How Pulsed MIG Welding Works...And do you need it?

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***Disclaimer***
Welding and fabrication can be dangerous. Always work safely. These videos are provided for entertainment and general information. TimWelds assumes no responsibility for anything you choose to do. This description contains affiliate links which provide a small commission at no cost to you.

[@TimWelds]

You can learn to weld. I'll show you exactly what to do in my affordable online welding courses at courses.timwelds.com.

[@codyestel3293]

We need a puddle weld video

[@EChunter]

You look like your just learning to weld yet you think you can teach others to weld?

[@timwilson1573]

Brutal heat? The undercut is your technique or other parameters not the process fault

[@Hey_Its_That_Guy]

Thank you, Tim! We learn something from you in every video. You make it so simple, even I can follow along. Hope you and yours have a great Thanksgiving!

[@stevejanka361]

Good morning Tim, great information. That pulse transfer is great for automotive sheet metal. I recently watched a shop use the pulse weld for spot welding. Those welds were much prettier than the compression spot welds. Thanks for the great information. Take care and good luck.

[@bhhdh658]

thank you for all the information you have provided, I have learned a lot from your video, the delivery is very clear and systematic, it makes it easy for those of us who are just learning

[@natequillin4365]

Dude you are super helpful. Love the channel

[@Mikefestiva]

Thanks Tim for the video 👍🙂

[@RogierYou]

I like your very neat shop 👍

[@barryjones7025]

you should make a specific video on distuinguishing different parts of the puddle \. With arrows and pointing what your looking at and terms like where is the leading edge toes wetting. Where do you specifically look at when your welding. The tail end of the puddle what exactly is that doing.

[@chrispoynton8642]

Double pulse in so much better for welding aluminium. I use kemppi and I've got a fronuis CMT robot. The arc is very stable and clean. The welds I can do are high spec.

[@salekanayake8416]

Omg love your videos mate All the way from Australia . ur the best . amazing .thank you

[@commentsedited]

It is about 30% faster. Which matters to the business. Welded miles of drilling pipe. Reverse type. Welding the airchambers pulse was better than regular globular transfer

[@TimeSensitiveOutdoors]

That crater could be solved by a nice little partial weave at the end. Also drop your heat a tad and you can slow it down and have a better pattern. We run Miller 350Ps

[@mahfoozrehman5311]

Great video as usual! How do you find out if your machine is capable of pulse or spray transfer?

[@kazbekdzhanibekov9154]

thanks, great educational info👍

[@allaboutdetails3356]

I’m thinking of pulling the trigger on a pro pulse 220 so I can weld an aluminum trailer and some equipment railing, i think I just need to get an outlet added to handle the plug 😢 maybe you could recommend a 110v mig machine

[@Stainlessslayer]

We run Miller 350p and a couple fronius machines in our shop. All pulse/spray transfer. They're definitely nice machines. I'm not a welder. But those machines would definitely help fool you otherwise 😂.

[@MadLadsAnonymous]

How does pulse MIG compare to TIG for thinner materials? (Al, steel) I'm still learning but hoping to find a good breakdown of the various MIG and TIG subtypes. I took a MIG welding class (gas) and loved it. Hoping to take the TIG one then buy a hobbyist machine. Love the channel! Subscribed.

[@hpk4917]

hello, great Video. Thx

[@ZILAwelds]

When you build fuel or hydraulic oil tanks it comes in really handy

[@TimWelds]

Thanks Peter! I’ve built several small tanks, but always TIG welded them. I can see how that would be awesome on outside corners and a big time saver vs TIG.

[@raymondcorreira847]

Tim are you using the setting straight from the machine for double pulse? I'm trying to get settings for double pulse with 035" 4043 for 1/8" and 3/16" what off set are you using? Please

[@viktorjenei6546]

Hey Tim, i would like to have some questions. I mostly weld from 4mm up to 8mm what techniek i should use nowdays ? At the company we have really good machines from Lorch . I tried to use Spary Transfer , Pulsed MIG but i just cant get a really smooth weld like yours . Can you help me out with some information ? Thank you in advance. Cheers!

[@nate91198]

Thank you sir!

[@rayg5445]

So how do you set your machine to increase and decrease the welding current to run pulse

[@norberth6225]

How about pulse for mig brazing on car sheet metal, is this something that one needs? asking as im getting ready to buy mig welder but confused if i need pulse or not.

[@abhaybhatia85]

Hi, I am facing a lot of issue trying to weld aluminium plates (20mm). Can pulse mig machines help?

