Arc Welding Power

Supplies
 Arc Welding Power Supplies
• The current for arc welder can be supplied by
line current or by an Alternator/generator.
– The amount of heat is determined by the current flow (amps)
– The ease of starting and harshness of the arc is determined by the electrical
potential (volts).

• Welding current adjustments can include:

– Amperage
– Voltage
– Polarity
– High frequency current
– Wave form

2
 Arc Welding Power Supplies
The type of current and the polarity of
the welding current are one of the
differences between arc welding
processes.
– SMAW Constant current (CC), AC, DC+ or DC-

– GMAW Constant voltage (CV) DC+ or DC-

– GTAW Constant Current (CC) ), AC, DC+ or DC-

– SAW CC/CV
3
0-400A

400A

Welding Transformer and

controls
Moving coil
Moving core
Magnetic amplifier control
Solid state controls
Thyrister control
Transistor control
Inverter control
Wave form control
 Welding Generators

The Lincoln Electric Co.

 Twelve (12) Considerations When Selecting
An Arc Welding Power Supply

1. Maximum Amperage 8. Future needs for a power

2. Duty cycle supply
3. Amperage range 9. Available skills
4. Amperage adjustment
10. Safety
mechanism
11. Manufacturer's support
5. Input power requirements
6. Initial cost and operating cost 12. Open circuit voltage

7. Size and portability

6
 1: Amperage Output

• The maximum output of the power

supply determines the thickness of
metal that can be welded before
joint beveling is required.
• 185 to 225 amps is a common size.
• For an individual weld, the optimum
output amperage is determined by
the thickness of the metal, the type
of joint and type of electrode.

7
 2: Duty cycle
• The amount of continuous welding
time a power supply can be used is
determined by the duty cycle of the
power supply.
• Duty cycle may be 100%, but usually
is less.
– Duty cycle is based on a 10 minute interval.
– Many power supplies have a sloping duty cycle.

• Note in the picture there is a circle

around the 75 amp setting. Why is it
there?
What is the most likely outcome of
exceeding a power supply duty cycle?
8
 Five Common Output Currents
For Arc Welding
1. AC (Alternating Current)

2. DC (Direct Current)

3. ACHF (Alternating Current-High Frequency)

4. PC (Pulsed Current)

5. Square wave

9
 Arc Welding Electrical Terms
To understand how an electric arc welder works, you must understand
the following thirteen (13) electrical terms.

1. Electrical Circuit 8. Constant potential

2. Direct current (DC) 9. Constant current
3. Alternating current (AC) 10. Voltage drop
4. Ampere 11. Open circuit voltage
5. Volt 12. Arc voltage
6. Resistance 13. Polarity
7. Ohms Law

10
 Electrical Circuit
• An electrical circuit is a
complete path for
electricity.
• Establishing an arc
completes an electric
circuit .

11
 Alternating Current

• Alternating current: The

type of current where the
flow of electrons reverses
direction (polarity) at
regular intervals.
• Recommended current for
SMAW general purpose
electrodes and flat position.

12
 Direct Current
• Direct current: The type of
current where the flow of
electrons (polarity) is in
one direction.
• Controlling the polarity
allows the welder to
influence the location of
the heat.
• When the electrode is • When the base metal is positive (+),
positive (+) DCRP or DCEP it DCSP or DCEN, the base metal will be
will be slightly hotter than slightly hotter than the electrode.
the base metal. • DC current is required for GMAW
• It is frequently used for SMAW

13
 Ampere
• Amperes: the unit of measure for current
flow.
• Electricity passing through a resistance
causes heat.
• An air gap is a high resistance

• The greater the amperage flowing through the resistance (air

gap)--the greater the heat.
• The electrode also has resistance.
• Excessive amperage for the diameter of the electrode (current
density) over heats the electrode.
• Insufficient amperage for the diameter of electrode makes the
electrode hard to start.

What are the characteristics of an electrode that was used with

excessive current density? 14
 Voltage
• Voltage is the measure of
electromotive force (Emf).
• Emf is measured in units of volts
• The voltage at the electrode for SMAW
determines the ease of starting and
the harshness of the arc.
– Higher voltage = easier starting.
– Starting voltage is called OCV.
• Voltage is adjustable in dual control SMAW machines.
• Changing the voltage adjusts a GMAW machine for different
metal thickness.

15
 Resistance
• Def: that characteristic of a material that
impedes the flow of an electrical current.
• Measured in units of Ohm’s (  )
• When an electrical current passes through a
resistance heat (BTU) is produced.
• The amount of heat produced is a function of the
amount of resistance (Ohm’s) and the amount of
current (amps).

Is the resistance adjustable in the SMAW process?

16
 Ohm’s Law
• Ohm's law states that, in an electrical
circuit, the current passing through a
material is directly proportional to the
potential difference.
• Commonly expressed as: E= IR
• Ohm’s law also be used to teach a E
principle of electrical safety. I=
 Amperage is the harmful portion of R

electrical current.
 Rearranging Ohm’s Law for What does this principle
amperage shows that amperage mean for SMAW?
(current flow) is determined by the
voltage divided by the resistance.

