Manual Kemppi A7 TIG Orbital System 300 (page 19 of 61) (English)

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A7 TIG Orbital System 300© Kemppi Oy 2016 1615

OPERATING MANUAL

Wire feed can be continuous, or you can select Step Mode.

In Step Mode, two levels of wire feed are synchronized

with pulsed current. Wire feed during the low current

pulse period is set as a percentage (0–99 %) of the high

pulse wire feed speed. This feature is useful to control

weld puddle size and to maximize ll rate. It may not be

possible to use the same wire feed speed for both high

and low current pulse periods, but the amount of wire fed

during low pulse can be tailored to optimize solidication

rate and puddle control.

3.1.4 Root-pass procedure

Filler wire to tungsten electrode gap should be

approximately 1.5 mm (rule of thumb is 2/3 the diameter

of the electrode). When welding a "J" prep, the wire entry

into the weld puddle is correct when it appears that the

wire is standing still. Wire should feed smoothly into the

front edge of the weld puddle. There should be no drip or

drag of the wire. When welding a 37.5 degree bevel, the

wire should push slightly into the work.

To make the wire enter the weld puddle directly under the

tungsten electrode:

1. Adjust arc length so that wire entry is correct. As

the weld puddle partially solidies during low

current, the edge of the puddle freezes, forming a

circular "chill mark".

2. Observe the chill marks on the weld bead surface.

If the chill marks are closer than 0.8 * root land

thickness, increase travel speed by 3 mm/min until

you have reached the needed reinforcement.

• If the ID bead is almost solidied between current

pulses, increase high-pulse heat input by doing

one or more of the following:

• Increase high pulse current.

• Increase high pulse time (0.2 s minimum).

• Decrease wire speed.

• Decrease travel speed.

• If the ID bead is too uid, reduce low pulse heat

input by doing one or more of the following:

• Reduce low pulse current (reduce % of high

pulse).

• Increase low pulse time.

• Increase wire speed.

• If there is insucient penetration on the I.D,

observe the chill marks on the weld surface.

• If chill mark spacing is adequate, check that low

pulse weld current is at least 50 % of the high

pulse level and increase high-pulse weld current

if necessary.

• Record all changes.

3.1.5 Hot-pass procedure

1. Set wire to tungsten electrode distance and ensure

that the wire is aimed laterally directly under the

electrode.

2. Ensure that the hot pass is not causing the root

bead to melt again as this may result in "suckback"

or concavity of a previously acceptable root bead.

3. If the root pass melts, reduce weld current.

4. Ensure that the weld puddle is fusing into both

sidewalls.

5. Check centering and increase oscillation width if

necessary.

6. If the puddle runs ahead of the tungsten electrode

on the downhill side, reduce wire speed.

7. If the puddle is sticking or making "wagon tracks"

on the sidewalls, reduce travel speed.

When using the pulsillation technique, the lower amperage

during torch excursion across the seam reduces the size of

the weld puddle. The weld puddle must be large enough

to ensure that the ller wire melts properly and does not

"drag" on the unmelted solid surface of the joint. Set low-

pulse amperage to approximately 70 % of high pulse.

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Kemppi A7 TIG Orbital System 300 Manual

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