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200i 2 User Manual

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1. As arule of thumb the electrode should be ground so that the taper is approximately 2 5x the diameter The resulting electrode shape is a good general shape for easy arc ignition and excellent weld spots Always grind the welding electrode so that grind marks run parallel to the electrode shaft Placing the electrode incorrectly on the diamond wheel will produce circular grind marks and poor weld results E a l rr T Incorrect Gindnd Position HANDS ON Grind your electrode so that grind marks run parallel to the electrode shaft Verify by looking under the microscope Try to produce a taper that is approximately 2 5x the electrode diameter ELECTRODE SHAPING EFFECTS There are two main electrode shape configurations that Orion users should consider when preparing for a new project The first is the sharp electrode which is the best for most applications and metals A sharp electrode is also the easiest to ignite and typically produces a good weld spot A sharp electrode is especially important for small parts where fine control is essential The second electrode shape is a flat ended tip This tip helps spread the energy more uniformly and is better suited for difficult metals like silver A combination of a pointed electrode with a Small flat tip can also be useful for a variety of metals This configuration will help improve arc properties for silver and like metals while still allowing smaller parts to be wel
2. Always keep cylinders in an upright position and secured to a fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A Safe distance from arc welding or cutting operations and any other source of heat sparks or flame PRINCIPAL SAFETY STANDARDS Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 5250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov National Electrical Code NFPA Standard 70 from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky Org Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Mississauga Ontario Canada L4W SNS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 25 West 45rd Street New York
3. NY 10036 8002 phone 212 642 4900 website www ansi org CE TESTED AND CERTIFIED Welder tested for electrostatic discharge immunity up to 2kV for CE compliance CE nor wae orion cht CHAPTER 1 WELDER SETUP amp ASSEMBLY What is in the Box See video explanations of setup at http www orionwelders com resources orion i series resources BOX The Orion 200i will arrive in 1 box Main Box 1 User Manual amp Getting Started Quick Setting Guide Orion 200i Power Supply Orion 200i Microscope Arm Orion 200i Microscope Extender Arm Orion 200i Microscope Arm Table Mount Orion 200i Microscope Arm Support Bar Orion 200i Interface Box 1 1 1 1 1 1 1 Orion 200i 10 pin power cable Microscope Arm Setup Box within main box Welder Power Cord Stylus Hand Piece Pair Alligator Clips Foot Pedal Shielding Gas Hose Cross Lock Tweezers Electrode Vile Sx 0 5mm 5x1 0mm Electrodes 1x Diamond Dremel Disk 1x 0 5mm Orion Collet 1 Fiberglass Brush 1 Stainless Steel Weld Sample Card 1 3 Allen Wrenches with green microscope protective cover 1 Pair Microscope Eye Piece Shields 1 Loop Closing Pliers 1 1 1 1 1 1 1 MICROSCOPE ARM SET UP BASE MOUNTING OPTIONS See video explanations of setup at http www orionwelders com resources orion i series resources Mounting Option 1 Clamp to table 1 Determine the height of the tabletop If
4. Stainless 304 Melting Point Boiling Point Specific Heat 388 Electrical Resistivity a w n E E 5 I a i E 5 t WU QA 1860 172 2468 2467 3080 2567 2800 3000 5827 5660 ape gt gt pee Pele letele fel fel fele pepe etete fo SOROS P bbs lel Le Some Values may be approximate JIN Melting Point The temperature at which the metal will begin to melt The molten metal of the weld pool will be at this temperature during the welding process Boiling Point If enough energy is added to the weld joint and heat is removed slowly by the surrounding solid metal the weld puddle can begin to boil Liquid metal will be turned into gaseous metal Specific Heat The energy required to raise the temperature of the metal per unit mass Think of this number as how much metal will melt for a given weld energy melting point also is important A larger specific heat means more energy is required to melt the metal Electrical Resistivity This number represents the resistance to the flow of electrons in a metal This property is especially important during a resistance or tack weld The more resistive the metal is the more easily it will resistance weld e g stainless steels the smaller this number is the more difficult it will be to weld the material e g silver especially in tack mode Density how much of the metal atoms mass is in a given volume of space This property will also
5. Metals that conduct electricity well e g copper are more difficult to weld in Tack Mode and require special Tack attachments to obtain a proper weld The second important factor when in Tack Mode is the weld contact pressure The weld contact pressure can be controlled by how much force you apply to the two pieces that are being welded together The harder you push the pieces together the lower you make the electrical contact resistance between them and the lower the created heat Conversely light pressure will result in high contact resistance and high heat For all welds the size and thickness of the metal will play a significant role in the energy settings that you choose Orion recommends that users Start at a low energy and work upwards until an appropriate energy setting is found WILL CONTAMINATE MY BASE MATERIAL WITH THE TUNGSTEN ELECTRODE There is a possibility of tungsten contamination when the Orion user forces the welding electrode into the weld material However with proper practice using the pulse arc welding stylus contamination is very unlikely DO I NEED TO USE ARGON TO WELD Argon is necessary to produce a clean and repeatable pulse arc weld Without protective argon oxygen may combine with the weld metal to produce brittle and porous welds In Tack Mode however protective argon is not necessary Other protective gases can also be used such as pure nitrogen However Orion recommends high purity argon This can be purchase
6. What is Resistance Welding Tack Welding Resistance welding often called tack or fusion welding takes place using a very different process from that of TIG welding In resistance welding a large electrical current is passed through two work pieces to join them together At the contact point between the two materials there is a resistance to the flow of the electrical current As electrical current is passed through this contact point resistive heating takes place When enough current passes through the work pieces the temperature especially at the interface between the two pieces can become hot enough to melt the metal in a Spot The terms resistance welder and spot welder are descriptive of this process If you limit the amount of energy and electrical current going into the weld you can create a temporary or weak weld called a tack weld It provides the ability to temporarily position a part before permanent welding This ability opens a multitude of creative possibilities It also helps eliminate the need for complicated binding or clamping of parts before permanent welding or soldering Because the heart of the Orion is an industrial capacitive resistance welder everything from one time custom pieces to production welding is possible Left A typical industrial welding configuration Right A close up zoom of the weld showing the electrical resistances that are used to create the weld spot As shown in the figure above a
7. due to surface tension and will not be added to the base material EE 200i User Manual A top electrode placement can work if the wire diameter is small compared to the energy setting In this case there is enough plasma pressure to force the molten wire onto the base material Placement of the electrode directly on top of the fill wire can melt the wire into the base if the energy is sufficient or the wire is very small Alternatively it may only melt _ the wire causing it to ball as shown here A final scenario can occur when the electrode is placed on top of a large wire being welded to a base material at a high weld energy setting In this case the plasma can push the wire metal down to the base metal surface but there may be no penetration into the base material HANDS ON Try adding fill wire using the top placement method Build up a small mound of material As arule of thumb it is always best to use the side electrode placement This is especially true of larger fill wire diameters If itis essential for a top placement weld the process will be improved by using very fine laser wire to ensure full wire melting Choosing the correct wire gauge for your application is very important For example micro scale applications it is important to select the smallest fill wire available If a wire is selected that is similar in size to the base metal there is agood chance that the energy setting required to melt the wire will also me
8. if the operator feels the LCD shutter is too dark or too bright during a weld the darkness slider allows the shade level to be easily adjusted up or down to preference The Orion 200i will continue to adjust the filter for each unique setting based upon your preference Safety measures have been installed that will not allow the user to change the darkness brightness to an 2 200i User Manual unsafe level e g too bright Weld Length Slider In Seam mode the weld length slider automatically changes its maximum value to insure each seam weld will take place at the selected power setting For example if the weld power for a Square wave is set to 4 kW and the welds per second is set to 25 the welder will only allow a weld time that allows the system to fully charge and provide for identical welds during the seam cycle The user can reduce the time to smaller values than the maximum allowed time if desired This automatic time adjustment can be turned off by unchecking the toggle box Adjust max length to give consistent welds during seam welds When automatic weld time adjustment is turned off the user can create situations where the first welds will be larger than the final weld This difference happens due to the insufficient charging time between welds to refill the lost weld energy before the next weld takes place Number of Welds Slider or Total Seam Duration Slider These two sliders are toggled by checking or unchecking th
9. important to understand the concentration of your weld energy relative to the size of the silver being welded For very small welds a sharp electrode poses no problem This means that in the Orion s arc mode silver will typically behave well even with a concentrated focused beam of energy i e a very sharp electrode tip point However as the desired spot size gets larger bigger arc mode welds and almost all pulse arc mode welds the liquid silver is easily pushed around by the welding pulse This will lead to large blobs of material being displaced from the weld site resulting in a noticeable hole To avoid this problem simply un focus the weld energy by creating a truncated electrode tip flat The size of the flat depends on the size of the weld For relatively small welds a small flat is all that is required For very high energy welds the electrode may be completely flat Imm diameter Resistance welding silver in tack mode is very difficult because of silver s high electrical conductivity Sterling silver has a high electrical conductivity very similar to that of copper However Argentium silver is approximately 30 less conductive This means that more heat can be generated during the spot welding process due to the additional material resistance Use Argentium silver if your application requires spot welding as opposed to pulse arc welding Even while pulse arc welding it may be desirable to use Argentium silver because of its Superior tarni
10. influence how large the weld spot is for a given metal All other things being equal a lower density metal will have a larger weld spot than a higher density metal for the same weld energy Thermal Expansion When a metal is heated it will expand or elongate slightly In some situations especially during resistance welding metal can expand quickly and spill out of the weld joint Thermal Conductivity This is a measure of how fast the metal conducts heat Metals that are good conductors of heat e g copper will dispel the heat away from the weld location quickly during the welding process This action reduces the size of the weld spot Metals that are poor conductors of heat e g titanium are slow to conduct heat away from the weld location and the weld energy has a greater affect on the weld size etc ch 200i User Manual 3 E E D e ww amp Inn si 6 Ww This measure of weldability comes from properties of the metal like melting point thermal conductivity density etc and is intended as a relative reference between the different metals It can be thought of as how much spot size and penetration a given amount of weld energy will have on the metal Please note that some metals may have properties not accounted for in this chart that may make welding more difficult than indicated e g palladium Titanium and Niobium Some metals may react easily with oxygen and even other gases like nitrogen Titanium Ti
11. made after the electrode lifts from the work piece surface therefore it is important to use very light pressure Remember that the weld is created only when the electrode lifts from the work piece surface This means that using too much pressure will prevent a weld from taking place and will also damage your electrode The penetration of your weld spot depends on many different factors However as arule of orion thumb you can expect the penetration of the weld spot to be approximately 4 of the diameter of the weld spot Factors like electrode shape and condition also effect the weld penetration and will be discussed in more detail later vw v PULSE ARC VS LASER Laser welding and pulse arc welding technologies are designed to create high quality welds in precious and non precious metals Laser welding uses collimated or focused light to add energy to the metal and melt it at a single location Pulse Arc welding uses electricity specifically electrons to add energy to the work piece and melt the metal in a spot Although laser welding devices are good welding tools the Orion can perform many of the same functions of a laser and in some cases can even perform actions that lasers cannot For example welding silver is difficult for laser light because of silver s highly reflective properties However the Orion does not have this limitation because electrons are electrically attracted to the surface of silver The Orion also has t
12. may be very important to get the welder to ignite reliably At higher energies the welding process may proceed virtually unhindered even with a metal contaminated electrode To remove the small crater weld over the crater witha newly ground electrode 2 The electrode may stick to the metal s surface This happens as the liquid metal bridge cools before the electrode tip has retracted sufficiently to leave the surface of the work piece A now solid metal to metal weld has taken place at the electrode tip preventing retraction and arc ignition This is often referred to as electrode sticking 5 What can be done if the weld spot doesn t look good asymmetric for example This may mean the electrode may be damaged sharp tips or jagged edges or strange shape due to contamination Poor tip condition can also lead to porosity small holes in the work piece Electrode condition greatly affects energy transfer and also weld properties see above discussions Left A perfect electrode Right An electrode in poor condition with metal contamination EE 200i User Manual Electrode contamination can lead to small explosions that create craters in the work piece All four welds were made at the same setting Metal contamination on the electrode caused one weld to create a crater It is recommended that the user pay close attention to the electrode condition see additional discussion A contaminated electrode can lead to inc
13. receptacle Check and replace any blown fuses in the Orion s Fuse Bay My electrode keeps sticking Clean the work piece at the weld site before I even weld Clean or sharpen the electrode Increase the energy slightly to add more energy to the arc can trigger a weld but it Hold the stylus steady so that the electrode continuously contacts the work piece If always aborts and does contact is lost even for an instant the weld will abort nothing Verify that the attachment plugged into the terminal is making constant contact with the work piece Clean the surface of the work piece at the weld site Oil carbon deposits and other residue can cause continuity to be lost Verify that the electrode is sharp and not deformed at its tip Replace or sharpen the electrode as necessary My electrode keeps sticking Verify that the current mode is not Tack Mode when weld Hold the stylus so that there is less pressure on the electrode Very low energy settings will require extremely little pressure on the electrode Increase the energy slightly to add more energy to the arc I m set to Auto Trigger Verify that the work piece is clipped to or touching an attachment that is securely Touch Detect but nothing plugged intothe Arc terminal ever happens when I touch Verify that the play button is green the electrode to my work Verify that the stylus connector is completely inserted into the stylus rece
