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Dynasty 350 Cuts Anodized Aluminum TIG Welding Time by 50%
- Welds completed in just one welding pass instead of two
- Dynasty TIG arc breaks through anodized coating and lowers heat input
- New technology is more operator friendly, provides more puddle control
- Estimated payback time of less than seven months
Customer Testimonial
“I've used just about every Miller machine over the last 30 years, and the Dynasty 350 is the best machine I've ever used.”
— Bruce Saad, fabrication manager, Birdsall Marine Design
Application
TIG welding of aluminum T-tops, leaning posts, towers, deck towers, rod holders, back rest arms and other different anodized aluminum components for marine applications.
Key Business Issue
- Improving throughput without sacrificing weld quality or increasing reject rates.
Challenge
- Overcoming the issues presented by the anodized coating, which melts at a much higher temperature than the base metal. Such a difference tends to increase incidences of burn-through, warping or poor bead appearance.
Previous System & Process
- Conventional AC/DC TIG welding power sources dating back 20+ years and older inverter AC TIG technology.
New Solution
- The Dynasty 350 DX AC/DC TIG inverter with advanced squarewave TIG technology, four different AC waveforms and independent current control.
- The four waveforms help meet specific requirements or operator preferences: 1) an advanced squarewave, which gives fast transitions for a responsive, dynamic and focused arc for better directional control, 2) a soft squarewave, which provides a smoother, softer arc with a more fluid puddle than the squarewave, 3) a sine wave, for welders that prefer a quiet, traditional arc with good wetting and 4) a triangular wave, which reduces heat input (good for thin aluminum) and may improve travel speed.
Results
- New technology improves welding results. A soft squarewave with an AC balance of 70 percent and frequency of 200 Hz works best for Birdsall Marine's work. "I get a tighter, crisper weld [that] cuts through the anodization better and eliminates the need for backing into the weld."
—Bruce Saad, fabrication manager, Birdsall Marine Design - Fifty percent production increase by eliminating one welding pass. "With the Dynasty 350, I can get the job done faster. That means the part goes to the riggers quicker and the parts fit better. The riggers can just take the parts and put them right on the boat without needing to perform adjustments."
— Bruce Saad, fabrication manager, Birdsall Marine Design - Fast equipment payback. Cutting welding time in half cuts total production time by one-third. For a TIG welder working eight hours a day and earning $20 to $25 an hour, the increased productivity results in a weekly savings of $262 to $330, enough to pay for a Dynasty 350 in less than seven months.
- Easier operator training. "We've found that the Dynasty 350 makes it much easier to take a guy that doesn't know how to weld anodized aluminum have him achieve a better looking weld. Finding a trained welder is an ongoing challenge in today's market. A machine like the Dynasty 350 allows us to find someone with a good work ethic, positive attitude and willingness to learn and teach him how to weld."
— Bobby Birdsall, Jr., company vice president, Birdsall Marine Design
