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Best Micro TIG and Pulse Arc Welders
Our Best-Selling Micro TIG / Pulse Arc Welder Products
Before we get started with our most popular products, you need to understand the concept behind these first. Get to know what TIG welding and pulse arc welding are, as well as what they’re used for, by reading on.
What is TIG welding?
Gas tungsten arc welding is also known as tungsten inert gas welding. It is an arc welding process that uses a dense, non-consumable tungsten electrode to produce a weld. As its name suggests, this process uses an inert gas, typically argon, to protect and cool the weld puddle.
What is TIG welding used for?
Now that we know what TIG welding is, let’s find out what we use it for. TIG welding offers higher precision and control than most welding processes and is used in a variety of industries where a certain level of control is necessary, such as:
1. Aerospace – Aircraft and spacecraft components are typically constructed using TIG welding. These include commercial planes that people fly on as well as the sophisticated International Space Station and the rugged space shuttles that the National Aeronautics and Aerospace Administration use. All of these have benefitted from the strength and precision of TIG welding techniques.
2. Automotive – Safety and Security are the primary concerns in the auto industry. Again, strength and precision that the TIG welding process offers in invaluable for carmakers around the world. In motorsports, TIG welding once again is used for fabrication of race cars – by keeping things light and durable, being able to withstand crashes and keep drivers safe.
3. Repairs – Smaller businesses that are staffed by skilled welders often use this process. With TIG welders, they fix smaller, more complex workpieces such as a child’s toy, a piece of furniture, or household metalwork.
4. Art and Jewelry – The level of control and precision that TIG welding offers is unparalleled compared to other welding processes. For this reason, TIG welding is used for crafting complex objects of varying sizes, shapes, and metals to produce great works of art. In jewelry, it is often used for crafting and repairing metals such as those found in rings, necklaces, bracelets, and so on.
What is a Pulse Arc Welder?
So how is a pulse arc welder connected to a TIG welder? Simple. Pulse arc welders are micro TIG welders.
A pulse arc welder makes use of a non-contact method involving electrical energy to produce high-quality welds. You don’t need to apply force. All you need is a non-consumable tungsten electrode, which some pulse arc welders usually feature as a sharpened tip. With the pulse arc welder, an arc is generated between the tungsten electrode and workpiece, as the name suggests. The generated arc creates a high-temperature plasma that can melt metal.
Pulse arc welding is a high precision, TIG type, plasma discharge, welding process. Sunstone Engineering’s pulse arc welders are capable of extremely precise energy discharge. Each plasma discharge creates small laser-like welds. Pulse arc welding, like laser welding, is typically an edge welding process. The weld spot is created as the tungsten electrode is withdrawn from the weld surface and the melting process starts from the outside and penetrates inwardly. Like traditional TIG welding, pulse arc welding can be used to add additional material, like fill wire. This is useful in many applications where additional material is needed for additional strength. Additionally, pulse arc welding can also be used to melt and fuse to parts together without the need for fill wire. Unlike traditional large-scale TIG welding, pulse arc welding can create welds that bridge gaps between parts. This is due in part to the high peak weld currents and liquid metal dynamics that occur during the short welding process.
An additional advantage of pulse arc welding is the extremely low energy input to create the weld. This welding property means that even heat sensitive parts or pieces can be welded with very low chance of thermal damage. Pulse arc welding also helps reduce any distortion that would typically happen during other welding processes.
Pulse arc welding is a versatile and economical welding process for a variety of applications. Sunstone is happy to help you weld your application or to help you bring pulse arc welding in-house to your facility. Contact us to see which solution will be the best for your business.
How do you use a Pulse Arc Welder?
Pulse arc welders are great to use on copper, platinum, titanium, stainless steel, silver, and gold. It makes welding a lot more efficient, clean, and controllable, especially when it comes to tasks like repairing castings and sizing rings. You can even use a pulse arc welder on more complicated jobs, like welding dissimilar metals together.
Because of how solid and robust the welds created with pulse arc welders are, the following industries utilize it for their welding needs:
- Mold and Die
- Research and development
Get a more detailed insight on the pulse arc welding process by watching this video.
Pulse arc welders are a top-rated product of ours, but the following are ones that our clients frequently buy.
