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Modern, ultra-lightweight places demands on welding technology that simply cannot be met with traditional
shielding gas welding processes. Variants of the robust arc welding process need to be developed which feed very
little heat into the material but which still guarantee strong connections. The coldArc is a variant of the MIG/MAG
process that meets these demands. In this process, all interventions in the process flow are carried out directly in
the power source without mechanical intervention in the wire feed, which means that standard welding torches can
be used and the process can also be used to produce excellent manual welding results.
In fact, immediately after the arc ignites, the output is The copper-based wires have a melting point of
reduced in an exceptionally dynamic and controlled around 1000 C. In comparison to the same type of
way, and then, after the arc has been stabilised, MAG welding, the heat loading of the surface layers is
increased to the defined melting of the electrode tip in already therefore considerably reduced. These are
a pulsed way. even more protected if MIG brazing is carried out
A process of this type can be used for many welding using zinc-based solder with melting intervals of
tasks, especially in vehicle construction where the around just 450 C. The use of these wires is only
normal short arc is no longer suitable. possible however, if the short circuit current is strictly
Even just a few years ago, it was assumed that the limited and the general heating feeding is also
MIG/MAG process should be used for steel over a reduced considerably. The vaporisation temperature
panel thickness of 0.7 mm and for aluminium over of the zinc/aluminium alloys used for arc brazing is
3 mm [7]. The panel thicknesses in vehicle just under 900 C, in other words still below the
construction today are becoming increasingly thin, melting temperature of copper alloys.
however. They already go down to as low as 0.3 mm,
and 0.2 mm is already being tested for composite
construction work. The difficulties in achieving an
even groove are even greater if there are larger air
gaps to be bridged. This is a typical task for the
coldArc process.
coldArc arc
Figure 5 Manual coldArc brazed joint of 0.8 mm
electrolytically plated steel plate with 4.0 mm
Output on
re-ignition air gap, 1.0 mm CuSi3 wire.