14. www orionwelders com resources orion i series resources 1 Completely remove the electrode from the stylus 2 Pinch the electrode between the thumb and middle finger with the point facing inward 5 Turn the Dremel or flex shaft on then hold it with the opposite hand If the Dremel is in the left hand then sharpen the electrode on the side of the diamond disk furthest from the body If the Dremelis in the right hand then sharpen the electrode on the side of the diamond disk closest to the body The reason for this is to keep the striations on the electrode moving towards the electrode point not away This will effect the quality of the weld if not done as explained above 4 Set the electrode on the diamond disk at a 10 degree angle and begin to spin the electrode with the thumb and middle finger A helpful way to get a sharp electrode is to push down on the electrode with your index finger while twisting the electrode with the thumb and middle finger 5 Once the electrode is sharp and clean turn the electrode to a 90 degree angle and push it against the dremel in order to place a flat blunt tip on the electrode 6 Once the electrode has a flat blunt tip turn the Dremel off and insert the electrode back into the stylus as explained above See chapter 6 and 7 for additional details about the Tungsten Electrodes MAKE AN ARC WELD 1 Select Clasic on Waveform Standart on Ignition None on Agitation 15 ms on Length 25Ws on the En
15. A blunt electrode tip can be helpful when making more powerful welds in silver to help overcome silver s high liquid mobility by un focusing the plasma over the entire flattened area A sharp electrode will help place the weld into tight geometries left a blunt electrode can spread the energy and prevent weld formation right As discussed above silver is really the major exception to having a sharp tip Because of silver s high liquid mobility a sharp electrode with a focused arc at the very tip will actually burrow a hole in the center of the weld spot at higher energies However for small spots a sharp tip is still recommended in silver By using a blunted or truncated tip the energy is effectively spread over the weld area and both the burrowing hole and the thin silver blow through can be largely avoided TROUBLESHOOTING THE ELECTRODE Poor weld results are most often traced back to electrode condition and shape Because the electrode condition is very important the following table will help troubleshoot problems quickly In the table below we see that trouble igniting the arc can be cause by several different reasons The most common is a contaminated electrode If the work piece metal contaminates the welding electrode the following may occur Symptom Symptom PossibleProblem Problem PossibleSoluton Solution 1 Trouble igniting the arc electrode Re re the electrode to remove con tamination Electro
16. Advantages Due to the electrode being off of the work piece surface when the main weld ignites less electrode contamination will occur and electrode life will increase significantly Disadvantages Tip Saver mode is not recommended for awkward or tight geometry welding surfaces Since the arc is generated after the electrode has left the work piece the arc will take the path of least resistance and might not touch the exact point that was desired For example welding a 90 degree joint in Tip Saver mode may produce a weld on the side walls of the joint instead of drawing the joint together Tip Saver Plus Weld Ignition In Tip Saver Plus weld mode the welder uses internal detection circuits in conjunction with the weld pilot arc to determine when the electrode has left the work piece surface When detection occurs the welder first initiates a higher current pilot arc that better helps the weld jump the electrode to work piece gaps After the higher current pilot arc has been activated the main weld spot occurs Advantages Due to the electrode being off of the work piece surface when the main weld ignites less electrode contamination will occur and electrode life will increase significantly Tip Saver Plus is also better suited for exceptionally small and fine pieces orion O h3 Disadvantages Similar to Tip Saver mode Tip Saver Plus mode is not recommended for awkward or tight geometry welding surfaces Since the arc is generated aft
17. Again weld strength and properties will depend on alloy properties orion cho HOW DO I DETERMINE THE BEST ENERGY SETTINGS FOR MY APPLICATION In Arc Mode metals will weld according to thermal conductivity and melting point For example a metal with lower thermal conductivity e g stainless steel titanium cobalt alloys will weld easily because the weld heat stays concentrated in the spot Therefore less energy is required to weld one of these metals than other metals of the same thickness that have a higher thermal conductivity Metals with higher thermal conductivity e g copper silver gold will require more energy to create the same spot because much of the heat is conducted away quickly The melting temperature of the metal is also very important when determining the necessary energy setting for a weld Knowing the approximate or relative melting temperature of your working metal will enable you to estimate the amount of energy required to create a spot High melting temperature translates to a large amount of energy required Low melting temperature translates into a smaller amount of energy required to make the weld In Tack Mode energy is important but there are two other important factors that need to be remembered These factors are electrical conductivity and contact pressure In Tack Mode the Orion is a full fledged resistance welder This means that the Orion uses a metal s electrical resistance to create the weld heat
18. M RESISTANCE WELDING TOOLS It may be helpful to shape the tool for the application Tools that clamp the parts e g brass lined pliers should have as much surface as possible in contact with the part to allow more energy to transfer to the weld location Remember that the area between the work pieces should be small to focus the energy if a strong weld is desired A weldment or bump can be used to help focus the energy if desired If you are shaping an electrode to actually perform the weld then the tip should be as small as is reasonable for the desired weld size e g Imm spot size or less is typical Remember that when using an electrode to perform the welding process the pressure applied by the electrode tip determines the weld pressure and the heat generated A weldment or bump between the two parts to be welded can still be used to focus the energy Place the electrode directly over the weldment location remember the weldment is actually between the two sheets etc not on the electrode orion h6 CHAPTER 6 TUNGSTEN ELECTRODES THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE The Orion welder comes standard with 5 0 5mm and 5 1 0mm electrodes The 1 0mm electrodes are a good all around electrode while the 0 5mm electrode is excellent for very small projects The larger Imm electrode allows more energy to come out at one time The smaller 0 5mm electrode may be better for cases when less energy is desired HA
19. NDS ON Make a weld using 15 Ws and 8ms using a sharp 1 0mm electrode Now make a weld using the same settings using a sharp 0 5mm tip In the HANDS ON examples above more energy was transferred from the Orion into the piece for the same setting using the 1mm electrode For very small parts using the small electrode is sufficient This option reduces the peak weld current versus using the large electrode and can also allow for a smaller weld spot For larger parts use the 1mm electrode The 1mm electrode is used when needing additional weld current more melting for same energy The larger electrode is recommended for metals such as silver due to higher welding energy requirements of such metals Note The 0 5mm small electrode will burn or oxidize at higher energy settings As a general suggestion the 1mm electrode is a good choice for most applications even very small ones Left Using too much energy with the 0 5mm electrode will cause it to overheat and reduce its life Right A 1 0mm electrode can weld at a variety of energies without overheating Why Use Tungsten Electrodes 1 Hardness tungsten is extremely hard and is therefore able to hold its shape during the welding process 2 Tungsten s melting temperature is much higher than most other metals This means the metals being welded will melt before the tungsten Melting temperatures of selected metals The table shows a variety of metals and their corresponding melting
20. SEAM MODE SAFETY 1 Always make sure your eyes and the eyes of those around you who might be exposed to the welding arc light are protected Because of Seam modes longer weld length and the high intensity of the welding flash it is important never to look at the arc directly Always view the welding arc through the protective Orion welding shutter or other safety approved welding filters minimum shade number 10 required 2 For seam mode welds lasting more than 1 2 seconds the use of dry hole free insulating gloves is recommended leather gloves being preferred Gloves will help prevent finger burns as the work piece can become exceptionally hot Consider holding your work piece with other metal tools when you expect elevated part temperatures 3 Because the welding arc produces a high brightness weld spot and produces UV radiation wear thicker clothing that covers as much skin as possible to prevent sun burns from prolonged welding exposure Thick clothing or a leather apron may simplify this protection process Pay special attention to your neck and lower jaw as these areas are typically not covered and will be exposed to the welding arc light THE SEAM MODE ADVANCED SCREEN ADL Shading Level On The Orion 200i automatically selects the appropriate filter darkness in Seam mode based on the selected weld settings This will help the operator experience a Seam weld filter brightness that feels comfortable on their eyes However
21. Sharp shape Palladium Pd Palladium Pd is a white lustrous metal that is typically a much lower cost than platinum Palladium is also much lighter having a density that of platinum It would seem that Pd is the perfect metal Unfortunately Pd is generally difficult to work with and is somewhat difficult to weld in a jewelry setting This is mainly due to palladium cracking during the welding process orion O h8 Palladium can be welded using the Orion welder however cracking can occur Palladium cracking is an especially difficult phenomenon to overcome with laser or pulse arc welding If only one weld spot is made cracking will typically not occur unless the weld joint is stressed by hammering etc This means that welding over porosity in a Pd piece can be accomplished with the Orion to help clean up the metal during the finishing process However welding more than one overlapping weld will inevitably lead to cracking laser or pulse arc welder Palladium cracking can be thought of as a combination of hot cracking and new weld puddle crystal structure problems After a weld the molten Pd re crystallizes typically forming a large and weak metal grain structure When welds overlap the new crystal structure in the last weld puddle is weak compared to the original metal The result a crack will start at the edge of the new weld where it overlaps with the old weld joint as the new weld cools and is stressed The crack will th
22. Undo and Reset Options The Play Pause Undo and Reset are the functions of the option section Play Pause Pressing the Play Pause icon toggles between Play and pause If the Play icon is green the welder is capable of making welds anytime a work piece connected to the positive alligator clip makes contact with the electrode When paused White Play icon users are unable to weld Undo The Undo icon allows the user to go back through the 5 previous screen taps This is helpful when a change is accidentally made Reset The Reset icon resets all the variables and parameters on the screen back to the factory default settings Trigger options These settings allow the user to select how the welds will engage The options are Touch o ch2 200i User Manual Detect or Foot Pedal Touch Detect In Touch Detect the welder will initiate the weld process any time that a grounded work piece makes contact with the electrode Foot Pedal When Foot Pedal is selected the welder will only initiate a weld on a grounded work piece when the Foot Pedal is pressed Weld Speed The 200i has three options to choose from to control how fast the welds occur Single Fire Mode In Single fire mode the 200i welder will go through the following steps each time a weld is initiated 1 The argon gas will pre flow 2 The weld energy will be released 3 The shutter will close 4 The electrode will retract 5 The arc will form 6 A weld will be m
23. ade 7 The energy will turn off 8 The shutter will open 9 The tip will return 10 And the gas will turn off Making a second weld will repeat this process Rapid Fire Mode In Rapid fire the welder is able to speed up the weld rate by eliminating some of the steps mentioned in the single fire mode Primarily the gas will stay on for as long as a Subsequent weld is initiated The electrode is able to retract make a weld and return and if it makes contact with the work piece it immediately retracts again to make another weld Rapid Fire makes it possible to have between 1 4 welds per second A slide bar will appear above the Rapid Fire button allowing users to select the weld speed Seam Mode Seam Mode operates as a combination of a pulse arc welder and a micro TIG welder Once a weld has been initiated the electrode retracts and produces a small pilot arc that will stay lit during the entire seam welding process While the pilot arc remains lit individual weld pulses are overlaid at speeds of up to 0 welds per second The Seam mode can also be used to pre heat difficult to weld parts as elevating the temperature of certain metals will greatly improve weld properties This mode allows for continuous seam welds and is effective in improving results for geometries and metals that are prone to hot cracking For best results users will need to maintain a close consistent distance between the work piece and the electrode Plea
24. aintain a sharpened electrode tip during the welding process ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WHEN PULSE ARC WELDING Pulse arc joint preparation is very similar to that of general tungsten inert gas TIG welding Some different types of weld preparation include the simple I seam but joint X Y and V joints named for the way they look The I seam may require no filler material while the X Y and V require filler material and may require successive layers of material to be 57 ag 200i User Manual added to the joint For joints were the Orion can penetrate approximately to of the way through the material an I seam may be appropriate The weld location should be cleared of solder as this will reduce weld quality ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WITH TACK FUSION WELDING Just as in pulse arc welding all solder should be removed if a strong metal to metal tack fusion weld is desired Tacking can be used to weld solder in place or to temporarily tack a work piece to a solder layer CAN I USE TACK MODE TO PLACE SOLDER GRANULES OR PIECES BEFORE A SOLDERING TORCH IS USED Yes this is avery simple process A variety of hand pieces are available Trouble Shooting souon My welder won t turn on Verify that the power cord is plugged into the rear panel of the Orion and also into a power outlet Do NOT use an extension cord with the Orion Check the circuit breaker for that particular power
25. c p W AF Lh w i SS 200i User Manual Table of Contents FOWAO EE Renae SEE PRT p 5 Manufacturer s Contact Information cece cece eee ees p 53 Welding safety Precautions ccc cece cece eee cece sees eens p 53 Chapter 1 Welder Setup and Assembly ravavuvunnsnsnsvene p 7 W atis NNE BOX 40 seexandadenciy aot eeenees ope 14 eae iiis p Microscope Arm Setup cece ccc eee eee eee enes p Orion 200i2 Welder Connection Setup cce ae p 9 External Power Supply Setup s20 c50 sax 0ns coavnsvensesavens p 10 SHE GaS SEP Lanseres era dre dressene p 10 Adjustments on the Microscope Arm cece cece e eas p 11 True Color Optical LCD Shutter 2uasvrsseddresakrirensk sk p 12 Become Familiar with the Microscope avavuuvsrrranene p 12 PICCHOGE SCO csvsieevece seen ceeatantaystscdnssensieyesnes p 153 Chapter 2 Welder Interface Overview cece eee es p 16 Header Area een p 16 Waveform Graph Area auvuvavanararanevenensnnnnnnnnnn p 16 Metals Tab Controls Area raruvannnnnrevarenrnennnnnn p 17 Arc Tab Controls Area aavuvuvavavavanennnvnnavenenenen p 17 Seam Mode Controls Area c cece cece eee p 20 Tack Tab Controls Area ccc ccc cece cece p 23 WIGGO TAD satescsctugesectaween gcc7bncta EEEE p 23 Bor aMi e E E EE p 24 SAVE TD ne p 24 EMOS TAD simone ciei ra EEE E p 24 Chapter 3 Reading the Waveform Graph rsuvuvavavavavene p 26 IOMON EEE p 26 Wave
26. can potentially melt This preheat mode of operation can also be used to produce a very low current seam weld for the specified weld time This can be useful for very small weld joints and very thin materials Even when the Welds per Second slider has been set to values above one the background arc will take place during the welding process Seam welding very small parts may require additional heat sinking to prevent them from melting in unwanted ways For smaller parts it is recommended that you use short seam weld times Power The power knob in the advanced seam welding screen acts the same as has been previously discussed orion 2 TACK TAB CONTROL AREA ere The Tack Screen controls the resistance welding aspect of the welder Tack welding is typically used to temporarily hold pieces together Users will generally utilize this type of welding to hold their work pieces together before soldering or performing a pulse arc weld Tack welding before pulse arc welding allows the user to verify the work pieces are placed together correctly Then the user can return to the Arc Screen and place a permanent weld between the two work pieces Tack welding can be used to permanently fuse the work pieces together if the energy level is high and the work piece are not to thick Tack welding does not work with resistive metals like silver or high karat gold Power Control This circular dial controls and selects the amount of weld energy or wel
