OTC Welding Process

Processes

Step into OTC DAIHEN’s world of innovative MIG/MAG processes. We invite you to explore specialized robotized welding techniques, including:

Synchrofeed: OTC DAIHEN’s dynamic welding process that combines high melting rates with low heat input, enabling the welding of steel, galvanized and stainless steel, as well as aluminum down to a thickness of 0.6 mm.

AC/MIG: OTC DAIHEN’s alternating current welding process, which utilizes electromagnetic forces (pinch effect) to form and control weld droplets. This method is ideal for welding thin materials at high speeds and for tackling challenging gap bridging.

D-ARC: OTC DAIHEN’s improved alternative for tandem or double wire welding solutions. It offers extreme deposition rates with flexible weld routing, all with a single wire.

Find more information below.

SYNCHROFEED

Discover our further improved SynchroFeed robot welding equipment. SynchroFeed Evolution features an improved compatibility to OTC DAIHEN welding power sources and a scalable setup of buffer and feeder combinations to fit best for your application without material limitations.

WHAT IS SYNCHROFEED?

Our OTC SynchroFeed process is a noteable improvement over conventional MIG/MAG welding processes. This is our welding solution to join medium and thin materials without deformation, account for gap tolerance, and significantly reduce welding spatter – all while being performed quickly and cost-effectively.

SynchroFeed utilizes precise wire guide synchronization principles to eliminate welding spatter. It works by retracting the wire at extremely high frequency of 100 Hz so that the droplet is directly dipped into the melt. The wire withdrawal from the melt is synchronized to ensure that no adhesion occurs, avoiding separation above the melt that causes spatter. The wire feed plays a decisive role in this process, and its withdrawal from the melt must be perfectly synchronized. This process cannot be achieved with commercially available push-pull systems. Through the high-dynamic control process, a larger amount of wire can be fed, resulting in an increase in melting deposit in the transitional arc area and a significant increase in welding speed.

The SynchroFeed system includes two wire feeders, one push feeder on the wire barrel, a push/pull feeder at the torch mount and a “S”-shaped wire buffer on the third axis of the robot to ensure the wire to expand in the middle without encountering resistance or friction.

These two motors are precise synchronized and controlled by the Welbee chipset in our Arxis welding power sources. This setup allows the peak dip transfer (PDT) process, a controlled droplet transition in the short circuit phase. The PDT process is a precisely controlled short arc, which is only possible with the use of our fast Welbee processor.

Advantages of SynchroFeed :

  • High weld deposition combined with low heat input
  • Consistent and predictable penetration adopted to the welding speed.
  • Reliable connection between base material and weld, blowhole free.
  • Low distortion due to low and stable heat input.
  • Reduced costs due reduced post-weld cleaning and finishing.

WHAT MAKES SYNCHROFEED EVOLUTION SPECIAL?

SynchroFeed Evolution offers software and hardware improvements:

Simultaneous robot welding
A new controlling software to support simultaneous welding with multiple robots on one work piece.

Compact pull torch
A new design pull torch with integrated cleaning feature and easy installation

Welding power source selection
An extended OTC DAIHEN welding power source selection from 400-500 Amp DC and 400A AC/DC offer a greater variety of processes such as AC MIG, Push Arc and SychroFeed Pulse.

Scalable Setup
SynchroFeed Evolution is available as LITE configuration for better price performance application and as PRO configuration for free material choice.

AC/MIG

High efficient MIG welding with TIG quality

OTC’s WELBEE AC/MIG FLAGSHIP FOR MANUAL AND ROBOTIC WELDING

The Welbee W400 welding power source is OTC DAIHENs flagship for AC/MIG welding. Main advantages over standard DC pulse welding processes.

