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ESAB introduces new pulsed welding systems  optimised for aluminium and stainless steel welding

June 14, 2016

  • New MA25 Panel simplifies pulsing control.
  • Enhanced Aristo Feed 3004 wire feeder provides more positive feeding performance.
  • Enhanced Aristo MIG 4004i Pulse power source improves arc starts.

By combining new and enhanced components, ESAB Welding & Cutting Products today introduced a pulsed GMAW (MIG/MAG) system optimised for greater productivity and better quality when welding aluminium, stainless and carbon steel. The system includes the new, highly intuitive MA25 Pulse Panel, the enhanced Aristo® Feed 3004 wire feeder and the upgraded Aristo MIG 4004i Pulse power source. ESAB offers the MA25 Pulse panel in two options: an aluminum panel with 30 pre-programmed synergic lines for aluminium wire 0,9 mm – 1,6 mm or a steel/stainless panel with 54 pre-programmed synergic lines for solid and cored wires 0,8 mm – 1,6 mm.  

“Our customers wanted all the traditional benefits of pulsed MIG welding in a more operator-friendly package, and the new MA25 Pulse panel is at the heart of the solution,” says Hans Örtengren, Product Manager, ESAB Welding & Cutting Products. “The MA25 control panel uses icons, push buttons and digital displays to simplify use and eliminate language barriers. The different welding programs are easy to find, set and fine-tune, which contributes to improved productivity.”

To begin pulsed welding, operators select the synergic line for the type of filler wire and gas being used, and the system then provides optimum dynamic arc control. No additional process knowledge is required. The system can automatically adjust for variations in arc length (voltage) and wire feed speed, helping to maintain consistent penetration and weld bead appearance. These functions especially help less experienced or moderately skilled welders produce better results. 

Pulsed GMAW welding provides numerous benefits, depending on the application. It may enable users to:

  • Standardise on a single, larger diameter aluminum wire for welding a broad range of metal thicknesses.  
  • Greatly reduce or eliminate weld spatter and associated post-weld clean-up.  
  • Control bead appearance, an important factor when customers value good-looking weld beads.
  • Weld thinner materials without burn-through or warping, increasing first-pass yield and reducing scrap rates.  
  • Better manage heat input to preserve mechanical properties while also increasing travel speed, especially on stainless steel.
  • Enable all-position welding while maintaining reasonably high deposition rates and travel speeds.

Better Arc Starts, Controlled Weld Stop

The MA25 Pulse panel connects directly to the Aristo Feed 3004 wire feeder. Now enhanced by a new motor drive, the system offers more torque for improved arc starts, more consistent speed and less noise. The Aristo Feed’s redesigned drive rolls and feed mechanism provide a more positive feeding performance and reduced risk of wire shavings. A function called start parameter R enables fine-tuning of the electrical arc during the start of the weld. At the termination of a weld, Short Circuit Termination (SCT) technology sharpens the wire to promote better arc starts and eliminate the need to clip the wire to remove the ball the would otherwise form. Both start parameter R and SCT are optimised using ESAB’s pre-programmed synergic lines. 

ESAB also upgraded its premium welding power source in the 400-amp category, the Aristo MIG 4004i Pulse, to help fabricators and manufacturers reach new levels of productivity and solve their toughest welding challenges. The Aristo MIG 4004i Pulse now incorporates quicker responding hardware and new software controls that provide better arc starts, especially with aluminum and stainless.  

ESAB Welding & Cutting Products is a recognized leader in the welding and cutting industry. From time-honored processes in welding and cutting to revolutionary technologies in mechanised cutting and automation, ESAB’s filler metals, equipment, and accessories bring solutions to customers around the globe.
The ESAB MA25 Panel provides the benefits of pulsed GMAW using operator-friendly, intuitive controls.