New Weldmodes Optimize Performance in Thin, Root, Pipe, and Pulsed Welding Applications

ESAB provided live welding demonstrations of its Warrior® Edge 500 DX multi-process power source in booth W3801 at FABTECH, October 15 – 17 in Orlando, Florida. The Warrior Edge 500 DX now features four advanced MIG WeldModes — THIN, ROOT, ROOT Pipe and SPEED — as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter by up to 85% (depending on the processes compared) for less post-weld clean-up. With Warrior Edge DX, manufacturers and fabricators can optimize productivity, improve quality, consistency, and simplify training.

Users set up material on an intuitive TFT LCD interface inside the RobustFeed Edge DX wire feeder. The feeder’s streamlined front panel features day-to-day controls, Quick Job (memory) buttons, WeldMode selection, and RFID badge-controlled access to promote consistency and manage a workforce with varying degrees of skills.

The Warrior Edge 500 DX, with a rated welding output of 500 amps at 60 percent duty cycle, has built-in connectivity and comes with a lifetime subscription to the InduSuite WeldCloud Fleet online software application.

“The Warrior Edge 500 DX enables ordinary welders to benefit from sophisticated WeldModes without needing continuous training or relying too much on individual operator skill,” says Arne Lagerkvist Global Director of Product Management – Heavy Industrial Products, ESAB. “The intelligence inside the system makes set-up fast and welding easier. When using a synergic WeldMode, operators can fine-tune performance simply by adjusting the wire feed speed and trim control knobs, and the system will maintain optimised arc characteristics and deliver excellent weld results.”

Productivity-Enhancing Modes

Compared to conventional short circuit transfer, the THIN WeldMode reduces heat input, typically by 20%, to minimize distortion when welding thin plates, such as from 22 to 11 gauge. It also reduces spatter and fume generation. With an ability to bridge gaps, the easy-to-control ROOT WeldMode is optimized for root passes on plates in all welding positions and creates a smooth arc even while weaving. The ROOT Pipe WeldMode optimizes gap bridging in vertical down pipe applications.

The THIN, ROOT and ROOT Pipe WeldModes use enhanced short circuit transfer processes with a novel type of adaptive control that delivers consistent and smooth metal transfer for a more stable weld puddle. Improved stability gives the operator better control even when welding at faster travel speeds, plus it suppresses the conditions that lead to the formation of spatter. Even though these WeldModes lower heat input for reduced distortion, their gap-bridging ability promotes consistent fusion without excessive reinforcement on the backside of the joint. In addition, there is no need for a voltage sense cable which simplifies set-up and reduces the risk for mistakes.

The SPEED mode creates a more focused arc by taking a conventional spray transfer arc and overlaying a modified pulsed current wave form on top. Benefits of the SPEED mode include improved control at higher travel speeds (up to 700 inch/min), reduced spatter, deeper more focused penetration in fillet welds and the ability to weld in narrower grooves. The Warrior Edge 500 DX also offers synergic Pulse MIG WeldMode, which generates 69% less fume compared to generic pulse waveforms. The power source also has outputs for conventional and synergic MIG welding, Stick, Live TIG and carbon arc gouging.

Warrior Edge systems also offer an Arc Dynamics function where the operator can set welding parameters and fine-tune by turning a single knob. Benefits include creating a more focused arc for faster travel speed when making fillet welds, adjusting arc energy for specific welding conditions, stability control for specific travel speeds, wire stick-out and better control of the weld pool, and weld bead geometry. Arc Dynamics works in all synergic WeldModes to provide customized control over welding.

The Warrior Edge power source is designed to work with the RobustFeed Edge wire feeder, which features an effective and quick to set-up operator management system that uses an RFID-reader to scan operator badges. This allows locking parameter limits for quick jobs, improving repeatability and adherence to Weld Procedure Specifications. The feeder also includes ESAB’s TrueFlow digital gas control technology for greater precision, confidence and cost savings. The system automatically prevents insufficient gas flow and optimises flow during arc starts and welding, a common source of quality issues and gas waste. TrueFlow can save $650 to $1,300 per year, per machine in gas waste in typical use cases.

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About ESAB
For more than 120 years, ESAB has been a world leader in fabrication technology. Our distinctive portfolio of fabrication solutions encompasses more than 40 of the world’s most trusted brands for welding and cutting equipment, automation, robotics, fabrication software, filler metals, gas flow control, and PPE. Industries and innovators that shape the world rely on ESAB’s products and solutions.