A8 X2 1 X2 2 M1 M X3 A6 A7 X1 2 X2 X1 X1 F2 1 4 3 X10 1 X10 2 M2 M A4 X7 1 X7 2 X7 3 X7 6 X7 4 X7 5 X7 7 X7 8 X7 9 X7 10 X6 1 X6 2 X6 3 X6 4 X6 6 X6 7 X6 8 X6 5 X2 3 X5 8 X5 6 X2 2 X7 1 X7 2 11 12 13 14 X6 9 X6 10 X6 11 X6 12 X5 3 X5 4 LP12 LP11 LP13 X2...

Страница 35: ...x80x38 Q 1 657 0121 0 Schalter 3 0 25A 3ph Switch 3 0 25A 3ph Выключатель 3 0 25A 3ph R 1 665 0519 0 Nebenwiderstand 350A 35mV 0 1mOhm Nebenwiderstand 350A 35mV 0 1mOhm Шунт 350A 35mV 0 1mOhm 4 8mm T 1 655 9076 0 Übertrager WA 13000061 Transformer WA 13000061 Трансформатор WA 13000061 X 1 661 7724 2 Netzkabel 4x2 5 CEE 32 3C 1RÖ 40 C Net cable 4x2 5 CEE 32 3C 1RÖ 40 C Сетевой кабель 4x4 CEE 32 3C ...

Страница 36: ...00 L2 LP1 A1 A2 AC AC AC 3 LP5 LP6 LP7 LP8 LP4 2 T1 R1 A9 X2 X5 1 X5 2 X6 1 9 X6 2 10 X6 3 3 X6 4 4 X6 5 5 X6 6 6 X6 7 7 X6 8 8 X4 A8 X2 1 X2 2 M1 M X3 L R K1 1 2 A6 A7 X1 2 X2 X1 X1 F2 1 4 3 X10 1 X10 2 M2 M A4 X7 1 X7 2 X7 3 X7 6 X7 4 X7 5 X7 7 X7 8 X7 9 X7 10 X6 1 X6 2 X6 3 X6 4 X6 6 X6 7 X6 8 X6 5 X3 1 X3 4 X3 3 X3 2 X2 3 X5 8 X5 6 X2 2 X7 1 X7 2 11 12 13 14 X6 9 X6 10 X6 11 X6 12 X5 3 X5 4 LP...

Страница 37: ...80x38 310mm Осевой вентилятор 12VDC 80x80x38 Q 1 657 0121 0 Schalter 3 0 25A 3ph Switch 3 0 25A 3ph Выключатель 3 0 25A 3ph R 1 665 0519 0 Nebenwiderstand 350A 35mV 0 1mOhm Nebenwiderstand 350A 35mV 0 1mOhm Шунт 350A 35mV 0 1mOhm 4 8mm T 1 655 9076 0 Übertrager WA 13000061 Transformer WA 13000061 Трансформатор WA 13000061 X 1 661 7724 2 Netzkabel 4x4 CEE 32 3C 1RÖ 40 C Net cable 4x2 5 CEE 32 3C 1R...

Страница 38: ... Nefi01 A2 AC AC AC 3 LP5 LP6 LP7 LP8 LP4 2 T1 R1 A9 X2 X5 1 X5 2 X6 1 9 X6 2 10 X6 3 3 X6 4 4 X6 5 5 X6 6 6 X6 7 7 X6 8 8 X4 A8 BF03 X2 1 X2 2 M1 M X3 A6 DC01 A7 Mapro01 X2 X2 X1 X1 F2 1 4 3 X10 1 X10 2 M2 M A4 DRV02 X7 1 X7 2 X7 3 X7 6 X7 4 X7 5 X7 7 X7 8 X7 9 X7 10 X6 1 X6 2 X6 3 X6 4 X6 6 X6 7 X6 8 X6 5 X2 3 X5 8 X5 6 X2 2 X7 1 X7 2 11 12 13 14 X6 9 X6 10 X6 11 X6 12 X5 3 X5 4 LP12 LP11 LP13 X...

Страница 39: ...xial fan 12VDC 80x80x38 310mm Осевой вентилятор 12VDC 80x80x38 Q 1 657 0121 0 Schalter 3 0 25A 3ph Switch 3 0 25A 3ph Выключатель 3 0 25A 3ph R 1 665 0519 0 Nebenwiderstand 350A 35mV 0 1mOhm Nebenwiderstand 350A 35mV 0 1mOhm Шунт 350A 35mV 0 1mOhm 4 8mm T 1 655 9076 0 Übertrager WA 13000061 Transformer WA 13000061 Трансформатор WA 13000061 X 1 661 7724 2 Netzkabel 4x2 5 CEE 32 3C 1RÖ 40 C Net cabl...

Страница 40: ...Lorch Schweißtechnik GmbH Im Anwänder 24 26 71549 Auenwald Germany Tel 49 7191 503 0 Fax 49 7191 503 199 info lorch eu www lorch eu ...

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