 The higher the resistance, the less
current that will flow for a given
voltage.
17
 Constant Current
• In the normal operation of a transformer as amperage is
increased, the voltage decreases, and vies versa.
• Electrical arc welding power supplies are modified so that
either the voltage or the amperage is relatively constant as
the other factor changes.
• This allows two different types of power supplies:
 Constant current
 Constant potential
• In a constant current power supply, the current (amperage)
stays relatively constant when the voltage is changed.
• GMAW
• In a constant potential power supply, the voltage stays
relatively constant when the amperage is changed.
• SMAW
18
 Constant Current
• Characteristics of constant current power supply.
• The machine provides a high voltage for striking the arc.
• Open circuit voltage (OCV)
• OCV is not adjustable for most machines
• When the arc is struck the voltage drops to the welding
voltage.
• Arc voltage
• Arc voltage varies with the arc length.
• As the welding proceeds the current will not vary much as
the arc length changes.

19
 Constant Current
• Increasing the
voltage from 20 to
25 volts (25%) only
decreases the
amperage from 113
to 120 Amp (5.8%).

20
 Constant Potential
• The constant potential power supply is modified to produce a
relatively constant voltage as the amperage changes.
80

70

60

50
Volts

40

30

20

10

0
0 50 100 150 200 250
Anperes

• Characteristic of GMAW power supplies.

21
 Voltage Drop
• Voltage drop is the reduction in voltage in an
electrical circuit between the source and the load.
• Primary cause is resistance.
• When an excessive voltage drop exists, the
electrical circuit will not perform as designed.
– Localized resistance (connection) can cause excessive heat.
– Excessive heat can cause component failure.

• When extra long welding leads are used, the

amperage must be increased to have the same
heat at the weld. 22
Thyristor Rectifier
EFFICIENCY 85%
Thyristor controlled
Power source 300A/
Available at 300A,400A 400A
 INVERTER POWER SOURCE
AC-50Hz HFAC Tr
20-80kHz L DC
DC
3 Phase

Rectifier Inverter

Shunt

PWM - Feedback
 HF Inverter Tr

Size Reduction of Welding Tr. due to inverter

 Transformer

Inverter based Unit - 20Kg

Welding Transformer – 200Kg

Insulated Gate Bipolar Transistor(IGBT),
150A, 4.2kg suitable for MMAW & TIG
Consumption:3.7kVA, Cost: Rs.40,000
Ergonomic design – portability even at heights-
Suitable for construction sites
 Inverter Based MMAW
Power Source

135 AMPS, 4.8 Kg

PS

PS

Caddy
 Energy Efficiency

OUTPUT POWER INPUT POWER

Welding Transformer 6kW 12kW

Welding Generator 6kW 10kW

Transformer-Rectifier 6kW 9kW

Thyristor-Rectifier 6kW 8kW

Transistor controlled PS 6kW 7kW

Inverter Based PS 6kW 6.2kW

 Wire spool
Wire feeder
Power source

Torch Gas
cylinder

GAS METAL ARC WELDING

GAS Metal Arc Welding Process Details

MIG Welding system
SAW
systems
Lincoln Power wave AC/DC1000
Creep Start
Hot Start
 Hot start / Soft start
• Start of welding on high wire feed speed ( > 23,0 m/min ) needs special
characteristics
• Soft start function allows to start welding with lower welding power to minimize
unstable arc and wire feeding in start
• Hot start function allows to pre heat thick base material effectively in arc
ignition power can also be set higher than actual welding power
• Adjustment range of function in SETUP is - 50% to 70% of welding power
• If Soft start is -30%, welding power 10,0 m/min Soft start welding power 7,0
m/min
• Before arc start Creep start slows wire feed speed to improve ignition
• Hot / Soft start function is working on 2T / 4T trigger function and in Synercig
control
• At the end of welding crater filler function eliminate ending failures from weld
P Hot start P Soft start
Welding power Welding power
Crater filler
Factory set Hot start 35% Soft start set in
SETUP
Creep start time Creep start time
Slope set up
Double Pulse
 Arc dynamic regulation
• By the arc dynamic regulation is influenced to the stability of welding arc in short arc.
• The current rising angle and height determines the roughness of the arc, it can vary
from soft to rough.
• Arc dynamic regulation is operating automatic in Synercig control

Soft arc ( -1….-9 )

– decreases amount of spatters 0
– welding with mix gases ( Ar / CO2 )
– for Aluminium and Stainless steel alloys min max
– welding with high parameters I/
A
Basic setting ( 0 )
– recommended basic setting
Rough arc ( 1….9 )
0
– welding with CO2 gas 0 t/
ms
– welding mild steel and thin plates with low parameters