27. ce the stylus hull is placed back on the stylus 6 Lock the electrode into place by hand tightening the collet cap in a clockwise direction 7 Replace the stylus hull by pushing it snuggly until you feel it snap back into place the electrode should stick out between 1 8 1 4in 3 75 6 75mm after the stylus hull is snapped back into place WORK PIECE TO ELECTRODE PRESSURE See video explanations of setup at http www orionwelders com resources orion i series resources Touch the work piece to the electrode with very light pressure Too much pressure will cause the work piece to stick to the electrode and in turn cause the electrode to be contaminated work piece material on the electrode This will shorten the amount of time you can weld before re sharpening or replacing the electrode As a general rule of thumb we recommend a freshly sharpened electrode anytime a new work piece is being welded WHEN TO SHARPEN THE ELECTRODE It is recommended that the user pay close attention to the electrode condition An electrode that appears to be dark colored or covered with material from previous welds can lead to inconsistent welding and poor igniting of the weld When this occurs simply sharpen the electrode with the included diamond disk The diamond disk can be attached to a flex shaft or Dremel tool Follow these steps for sharpening the electrode See video explanations of setup at http www orionwelders com resources orion i
28. compared to Classic and Triangle is the abruptness of power at the start and end of each weld The Square waveform closely mimics the weld output of a typical laser welder Ignition The ignition options control the electrode tips position at the moment the energy is released Standard In the Standard ignition option the energy discharge occurs at approximately the Same time as the tip lifts off the work piece surface Since the electrode is close to the work piece when the weld is formed it s easier to get a weld on any surface or angle This mode provides the most accuracy but requires the operator to hold the work piece steadily below the electrode This mode is perfect for metal types that do not require a pre heat phase during the weld Because the electrode is closer to the work piece the electrode may dull more quickly Standard In Standard the energy discharge happens well after the electrode tip lifts off orion 2 the work piece surface While similar to the Standard option Standard includes a pre heat function before the main weld During this time a very low amount of energy flows through the electrode and work piece This preheating of the tungsten electrode helps create a more efficient weld area in preparation to the main weld The Standard ignition helps provide better weld consistency by allowing more variation in contact pressure before the weld takes place Agitation During the weld a high frequency agitat
29. ctly where the electrode is touching Disadvantages Due to the fact that the electrode is touching the weld surface when the main welding pulse is turned on molten material can accumulate more frequently on the electrode This metal build up on the electrode reduces its effectiveness over time and can require more frequent electrode sharpening cleaning Standard Plus Weld Ignition Standard Plus weld ignition mode is similar to Standard weld mode with the addition of a pilot arc The weld timing is adjusted to have the weld take place soon mi after the electrode lifts off the work piece surface The pilot arc insures that the weld will take place even if there is slight movement from the user Advantages Produces considerably less electrode contamination Standard Plus weld ignition is a great all around weld ignition mode and recommended for most welding applications Disadvantages The possibility of electrode contamination remains if the operator pushes the electrode into the work piece too forcefully remember to touch with light pressure for best results Tip Saver Weld Ignition In Tip Saver weld ignition mode the welder uses internal detection circuits in conjunction with the weld pilot arc to determine when the electrode has left the work piece surface When this internal detection occurs the welder initiates the main weld pulse to produce the weld spot Tip Saver mode is recommended for flat easy to reach weld surfaces
30. ctrode shape e g sharp blunt or a sharp tip with a small flatted end The most helpful of these is to spend time with the Orion and get to know how it responds to different electrode shapes and metals 6 200i User Manual CONSIDERATIONS FOR ELECTRODE SHAPE 1 When welding very small features under about Imm the electrode should be sharp to help focus the weld energy 2 When welding with less than 20 30 Joules Ws the electrode will typically be sharp 3 Some materials weld better with a sharp electrode e g Stainless Steel 4 When welding at very low energy settings a sharp electrode will help ignite the arc more easily 5 Flattened tips provide arc stability at higher energies 6 At high energies a sharp tip may melt off during the welding process and contaminate the work piece 7 Alarge flat or completely blunt electrode tip for some metals is desirable e g silver aluminum 8 Alarge flat can be helpful on all metals depending on the desired weld puddle and the work piece geometry 9 Truncating the electrode helps to un focus the weld energy and prevents burrowing in mobile metals like silver 10 How large you make the tip flat e g a very small flat vs a completely blunt electrode is determined by the amount of energy the Orion will deliver At low energies no flat is needed where at maximum energy the tip can if desired be completely blunt Remember the smaller the flat the easier the weld ignition
31. d leave your workpiece looking blackened or burnt CAN I BUILD UP OR ADD MATERIAL TO A WELD LOCATION Yes the Orion is very versatile In Pulse Arc Mode filler wire can be used to add metal to a weld location In Tack Mode filler wire or sheet filler can be permanently affixed to a location Wire sizes up to and greater than Imm in diameter can be added However the user should select wire diameters that match the size of the feature being welded Users should also select wire with similar material to that of their workpiece For example when re tipping a gold ring 0 25mm gold filler wire is an excellent choice If filling a large gap in a steel workpiece 1mm steel wire may be more suitable The Orion has the energy and versatility to weld both of these and many more applications with ease CAN THE ORION WELD SILVER Yes the Orion has been specifically designed with the more difficult to weld materials in mind Silver requires appreciable energy for a sustained period of time The Orion has enough energy and capacity to make quick work of your silver applications CAN I WELD DIFFERENT DISSIMILAR METALS TOGETHER Yes inmany instances different metals can be welded easily together with the Orion In pulse arc welding the weld spot location becomes a new alloy of the two primary metals this new alloy will adopt new properties that may be better or worse than the primary materials Dissimilar metals can also be joined in Tack Fusion Mode
32. d at your local welding supply shop HOW DO I CONTROL WELD SPOT SIZE AND WELD DEPTH Simplified answer Energy adjusts your spot size while your weld time controls penetration In reality both of these factors energy and time influence both welding characteristics spot size and weld depth However the above rule of thumb will allow good and intuitive control of your welding parameters It is also important to keep your tungsten electrode sharp to maintain precise control over the characteristics of the weld spot size and weld depth HOW MUCH HEAT IS ADDED TO MY WORKPIECE The Orion is capable of extremely fine welds In low energy settings small amounts of energy are added and cause virtually no heat to be added to the workpiece During small welds involving little energy it is possible to hold the work piece in hand For applications that require higher energy the Orion is capable of adding up to 200 Joules Ws of energy to a weld Until the user is familiar with the welding characteristics of the Orion we recommend holding all parts with the pulse arc attachments e g alligator clip and not with your fingers HOW DEEP CAN MY PULSE ARC WELD PENETRATE Depends on the material being welded however spot depth of down to 1mm can be achieved HOW LONG WILL ELECTRODES LAST Under normal use electrodes will last for approximately 8 000 welds To ensure that you get the most life out of your electrodes use argon gas for pulse arc welding and m
33. d power Users can touch or slide along the circular path to adjust and set the weld energy Additionally users can input weld energy settings via a number pad To access the number pad tap on the weld energy numbers inside the dial This allows users to directly enter the exact desired weld energy values Once the numeric value is entered tap OK to set the value and exit the number pad Quick Power Settings For quick power control choose one of the three energy presets Pre Weld Delay This controls the amount of time before the weld takes place Trigger Type Touch Detect The weld will occur after the two work pieces touch each other If the pre weld delay is set to short it will happen quickly after the two work pieces touch To allow more time before the weld set the pre weld delay to long when touch detect Foot Pedal This option will not weld unless the users presses the Foot Pedal after the two pieces are touched together This option allows the user to precisely position the work pieces together and make sure they are aligned correctly before initiating the weld VIDEO TAB The Video Tab takes users to our instructional videos page It s like having the Orion YouTube page on your welder See welding tips and tricks here and other instructional videos Simply select the video from the list on the left hand side on the screen Touch the Load Button to open previously saved weld parameters This feature w
34. d to the positive alligator clip makes contact with the electrode When paused White Play icon users are unable to weld Trigger Options Touch Detect the welder will initiate the weld process any time that a grounded work piece makes contact with the electrode Foot Pedal The welder will only initiate a weld on a grounded work piece when the Foot Pedal is pressed ARC TAB CONTROL AREA This section contains the different controls to customize the 200i s settings for welding output Power Control This circular dial controls and selects the amount of weld energy or weld power used based on the waveform selected Users can touch or slide along the circular path to adjust and set the weld energy 2 200i User Manual Notice that the dial s controls are non linear This allows users greater refinement and control when selecting lower level settings This means when welding with the classic waveform the first section of the dial represents 0 01 1 5 Joules the next section represents 1 5 3 Joules the third represents 3 5 Joules the fourth represents 5 30 Joules and the final represents 0 200 Joules Additionally users can input weld energy settings via anumber pad To access the number pad tap on the weld energy numbers inside the dial This allows users to directly enter the exact desired weld energy values Once the numeric value is entered tap OK to set the value and exit the number pad Wavefo
35. de shape not conducive to Shape the electrode to a very sharp tip ignition at low energy 2 Broken electrode jagged edges Re grind electrode to desired shape Cratering of the weld spot Electrode contamination leading toa Re grind the electrode te bridge explosion see discus sion ee Truncate the end of the electrode to help such as silver un focus the weld energy 5 weidspotnotsymmetric Damagedoriaggedelectode _ Re grindelecrode 4 Porostyinthe workpiece Damagedelectode withjaggedtips Re grindetedrode Metal may contain zinc and boil Often welding over the same location two during the de process e g or three times will smooth the weld spot white gold TT ll Truncate the end of the electrode to help such as silver un focus the weld energy 1 During the ignition process the electrode is touching the work piece surface when the weld current begins to flow The metal contaminate may form a liquid metal electrical conduction bridge During the weld ignition process the electrode will retract and this may lead to the vaporization of the liquid metal bridge as it is necked down during the electrode retraction process This vaporization process can be explosive on a very small scale and leaves a crater in the metal s surface The result will be a small pock mark in the metal s surface The electrode must be reground before reliable welding can continue at this setting At lower energies this resurfacing re tipping
36. ded As a general rule of thumb you can think of a sharp tip as a weld focuser while a blunted or truncated tip is a weld un focuser The tip shape changes the energy focus and weld penetration The weld spot on the left was formed with a blunt electrode while the spot on the right was made using a sharp electrode The shape of the electrode will influence the shape and penetration of the weld spot There are advantages and disadvantages to each electrode shape As shown in the illustration above the electrode shape greatly influences the weld spot s shape and penetration By looking at the figure one might assume that the 180 degree shape is the best electrode configuration to achieve an optimal weld spot However the 15 degree electrode Shape has the advantage of easy weld ignition at lower energy levels In some situations it is advantageous to place a small flat on the end of the sharper tip or truncate the weld tip This has a Stabilizing effect on the arc and also allows deeper weld penetration Even a small flat on an otherwise sharp electrode can be helpful in making repeatable welds while still allowing easy arc ignition For the smaller energy settings an extremely sharp electrode is essential Remember the size of the truncation flat is related to the energy setting Use smaller flats for lower energy larger flats for high energy There are several considerations that can be helpful when selecting ele
37. difficult to weld parts can simplify the welding process If using tools to hold the work pieces remember that firm pressure between the tool and the work piece is important to prevent welding the tool to the work piece e g brass lined pliers Then apply the correct pressure between the work pieces to achieve your weld HANDS ON Try turning the Tack Mode energy to 50 Ws and make a weld 1 First weld with very firm pressure between the parts The result may be little or no weld 2 Next clamp the parts firmly in the tool but apply virtually no pressure between the parts make sure these are parts you no longer need The result will be a very large spark or at least a much better weld EE 200i User Manual 5 Practice at different energies and pressures until you feel comfortable with the process and results The pressure between the tool holding the part is also very important If insufficient pressure is applied between the tool and the part the weld may take place between the tool and the part Always grip the part firmly in the tool to reduce the contact resistance between the tool and work piece Doing this will reduce the amount of heat created where the tool and part meet RESISTANCE WELDING TOOLS It is always a good idea to have the resistance welding tool made from a material like copper when welding more resistive parts such as steels If using a tool to hold the work piece together remember that firm pressure between the
38. e Show Total Number of Welds check box When the Total Weld Time slider is activated the user selects the total time they would like the seam weld to occur The welder will fit the number of welds into this time based on the weld rate selected Welds per Second slider When the Total Number of Welds slider is active the screen will display the maximum number of welds that can fit into the welder s maximum allowable seam weld time In either mode of operation the user should be cautions in selecting a setting Start with small seam times or small total number of welds until a feel has been developed for how much energy the welding process places into the work piece The default setting for this slider is to adjust the Total Weld Time The Total Weld Time slider will default to a two second burst Also note that the welding process can be interrupted at any time by use of the foot pedal If the seam weld was initiated in Foot Pedal Trigger mode the user can simply disengage the foot pedal to abort the welding process If the weld was started in automatic trigger mode the user can depress the foot pedal to stop the welding process Welds per Second Slider This slider changes the rate of welding that the user would like between 0 to 30 welds per second The zero welds per second setting can be used for pre heating the work piece as mentioned earlier When preheating a part pick a location that does not have small features prongs etc as these
