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HYPERFILL®

HYPERFILL®

HYPERFILL®

Product catalog summary
Introduction to HyperFill® Technology
HyperFill® is an innovative twin-wire GMAW (Gas Metal Arc Welding) solution designed to increase deposition rates by up to 50% compared to traditional single-wire processes. This is achieved through the use of two smaller diameter wires that create a larger weld droplet and arc cone, resulting in a large, manageable weld puddle.
Specifications and Features
  • Utilizes a single power source, feeder, gun liner, contact tip, and electrical arc.
  • Offers higher deposition rates and easy molten puddle control.
  • Capable of producing large beads and is comfortable for welders.
  • Reduces the tendency for undercut and allows for higher deposition rates at lower voltages.
User Advantages
  • Increased efficiency through faster welding speeds or larger bead sizes.
  • Reduced number of passes and downtime, leading to higher productivity.
  • Suitable for robotic and automatic applications, and compatible with both drums and spools.
Technical Comparisons
  • HyperFill® provides a wider, evenly-distributed arc cone compared to single wire, which generates a deep, narrow arc cone.
  • Allows for larger beads at higher speeds while maintaining symmetric weld geometry.
  • Demonstrates higher deposition rates with reduced fume generation.
Implementation and Requirements
  • Requires a Power Wave® S500 with a reel stand conversion kit and Cool Arc® 50.
  • Compatible with specific Lincoln Electric welding wires and requires activation through the Lincoln Electric REVEAL™ Activation Platform.
Cost and Savings
Cost-saving estimates are provided for reference and are not guaranteed. Actual results may vary based on various factors including weld procedure and material properties.
Customer Assistance Policy
Lincoln Electric provides technical information based on customer specifications but does not guarantee or assume liability for the information provided. The selection and use of products are the customer's responsibility.
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Catalog excerpts

HYPERFILL®-1

GMAW WELDING HYPERFILL® BIGGER WELDS, FASTER WELDS IN SEMI-AUTOMATIC

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HYPERFILL®-2

INNOVATIVE TWIN-WIRE DESIGN USER ADVANTAGES HyperFill® is a patented twin-wire GMAW-P solution that utilizes two electrically conductive wires, energized by a single power source and fed through a single wire feeder, single gun liner and a single tip. Single Wire Generates a deep, narrow arc cone Arc stability deteriorates at higher wire feed speeds making process more difficult to use Single power source Single feeder Single gun liner Single contact tip Single electrical arc Generates a wide, evenlydistributed arc cone Smooth, stable puddle is more favorable and makes process easy to use at...

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HYPERFILL®-3

INCREASE YOUR EFFICIENCY BY IMPROVING WELDING SPEED OR INCREASING BEAD SIZE Weld length achievable with HyperFill® compared to single wire. HYPERFILL® EFFECT ON TRAVEL SPEED Based on 8 x 8 mm legs size, realized with Power Wave® S500 HYPERFILL® 2x1.0mm – SINGLE WIRE – WELD LENGTH IN ONE MINUTE •  xtendable to robotic and E automatic applications •  sable with both drums U and spools • Extendable to mechanisation thanks to WELDYCAR USER ADVANTAGES • Reduce number of passes • Higher productivity • Reduced downtime HYPERFILL® AGAINST THE GRAVITY PRODUCE LARGER BEADS AT HIGHER SPEED, KEEPING SYMETRIC...

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HYPERFILL®-4

HIGHER DEPOSITION RATE PROCESS COMPARISON – DEPOSITION RANGE IN SEMI-AUTOMATIC WELDING PROCESS EASE-OF-USE EASY WITH EASIER PUDDLE CONTROL UP TO SINGLE WIRE REDUCED FUME GENERATION 1.0 mm HyperFill 8.2 kg/h 1.2 mm Supramig® HD Pulse 6.4 kg/h 1.2 mm Supramig® HD Pulse 8.2 kg/h 1.3 mm Supramig® HD Pulse 8.2 kg/h 1.3 mm Supramig® HD CV 8.2 kg/h 1.6mm MC-706 8.2 kg/h 0.0 Total Fume Generation (gr / min) EASY IMPLEMENTATION SINGLE POWER + SINGLE FEEDER + SINGLE GUN LINER + SINGLE CONTACT TIP + SINGLE ELECTRICAL ARC = LOW SYSTEM COMPLEXITY + EASY IMPLEMENTATION + LOW INVESTMENT THE SOLUTION COMPONENTS...

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HYPERFILL®-5

HYPERFILL® CAN INCREASE YOUR PRODUCTIVITY BECAUSE: Solution Requirements: HyperFill® is a patented and licensed twin-wire MIG solution that is designed to perform specifically with select Lincoln Electric welding wire. To access this licensed solution, activation is required through the Lincoln Electric REVEAL™ HyperFill® will provide all users with the opportunity to achieve higher deposition rates, faster travel speeds, and make bigger welds with greater ease. Activation Platform. For more details, reference document MC20-106 BIGGER WELDS HIGHER DEPOSITION RATE FASTER TRAVEL SPEED HYPERFILL®...

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HYPERFILL®-6

BEING PRESENT LOCALLY MAKES US MORE AWARE GLOBALLY NETHERLANDS UNITED KINGDOM FRANCE UNITED STATES Global Headquarters Solution Centers NETHERLANDS PERU UNITED KINGDOM BRAZILFRANCE SPAIN CANADA UNITED STATES CHILE POLAND GERMANY RUSSIA SOUTH AFRICA JAPAN EMPLOYEES WORLDWIDE Global Headquarters Global Headquarters Solution Centers PERU BRAZIL CHILE SOUTH AFRICA AUSTRALIA HYPERFILL® WAVEFORM ACTIVATION CAPABILITY WITH POWER WAVE® AND PIPEFAB™ SYSTEMS Your purchase of a Lincoln Power Wave or PIPEFAB Welding System comes with (I) a license to use Lincoln Electric standard Power Wave / PIPEFAB waveforms,...

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.