Whether in the construction industry, mechanical engineering or the automotive and supply industry: steel is one of the most commonly used materials and is available in different alloys and in large volumes. Moreover, steel can be recycled without any loss and is easy to work. Push systems are often used for steel welding. They offer the advantages of a simple design and high productivity at a low cost.
The Challenges of Steel Welding
Manufacturers are often faced with significant challenges: competition and price pressure are extremely high, while at the same time customers expect high quality and good reliability. Consequently, production welding processes with high welding speeds that also create minimal need for rework are in demand.
What is a Push Welding System?
Push systems have a simple design and are easy to use. They mainly consist of a digitally-controlled power source, a wirefeeder controlled by the power source and manual or robot-operated welding torch. The motor in the wirefeeder feeds the wire forward through the hosepack and toward the welding torch. Unlike push-pull systems, an additional motor on the welding torch is not required. This means that the torch is very lightweight – a definite benefit for welders and robots alike.
Which Welding Processes are used for Steel Welding?
MAG welding is most often used for steel welding with a push system. The process variants that are most suited to this type of welding are Low Spatter Control (LSC) and Pulse Multi Control (PMC). They provide special assistance systems for both manual and robot-assisted applications that allow high-quality results to be achieved, even under tough conditions.
During the LSC dip transfer arc process, the droplets are transferred to the weld pool at a low power level. Droplet detachment takes place in a controlled manner and little if any welding spatter is created. This saves time and money during rework. The digital control of the power source enables a high degree of control over the arc: When the distance between the torch and the workpiece is changed the penetration stabilizer resets the wire, ensuring a constant welding current and therefore consistent penetration.
PMC uses a pulsed arc. This process is predominantly characterized by its high stability and deposition rate. As well as a penetration stabilizer, PMC also features an arc length stabilizer. This keeps the arc constantly short, thereby ensuring a stable welding process – even at high speeds and with varying air gaps and material thicknesses. This allows users to achieve a high degree of productivity when joining steel components.
An Overview of the Advantages of Push Systems:
- High productivity
- Simple and cost-effective design
- Easy to use and maintain
- Consistent weld seam quality
- High availability
- Excellent welding results