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CAN I BUILD-UP OR ADD MATERIAL TO A WELD LOCATION?
Yes, the Orion is very versatile . In Pulse Arc Mode, filler wire can be used to add metal to a weld
location . In Tack Mode, filler wire or sheet filler can be permanently affixed to a location . Wire
sizes up to and greater than 1mm in diameter can be added . However, the user should select wire
diameters that match the size of the feature being welded . Users should also select wire with
similar material to that of their workpiece . For example: when re-tipping a gold ring, 0 .25mm
gold filler wire is an excellent choice . If filling a large gap in a steel workpiece, 1mm steel wire may
be more suitable . The Orion has the energy and versatility to weld both of these, and many more
applications with ease .
CAN THE ORION WELD SILVER?
Yes, the Orion has been specifically designed with the more difficult-to-weld materials in mind .
Silver requires appreciable energy for a sustained period of time . The Orion has enough energy
and capacity to make quick work of your silver applications .
CAN I WELD DIFFERENT (DISSIMILAR) METALS TOGETHER?
Yes, in many instances different metals can be welded easily together with the Orion . In pulse-arc
welding the weld spot location becomes a new alloy of the two primary metals (this new alloy will
adopt new properties that may be better or worse than the primary materials) .
Dissimilar metals can also be joined in Tack / Fusion Mode . Again, weld strength and properties
will depend on alloy properties .
HOW DO I DETERMINE THE BEST ENERGY SETTINGS FOR MY APPLICATION?
In Arc Mode, metals will weld according to thermal conductivity and melting point . For example,
a metal with lower thermal conductivity (e .g . stainless steel, titanium, cobalt alloys) will weld
easily because the weld heat stays concentrated in the spot . Therefore, less energy is required
to weld one of these metals than other metals of the same thickness that have a higher thermal
conductivity .
Metals with higher thermal conductivity (e .g . copper, silver, gold) will require more energy to
create the same spot because much of the heat is conducted away quickly .
The melting temperature of the metal is also very important when determining the necessary
energy setting for a weld . Knowing the approximate, or relative, melting temperature of your
working metal will enable you to estimate the amount of energy required to create a spot . High
melting temperature translates to a large amount of energy required . Low melting temperature
translates into a smaller amount of energy required to make the weld .
In Tack Mode, energy is important but there are two other important factors that need to be
remembered . These factors are electrical conductivity and contact pressure . In Tack Mode the
Orion is a full-fledged resistance welder . This means that the Orion uses a metal’s electrical
resistance to create the weld heat . Metals that conduct electricity well (e .g . copper) are more
difficult to weld in Tack Mode and require special Tack attachments to obtain a proper weld .
The second important factor when in Tack Mode is the weld contact pressure . The weld contact
pressure can be controlled by how much force you apply to the two pieces that are being welded
together . The harder you push the pieces together the lower you make the electrical contact
resistance between them and the lower the created heat . Conversely, light pressure will result in
high contact resistance and high heat .
