Master Steel Upgrades to New Welding Technology
by Master Steel Engineering Team | 15 September 2020

Master Steel has recently acquired multiple welding machinery that is more efficient than conventional MIG (metal inert gas) welding equipment, further increasing our ability to accomplish more projects at a given time.

 

The machine's main advantage is its pulse MIG functionality. Pulse MIG is an alternative to standard MIG welding. Here, the current is delivered in intervals instead of a continuous stream. It is a modified spray transfer process that switches between high peak current and low background current. Droplets of the wire transfer to the weld joint while the heat input is kept at a low level, making the weld puddle freeze slightly to prevent a burn-through. Controlling the heat input also reduces warping on thin sheet metals. For thicker joints, the cooler weld puddle allows for shorter downtime for repositioning parts.

 
 

Master Steel spark-less / spark-free welding

 

The pulsing results in smooth and spatter-free welding at mean currents of 50A to 150A. The process gives good directional control over the weld puddle and results in good bead appearance. Pulse MIG welding increases productivity through faster wire feed and travel speed. It reduces heat input at the same time, lessening residual stress and distortion. The pulsing current gives out higher deposition rates in all positions where spray transfer or dip is not available.

 

Aside from its pulse MIG welding functionality, the unit is also capable of MIG, MMA (manual metal arc), and TIG (tungsten inert gas) welding operations.

 

MIG welding is an arc process where a solid wire is fed continuously through the welding gun and into the weld pool to join two base materials together. The wire acts both as the heat source and the filler metal. The use of filler rather than fusing allows thicker pieces to be joined without having to heat them all the way through. It has wide applications in fabrication and maintenance welding due to its flexibility, high deposition rate, and suitability for mechanisation. It is highly productive and cost-effective, making it the most common process in metal fabrication.

 

Meanwhile, MMA welding is also called shielded metal arc welding (SMAW), flux shielded arc welding, or stick welding. This process involves the use of a coated metal-cored electrode that creates a high-intensity electric arc. The heat from the electric arc melts the base metal, the metal core, and the flux coating of the electrode, generating gas and slag that protects the weld pool from pollutants. It is economical and produces strong welds. It is widely used on cast iron and steel.

 

Also known as gas tungsten arc welding or GTAW, TIG welding uses a non-consumable tungsten electrode that heats the base metal while the shielding gas protects the weld puddle from contaminants. Only the necessary amount of filler is used, and the process does not create smoke or slag. The resulting weld is clean and precise, making it ideal in cosmetic welding. TIG welding can be applied on a wide range of metals and alloys.

 

Our new machine provides 350A with 100% duty cycle and 450A with 60% duty cycle, making it fully compliant in fabricating the majority of Department of Transport and Main Roads (TMR) infrastructure. It is protected by IP23S and adheres to IEC 60974-1, IEC 60974-5, and IEC 60974-10 standards. It incorporates a digital display which helps the welder glide between welding modes, current, and other settings.

 

Master Steel is now TMR qualified for MRTS78. We always look for ways to advance our technical knowledge and manufacturing processes in delivering projects that are critical to our clients. Call us on 07 5594 7944 or email us at engineering@mastersteel.com.au.