MEDIUM FREQUENCY WELDING Introduction With the introduction of carbon foot printing, a measure for determining the quantity

of greenhouse gases released as a result of an activity, it has become important to minimise energy consumption for any given process. To this aim, medium frequency welding (MFDC) is becoming more prevalent in the welding arena. MFDC vs. AC Welding MFDC utilizes IGBTs for switching the power (see fig 1). These are switched on and off at a rate of 4002000 times per second, resulting in a DC type output (see fig 2). Whereas AC controls utilize SCRs for switching. These are switched on by the control and remain conducting until the line voltage crosses the zero point during the base frequency line cycle. This results in a sine wave form output (see fig 2).

Fig 1 MFDC Circuit Schematic

Fig 2 Wave forms of AC and MFDC welding

Benefits of MFDC Welding 1. Significant energy savings: because the output is DC shorter weld times are required. 2. Improved and consistent power factor: MFDC results in a unity power factor, thus reducing cost penalties introduced by the power generating companies. 3. Automatic load distribution: MFDC uses 3 phases and current is also drawn from the capacitors that are used in the system, as well as from the mains thus reducing peak line currents. 4. Welding tolerance: because the capacitor bank smoothes out the line spikes and troughs during welding, the effect of electrical line disturbances are minimised 5. Optimum response: due to the responsiveness of MFDC, it is possible to create full phase firing during the natural rise time to minimise that period of time 6. Precise weld control: because the current is switched at a rate of 200-4000 times per second, MFDC only needs a fraction of a second (1/20 th nominal) for applying over or under current adjustments 7. Process friendly: MFDC eliminates the intercool state between cycles, thus permitting shorter weld times 8. Flexibility: MFDC systems are very stable between 20-95% of the maximum rating, whereas AC system are unstable and inefficient when used outside the 70-90% range

Resultant Savings

These results show a case study comparing MFDC welding with conventional AC welding. These results illustrate the levels of tangible savings that can be achieved. In addition to these, there are intangible savings such as: Reduced tip wear resulting in up to 30% increased electrode life Minimised surface marking Reduced weld splash

Applications MFDC is suitable for all the welding applications that AC is traditionally used. However as shown in figs 3 and 4, MFDC has greater tolerance levels to parameter settings as illustrated by the larger welding lobes when welding uncoated and coated steels. It should also be noted that the MFDC welding lobes are to the left of the AC welding lobes, hence demonstrating that MFDC uses lower current for a given welding time. MFDC is particularly suited to aluminium welding, because welding is usually performed with short welding times. For a given welding time more heat is produced with MFDC welding than conventional AC.

Fig 3 Welding Lobes for Uncoated Steel

Fig 4 Welding Lobes for Coated Steels

Table showing relationship between cycles and ms

Weld Time Cycles(base 60 cycles) 4 6 8 10 12 14 16 18

Weld Time ms 67 100 133 167 200 233 267 300

It should be noted that in the UK when using cycles to measure weld time the base is 50 cycles per second or 1 cycle = 20ms

Conclusions Therefore, by using MFDC welding the following benefits will be achieved: 1. 2. 3. 4. 5. 6. 7. Unity power factor Reduced weld times Even mains distribution Improved weld quality Greater flexibility More precise weld control Increased electrode life

Also MFDC welding can be used for all the applications generally performed by AC welding. In some cases, particularly aluminium welding, MFDC is better suited. All these factors result in reduced energy consumption and costs, and a lower carbon footprint.