39. e location with porosity again will help remove the porosity A fresh sharp electrode will help with this process Sometimes adding pure laser wire will also help in removing porosity In general gold welds easily Here are some tips when working with gold 1 Typically a sharp electrode is preferred when welding gold 2 Gold can easily accept small or large weld spots 5 Itis often typical that gold will look black surrounding the weld location This black layer is easily removed with steam cleaning clean rag or a small glass brush 4 Gold can easily be added to almost any other metal 5 Very interesting welding combinations are possible Platinum Pt Platinum Pt has a melting temperature that is similar to stainless steel but a density that is 3 times higher In addition the specific heat of Pt is lower by a factor of 4 than stainless steel This means that it takes less energy to raise the temperature of Pt to its melting temperature The end result is that Pt is a little more difficult than stainless steel to weld but very similar in overall behavior One important consideration when welding Pt is its high boiling temperature 3827 deg C relative to tungsten s melting temperature 3410 deg C What this means if the tungsten electrode is contaminated with Pt metal the Pt metal may superheat and start to boil right on the electrode This boiling of the Pt will in turn melt the tungsten electrode causing it to lose its
40. e of a Tungsten Inert Gas TIG welder In TIG welding a sharpened tungsten electrode is used in combination with electrical energy to start and sustain a high temperature plasma stream an arc This plasma arc is used as a heat source to melt the work piece metal Filler metal can also be added to build up joints and create strong and reliable weld beads or weld seams TIG welders can use AC alternating current or DC direct current energy to initiate the pulse arc weld The Orion uses industrial capacitive discharge technology to produce the pulse arc weld Because AC wall voltage can vary up to 20 during the day capacitive welders have the advantage over AC technologies of precisely storing energy before the welding process This means that the Orion will produce a repeatable weld independent of AC power fluctuations PULSE ARC WELDING FUNDAMENTALS Pulse Arc welding uses electrical energy to create a plasma discharge The high temperature plasma in turn melts metal in a small spot This process takes place in milliseconds The process is clean and very controllable perfect for intricate and minute welding applications The Orion s welding process See image on top of next page 1 The user touches the electrode to the surface with very light pressure 2 The Orion turns on the shielding gas argon 3 The Orion retracts the electrode and sends a burst of electrical energy forming a plasma arc Please note that the weld is only
41. en run along the middle of the weld puddle in the direction of the overlapping joints This cracking is due to the stresses created during the weld puddle cooling process as described above with hot cracking However this time instead of geometry causing the cracking a rip starts in the old crystal structure and propagates during the cooling process much like ripping a piece of paper The result Pd is difficult to weld successfully without breakage Typically single spots of porosity can be welded and fixed but overlapping welds will crack There is a welding solution that can stop this cracking process The addition of gold fill wire to the weld joint creates a new alloy and stronger crystal structure The gold can discolor the weld joint However by welding over the joint several times the gold will diffuse into the Pd Another possible solution is to use a high gold content white gold Pd alloy laser wire Silver Ag Silver is an interesting metal with several properties that must be considered during the welding process First silver is highly reflective over a large range of light wavelengths This metal characteristic makes welding silver difficult for a laser but poses no problems for a Pulse Arc welder Second silver is a very mobile metal when in a liquid state and has low surface tension when compared to other metals Because of these properties how the weld energy is applied to silver is important When welding silver it is
42. er out The length parameter in the welder can be thought of as how long the valve is left open You can discharge a very small amount of water by only having the valve open a short time or you can allow all of the water out of the tower by leaving the valve open for a longer period of time The actual weld puddle can be understood better using the following analogy Think of the metal Surface as a pool of water in its frozen state The welder s arc discharge impacts the water causing it to melt The arc discharge also causes the now liquid water to ripple similar to when a stone has been thrown into a body of tranquil water If the arc energy is removed quickly the water freezes instantly and the ripples remain frozen into the water s surface If the arc heat is removed more slowly the ripples have a chance to dissipate and go away completely before the water s surface refreezes This is why short weld time causes the weld spot to look rippled Keeping the weld time at its max will leave the weld looking smooth and clean Using a more technical description during the welding process the weld spot becomes a liquid pool of metal The impact of the welding plasma causes vibrations on the molten pool s surface much like a stone causes ripples on the surface of a still body of water The Orion welder s energy discharge has been designed to ramp down the weld energy for longer weld time This gives the molten metal vibrations time to s
43. er pieces deeper weld penetration and for welding highly conductive metals like silver Hands on Try welding on a flat plate with 30 50 75 100 and 200 Ws of energy Stay at max length and make sure you have a sharp welding electrode Lower energy settings allow for welds on small parts and delicate features Having both power and precision allows users to have maximum versatility Selecting the proper weld setting is a matter of user preference and application necessity Hands On Try welding at 3 10 25 Ws of energy Make sure you have a ee Sharp welding electrode ENERGY VS TIME What happens if the time duration of the weld is adjusted As can be seen in the figures below the weld time controls the size of the pulse toa Smaller extent then the energy It also controls the smoothness of the weld puddle Because the smoothness of the weld spot is also related to the internal stress of the weld joint a smoother weld will have less stress It is recommended that the user keep the weld time at max time for most applications The top image was welded at 25 Ws with 0 2 4 8ms weld time The bottom image was welded at 75 Ws with 10 20 S0ms weld length The two weld parameters energy and time can be understood with the following analogies Consider the Orion welder to be like a water tower The amount of water in the tower is like the energy stored in the welder Firing the welder is like opening a large valve to let wat
44. er stronger alloy with the two primary metals An example of titanium welded to gold and silver The gold to titanium weld looks clean but is brittle The silver to titanium weld also looks good and is strong The Silver to gold weld looks good and is strong ag 200i User Manual CHAPTER 9 FAQ TROUBLESHOOTING GLOSSARY Frequently Asked Questions CAN I USE ANY ATTACHMENT WHILE IN TACK MODE NO The pulse arc welding stylus should never be used while the Orion is in Tack Mode However any other attachment can be used Attachments sold as tack welding attachments have been designed to transfer more energy to the weld These attachments help the Orion work as not only a tack welder but as a permanent fusion resistance welder CAN ATTACHMENTS LABELED TACK BE USED WITH THE PULSE ARC WELDING STYLUS Yes The pulse arc welding stylus requires an electrical contact to the workpiece Tack welding attachments can be used for this purpose Please note that tack welding attachments will also transfer more energy to the arc when used for Pulse Arc Mode This means that you should use lower energy settings than you would need with pulse arc attachments WANT TO GET THE MOST POWER POSSIBLE OUT OF THE ORION WHAT CAN I DO The Orion is designed to deliver a tremendous amount of energy in Tack Mode You can use up to 10AWG cabling to deliver more energy to the work area NOTE Using larger cabling ex 8 AWG or larger may damage the welde
45. er the electrode has left the work piece the arc will take the path of least resistance and might not touch the exact point that was desired However Tip Saver Plus will give better results than Tip Saver in these awkward welding surfaces WAVEFORMS Classic Classic weld waveforms have the advantage of high peak currents powers with exponential waveform decay The weld waveform decay allows the molten material to settle and cool more gradually by the end of the weld Advantages Good weld penetration with good weld smoothing Disadvantages Weld times and shapes are limited to preset values Triangle The Triangle waveform behaves similarly to classic mode in weld cooling characteristics However Triangle mode allows the user to adjust the slope of the weld waveform by adjusting the weld time The combination of weld power current and weld time determines the total energy contained in the weld waveform Advantages Good weld penetration with good weld smoothing Deeper penetration welds can be produced with lower power and longer weld time Disadvantages Slightly more complicated to learn than classic mode Square Square waveforms produce a constant power current for a specified weld time Users are able to independently adjust both the power of the weld as well as the length of the weld Advantages Users have the capability to adjust the weld to their circumstances For example users can produce a soft weld discharge for a relati
46. ergy dial Single on Mode Touch Detect on Trigger and then hit play Verify Gas Pressure is between 7 and 11 PSI 2 Lightly touch the electrode in the 25 Ws box on the provided weld plate Maintain contact amp keep hands steady by resting orion eres them on the table 3 Use the provided stainless steel weld plate as a guide to ar ikke i try different settings Make several welds on the weld plate FJERNE p to get comfortable with the stylus and the different weld GET EET parameters HOW TO MAKE A TACK WELD 1 Select low on quick power settings short on pre weld delay Foot Pedal for the Trigger and then touch the Play button 2 Attach the negative alligator clip to one work piece and the positive alligator clip to the other work piece 5 Lightly touch the two work pieces together where you want to tack them 4 Step on the foot pedal 5 If the work pieces stay together proceed to the Arc screen to perform a permanent weld using the Pulse Arc Welding Stylus If the pieces do not stay together move to the medium settings and repeat steps 2 4 15 2 200i User Manual CHAPTER 2 THE USER INTERFACE PART 1 Overview HEADER AREA Metals Arc Tack and Videos Tabs These four tabs contain features and settings specific to each view We will go over each tab in more detail throughout this chapter Save Icon The save icon allows users to create a custom weld parameter based on their current weld setting
47. erly grounded receptacle outlet Do not remove or bypass the ground prong Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect the input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill Check ground conductor for continuity Turn off all equipment when not in use Use only well maintained equipment and repair or replace damaged parts at once PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND ARC RAYS It is essential for every person in the immediate work area to wear utilize proper Personal Protection Equipment Often sparks fly off from the weld joint area therefore take the necessary precautions to avoid trapping a spark within your own clothing orion Also arc welding gives off infrared and UV rays that can burn the retinal tissues within the eyes and cause surface burns to exposed skin similar to a sun burn The stereo microscope provides proper eye protection when pulse arc welding No additional protection is necessary Wear protective garments such as oil free flame resistant leather gloves heavy Shirt cuff less trousers high shoes anda cap Avoid synthetic fibers as they melt easily Use an approved face shield or safety goggles with side shields when tack welding or when observing others performing pulse arc and tack welds Use a sunscreen of SPF 30 or high if we
48. etimes it can be helpful to focus the energy of a resistance weld for larger parts This can be done by using a weldment or bump between the parts to be welded This bump forces the electrical current to pass through a concentrated point especially important for thicker parts The smaller the bump tip diameter the more heat that can be generated at that point This technique is also very helpful for welding dissimilar conductive metals For example resistance welding silver to gold can be difficult however if I place a gold weldment on the silver part the gold to gold resistance weld become very simple To aid in resistance welding difficult thicknesses or material combinations 1 Place a weldment or bump on one side to focus the energy 2 Use an electrode configuration that is simple and has as much contact area as possible on the outside of the parts 3 The weldment or bump will fuse into the other part making a resistance weld that cannot be seen on an edge TIPS WHEN RESISTANCE WELDING With the above in mind there are several different helpful recommendations to use when resistance welding 1 The pressure between the two parts is the most important variable in resistance welding even the amount of energy being used for the weld plays to a degree a lesser role 2 High pressure will create a cool weld 5 Light pressure will create a hot weld 4 No pressure will produce an arc 5 Placing a small bump or weldment between
49. event weld cracking Palladium and high carbon steel cracking is a special case and is difficult to overcome when laser or Pulse Arc welding If only one weld spot is made cracking will typically not occur unless the orion 7 weld joint is stressed by hammering etc This means that welding over porosity in a Pd piece can be accomplished with the Orion or laser to help clean up a ring during the finishing process However welding more than one overlapping weld will inevitably lead to cracking laser or Pulse Arc welder Palladium cracking can be thought of as a combination of hot cracking and a new weld puddle crystal structure problem After a weld the molten Pd re crystallizes typically forming alarge and weak metal grain structure When welds overlap the new crystal structure in the previous weld the new puddle will be weak compared to the original metal The result is a crack will start at the edge of the new weld where it overlaps with the old weld joint The crack will then run along the middle of the weld puddle in the direction of the overlapping joints This is due to the stresses created during the weld puddle cooling process as described above with hot cracking However this time instead of geometry causing cracking a rip starts in the old crystal structure and propagates during the cooling process much like ripping a piece of paper The result Pd is difficult to weld successfully without breakage Typically with Pd single
50. formS ET p 27 WA TINIO oarra EE A REEE p 27 Waveform Graph Overview ssssssssererrerrerrrrrrrr p 27 Chapter 4 Pulse Arc Welding arararavrvrnnnnnnnnrnenenene p 50 Chapter 5 Tack Resistance Welding aravuvnanannnnvnnnne p 54 Chapter 6 Tungsten Electrodes cece cece eee ees p 58 Chapter 7 Orion Techniques Tips and Tricks s p 45 Chapter 8 Metals cscscticsssiccunane susivied eeeeedediceseavcaends p 48 Chapter 9 Troubleshooting FAQ cc cece cece cece eee ees p 56 Warranty Information EET p 59 orion FOREWORD Thank You for Choosing Orion Welders and congratulations on your purchase You are now the proud owner of an Orion 200i Welder This manual was designed to help you set up the welder and begin welding Please read and follow all safety precautions before proceeding with the welding process Sunstone Engineering is the parent company of Orion Welders At Sunstone amp Orion we are committed to producing quality products and ensuring complete owner satisfaction If you require assistance after reading this manual please contact us with the information provided below Orion Welders a Subsidiary of Sunstone Engineering R amp D Corp 1695 American Way Suite 5 Payson UT 84651 Email sales orionwelders com Voice 801 658 0015 Fax 866 701 1209 Welding Safety Precautions READ BEFORE WELDING The following safety advice is generalized advice for the arc welding industry These safety precaut
51. he advantage of only welding on metal Lasers can strike precious stones or other nonmetals and can even crack or evaporate the target Because the Orion is electrically driven it requires a conductor such as a metal to allow the welding process to take place Tu nesten R High Ter Ar Shielding Plasma Collimated Laser Light olten Pool The Orion welder uses the same high temperature plasma that can be found on the surface of the sun The sun creates this plasma via internal fusion reactions and the plasma temperature measures about 5 500 deg C at the sun s surface The Orion creates it s plasma via electrical discharge and can generate temperatures of 5 500 8 000 deg Cin very controlled small bursts START WELDING To become an expert and to really learn how to maximize the capabilities of the Orion we recommend that you dedicate time for real hands on experience We recommend that you read and complete the following sections while you are in front of the Orion The Orion is very easy to use and many users will be making quality welds within minutes The purpose of this section is to help the user to better understand some of the fundamental welding principles to utilize all of the functions of the Orion and to adapt this Knowledge to specific applications EE 200i User Manual As you can see from this example the Orion s Arc Mode offers a lot of energy At higher energies this mode is perfect for larger thick
