TAWERS SP-MAG Process Shielding Gas Mild Steel Material Thickness Ultra Thin SP-MAG The TAWERS welding platform is driven by a 100kHz super high frequency primary side inverter which permits a welding arc control cycle of 10 micro-seconds. This precise control capability allows the TAWERS to control in real time the welding waveform. One example of this is the SP-MAG (Super-Imposition Metal Active Gas) welding process which is available as a standard waveform (optional waveforms also available) perfectly suited for thin material mild steel welding of 1mm to 2mm materials. The waveform is a short arc welding process with advanced weld spatter control while maintaining fast travel speeds and a wide process window. Benefits Spatter Reduction Using the processing speed made possible by the 100kHz primary side inverter the 10 micro second control cycle (ability to make a change to the waveform every 10 micro seconds) enables the SPMAG process to reduce spatter up to 90%. The reduction in weld spatter lowers the overall welding cost by increasing the rate of deposition, reducing post weld cleanup to the parts and the jigs. The reduction in total spatter is complimented by a reduction in the size of the spatter that is generated – smaller spatter equates to a lower chance for the spatter to stick. Photo showing collected spatter compared between typical inverter machine and SP-MAG process. Volume as well as size of spatter is reduced. Fast Travel Speeds By actively controlling the waveform, using the secondary switching circuit standard in the TAWERS, the arc is able to run at much lower voltages than conventional systems (typically 1-2 volts lower). Running at lower voltages allows a crisper (tighter) arc allowing the process to run faster (benchmarked at 1m/min, reducing the chances for undercut while maintaining exceptional bead quality with low spatter output. Material thickness: 2.3mm, travel speed: 1m/min Weld current: 220A, Shielding gas: Ar+CO2(20%) Typical Control SP-MAG Control Spatter Comparison Gap Handling An added benefit of the ability to run at lower arc voltages is a reduction in the total heat input into the part. Compared to a typical short arc process this can mean a 5-10% heat input which assists in preventing burn through common with higher heat processes and weld with gaps. The TAWERS also allows the user to switch between modes (at any time, even while welding) which allows the user the flexibility to use this lower heat input, low spatter process even for non-thin applications. P0003EF

Theory Short-Arc is a wire transfer method which is frequently used for welding thin materials less than 3mm and is by nature is a welding process that produces spatter which can adhere to parts, welding jigs, inside the nozzle requiring additional clean up time. Most of the spatter is produced when the process changes state between shorting and arcing which can occur over one hundred times per second. This change results in huge changes in the arc phenomena which causes the explosion of spatter out of the welding arc. The goal of advanced waveform is to control the volatility during the change...