[@constructionsecrets]

Very nice 👍 👍

[@welderteach]

What’s a good machine with this capability? And economical

[@johnmacmillan627]

Greetings Tim! Question: what voltage do you need to attain spray transfer? If you used quite high voltage to attain spray transfer in regular mig welding , say on 1/4 in material would you not have problems with the weld? Presume if using pulse too high voltage would not be a problem as less time on high voltage. Also, why longer stick out for spray transfer? Always learn from your videos. Merry Xmas

[@tomthompson7400]

Its a nice option to have ,,, and the prices for single pulse machines are dropping every year ... I would be buying double pulse though ,,, but its still pricey.

[@ryanharrison8650]

Quick question for you..im currently using a parweld xtm 4035 had no issues until recently where all of a sudden after almost every weld im left with a small hole at the end of each weld..tried different things from lettin it burn bit longer taking it off quicker..different settings..new gas new wire all with no joy.. HELP!!

[@benwarner5389]

Thank you. I have a Miller Multimatic 255 that has the Pulse Mig feature with 100% argon. You mentioned that welding Aluminum without a spool gun. I’m sure you know how expensive even the standard spool gun is and even more money for the push pull gun? I have asked my dealer that sold me the welder to have a demo gun available for me to try out. So far they have not set something up with Miller. It is just too much money without welding with either the spool gun or the push pull gun. So, you have tweaked my interest so where do I get a graphic liner for a Miller mig gun?

[@ZILAwelds]

Amazon

[@ALSomthin]

Hi Tim so, what type of mig welder do you need to do this pulse mig welding? This doesn't seem to be the same regular spray welding I can do on my big old Miller 210 mig? If I do silicon bronze wire with it I get a huge case of the spatters really bad. I play around with the wire feed but still my .030 hard wire never sounds like this . If I could get this to do pulse welding with silicon bronze wire and aluminum with the Miller 210 and a spool gun that would be pretty cool. So do I need a different welder?

[@ZILAwelds]

You need a pulse mig welder …. Like a miller 255, 355 or 350p or lincoln 350 mp or HTP pro pulse 220 or 300….

[@sitarammore8362]

Esab Aristo pulse setup

[@laszlovona]

I like pulse mig due to the nice penetration, but it is easier to encounter undercut due to the brutal heat.

[@hpskater29]

Anyway you could elaborate on how to not run into that? Fairly new to pulse and have a test for it coming

[@laszlovona]

@@hpskater29 Hi, I am trying to avoid it with balancing the heat/added material between the edges. I stay longer on the 'upper part ' of the bead thus filling the part prone to undercut.. Or even better if you can lay your part horizontally. But you can always back up the heat till you have the penetration/'low enough' bead profile you want. Playing with inductivity does not help since it only works in short circuit MIG. So you see it is trial and error eventually, but you will find your way. In a nutshell: you either backup tye heat, or play with your movement/puddle to 'fill' the undercut 'zone'.

[@hpskater29]

@@laszlovona thank you for the fast reply bro you’re the man. Much appreciated Good luck wherever and whatever you’re doing

[@johnmacmillan627]

Thx Tim. I have a relatively inexpensive pulse mig weilder. When you setup for double pulse you can select a frequency but you cant when in single pulse. This leads to my question: what is changing frequency? As I understand it in single pulse the amps and volts change many times per second (perhaps greater than 60?) . In double pulse there is a pulse on pulse. From diagrams I see that the frequency of the secondary pulse appears much greater than the primary pulse. So what am I changing when I select 2 pulses per second? The primary or secondary pulse? When I select 2 pulses per second I can hear this pulse surge and ebb very clearly. Thanks for your input. I see you have quite a CV in the metallurgical field!

[@TimWelds]

Hi John, With most machines, the primary pulse is automatic. On double pulse, the frequency can be set on some machines, so that’s most likely the setting you have. I use between 1 and 3 PPS for secondary pulse. You’ll hear it cycle between the high and low setting as you described when using double pulse.

[@johnmacmillan627]

Thx Tim

[@vladtepes97]

yesterday i finished my first full week in the shop, and i passed my 6mm and 8mm. i got my first of four 6mm pulse welds before closing up shop for the weekend. i also borrowed my friend's flux core machine to practise on at home, forgetting that my doggone helmet, jacket and gloves are in my locker at school. frustratiooooooooooon, frustration.

[@nickkok2]

Looks like you got a new welding table. Can you share which one it is?

[@TimWelds]

I’m super excited about it. It’s a Siegmund 3’x4’ from Quantum Machinery. I’ll have a video about it in the next couple weeks.

[@nicholaskok2961]

@@TimWelds looking forward to the video on the siegmund! I was actually just about to order two Langmuir ArcFlats. Your review convinced me. But I wonder if I would do better with the siegmund’s nitride coating given I live next to the ocean…

[@internetaccount2725]

For someone who occasionally welds personal projects and wants to be able to do it all. Would you choose a machine which is capable of dual pulse mig, or high frequency ac/dc tig?