52. he total energy contained in the weld Ina Square wave the same amount of energy can be contained in a high power short weld as would be contained in a low power long weld However the weld itself will be different in size and depth between the two types High power short welds can produce a larger weld spot at typical penetration Low power long welds with the same total energy will produce a smaller diameter weld spot with deeper weld penetration E A Square wave cuts off power abruptly to the molten weld puddle In short square wave pulses this may create a rippled weld surface as the oscillating molten surface is frozen almost instantly as heat is removed For longer square waveforms the puddle oscillations may damp out before energy is removed and will still produce a smooth weld surface EE 200i User Manual CHAPTER 4 PULSE ARC WELDING Welding Basics The Orion is a pulse arc welder and a capacitive discharge resistance welder in one This combination of abilities allows for infinite creative possibilities In its Tack Mode the Orion can be used to temporarily position parts before welding or soldering By increasing the energy output it can also be used as a permanent fusion welder resistance welder spot welder In its Pulse Arc Mode the Orion can be used to perform permanent welds add metal and do a variety of other amazing and time saving applications WHAT IS A PULSE ARC WELDER A pulse arc welder is a specialized typ
53. ical member Material is pushed from the vertical member onto the horizontal member to prevent part damage EE 200i User Manual Inthis example the vertical member is more heat sensitive or is thinner than the horizontal member Material is pushed from the horizontal member onto the vertical member to prevent part damage Pulse Arc Welding Weld Cracking Some materials are prone to crack because of their metal properties For example High Carbon steel Palladium Pd and some silver alloys Why does the cracking take place With some metals it is the new crystal structure created during the welding process e g palladium and high carbon steel However another cracking process often called hot cracking can occur when the cooling process and the resulting thermal shrinkage create high stresses in the work piece Hot cracking is very geometry dependent and can be avoided by carefully considering the weld joint before welding Ideas to overcome hot cracking 1 Keep joint gaps as small as possible 2 Keep the Weld Time Duration at Long to help ramp down the heat more gradually Improper joint preparation or geometry can lead to uneven weld puddle cooling If the puddle cools in such a way to create a hot center section the hot section will be pulled apart by the stresses from the cooling out metal A proper weld joint will help the weld puddle cool uniformly This will allow even stresses within the weld puddle and pr
54. ignment Even if warping is not desired there are steps to avoid this problem EE 200i User Manual To do this start with lower Energy settings This will minimize the initial warping as you stabilize the work piece Always alternate sides during the welding process several welds in a row on one side can exaggerate the warping while alternating welds will pull the part back and forth eliminating most warping After the smaller stabilizing welds have been placed you can turn up the energy and make the larger welds alternating sides as done with the lower Energy welds Pulse Arc Welding Weld Cleaning For many applications the weld joint will require very little preparation Keep the weld area clean and free from debris Remember that finger oils etc will cause blackening around the weld spot This blackening can easily be wiped away with a clean rag or taken off with a glass brush one is included with your Orion system sand blaster or steam cleaner During the welding process small amounts of metal will be vaporized from the weld joint and can be deposited elsewhere on the work piece Typically this thin film of metal will look black and can easily be cleaned off with a glass brush ultrasonic cleaner etc If the welds themselves look black or discolored it may be an indication of oxidation and can come as a result of too little or too much argon gas flow If the part is too hot some metals will readily react with oxygen to form o
55. ill allow users to select from their list of previously saved weld parameters by simply scrolling through and touching the desired previously saved weld parameter they would like to load to the welder After selecting the saved setting remember to verify the spot size before welding a new work piece Remember to touch Reset before welding anew work piece that will require different parameters Touch the Save Button to create a custom weld parameter This feature will save all the current weld parameter settings as seen on the Arc Screen After touching the save button follow these steps 1 Type in a name for the new setting or choose an existing saved setting on the left and it will be replaced with the current setting 2 Insert any notes that would be useful to remember when returning to this custom setting The settings button gives users the ability to change system preferences Interface Tab Here users can adjust the Volume Screen Brightness Microscope Brightness and Logo Brightness Simply slide your finger left and right on the slider bars to change these settings Language Button Touch the Language dropdown to select the language option of your choice Theme Bu Touch the Theme dropdown to select the Screen a your choice Power Control Knob Placement Choose to have the power control knob on the left or right The Gas Tab allows users to change the default gas flow settings to adjust gas flow behavio
56. ing Metal is accomplished by placing the electrode at a 90 deg angle from the work piece surface with the electrode tip on the edge or slightly interior to the edge of the metal mound The welding process will then take material from the mound and spread it into the surrounding material One should repeat this process until the proper spread of material is achieved By placing the electrode between a high and low spot the melting process will try and flatten the two taking material from the high area and moving it toward the low area Placing the weld electrode on the edge of abump will smooth away the bump as surface tension spreads the metal over the molten base material HANDS ON Use your electrode with several different materials to push metal around or to use surface tension to smooth a metal mound out Please note that various metals will react differently to pushing and surface tension smoothing For example silver has a relatively low surface tension while in a liquid state This means that the plasma push method may be more successful than it would be with stainless steel with a much higher surface tension On the other hand because of the high surface tension of stainless steel the surface tension smoothing method will proceed quickly Pushing metal is especially helpful if one of the parts to be joined is heat sensitive In this example the horizontal member is more heat sensitive or is thinner than the vert
57. ion feature can be used to improve weld formation and strength Additional energy is added to the weld in the form of micro energy bursts These energy bursts occur at arate of up to 600 times per second Using agitation can produce an audible high pitched ping noise None With None selected no agitation is added to the weld This is the standard weld discharge curve with a smooth slope Sloped The Sloped agitation option offers low levels of agitation It has minimal impact on spot size formation but yields additional penetration and enhanced weld strength Sustained The Sustained option offers high levels of agitation for improved weld spot strength in some metals The high levels of agitation energy will affect the spot size because of the extra energy used in this option To compensate for this addition of agitation energy it s recommended to lower the overall weld energy slightly when using this option Length Length adjusts the amount of time that the energy is discharged from the welder In classic waveform mode the length will automatically adjust to the recommended time as the users adjust the power dial In the Triangle and Square waveform mode the length will not adjust automatically Users will set the length and power independently in Triangle and Square waveform modes Increasing or decreasing Length allows for more or less total weld energy and will change the size and penetration of the weld spots Play Pause
58. ions are not all inclusive All users should exercise reasonable caution while using this device The following group of symbols are warning symbols CAUTION ELECTRIC SHOCK HAZARD EYE PROTECTION REQUIRED Consult these symbols and the related instructions listed next to the symbols for proper action when dealing with these hazards READ INSTRUCTIONS Read the owner s manual before using the Orion Only personnel trained and certified by the manufacturer should service the unit Use only genuine replacement parts from the manufacturer SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION Sparks can fly off from the welding arc The flying sparks hot work piece and hot 200i User Manual equipment can cause fires and burns Ensure that your work area is clean and safe for welding before starting any weld job Do not install or operate unit near combustible surfaces Do not install or operate unit near flammables We Do not overload your building s electrical wiring be sure the power distribution system is properly sized rated and protected to handle this unit NZ Remove all flammable materials from the welding area If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Watch for fire and keep a fire extinguisher nearby mm Do not weld where the atmosphere may contain fla
59. itis thicker than 2 3 4 7cm follow arm base mounting options 2 or 3 2 Position the microscope arm clamp under the tabletop 3 Place the included allen wrench in the opening at the bottom of the clamp bolt Turn the bolt clockwise until the clamp is very snug PE ch 200i User Manual Mounting Option 2 Bolt through table 1 Using the provided allen wrench unscrew the 10m x 1 5 allen bolt underneath the arm base 2 Drill a 3 8 10mm hole through the tabletop 3 Place a washer on the 10m x 1 5 bolt length will dependontabletop I thickness and run it up through the tabletop into the arm base 4 Tighten the bolt until it is very snug Mounting Option 3 Bolt to table 1 Position the base against the table 2 Trace drill holes with a pen or marker 5 Drill 1 4 holes in the tabletop 4 Run screws through the base into the drilled holes MICROSCOPE ARM SETUP UPPER HALF See video explanations of setup at http www orionwelders com resources orion i series resources 1 Place the microscope extender arm into the arm base 2 Place the microscope arm into the top of the extender arm 3 Place the touch screen box into the slot on the microscope arm above the microscope optics 4 Loosen tighten the allen on the top of the microscope extender arm to adjust the spring pressure Turn the allen counter clockwise if the arm does not hold the microscope up Turn the allen clockwise if
60. iver on the piece front panel Disconnect and reconnect it following the procedure given in the Setup Instructions The work piece is not conductive and cannot be arc welded with the Orion My welds look dirty or Change the flow rate of the shielding gas Between 5 10 PSI is recommended blackened Decrease the length of exposed electrode to bring the work piece closer to the stylus nozzle Verify that there are no gas leaks at the gas receiver on the rear panel of the Orion and also at the stylus connector on the front panel Note Gas cannot leak from the stylus connector except during a weld The Orion still shows that Even though the tank s valve has been shut there may still be residual pressure in the have gas connected even gas tube After the pressure is released the Orion will display the gas connectivity after I ve turned my tank status correctly off orion cho Glossary Capacitive Discharge CD An effective resistance welding technology that stores energy in capacitors in order to release a consistent amount of energy in every weld Orion uses this technology to produce clean and smooth welds Custom Setting The available slots for settings that a user may customize and then save Factory Preset Setting Refers to the settings that have been pre programmed into the Orion Hand Attachment The Orion comes with a variety of hand attachments that can serve as a positive or negative electrode depending o
61. lding for extended periods of time SAFETY PRECAUTIONS FOR HOT METAL Welding material that has a high thermal conductivity will cause metal to heat rapidly Repetitive welds in the same location can cause metal to become hot Do not touch hot weld areas bare handed Allow sufficient cooling time before handling welded pieces SAFETY PRECAUTIONS FOR FUMES AND GASES Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health The Orion produces minimal fumes and gases when compared to large scale arc welders Though not required some form of ventilation is recommended Keep your head out of the fumes Do not breathe the fumes Ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDS and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Welding in confined spaces requires good ventilation or an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do no
62. lly backed out to prevent over pressurization of the line 3 Screw the gas regulator onto the shielding gas tank 4 Connect one end of the gas tubing into the gas regulator It will stop when it is fully connected Tug gently onthe tube to verify a tight fit 5 Insert the other end of the gas tubing into the gas port on the back of the power supply It will stop when it is fully connected Tug gently on the tube to verify a tight fit 6 Open the gas tank slowly The dial on the right should pressurize and the dial on the right should remain at zero when the regulator dial is fully backed out see step 2 7 Slowly turn the regulator dial CLOCKWISE until the gas Regulator Ual pressure reads between 7 10 psi This will adjust the dial on the left side of the regulator ADJUSTMENTS ON THE MICROSCOPE ARM ADJUST WELDING STYLUS POSITION See video explanations of setup at http www orionwelders com resources orion i series resources 1 Insert the welding stylus into the stylus holder under the microscope head then tighten the stylus holder knob 2 Loosen the screws on either side of the stylus holder 3 Adjust the welding stylus to a 45 degree angle then slightly tighten the screws just enough to hold the stylus in place at a 45 degree angle 4 While looking through the microscope slide the welding stylus holder forward backward until the tip of the stylus is in the center of your focus OrionWelders c
63. lt the base metal Alternatively if the wire is small relative to the base metal the wire can be melted adding material to the base metal without any damage or warping to the base metal For larger features select a wire size that will allow you to perform your task efficiently For example filling a large pore should not be done with ultra fine wire but instead with wire of approximately the same diameter as the pore In this case the repair can be accomplished in literally one weld In comparison with the ultra fine wire the repair would take many welds Pulse Arc Welding Pushing Metal There are two competing forces at work during the pulse arc welding process The first is the surface tension of the molten metal Surface tension is a force between the metal atoms that is pulling the molten pool of metal flat during the metal s liquid phase The Secondis the electrons from the plasma pushing the molten metal in the direction the electrode tip points The plasma orion em tries to push the molten metal while the surface tension tries to keep it in place This means 1 Some metals with lower surface tension e g silver are easier to push around than metals with high surface tension e g Stainless 2 Surface tension itself can be used to move metals around By placing the electrode between a high and low spot the melting process will try and flatten the two stealing material from the high and moving it toward the low Push
64. mm electrodes are a good all around electrode while the 0 5mm electrode is excellent for very small projects less than Sws of energy Stylus components 1 Stylus Shaft 2 Collet 5 Collet Cap 4 Electrode 5 Stylus Hull m ell INSTALL THE TUNGSTEN ELECTRODE ONTO THE WELDING STYLUS Follow these steps to properly install the tungsten electrode See video explanations of setup at http www orionwelders com resources orion i series resources 1 Remove the stylus hull by pulling it away from the stylus 2 Loosen the collet cap by twisting it counter clockwise 5 The welder comes with 2 electrode collets One that fits 0 5mm electrodes and one that fits 1 0mm electrodes The electrode stylus will be shipped with the 1 0mm electrode collet installed 4 Insert the 1 0mm electrode into the collet a There is a groove around the Stylus Hull that will help measure the electrode length b Place the end of the stylus hull up against the collet cap F c Make sure the electrode tip falls between groove There should be between 0 6 0 7in 1 5 2cm of the electrode protruding from the stylus shaft This will allow the electrode enough room to stick out from the stylus once the stylus hull is placed back on the stylus ch 200i User Manual 5 There should be between 0 6 0 7in 1 5 2cm of the electrode protruding from the stylus shaft This will allow the electrode enough room to stick out from the stylus on
