Mig Welding - Setting Inductance

MIG Welding - Setting Inductance
Some MIG welders have an adjustable weld inductance setting. But many MIG welding machines
have this setting fixed; meaning the MIG welding inductance is preset to a level that works for
most everyday applications. The inductance setting on a MIG welder controls the rate of current
rise following the short circuit state. That is during the time when the wire is short circuiting into
the weld puddle. This setting affects the arc on time too. That is the amount of time the short
circuit cycle spends arcing and providing heat to the puddle.
That is why adjusting the inductance makes the arc sound entirely different. It has a similar effect
as setting frequency on a TIG welder while TIG welding on AC. A high inductance setting
increases the time of each individual arc cycle and therefore can improve wetting of the puddle. A
low inductance increases the frequency of each short circuit/arc cycle and can be useful for
pinpointing a narrow bead in some joints. What this means to most folks is high inductance is good
for thicker metals where good wetting at the toes of the weld is a priority and low inductance works
better on thin metal.
Another thing about being able to set MIG inductance is that straight CO2 can work nearly as well
as C25 (75/25 Ar/ CO2). Generally CO2 is cheaper than argon/CO2 mixes so for some businesses,
being able to use straight CO2 instead of C25 can translate into quite a savings over time.
But it is never quite as simple as just setting inductance to achieve a good arc. Wire feed speed, wire
diameter, wire type, and shielding gas have a big effect as well. But once you have all those dialed
in, MIG inductance setting is one more tool to help you out.
The bottom line is that every welding machine requires a bit of trial and error in order to optimize
the settings to the point where you get minimal spatter along with appropriate penetration for the
weld being done.
I recommend to get some metal of different thicknesses ranging from really thin to really thick and
adjust voltage, wire speed, and inductance on each until you get a near optimum arc then write it
down either on the inside panel of your MIG welder, in a notebook, on your smart phone, or any
other way that will keep you from having to find new settings for every job that comes into the
shop.
What does Inductance Do
When MIG welding in the dip transfer mode, the welding electrode touches the weld pool and
causes a short circuit. During the short circuit, the arc voltage drops to nearly zero (short circuit
voltage is zero and current in very high). This change in the arc voltage results in a corresponding
change in the welding circuit current, the precise magnitude of which depends on the slope of the
output characteristic (the resistance of the welding circuit), Fig. 1. If the constant voltage power
supply responded instantly, very high current would immediately begin to flow through the welding
circuit. The rapid rise in current to a high value would melt the short-circuited electrode free with
explosive force, dispelling the weld metal and causing considerable spatter.
Inductance is the property in an electrical circuit that slows down the rate of current rise, Fig. 2.
The current travelling through an inductance coil creates a magnetic field. This magnetic field
creates a current in the welding circuit that is in opposition to the welding current. Increasing the
inductance will also increase the arc time and decrease the frequency of short circuiting.
For each electrode feed rate, there is an optimum value of inductance. Too little inductance results
in excessive spatter. If too much inductance is used, the current will not rise fast enough and the
molten tip of the electrode is not heated sufficiently causing the electrode to stub into the base
metal and sluggish starts. Modern electronic power sources automatically set the inductance to give
a smooth arc and metal transfer.
Inductance and its Role

Inductance is a key parameter in electrical and electronic circuits. Like resistance and capacitance it
is a basic electrical measurement that affects all circuits to some degree. Inductance is caused by the
magnetic field generated by electric currents flowing within an electrical circuit. Typically coils of
wire are used as a coil increases the coupling of the magnetic field and increases the effect. When
indicating an inductor on a circuit diagram or within an equation, generally the symbol "L" is used.
The inductance of a circuit is one henry if the rate of change of current in a circuit is one ampere
per second and an electromotive force of one volt.
Welding power sources do not respond instantly to load changes. The current takes a finite time to
attain a new level. Inductance in the circuit is responsible for this time lag. The effect of inductance
can be illustrated by analyzing the curve appearing in figure below. Curve A shows a typical
current-time curve with inductance present as the current rises from zero to a final value. Curve B
shows the path which the current would have taken if there were no inductance in the circuit. The
maximum amount of current attainable during a short is determined by the slope of the power
source. Inductance controls the rate of rise of short circuit current. The rate can be slowed so that
the short may clear with minimum spatter. The inductance also stores energy. It supplies this
energy to the arc after the short has cleared and causes a longer arc. In short arc welding, an
increase in inductance increases the arc on time. This, in turn, makes the puddle more fluid,
resulting in a flatter, smoother weld bead. The opposite is true when the inductance is decreased.
Figure 3-6 shows the influence of inductance on the appearance of short-arc welds made both with
an argon-oxygen gas mixture and with a helium-argon-carbon dioxide mixture. Weld No. 1, made
with a mixture of 98% argon and 2% oxygen shielding gas and no added inductance, is rolled or
peaked as seen in the top cross-section. Midway along the sample, inductance of about 500 micro-
henries was added. Freeze lines are not as prominent, and the bead remains convex. Weld No. 2,
made with the He-Ar-Co2 mixture is also convex. Spatter on the plate is considerable. When
inductance is introduced midway through the sample, the reduction in spatter is dramatic; the bead
becomes flat and the cross-section on the bottom right shows penetration of the weld bead into the
workpiece has increased. In spray arc welding, the addition of some inductance to the power source
will produce a better arc start. Too much inductance will result in erratic starting. When conditions
of both correct shorting current and correct rate of current rise exist, spatter is minimal. The power
source adjustments required for minimum spatter conditions vary with the electrode material and
size. As a general rule, both the amount of short circuit current and the amount of inductance
needed for ideal operation are increased as the electrode diameter is increased.

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Inductance and its Role

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