Last week we discussed the hot wire process, its history, and applications. This week Dave Hebble and I demonstrate how to tune process variables to make sound welds. We show what we look for in the arc with the help of a Xiris Automation Inc. weld monitoring camera.

We are using the ARC Specialties Hot One power supply. This is an AC constant voltage power supply with low open-circuit voltage. We prefer AC because it improves electrode follow and stirs the puddle. Constant current means that the system self adjusts to changes in wire speed and electrical stick out much like a gas metal arc (MIG) welding system. This makes the process stable and easy to tune.

Hotwire is underutilized in industry and I don’t understand why. Hotwire increases deposition rates which is how you measure productivity in welding. It also reduces dilution and heat input. And it does so with little additional cost or complexity. 

Watch the video below to see how we refine welding parameters. Meters readings are affected by cable length, shielding gas, filler material size, and alloy. In the video, Dave and I show you how to use your eyes and ears to make the initial adjustments. Once the weld is dimensionally acceptable and we achieve mechanical properties, then we note meter values.

Once you understand how welding amps & volts, travel speed, wire-speed, and hot wire amps & volts interreact then refining welding parameters is a simple matter. 

If you have a TIG, plasma, or laser welding project which might benefit from the higher production, lower heat input, or lower dilution rates achievable with hotwire call me. 

ARC Specialties thrives on problems, send us yours!