65. mmable dust gas or liquid vapors Remove any combustibles such as butane lighters or matches from your person before doing any welding Do not exceed the equipment s rated capacity Use only correct fuses or circuit breakers Do not oversize or bypass them SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK Touching live electrical parts can cause fatal shocks or severe burns The input power circuit and the internal circuits of the Orion welder are live when the power switch is turned on Additionally the internal capacitors remain charged for a period of time after the Orion is turned off and or power is disconnected Incorrectly installed or improperly grounded equipment is ahazard This device was designed to operate indoors only Do not operate welder in a wet damp environment Holding the hand pieces connected to the front of the welder is okay and will not generate an electrical shock Remove personal jewelry before welding i e rings watches bracelets etc Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Properly install and ground this equipment according to this manual and national State and local codes Do not weld with wet hands or wet clothing Always verify the supply ground check and be sure that the input power cord ground wire is properly connected to a ground terminal in the disconnect box or that the input power cord plug is connected to a prop
66. mooth out before the metal re solidifies It is recommended that the user keep the time at its max length for most welding applications In addition a longer weld time will also help prevent cracking in some metals as the extended time and longer discharge curve allows the molten pool to cool more slowly When the energy is cut off suddenly by shortening the time setting the liquid metal freezes in place This rapid freezing can cause micro stresses in the weld spot and may make the metal more prone to cracks under additional stress like hammering Time In most cases It Is recommended to leave the weld time at max length with one important exception If welding a very small part at less than 5 Ws of energy it is very helpful to turn down the time By turning down the time the arc will still ignite easily but the energy that the welder allows out during the weld is limited by the shorter amount of time The larger weld in this image was done at 5 Ws and 15 Ms time The smaller weld on the right was done at 5 Ws and 3 Ms time Alternatively the user can sharpen the welding tip to a very fine point to help ignite the welding arc at very low energy levels HANDS ON Try making a small weld spot using 5 Ws of energy and maximum length and then 5 Ws of energy and minimum length Now with a very sharp electrode try making a weld spot at 1 3 Ws of energy and maximum length chs 200i User Manual CHAPTER 5 RESISTANCE WELDING
67. n the circumstances Joule See Watt Second Liters Per Minute lpm Used to reference a gas flow rate for shielding gas argon Millisecond ms One thousandth of a second 001 Used to reference the Weld Time or length of a weld pulse Plasma Plasma is an ionized high temperature gas in which a certain proportion of electrons are free rather than being bound to an atom or molecule The ability of the positive and negative charges to move somewhat independently makes the plasma electrically conductive The Orion s pulsed arc uses this high temperature plasma to create a weld Pulse Arc Welder Arc Welding uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point Pulse refers to the intermittent nature of the weld arc produced Resistance Welding A process that uses the electrical resistance properties of a metal as a method of welding Shielding Gas Argon or other inert gas is used while welding to displace the regular atmosphere from the weld location This drastically reduces oxidation and carbonization of the metals increasing the weld quality Stylus On the Orion the stylus is the main hand piece used for arc welding It safely encloses the electrode and directs the shielding gas to the weld area Tack Fusion Welding Tack welding can refer to a semi permanent weld to place parts prior to permanent pulse arc welding Fusion welding can also refer t
68. ng gas is used such as 99 996 pure Argon Argon 4 6 or higher to prevent these effects Shielding gas is necessary to produce clean and repeatable pulse arc welds We recommend high purity argon This can be purchased at your local welding Supply shop PRESSURIZED GAS SAFETY There are several important rules that should be followed when using a compressed shielding gas such as argon 1 Always secure the pressurized gas tank to a fixed location such as a sturdy table leg If the pressurized gas cylinder were to tip and become damaged there is possibility that the tank could become rocket like expelling the high pressure shielding gas as propellant 2 ALWAYS TURN OFF THE SHIELDING GAS AT THE MAIN VALVE WHEN FINISHED This will help your shielding gas supply last longer in case there is a small leak in the tubing This is also a good Safety practice If the tube becomes dislodged shielding gas could fill the room displacing needed breathing oxygen Argon is heavier than air and will fill the room from orion cht the bottom upward If you experience a large shielding gas leak open all of the doors and windows in the room SHIELDING GAS TANK AND REGULATOR SETUP See video explanations of setup at http www orionwelders com resources orion i series resources 1 Ensure that your shielding gas tank is securely fastened to a stationary point near the welding area 2 Turn the regulator dial COUNTER CLOCKWISE closed until it is fu
69. ng similar to that achieved in Classic Mode but not quite as refined In a triangle waveform the weld time and peak weld power can be adjusted independently to produce useful weld characteristics similar to those found in the different classic weld modes e g Ultra micro nano etc D As in all waveform graphs the area in this section represents the total energy in the weld E This section represents the end of the triangle wave and is close to the minimum energy required to sustain a plasma arc as seen in the waveform of Classic Mode Square In this example we see a Square waveform with Tip Saver weld ignition and no Agitation A Point A represents a standard weld ignition B This point shows the leading edge of the square wave form In a Square wave the weld current is produced at a constant level for the weld duration and then is turned off quickly At higher power levers higher weld current the square wave can be quite forceful At lower power levels low currents the square wave can be gentler Short high power square waveforms can push metal aside to create holes while long low power square waves can create deep weld penetration C Sustained Weld Agitation is represented in area C of the graph Agitation produces a hammering and mixing effect on the weld joint Sustained Agitation means that the intensity of the agitation remains the same throughout the weld D Physically this area under the curve represents t
70. nt the weld is initiated either by compressing the foot pedal or touching the work piece to the electrode to the time the weld process begins Shorter time will cause the weld process to begin immediately Longer time will cause the weld to have a noticeably extended delay before it welds As such other factors add to this delay for a total time between trigger and weld energy release i e Gas Delay settings Shutter Delay This option controls how long the shutter in the microscope will stay shut after the weld has completed Even at the shortest time setting the shutter will remain closed for the duration of the weld and protect the eyes of the user from the weld flash System Tab Cartes Restore All Defaults This will reset all welder settings back to their factory default settings This will not affect saved Settings Clear All Memory This button will erase all the users Saved settings This can take up to 45 seconds Update Welder When updating the welder insert the USB stick into the USB slot on the side of the welder and then touch this button OrionWelders com chs 200i User Manual CHAPTER 3 READING THE WAVEFORM GRAPH IGNITION Standard Weld Ignition In Standard weld ignition mode the timing is arranged so the weld starts on the surface of the work piece as the electrode is lifting off md Advantages This is very useful for tight difficult weld joints because it insures that the weld is located exa
71. ntinue to turn the outside layer of the stylus connector clockwise until it stops 5 Now push in on the stylus connector you will feel it move in a couple centimeters Then turn the outside layer of the stylus connector clockwise until it stops 6 Repeat steps 2 5 until you feel the stylus connector bottom out and you can no longer screw the stylus connector clockwise This will insure that the stylus connector is firmly seated CONNECT THE REMAINING CABLES TO THE BACK OF THE TOUCH SCREEN BOX 1 Place an alligator clip into the positive port on the back of the touch screen box Remember to attach the alligator clip to the work piece before welding 2 Plug the foot pedal into the trigger port on the back of the touch screen box 5 Verify that the RJ45 cable is securely fastened in the RJ45 port 4 Insert the 1 4 gas tube firmly into the Gas port It may wiggle when connected but should not come out if pulled on CONNECTOR PORTS ON THE BACK OF THE INTERFACE BOX See video explanations of setup at http www orionwelders com resources orion i series resources 1 Foot Pedal Connection Port 2 Shutter Darkening Lens Connection Port 5 Stylus Connection Port 4 Power Supply Connection Port 5 External Device Port 6 Positive Grounding Port Use for Arc Welding 7 Negative Grounding Port Use with Positive when Tack Welding 8 Inert Gas Connection Port ch 200i User Manual External Power Supply Se
72. o a permanent resistance weld See Resistance Welding TIG Welding Also Known as Tungsten Inert Gas Welding is an arc welding process that uses anon consumable tungsten electrode to produce a weld The weld area is protected from atmospheric contamination by an inert gas such as argon Watt Second Ws The reference for weld energy A Watt second is the same as a Joule 1 Ws 14 Workpiece In this manual workpiece refers to anything being welded or worked on WARRANTY AND CONTACT INFORMATION All Orion products come with a 2 year limited repair warranty Orion Welders will repair all defects in craftsmanship without charge during this time period excluding the cost of shipping This warranty does not cover damage caused by improper use of Orion Welder products This warranty does not include consumable items such as welding electrodes or hand piece attachments Orion Welders is dedicated to keeping our products operating at peak performance for years to come Any repairs needed after the 2 year warranty period are performed at cost Orion Welders offers a 30 day money back guarantee on all of our products Before sending a product back please contact Orion Welders to receive an RMA number The RMA number should appear clearly on the outside of the package Customer refunds are accomplished via check Please note that a 3 restocking fee will apply to all returns In some cases a merchant fee may apply Equipment damaged by improper use or in
73. o be placed at a 45 degree angle in front of the wire However less material will be added with every weld and a portion of the wire will typically ball up in the process Remember that for a larger fill wire the energy must be increased to completely melt the wire If there is insufficient energy there may only be partial melting of the wire However in some situations this may be advantageous HANDS ON Try adding fill wire using the side placement method Build up a small mound of material TOP PLACEMENT With top placement the material addition process will depend a great deal on the wire size and the weld energy If the wire is very small the results will be similar to the side placement discussed above For a small wire welded with high weld energy relative to the wire size the weld plasma powers through the wire This technique melts the base metal and joins the melted wire to the base plane However if the wire is larger or the energy is set to produce only a small spot size the wire will typically fail to be added to the base material Instead the wire will ball and some melting of the base material will occur which is insufficient to add the wire Fal Fill Wire m Fill Wire ud Placing the weld electrode on top of the fill wire at a 90deg angle from the base material surface is typically not the preferred method of adding material If the wire is large compared to the energy setting the wire will ball
74. o help users that are first learning to pulse arc weld or not sure which weld parameter to use Metals To begin simply select the metal that will be welded Each metal has been pre programed to load the best settings we have found for welding that particular metal If welding two different metals we suggest using the welder factory default settings Touch the reset button in the control area of the Arc Tab to load these settings Power Control This circular dial controls and selects the amount of weld energy or weld power Users can touch or slide along the circular path to adjust and set the weld energy Notice that the dial s controls are non linear This allows users greater refinement and control when selecting lower level settings This means that the first section of the dial represents 0 01 1 5 Joules the next section represents 1 5 3 Joules the third represents 3 5 Joules the fourth represents 5 30 Joules and the final represents 30 200 Joules Additionally users can input weld energy settings via a number pad To access the number pad tap on the weld energy numbers inside the dial This allows users to directly enter the exact desired weld energy values Once the numeric value is entered tap OK to set the value and exit the number pad Play Pause Pressing the Play Pause icon toggles between Play and pause If the Play icon is green the welder is capable of making welds anytime a work piece connecte
75. om ch 200i User Manual 5 Now securely tighten the stylus holder screws ADJUST THE MICROSCOPE FOCUS See video explanations of setup at http www orionwelders com resources orion i series resources 1 Twist this knob above the 1x 2x knob to focus the microscope When adjusting the microscope focus place a finger under the welding electrode to help judge the correct focus location Focus the microscope till the texture on the skin of the finger is clearly visible True Color Optical LCD Shutter Sunstone Engineering has developed a truly revolutionary optical LCD welding filter The True Color TM Optical LCD shutter system allows Orion users an unimpeded full color view of the welding work piece before welding During a weld the Orion pre darkens the shutter to provide complete eye protection Even when a weld is not taking place the user s eyes are always protected from harmful UV and IR radiation to levels exceeding typical safety requirements The True Color TM Optical LCD shutter system has been specifically design for the Orion 200 seam mode Inseam mode the Orion 200i automatically adjust the filter darkness according to weld intensity to provide a comfortable and safe view of the welding process The operator can then see the molten weld puddle flow as the welding process takes place This visibility allows the user to adjust electrode position during the welding process to perform the best weld seam every time Bec
76. ome Familiar with the Microscope See video explanations of setup at http www orionwelders com resources orion i series resources The Orion Microscope has been designed to provide maximum visual clarity eye protection and ease of use One challenge using the microscope is getting used to bringing the work piece to the welding electrode while looking through the microscope This is an easy challenge to overcome To begin follow these steps with the welder on pause While the welder is on pause it will not weld when the work piece touches the electrode orion cht 1 Rest your hands on the table and position the work piece close to the welding electrode before looking into the microscope 2 Make sure your focus is at the tip of the electrode 3 Use slow controlled movements 4 It is helpful to have your hands resting and to only use your fingers to move the work piece up to the electrode 5 Place the work piece surface perpendicular to the point of the electrode As will be discussed the angle of the electrode tip relative to the work piece surface is very important and will take practice 6 Now practice making light contact with the work piece to the electrode Remember to follow these steps once the welder is completely set up ready to begin welding Electrode Setup The Orion welder comes standard with a 0 5mm electrode collet and 5 0 5mm electrodes anda 1 0mm electrode collet and 5 1 0mm electrodes The 1 0
77. onsistent welds and poor arc starting Only light pressure is needed to start the welding process too much pressure will interfere with the welding process lead to electrode metal contamination and will shorten the amount of time you can weld before re sharpening or replacing the electrode CHAPTER 7 TECHNIQUES TIPS amp TRICKS Pulse Arc Welding Adding Material Typically material is added with a small laser wire one weld at a time However there are many additional options to add material One for example is instead of using small laser wire the Orion can weld a much larger wire or rod to fillin more metal in a single weld There are several methods to aid in the addition of fill wire which are mentioned below The placement of the electrode relative to the wire is very important and will influence how the material behaves during the addition process SIDE PLACEMENT Placing the electrode on the side of the wire is generally the best method of adding fill wire As shown below place the electrode at an approximate 45 degree angle between the wire and the base material As the electrode pulls away from the base material and the arc ignition happens the base material will melt first and then the wire will be melted and pushed or pulled by surface tension into the base material This is an excellent method to produce a uniform molten pool of metal and ensure the proper mixing of the base material and the fill wire The electrode may als