WELDING OF THIN MATERIAL AT HIGH SPEEDS WITHOUT MATERIAL DISTORTION

AC/MIG welding is a highly effective welding process that combines two important features: a higher melting rate and an improved penetration control. The increased melting rate at constant current input lowers the heat input into the workpiece. These features make it an ideal choice for welding thin metal sheets up to 0.6 mm in thickness without sacrificing the quality of the weld. AC/MIG welding is applicable for a wide range of materials, including steel, stainless steel, and aluminum.

IMPROVED GAB BRIDGING

One notable advantage of AC/MIG welding is the flexibility it offers with regard to electrode polarity. In addition to the commonly used positive electrode, known as direct current electrode positive (DCEP), AC/MIG welding allows for the utilization of a negative electrode, referred to as direct current electrode negative (DCEN). This unique feature forms the basis of the welding process, as it involves the alternating current (AC) between DCEP and DCEN.

An important aspect influenced by the welding parameters is the EN Ratio, which refers to the proportion of time allocated to the DCEN polarity. By increasing the EN Ratio, there is a corresponding increase in the wire feed rate. Consequently, the higher wire feed rate leads to a greater deposition rate of the welding wire onto the workpiece. This enhanced deposition rate results in an improved capability to bridge gaps between materials during the welding process.

By adjusting the EN Ratio and increasing the wire feed rate, the deposition rate of the welding wire can be heightened, resulting in improved gap bridging capabilities.

LESS WELDING FUMES AND OXID LAYERS

AC/MIG welding also offers the benefit of producing less welding fumes and oxide layers. This results in a cleaner weld surface compared to other welding methods. The low temperature required for drop transfer in AC/MIG welding reduces the production of welding fumes. Consequently, there are fewer burn marks and less fume generated during the process. This contributes to a cleaner and visually appealing weld finish.

WHAT IS THE DIFFERENCE BETWEEN DC AND AC/DC WELDING?

DC welding is a welding process that utilizes a unidirectional flow of electrical current. In this process, the current flows continuously from the power source to the welding electrode in a single direction. DC welding is commonly employed for welding steel and stainless steel, offering benefits such as better control over the welding pool and deeper penetration.

In contrast, AC/DC welding combines both alternating current (AC) and direct current (DC) in a single welding process. This versatility allows for the flexibility to switch between AC and DC modes.

Nevertheless AC/DC welding machines provide the convenience of switching between AC and DC modes, making them highly versatile for a variety of welding applications. This capability enables welders to work with different materials and adjust the welding process to suit specific requirements.

D-ARC

DISCOVER OUR MIG/MAG PROCESSES

HIGHLY EFFICIENT THICK SHEET WELDING PROCESS
OTC’s D-Arc Process is an innovative welding technique that allows for the efficient single-pass welding of thick plates. It represents a significant advancement in the field of thick-plate welding.

ADVANCEMENT IN THICK PLATE WELDING

The D-Arc Process represents a significant advancement in the welding of thick plates. It utilizes a rotating and oscillating arc that generates a high level of material deposition while maintaining controlled heat input. This results in improved efficiency and reduced requirements for weld preparation, such as the need for extensive joint bevelling.

REPLACEMENT OF CONVENTIONAL MULTI-LAYER WELDING

Unlike conventional multi-layer welding techniques, the D-Arc Process enables single-pass welding. This significantly reduces the process time, as there is no need for multiple layers of welding. By eliminating the time-consuming process of layer-by-layer welding, productivity is increased, and overall costs are reduced.

OPTIMAL ROOT FORMATION

The D-Arc Process allows for optimal root formation without the need for back welding. The unique characteristics of the rotating and oscillating arc ensure that the root of the weld is well-formed and fused without requiring additional welding from the backside. This simplifies the welding process and improves the overall quality and integrity of the weld.

D-ARC WELDING PATTERN

The D-Arc Process follows a specific welding pattern that is designed to achieve optimal results. This pattern ensures proper penetration, uniform heat distribution, and reduced distortion. By adhering to the D-Arc welding pattern, welders can consistently produce high-quality welds with minimal defects and improved visual appearance.

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