The Benefits of Synergic MIG Welding

Speed Up and Simplify Welding Setup with Synergic MIG

Synergic MIG Makes Setup Easy

Ask a fabrication shop owner the reason for their success, and you’ll likely hear the phrase, “Our people are our strongest asset.” However, finding skilled welders remains an ongoing challenge. As a result, managers are hiring people with a good attitude and work ethic and then teaching them to weld. At the same time, managers want their highly skilled welders to work as efficiently as possible.

Reflecting the needs of the market, welding equipment manufacturers pack MIG and multi-process welders with advanced welding technology that makes it easier to learn to weld, achieve consistency and reduce set-up/change-over time. Some of the features to look for include synergic MIG mode, arc dynamics and job recall, which are featured in ESAB’s Rustler EM 350C PRO Synergic welder.

Appreciating the Challenge

MIG welding in the standard mode requires set-up, as well as fine tuning wire feed speed and voltage. Users start by setting wire feed speed, which controls amperage and penetration. Voltage controls height and width of the weld bead, and wire burn-off rate; adding more voltage will produce a flatter and wider bead and provide a faster burn-off rate.

A harsh sound with a lot of popping usually means that the wire is melting faster than it is coming out of the MIG torch. To solve the problem, operators can either decrease voltage or increase wire feed speed. If the wire stubs into the base metal, there is not enough voltage to melt the wire, so users need to increase voltage or reduce wire feed speed.

Even with a parameter chart, less-skilled welders can struggle to fine tune the arc. To complicate matters, to finely-tune a MIG other variables need to be considered that include: wire diameter, shielding gas, material thickness, joint design, welding position and welding mechanics such as contact-tip-to-work distance, travel speed, torch angle and torch manipulation (if any).

Synergic Control

With synergic control and job recall, operators can focus on good mechanics, which promotes consistency and productivity while making it easier to learn to weld. “Synergic” comes from the ancient Greek word synergia, which means “joint work, working together, cooperation.” As far as welding operators are concerned, synergic simply means “one-knob control.”

Instead of fine tuning the arc in standard MIG mode, operating a MIG welder in the synergic mode starts by using a digital control panel to select wire type, wire diameter and shielding gas type.

After making the correct wire type, wire diameter and gas selection, the machine will then access the “synergic line data” where the manufacturer’s application engineers have factory-programmed all welding variables in relation to the material thickness which equates to wire feed speed. To weld thicker material (or “weld hotter and faster” in layman’s terms), the operator simply increases wire feed speed. To weld thinner material (e.g., reduce heat input), the operator decreases wire feed speed. The synergic line will provide an optimized, stable arc throughout the machine’s entire output range.

Synergic MIG works for the short circuit, globular and spray transfer modes for conventional MIG systems, as well as with the pulsed MIG process for systems with pulsing capabilities.

A function called trim control enables further fine tuning by adjusting arc length/voltage, such as in 0.1 volt increments throughout a 2 to 5-volt range, machine dependent. Operators typically adjust trim to shape the weld bead profile, such as for a flatter crown and better tie-in at the toes of the weld. No matter how much the operator adjusts trim, the synergic control will maintain a stable arc.

When operating in the short circuit transfer mode, some welding machines offer one more technology to refine the MIG arc. Arc Dynamics (sometimes called inductance) modifies the rate and duration of the short circuit cycle, which affects the intensity of the welding arc. A lower Arc Dynamics setting creates a softer arc with less weld spatter and better wetting action, which is especially helpful on stainless steel. Higher arc control settings give a more driving arc which can increase weld penetration.

With a traditional welder, “job recall” involves writing down preferred parameters on a sticky note, tick mark on the front panel of the machine, or some other form of documentation. To promote fast and accurate set-up, more and more welders offer digital job recall. Some machines have “quick job” buttons on the front panel, while others offer a job recall function through the graphical interface. Either way, the combination of job recall and synergic controls gives fabricators new tools to promote consistency and productivity.