Because its surpasses past innovations, the emergence of “digital technology” has changed the way we live and play. The quality, consistency, and repeatability of digital technology have rewarded those who long for the best in audio and visual capabilities. So it's no surprise we've traded our cassette tapes for CDs and MP3s, our VHS for DVDs, and analog TV for digital TV.

The benefits of digital can be experienced on the job site, too. In the welding industry, digital technology is transforming how today's operators work, giving them more control and more consistency than they ever thought possible. Because digital welding can reproduce every weld for a given setup 100% of the time, welders and job shops alike are embracing this new technology to remain competitive in a changing industry.

Digital driving force

One of the first companies to adopt digital technology has been Thermal Arc, a supplier of arc welding technology worldwide. Its new choices in digital power sources - the PowerMaster SP SmartMIG^™, PulseMIG^™ and TwinPulse^® GMAW (MIG) systems - were created by taking the most advanced inverter-based digitally controlled welding technology in the world and developing a complete product line for welding a variety of materials, including aluminum, stainless steel, and specialty alloys.

The innovative, digital microprocessor-based PowerMaster SP uses intelligent pulsing and synergic wave design to give precise, repeatable welds on almost any material type with advanced control for the operator. Simultaneous control of the wire-feed speed, arc current, and voltage ensures a clean, TIG-like finished appearance with GMAW productivity. The result? Improved productivity reduced clean-up time and fewer component reworks.

PowerMaster SP technology gives the operator enhanced control when adjusting for a new weld. In the past, operators had to use a series of dials, knobs and switches to alter welding parameters. In many cases, an adjustment was a trial-and-error process - operators had to depend on the feel of the weld and hope the parameters delivered the consistency they expected. In addition, if more than one operator was working from a single power source, the risk of inconsistency on the project was especially high.

Digital technology improves on these issues by using completely automated controls to simplify any adjustments. The new technology is centered on synergic control, otherwise known as “one-knob control.” The wire-feed speed is linked to the arc voltage, and when an operator makes adjustments, the two are matched through the machine's software to deliver perfect, consistent welding parameters every time.

Thermal Arc developed multiple synergic lines, a system that is centered on automatic parameters matching unique settings, allowing for smooth, worry-free transitions between welds. A synergic line for each wire and gas combination using up to 29 different variables was developed and programmed into the machine's digital microprocessor. The PowerMaster SP features up to 100 pre-programmed SmartMIG, PulseMIG, and TwinPulse programs standard, and up to 100 independent user-defined programs can be manually entered and saved through the software.

To find the perfect balance between voltage and wire-feed speed, while ensuring a consistent delivery, the welder simply selects the welding process, filler metal type and size, and a shielding gas, and adjusts the machine by welding current, material thickness or wire-feed speed. Immediately, PowerMaster SP takes all the guesswork out of the process, matching up parameters to the operator's needs. If a particular program one requires is not available through the software, or if the welder has a special filler, base metal or gas mix, Thermal Arc can customize a synergic line and program it into the software.

Finally, welding control is literally in the operator's hands. Thermal Arc has developed a complete line of Pulsemaster MIG guns, including standard air- and liquid-cooled versions, push/pull guns, and smart guns with advanced digital displays. The smart gun has an on-board digital control that allows the operator to control welding voltage, wire-feed speed, and wire trim adjustment, as well as to access any of the 100 programs from the machine and change them on the fly.

Each gun uses high-grade consumables for spectacular performance, including tips offering optimal life and current transfer, nozzles tuned for high heat resistance and gas coverage, smooth wire-feed liners for all materials, and gas diffusers providing optimal tip cooling and featuring a 12-hole design, giving the operator the ideal amount of gas coverage.

PowerMaster SP benefits

Like each new welding innovation that came before it, digitally controlled welding takes the best of current technology and improves on it. But, never before has a technology truly revolutionized the market in terms of consistency, safety and intelligence like digital. Benefits for the operator include:

Perfect starts — Digital welding systems can react extremely quickly, immediately providing the operator ideal and consistent welding outputs. This has proven helpful with arc starting, and nearly eliminates the momentary short-circuiting when the wire initially touches the plate to begin welding. The control system senses the plate, and provides the ideal arc-starting parameters instantaneously. This can eliminate cold starts and lack of fusion at the beginning of welds.

Elimination of spatter — The reduction of spatter provides several benefits, including more consistent end products and enhanced safety for the operator. Digital welding power sources can deliver more exacting welding parameters, offering smoother bead appearance. The power supply reacts extremely quickly to variations in arc length, and changes in material height, to deliver consistent arc length control.

Lighter weights, lower power consumption — Components used to produce digital welding power supplies make them much lighter and electrically efficient. For instance, the PowerMaster 320SP, capable of peak currents approaching 600 amps, weighs only 77 lbs, and can use nearly 46% less energy than older transformer style machines with similar outputs. Many companies have realized substantial electrical cost-savings when running these new digital systems.

Enhanced digital control when welding different joints — With traditional welding technology, when an operator had a number of different joints to complete on one project, he would typically weld each type before returning to the machine to tweak the variables for other welds. For instance, he would weld all the T-joints, stop, change the machine and then proceed to a vertical up-weld, etc. With digital control and Smart Mig Guns, the operator can set up multiple programs with key welding parameters stored, hit a button on the torch, and immediately switch the parameters to weld any joint in any order, saving a considerable amount of time and energy.

Completely computer controllable — The digital welding technology in the PowerMaster SP can easily be linked to any PC. Once a program is set up on one digital machine and synced with a laptop, the PC can be connected to different machines in the shop or in the field for simple program downloads. When all machines use the same parameters and variables, each welder on staff enjoys an unmatched level of reliability and consistency, no matter which projects he works on or when he works on them.

More choice in digital options

Thermal Arc offers a complete line of PowerMaster SP machines to fit the needs of any welding shop and application. Operators can choose 320- to 500-amp systems, manual or automated systems, and air- or liquid-cooled options.

In addition, the PowerMaster SP equipment offers welders several options and flexibility in how they control programs and parameters when welding. Operators can use the wire feeder on the base machine, the MIG gun, a pocket pendant, or a fully-function remote control. So, no matter how one chooses to adjust welding parameters or programs, it's no further than one knob away. That's added control an operator can't find anywhere else.

Thanks to advanced digital technology, today's operators will quickly discover the old way of welding just can't deliver the reliability, consistency, safety, and dependability a shop dedicated to excellence relies on to stay successful.

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Peter Anderson is the Product Manager for Thermdayne Industries' Americas Welding Equipment & Arc Accessories. Contact him at PAnderson@thermadyne.com.