78. porate Different metals will evaporate at different rates from the weld pool The evaporated metal can deposit around the weld location in a very thin layer that can look black This type of deposit can typically be removed by steam cleaning wiping with a clean rag or witha glass brush Please also note that some gold alloys can contain small amounts of zinc 0 5 1 0 This zinc addition is used as a deoxidizer during casting and can improve the fluidity of the molten metal As discussed above zinc can cause porosity and will contribute to a black film that must be ch 200i User Manual removed via glass brush or clean rag Yellow gold physical properties and composition one possible 58 75 gold 12 27 silver 9 15 copper and some zinc White Gold White gold is also a relatively simple metal to work with There are two main types of white golds palladium white gold and nickel white gold Palladium white gold composition one possible 58 5 gold 10 palladium 28 5 silver 2 5 copper nickel zinc Nickel white gold composition 14k one possible 58 5 gold 25 8 copper 15 5 nickel 0 4 Zinc Gold color can be changed with the following alloying show alloy chart by composition and color Note the zinc content of white gold High zinc content can lead to weld defects like porosity etc as the zinc boils out of the weld joint Please see the previous discussion on overcoming porosity In short welding over th
79. power of the weld can be adjusted independently in Triangle mode Square This graph shows how changing the weld time changes the Square waveform The power level stays the same and the weld length increases or decreases the area energy of the weld waveform High power welds produce a deeper penetrating weld For example by turning up the weld power to maximum and reducing the weld time to a very small value the weld can be used to punch through a thin sheet of metal This happens as the weld plasma melts and then pushes the molten metal out of its path Using lower power with a longer weld time can produce deeper weld penetration without as much pushing this produces smoother welds WAVEFORM GRAPH OVERVIEW Classic The classic waveform image displayed here shows users what is happening during each weld Below we will talk about each section of the waveform A This graph shows standard Plus ignition is being used B The top of waveform shows the relative intensity of the weld at this point in the welding process Note that the total weld energy contained in the weld is located on the screen near this point C The shape of the waveform at this point determines the weld puddle characteristics In Classic mode the actual weld discharge happens in an exponential decay fashion which would appear like a smooth curve as shown This will result in a high intensity weld start with a quick fall off of energy finalizing in a lo
80. r Pre flow Delay Allows users to control the amount of shield gas released before the weld occurs An increased pre flow delay can be used to allow for complete clearing of the gas line and good shielding at the weld spot This can be used in applications that require the electrode orion tip to stick out further from the Stylus Hull opening than is normal The pre flow delay can be alternatively shortened for applications that have a short distance from the electrode tip to the Stylus Hull opening It is recommended to use the default settings for all other applications Post flow Delay Allows users to have control of the amount of shield gas released after the weld Materials that solidify quickly do not need the system to maintain an inert gas environment for as long while materials that remain in a molten state for an abnormally long time may require a longer post flow delay to maintain good shielding at the weld spot Purge Touch this button to send a shot of shielding gas through the gas flow system This is used to test if gas is flowing through the system properly to check the pressure and to clear the gas line of any oxygen that may have entered between welds Timing Tab The Timing Tab allows users to control the amount of time used on different weld parameters Time Between Welds This sets the minimum or maximum time the welder waits before another weld Pre Weld Delay This is the time from the mome
81. r and will void your warranty CAN MAKE MY OWN WELDING ATTACHMENTS Yes the Orion welder is very versatile You are welcome to make your own pulse arc and tack fusion welding attachments NOTE 10 AWG is the largest cable that should be used with your Orion welder The 10 AWG cable should not be shorter than 3 5 feet 1m CAN I MAKE PERMANENT WELDS IN TACK MODE Yes the Orion has been designed with Sunstone Engineering s industrial spot welding resistance welding technology By turning up the energy and using tack welding attachments the Orion is a fully fledged resistance welder often called a fusion welder Alternatively by using low energy or small cabling the Orion will act as a temporary tack welder This temporary tacking allows positioning of a weld piece before permanent welding in Pulse Arc Mode WHAT MATERIALS CAN YOU WELD WITH THE ORION The Orion can weld a wide variety of materials Some examples include gold silver platinum steel stainless steel titanium and virtually all other precious metals In addition cobalt alloys aluminum tin brass and EVEN copper can be welded with the Orion Even with an ideal welder some materials and alloys will be difficult to weld Furthermore some materials such as zinc should not be welded because they may produce fumes that will make the welding technician sick Pulse arc welding of solder is also not advised because of its low melting temperature Solder will vaporize easily an
82. reacts with both oxygen and nitrogen at elevated temperatures Ti burns to form TiO2 in air at 1200deg C Ti will also burn in pure N2 gas at 800deg C to form TIN Titanium nitride TiN is inherently brittle which will result in a weak weld joint Very light reaction mostly shielded may just include slight discoloration However a heavy reaction will cause absorption of gas and will cause a dark gray and porous result If the reaction is too heavy the weld location will become very weak and porous Niobium Nb reacts with both oxygen 02 and nitrogen N2 gas Niobium will oxidize react with oxygen at 200deg C The reaction with N2 starts at 400deg C As you can see niobium is even more reactive than titanium This means that greater care must be taken when welding Nb to ensure proper gas shielding and clean welds For thin parts this is particularly difficult as heat is easily conducted to the opposite weld side the underside of the sheet for example This heat on the underside causes the Nb to absorb 02 and N2 gases resulting in brittle welds For both Ti and Nb the level of oxidation can be observed visually Heavy oxidation will cause a gray porous surface however oxidation or nitrogen absorption in smaller degrees will cause the surface of the metal to color This principle can be used to actually paint on oxide in different colors on Ti and Nb parts orion ang Titanium and Niobium metals will o
83. results For example Ti to Gold Au results in a clean looking but brittle weld Copper to Ti has similar results Silver to Ti is relatively strong When welding Ti to other materials remember to test the weld strength with scrap pieces before welding the final work piece One important consideration when welding Nb is it s high boiling temperature 4742 deg C relative to tungsten s melting temperature 3410 deg C What this means if the tungsten electrode is contaminated with Nb metal the Nb metal may superheat and start to boil right on the electrode This boiling of the Nb will in turn melt the tungsten electrode causing it to lose its sharp shape Yellow White Gold Au Yellow gold is a relatively simple material to weld Typically it will produce a strong and symmetric weld spot and resulting welds are smooth and require little cleanup This is true for even lower Karat golds however please note that weld results will improve with higher gold content Typically the different metals added to gold are used to change its wear characteristics and color The more additional metal added not gold the lower the karat value Lower karat golds that contain copper and silver etc can produce a black coating around the weld s surface This can easily be steam cleaned wiped off with a clean rag or taken off with a glass brush Please also note that sometimes during the welding process a small amount of the welded metal will eva
84. rm The waveform selections determine and control how energy is released when welds are made Classic The classic waveform is the default waveform for welding on all Orion welders It has a high peak current which is the peak of the energy level followed by a curved discharge Slope The curved discharge slope allows the weld spots to cool with less internal stress and without surface ripples Classic welds will typically have a smoother surface than other waveforms Triangle The Triangle waveform is similar to the classic waveform s ability to make smooth and uniform weld results One key advantage of the triangle waveform is the ability to set the peak and the length independently Meaning a weld could have a very high peak anda very short time or a very low peak with a very long time or any other combination of these two parameters A Triangle waveform s weld power will always go to zero In comparison adjusting the weld time in Classic Waveform to be shorter does not guarantee that the weld energy discharges to zero Instead the energy is simply cut off and not allowed to fully discharge Square Similar to the triangle waveform a Square waveform allows users to adjust the peak and the length independently Again the user can select Square waveform so that a weld could have a very high peak and a very short time or a very low peak with a very long time or any other combination of these two parameters The difference of this waveform
85. s Users can create up to 1000 custom weld parameters Load Icon The load icon allows users to select those pre saved custom weld parameters and use them again Settings Icon The settings icon opens a window to adjust Interface Gas Timing and System settings We will go over the save load and settings tabs in more detail at the end of this chapter WAVEFORM GRAPH AREA In this area the user has a full preview of the current weld settings and can see exactly what will take place during each weld The waveform displayed will change based on the control settings the user selects Along the left side of the graph the numbered scale changes as the weld energy is increased or decreased You ll also notice that the time of the weld is represented by the length measurement shown at the bottom of the graph These settings show what s happening during the weld In the upper right hand corner an approximation of the weld size is shown based on the current settings This helps users have a visible reference when setting power and other parameters Lastly in the lower right portion of this section all the currently enabled Waveform Ignition Agitation and Length values are displayed CONTROL AREA This section contains the different controls to customize the 200i2 s settings for welding output We will go over each tab in more detail throughout this chapter orion 2 METALS TAB CONTROL AREA This section was created t
86. se note that in this mode the work piece will become hot A leather glove is highly recommended to prevent finger burns while welding SUGGESTED USES FOR SEAM MODE a Anywhere that a continuous seam needs to be made b In large parts where hot cracking is an issue c Smoothing excess material in joints where filler material has been used d To pre heat weld parts often metal that has been heated to higher temperatures will orion 2 have better weld joint penetration surface finish etc SEAM MODE TIPS AND TRICKS a Start small Always start small and work up in power Develop a feel for the power contained in your Seam mode setting by welding on a scrap piece of material Once you have tested your setting move on to the final work piece b When the weld electrode is hot it will operate in seam mode more easily c If seam mode is not igniting properly it is likely your electrode has been contaminated A clean electrode will produce welds more easily d Shield gas coverage during a seam weld is very important During your practice experiment with gas settings and electrode distances to see what produces the cleanest and shiniest weld results e For large welds the welding stylus retract distance will provide good welds Try and maintain this distance during the weld f For small welds the operator may need to bring the electrode closer to the weld surface during the welding process g Practice practice practice
87. series resources 1 Completely remove the electrode from the stylus 2 Pinch the electrode between the thumb and middle finger with the point facing inward 5 Power on the Dremel or flex shaft then hold it with the opposite hand If the Dremelis in the left hand then sharpen the electrode on the side of the diamond disk furthest from the body If the Dremel is in the right hand then sharpen the electrode on the side of the diamond disk closest to the body The reason for this is to keep the striations on the electrode moving towards the electrode tip not away This will effect the quality of the weld if not done as explained above 4 Set the electrode on the diamond disk at a 15 degree angle and begin to spin the electrode with the thumb and middle finger A helpful way to get a sharp electrode is to push down on the electrode with your index finger while twisting the electrode with the thumb and middle finger See the video on our website for additional instruction on this method 5 Once the electrode is sharp and clean turn the Dremel off and insert the electrode back into the stylus as explained above See Chapter 5 for additional information on the Tungsten Electrodes orion cht WHEN TO FLATTEN BLUNT THE ELECTRODE When working with silver copper and other highly conductive metals in energy levels above 20ws it is recommended to blunt the electrode instead of sharpening it See video explanations of setup at http
88. sh resistance Thin Argentium silver parts can be welded directly using copper electrodes Thicker ch 200i User Manual silver parts may require a weld projection or bump to focus the weld current This welding strategy Is discussed in detail in Chapter 4 Tack Welding Aluminum Al Aluminum behaves very much like silver during the pulse arc welding process Aluminum has a very low melting temperature 660 deg C andis very mobile when in a liquid phase This means that the same principles that apply to welding silver also apply to Aluminum Aluminum also has one additional complication that may make it difficult to work with in some situations This metal is very susceptible to hot cracking On occasion the weld parameters or geometry may be such that a crack may appear in the weld Always perform test welds for strength verification In general pulse arc welding in aluminum will produce a weaker weld than with other metals Stainless Steel Stainless steels are relatively simple to weld The weld puddle looks smooth and joins easily and the resulting weld joint is strong Because of the low thermal conductivity of stainless steel it is easy to hold the work piece in hand while welding without weld heat immediately making the work piece too hot to hold Use only stainless steel fill wire when welding If regular low carbon steelis used the weld joint will eventually rust over time Austenitic stainless steels 304 for example weld easil
89. spots of porosity can be welded and fixed but overlapping welds will crack Pulse Arc Welding Joint Preparation The Orion 200i can be adjusted to a weld penetration of up to approximately 0 66 mm in depth depending on the material However deeper penetration usually also means large spot size around 1 5 to 2 mm When deep penetration is desired but the weld spot size needs to remain Small or the work piece thickness is very thick additional weld joint preparation may be necessary The Y joint is the simplest joint to prepare Use fill wire of an appropriate diameter to build up material in the joint Weld with no fill material for the first pass to increase the weld penetration into the joint Then add fill wire to build up material in the top of the Y until the material is flush with the top surface I Other joint preparations like X V etc are possible and the welding procedure is similar Pulse Arc Welding Warping In some specialized applications precise positioning of the work piece relative to a model is very important However during the melting process the weld pool will expand and shrink asymmetrically meaning that the expansion during melting is less than the shrinkage during cooling This asymmetric expansion can warp the work piece The warping can be used to one s advantage if done correctly Often the user can simply observe the natural warp in the work piece and place welds to warp the part back into proper al
90. sufficient shipping precautions will be charged additional fees Orion Welders is dedicated to providing quality products and support Please feel free to call with any questions before or after purchasing our products welders Orion 200i User Manual Go to http www orionwelders com resources orion i series resources for full video tutorials Orion Welders 1693 American Way Unit 5 Payson UT 84651 USA 1 801 658 0015