1. The Orion mPulse 30 Pulse Arc Welding System
The Orion mPulse 30 Pulse Arc Welding System is particularly suited for light repair work and jewelry. With a 30ws power potential, this thermocouple welder can be used by almost anyone and has the power to tackle all sorts of jobs. It’s the perfect tool for hobbyists and beginners with its compact size and easy-to-use touchscreen user interface.
Power settings range from 3.0ws to 30ws, in 1ws increments, making a total of 27 different power settings to choose from. Spot weld sizes vary from 1mm to 1.5mm depending on the material of the workpiece and power setting that you selected.
The Orion mPulse 30 is the ideal tool for working with gold, silver, and many other metals used in jewelry crafting and repair. Other fragile items such as metal glass frames can now be fixed using the Orion mPulse 30. This makes it a great addition to any eyeglass repair shop. The design is such that it allows the operator to use the mPulse 30 using both hands, for more precision. The built-in touchscreen LCD user interface also makes it easy to select the right power setting on the fly, without having to fiddle with primitive knobs or buttons. Everything you need to know is displayed onscreen, so there is absolutely no guesswork involved.
Overall, the Orion mPulse 30 Pulse Arc Welding System is an excellent tool for light repair duties and crafting smaller items such as jewelry. A complete product worth your money.
2. The Orion 150s Pulse Arc Welding System
A micro welder’s dream, the Orion 150s Pulse Arc Welding System is a versatile tool. You can see it in laboratories, universities, and research and development institutions around the world. The Orion 150s is a combination of a pulse arc welder and a discharge resistance welder in one great package. This allows the Orion 150s for any skilled welder to perform a nearly infinite number of creative possibilities.
The Orion 150s has a considerable power potential clocked at 150 joules of pulse arc weld energy. Despite the immense power the Orion 150s offers, it is also perfect for low-power work as well. It can yield as low as 1 joule of energy and can be raised for as little as 0.2 joules per increment, up to 150 joules for a total of 1000 power settings. These settings are an unparalleled level of control not found in other competitors.
Like all Orion products, the 150s sports a very detailed touchscreen LCD user interface. The screen displays everything you need from power settings, type of material, and even dual language settings for both English and Spanish.
Other unique features of the Orion 150s are the weld ignition and weld speed mode technologies that are unique to every Orion product. By monitoring and lifting the electrode before releasing the weld, the life of the electrode will be prolonged. This also safeguards the electrode from misfires and sticking to the work material. Weld speed mode allows you to use single (1 weld per second) or rapid fire (5 welds per second). This will enable you to work at the pace you want.
Overall, the Orion 150s Pulse Arc Welding System is a remarkable tool for nearly every type of micro welding work and is a must-have for any business. An investment worth every penny.
3. The Orion 100c Pulse-Arc/Micro-TIG Welder
The 2 in 1 combo of the Orion 100c makes it a reliable tool for any metalsmith to handle virtually any type of application you may encounter. The Orion 100c is a combination of a pulse arc welder and a discharge resistance welder in one great package. This allows the Orion 100c for any skilled welder to perform a nearly infinite number of creative possibilities.
Like the Orion 150s, the Orion 100c is also capable of producing up to 100 joules of pulse arc weld energy with a high level of control.
The full touchscreen LCD user interface allows the operator complete control of the Orion 100c, with everything you need in the display. This makes the Orion 100c very intuitive and easy to use as you are not being slowed down by primitive knobs or buttons compared to other products in the market.
The Orion 100c also features weld ignition technology that prolongs electrode life by lifting the electrode before making contact with the workpiece and releasing the weld. This protects the 100c from misfires and keeps the electrode from sticking to your workpiece.
For power and precision, nothing comes close — a truly great product.
- A very small heat affected zone during weld
- Ability to easily position welds exactly where you need them
- The versatility of welding of very small, thin, and delicate metal parts
- A wide range of metals that can be welded
- Simple and easy to use touch screen interface
- High level of precision with microscope
- Consistency and repeatability
- A simplified repair process by eliminating soldering
- Quality welds
- Very low maintenance on machine
- Small compact size designed to fit on and around any work bench.
The most powerful Sunstone pulse arc welder delivers 250 joules of energy with precision and accuracy.
When your production needs require more welding power, turn to Sunstone’s Omega PA250i Welding System, where maximum digital energy control is combined with maximum energy availability. With 250 joules of power your welding capabilities are greatly increased. Available in three different configurations, the PA250i fits any production floor: In your shop, in an automated production line, or anywhere in between.