[@TimWelds]

AC/DC TIG. The learning curve is a little longer, but it is more capable and welds any metal with the same gas. MIG needs different gasses for different materials, which complicates the matter.

[@internetaccount2725]

@@TimWelds legend!

[@jeffthompson5690]

Which "heavier duty" gun from HTP did you use on your Pro Pulse 220 MTS to weld the aluminum? I'm on USWeld's site, but can't seem to find a specific aluminum welding gun (not a spool gun) with a graphite liner. I'm trying to decide between the Pro Pulse 220 or the much more expensive Millermatic 255 and the XR-Aluma Pro gun. Any recommendations on quality of the machine as well as weld quality between the two? I'm mainly going pulse to get a stacked row of dimes look with improved fusion on mostly steel and just recently saw the XR-Aluma Pro (and it's $3400!!! price tag)....but it would be nice to weld thicker aluminum with it as well.

[@TimWelds]

It’s a 26 series gun, if you go on their website to MIG, then accessories, then MIG guns, you can find those that are compatible with the pro pulse. You can also get a pro pulse with both guns included. The HTPs can also run a push pull or spool gun if you need more length, but the wire does feed through the lead quite well. I have owned several Miller welders and they’ve been great, but the HTPs really give a lot of bang for the buck. Quality of machine wise, the HTPs are just as good. I haven’t used a 255, so I can’t give a comparison of performance for this specific application. The only pulsed Miller I’ve used is a 350P, but I don’t think those are in production any more. Pulse on steel usually gives a very smooth bead. It can be possible to get some dimes with double pulse, but it’s not how most of the motor sports guys do it if that’s what you’re going for. Also, I believe that the frequency of double pulse is fixed on the pro pulse, so that could be a limitation if you have a very specific look you’re going for. (it’s fully adjustable on the HTP Revolution 2500) I only bring this up because it might be good to demo what you’re looking for before investing in the equipment. If you have other questions about the HTP, you can just call them and they’ll be straight with you about what it can and can’t do.

[@jeffthompson5690]

@@TimWelds Thanks Tim. I apologize....I should have done my due diligence before asking as I found all this info after I asked. After reading quite a bit on welding forums and looking at the HTP Revolution 2500 with the All In kit, I've decide to get the Miller instead. I've got the HTP Invertig 220 for Tig work and already mastered the stack of dimes MIG look with short circuit with my Miller Vintage 250 and 211 and a Lincoln Power Mig 256...but want the added penetration that pulse should provide. The MM 255 just has a lot more amps and higher duty cycle and since pulse is really what I'm after with this machine, I don't really need the multiprocess capability of the HTPs. You have to pay to play if you want to weld really heavy material, so I guess it is what it is. Thanks again!

[@sitarammore8362]

Esab aristo 500ix model

[@haircvt8461]

What machine are you running?

[@TimWelds]

I’m using the HTP Pro Pulse 220: usaweld.com/products/pro_pulse_220_mts?ref=timwelds

[@tiejdzsi6224]

Im wondering how puls will work with vertical 3f 😎

[@TimWelds]

It’s awesome if the setup is right.

[@internetaccount2725]

Can dc tig do everything this process can do with aluminium?

[@TimWelds]

No, for TIG welding aluminum, you’ll need AC. With AC TIG, you can. MIG will be faster and TIG more precise.

[@internetaccount2725]

Thank you very much. Great videos

[@jasoncousins1343]

Problem is that people use pulse on everything its really only beneficial for outta position or if heat input is a issue axil spray gets better penetration than pulse

[@TimWelds]

True story, unless you're working on thin stuff or out of position, spray is generally better. As more of a fabricator than a production welder, I do it just because it's too much time to switch material.

[@mdover2961]

Hi , For MIG pulse welding, can we say that it is a process that combines Short Circuit Mode and Spray Arc Mode

[@TimWelds]

From a practical perspective, yes it has characteristics of both. The mechanism is completely spray transfer, though. I’d think of pulsed spray more like electronic fuel injection and short arc more like a carburetor. Just different ways to reduce the rate of energy input.

[@davidforbes6250]

We didn't get to see your lathe?

[@TimWelds]

I sold mine and bought a new one, which got dropped off a truck 😭. The replacement will come in early December.

[@davidforbes6250]

@@TimWelds Very good.

[@banzaiib]

Most cheap machines can't do it, which is what I have, since I'm not a pro, but as a relative noob, why wouldn't you use pulse spray if possible?

[@SnarkySod]

Pulse for welders who can't 😂

[@TimWelds]

I’ll take all the help I can get 😃. There are situations where short arc and straight spray just can’t get the job done and this keeps the productivity up a bit compared with TIG.