91. t weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded SAFETY PRECAUTIONS FOR FALLING EQUIPMENT Use a working surface of adequate physical strength to support the welding unit during operation or storage Secure welding unit during transport so that it cannot tip or fall SAFETY PRECAUTIONS FOR HIGH FREQUENCY PITCH AND VOLUME Welding with high frequency pulse agitation can produce loud high pitched sounds It is recommended to use hearing protection when welding with agitation turned on 200i User Manual MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES Wearers of pacemakers and other implanted medical devices should keep away Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations OVERUSE CAN CAUSE OVERHEATING Allow a cooling period between strenuous welding schedules follow rated duty cycle If overheating occurs often reduce duty cycle before starting to weld again OBSERVE ALL NECESSARY PRECAUTIONS ASSOCIATED WITH COMPRESSED GASES Use only compressed gas cylinders containing the correct shielding gas for the process used
92. temperatures Note that tungsten has a significantly higher melting temperature than the other metals This is an important attribute of tungsten that aids the welding process While welding electrons from the weld plasma impact the work piece and form a weld spot At the same time positively charged gas atoms impact the electrode Both of these processes create heat However more heat is 200i User Manual f generated by the electrons impacting MENGE ou deg c the work piece than the atoms striking the electrode Aluminum 660 1064 1083 ELECTRODE SHAPE The electrode shape is a very important aspect to consider and has a significant impact when welding various metals The shape of the electrode will greatly affect the welding plasma created during the arc Poor electrode shape will lead to plasma arcs that are not repeatable while good electrode shape will help the plasma arc to discharge smoothly from the welding tip The grinding direction to sharpen the electrode is very important When grinding make sure that grind marks run parallel to the electrode shaft Parallel grind marks will allow the plasma to discharge uniformly and smoothly from the electrode Grinding the electrode such that circular rings or marks show up will lead to a poor plasma arc affecting weld quality The plasma will discharge inconsistently from the electrode ridges and may become unstable oscillating in time The weld spot will not be repeatable
93. the arm does not allow the microscope to come down 5 Ensure the RJ45 microscope cable is plugged into the RJ45 port on the light ring below the microscope optics 6 Plug the other end of the microscope cable into the RJ45 Shutter port on the back of the touch screen box Orion RJ45 ports are not compatible with any other RJ45 ports Connecting them to other devices may damage the welder and or the other devices 7 Install the rubber eyepiece covers onto the optics 8 Loosen the bolt in front of the microscope mount to move the microscope head left and right When adjusting the spring pressure as described in step 4 be sure the armis parallel to the table as seen here orion cht Orion 200i Welder Connection Setup CONNECT THE WELDING STYLUS TO THE BACK OF THE TOUCH SCREEN BOX See video explanations of setup at http www orionwelders com resources orion i series resources The welding stylus requires the most attention during setup Since argon gas will flow through the Stylus a tight fit between the power supply and the stylus is critical This will insure that no oxygen is entrained into the weld To accomplish this follow the steps below 1 Position the end of the stylus so that the notch is facing down 2 Push the stylus into the stylus connector port on the back of the touch screen box 5 Turn the outside layer of the stylus connector clockwise so it screws onto the stylus connector port 4 Co
94. to consider The zinc will evaporate quickly from the weld area causing a black coat to spread to the surrounding metal including the welding stylus The zinc evaporation may also cause strange weld behavior etc For best results select alow carbon steel without a zinc coating Make sure the steel is free from other contaminates such as rust or oil Remember that if using the Orion to produce welds in very thick pieces the weld joint may need to be prepared as discussed previously orion O h8 High Carbon Steels Spring Steel Tool Steel High carbon steel welds easily but may become brittle after the welding process To avoid weld failure the part must be heat treated after the welding process Cobalt Chrome Alloys Cobalt Chrome is very sensitive to oxygen contamination If there is insufficient argon coverage or oxygen present in the argon gas this alloy will crack Once oxygen embrittlement has occurred the weld area must be removed via grinding etc to prevent future cracking over the same area Copper Copper is one of the more difficult alloys to weld because of its high heat capacity and high thermal conductivity These factors make it even more difficult to weld than silver Copper also requires more energy than silver for the weld to take place about 30 more Thin copper however welds very easily and lower energy is typically sufficient to produce very strong welds For thicker copper similar techniques as those employed to
95. tool and the work piece is important to prevent welding the tool to the work piece e g brass lined pliers Then apply the correct pressure between the work pieces to achieve your weld This will help to ensure the resistance between the tool and the part is very low and no weld is made at this location Typically it is not good practice to use a set of steel pliers to hold a steel part for example during resistance welding The tool can easily fuse to the work piece Typically steel is not used for resistance welding because of steel s high internal resistance This high resistance means that a great deal of energy is dropped in the tool before even making it to the weld location The exception to making a resistance welding tool from steel is when only a Small amount of energy is needed This may happen when only a light tack weld is needed before pulse arc welding CABLES FOR RESISTANCE WELDING A true resistance welding hand piece should transfer as much energy to the weld location as possible The Orion is capable of transferring over 5000 amperes to the weld location To enable this full energy transfer 1 The welding attachment should use 3 5ft 1m of 1OAWG cable 2 IMPORTANT the cable should be no larger than 10 AWG or damage to the welder may occur e g SAWG is a larger cable Not all tack welds require this amount of energy Smaller cabled pulse arc attachments can be used for simple tack welds that require lower energy CUSTO
96. tup SET UP THE EXTERNAL POWER SUPPLY The Orion has an internal switching power supply that can accept 90VAC to 240 VAC See video explanations of setup at http www orionwelders com resources orion i series resources 1 Plug the female end of the power cable into the AC Power port on the side of the external power Supply 2 Connect the male end of the power cable into AC power 5 Plug the 10 pin external power supply to touch screen box cable into the 10 pin port on the external power supply 4 Run the cable from step 3 to the microscope extender arm Remove the plastic piece on the underside of the microscope extender arm by squeezing the plastic piece on both ends with your thumb and index fingers 5 Place the cable in the plactic piece 6 Connect the plastic piece back to the extender arm 7 Plug the end of the cable into the 10 pin port on the back of the touch screen box 8 The red LED indicates that the power supply has AC power applied and is ready to use Shielding Gas Setup During the pulse arc welding process high temperature plasma quickly melts metal into a molten pool As the weld is performed a small amount of shielding gas is released through the weld stylus to prevent oxygen from entering the molten pool After the weld has occurred the protective gas turns off If oxygen from the air enters this molten pool the result is a metal oxide that is brittle porous and burnt looking Protective shieldi
97. typical weld configuration requires a positive and negative electrode with pressure applied to the work piece parts As we zoom in on a cross sectional view of the work piece parts we can identify the electrical resistance locations where heat is generated For fine spot or small scale resistance welding most of the heat is generated at the contact point between the two work pieces This has been identified on the figure as the largest resistance point During the weld a large pulse of electrical current is dumped quickly through the work piece causing rapid heating and melting at the electrode location Left On the micro scale all surfaces have a degree of surface roughness This roughness causes the work pieces to only contact in a limited number of locations Middle Applying more pressure will cause more Surface contact less resistance and less resistive heating Right Applying less pressure will cause less surface contact more resistance for better resistive heating orion chs A resistance welder uses the resistance to the flow of electricity to heat h and melt the part via a large electrical current This contact point is where T the highest heat is generated Light pressure between the parts means wars less contact between the two surfaces more resistance and hence more heating and melting Heavy pressure between the parts translates to more contact between the two surfaces less resistance and less heating Som
98. vely long period of time for smooth welds or a forceful discharge for a Short period of time for increased depth Disadvantages Limited weld length at higher powers Smoothing occurs only at low power settings WELD TIME Classic The above graphs show how the amount of time used in each waveform affects each weld shape independently Notice that each waveform is affected differently than the others This graph shows the classic waveform at a reduced weld length Notice that reducing the time in the classic waveform mode simply truncates the weld waveform delivering the same amount of energy in a shorter time This time reduction in the Classic mode reduces the smoothness of the weld spot chs 200i User Manual Triangle This graph shows how the time adjustment changes the shape and area of the Triangle mode A shorter time will contain less energy but will have the same initial punch as a longer weld time would at the same power level Both welds will have a degree of weld smoothing with the longer weld time achieving the smoothest results Triangle mode is a great way to produce a smooth weld with a deeper weld penetration Weld penetration comes from a combination of weld power and weld time Deep larger welds can be achieved with high power and short time while deep Smaller welds are achieved with low power and longer time The length of the weld affects how hard the initial punch will be Remember that both the length and
99. w current low intensity weld at the end of the weld process The high current and high intensity at the beginning of the weld helps start the melting process quickly while the low current and low intensity at the end of the weld allows the weld puddle to smooth and start cooling around the outer edge of the weld before the energy has been shut off The result is asmooth weld finish D Graphically the area under the weld waveform curve represents the energy contained in the weld For example if the user selects 10Ws of energy then this area would represent 10Ws of energy The energy is calculated from the power weld current and voltage multiplied by the time of the weld E The end of the waveform shows the intensity of the weld at end of the welding process In Classic mode this point represents a very low weld current value almost to the point where the plasma can no longer sustain itself orion O h3 Triangle In this example we see a Triangle Wave with Standard weld ignition and no agitation A This image shows a representation of Standard Weld Ignition In this mode no pilot arc is used and weld ignition happens based purely on electrode retract timing B The highest current and power in the triangle waveform comes at this point in the weld cycle In many ways triangle waves act very similar to the classic waveform C In Triangle mode the slope decreases linearly until the end of the weld This provides weld smoothi
100. weld silver must be used Brass Brass is a material that contains a large amount of zinc 30 37 zinc by composition The remaining material is copper As discussed previously zinc is a hard metal to pulse arc weld or resistance weld because of its low melting and boiling temperature 420 deg C 907 deg C During the melting process the low temperature zinc evaporates boils out of the brass alloy For low energies this simply coats the surrounding material in a black zinc film that can easily be removed with a glass brush For larger pulse arc weld energies the black coat can cover larger areas and porosity can develop at the weld location as zinc boils from the weld Joining Different Metals Welding different metals together will produce a new alloy at the weld location The new alloy will have different properties although in many cases similar properties to the base metals Some metals combine well forming a strong and useful new alloy Other metal combinations are weak and brittle Helpful Hints for Combining Different Metals 1 Check the new alloy strength with scrap material to ensure the joint will turn out as expected 2 You may need to weld over the joint location several times to get complete mixing of the weld pool and a uniform new alloy In most cases this is not necessary for a strong joint and the first weld will be sufficient 5 Some material combinations may benefit from a third metal at the joint which forms a bett
101. xide layers If gas flow is insufficient the weld spot may be poorly covered and oxygen may be present during the weld On the other hand if the protective gas flow is too high the gas may exit the stylus nozzle in a turbulent state When the gas flow is turbulent it will grab oxygen and other atmospheric gases and bring them inside the protective argon gas Shield This will also lead to the molten weld puddle being exposed to oxygen PROTECTIVE GAS RULES OF THUMB 1 5 10 PSI is a good shielding gas rate 2 The shorter the electrode is the less gas flow is necessary 5 Gas flow may need to be increased if the electrode is lengthened Any discolorations that shows in titanium is an indication of poor shield gas coverage For this reason it may be helpful to practice on titanium to make sure your gas flow is correct Adjust your gas to ensure no discoloration in a small titanium weld spot This will give you confidence of proper argon shielding for other materials CHAPTER 8 METALS Weldability of Common Metals One very important aspect of Pulse Arc welding is a working Knowledge of material properties This knowledge will help you understand why various metals will react differently during the welding process Shown below is a table of properties of some common metals These metals have been arranged by melting temperature for convenience Each of the properties listed below will have an effect of the weldability of the metals Palladium
102. xidize readily at elevated temperatures and voltages The charts show Ti and Nb painting with electricity showing the voltage at which the color will appear However similar colors will appear due to heat if welding without sufficient shield gas These colors during welding need to be avoided Picture courtesy of Reactive Metals How to avoid oxide and nitride formation these will work for other metals as well In many situations this is not an issue because the argon Ar coming from the welding stylus completely covers the molten weld pool However in some situations this is not the case For example welding on a thin material the back of the material is unshielded from oxygen and the exposed metal will react with oxygen Using the following can help reduce oxide formation on the back of the work piece 1 Argon flood on both sides of the work piece during the welding process This is the best method but can use a lot of gas and requires additional setup 2 Solder flux A thick layer of solder flux can help reduce oxide formation Place the flux on the back side of the work piece The flux should be as viscous and thick as possible Some fluxes may work better than others After saying all of the above it should be noted that titanium is very simple to weld With proper gas Shielding the weld looks bright and clean Titanium to titanium welds are simple to perform and are strong Titanium welded to other metals can have a variety of
103. y However hot cracking is a possibility with this material To help avoid any cracking it is helpful to weld using an alloy that will produce a small amount of ferritic crystal structure in the weld joint The addition of the ferritic crystal structure will help suppress cracking For example when welding 304 stainless a 508 stainless fill wire can be used Not all situations will require crack Suppression techniques Smaller parts like those typically welded using the Orion do not require these procedures 201 202 205 216 301 502 303 504 505 508 309 510 512 514 316 317 521 529 350 332 547 548 584 585 stainless steels Martensitic stainless steels 410 for example have a high carbon content This high carbon content increases the risk of cracking To decrease the risk of cracking it may be helpful to increase the work piece temperature to between 200 300 deg C Often material thinner than mm can be welded successfully without heat treatment provided that pure argon is used during the welding process 403 410 414 416 418 420 422 431 440 501 502 503 504 stainless steels Low Carbon Steels Mild Steel Low carbon steels typically weld easily with no major cautions Please be advised that low carbon steel will rust and will often come with a coating of zinc The zinc coating will cause the metal to appear more white or lustrous than typical steel As discussed above welding on zinc will cause many issues

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