Keygree MIG pulse machine

A dual-pulse can be understood as adding a longer-period "energy pulse" to a regular pulse. It essentially involves periodically modulating the peak and base currents of the regular pulse.

The working principle of dual-pulse technology

It divides the current waveform into two levels:

1.High-Frequency Pulse (Microscopic Level):

This is the ordinary pulse mentioned above, responsible for droplet transfer. For example, the frequency is in the range of 70-150 Hz.

This high-frequency pulse itself has its peak and base values.

2.Low-Frequency Modulation (Macroscopic Level):

A lower frequency (e.g., 0.5 - 5 Hz) is used to periodically increase and decrease the overall intensity of the high-frequency pulse.

Strong Pulse Phase: The overall current level of the high-frequency pulse is increased. The peak value is higher, and the base value also increases accordingly. The weld penetration is greater, and the weld pool is more "active."

Weak Pulse Phase: The overall current level of the high-frequency pulse is decreased. Both the peak and base values ​​decrease, the weld penetration becomes shallower, and the weld pool becomes "milder," facilitating cooling and spreading.

Final output waveform: The current/voltage meter you observe will oscillate periodically with the low frequency, and the welding sound will also rhythmically alternate between a rapid "hissing" sound (strong) and a gentler "hissing" sound (weak).

The main functions and advantages of dual-pulse technology.

The alternating strong and weak pulses of dual-pulse welding offer advantages unmatched by single-pulse welding, especially for materials like aluminum alloys and stainless steel:

1.Significantly improved weld bead formation (fish-scale pattern effect):

This is the most intuitive advantage of dual-pulse welding. The strong pulse phase creates penetration and forward movement; the weak pulse phase allows the weld pool to cool slightly and spread out, forming a clear "fish-scale" pattern.

The weld bead is uniform, dense, and aesthetically pleasing, with a regular fish-scale pattern, similar to the appearance of high-quality TIG welding. This is an important visual indicator of welding skill and quality.

2.Better control of heat input:

The alternating strong and weak pulses result in a lower overall heat input compared to continuous strong pulses, while achieving better fusion than continuous weak pulses.

This is particularly advantageous for thin-plate welding and all-position welding, effectively preventing burn-through and sagging while ensuring sufficient penetration.

3.Enhanced weld pool stirring and oxide film removal (critical for aluminum alloys):

The increased arc force during the strong pulse phase better breaks down the aluminum oxide film (Al₂O₃, with a very high melting point) on the surface of the aluminum alloy, allowing the pure aluminum metal to fuse.

The weld pool flow caused by the strong and weak pulse changes acts as mechanical stirring, facilitating the removal of gases and impurities, reducing porosity, and improving the density and mechanical properties of the weld.

4.Expanded welding parameter adaptability:

By adjusting the low-frequency frequency and the duty cycle of the strong and weak pulses (the time ratio of strong to weak pulses), it can be flexibly adapted to different plate thicknesses, positions, and appearance requirements.

Application Scenarios

Aluminum alloy welding: This is the main application area for double-pulse welding, and almost all MIG welding of aluminum and aluminum alloys requiring high-quality formation uses double-pulse technology.

Stainless steel welding: Used when high demands are placed on the weld appearance.

Thin sheet welding: Used in situations requiring precise control of heat input to prevent deformation.

Workpieces requiring aesthetically pleasing weld appearances: such as display items and exposed welds on equipment.

KeyGree Group Co., Ltd. is a wholly foreign-owned enterprise invested by British in 2009:

· Established: Founded in 2009 (UK investment).

· Scale & Capacity: 80,000m²+ facility producing 700,000+ welding units annually.

· Quality Assurance: Certified to CCC, CE, ISO9001:2015.

· Full-Spectrum Expertise: Vertically integrated from R&D and component manufacturing (transformers, heat sinks, PCBs) to final assembly of machines, torches, and laser systems.

· Complete Solutions: Offering both INDUSTRIAL-grade and household welding equipment lines.

Contact us

Schedule an On-Site Demo (Client-Funded): Contact our engineering team to arrange verification testing of MIG-300DP's zero-porosity welds on your battery tray designs.

Tel: +86 18058395375

Email: info@keygree.com