Sunday, September 16, 2012

PAGE 2: First weld

I put all the boards and circuits together this weekend and made a couple of test welds. The capacitor I used  is the biggest of 7 capacitors  and the capacitance is 35 % lower than it should be.  I welded a couple of small washers together and there were problems from the start. At first I could not get a plasma flame going and after adjusting the argon gas pressure lower I started seeing results. Another problem was that the capacitor was not discharging completely and it means that the plasma flame was dieing half way through the weld. The total energy roughly worked out was about 50Ws and with only half the capacitor discharging was more in the 25Ws range. This welder is going to be 250Ws and after I get all the little growing pains shorted out, It just might live up to its full potential.
 The following two photos was taken with my microscope of both sides of the washers :

 Three welds on this side


Two welds on this side


It doesn't look like much but it is a start.

SUCCESS
The welder needed to be tweaked and after receiving some parts from Digikey today I managed to adjust the precise pulse timing for this welder.I welded two screws together with the weld energy set to 50Ws. The welds are very shiny, clean and strong.




Two 9mm casings (Brass) welded together







23 comments:

  1. Looks promising :-)
    What next are You planing?

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  2. I hope my small donation is welcome.
    jmher@ono.com

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    1. Yes your donation is very welcome Thank You and thank you to everyone that gave me donations!!!

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  3. How is going construction?
    Movies suggest that You're doing great.

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    1. Peter I am experimenting with the start circuit. I'm looking into adding a high voltage plasma start to the circuit. I do not like working with High voltages and are very afraid that I might kill myself :)) I am going to switch the High voltage circuit at 25khz at a current below 1ma which should make it skin effect safe. Anyone with some knowledge that can help will be greatly appreciated.

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  4. Have you got scheme for stylus?

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  5. Hi Fritz,if you want to use ABI welder concept(high voltage arc/the electrode not in contact with the welding object) you lose control.The arc will go to the closest to the electrode spot.Imagine that you want to weld in the bottom of narrow channel.The arc will go to the side of the channel.This is working for big TIG welders,but not for micro welding where you need much more accuracy.
    I can't wait to build your pulse arc welder.

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  6. Chris, yes it makes sense. My plan is to make the High voltage selectable. Three modes 1:lift start 2:lift start with high voltage assist 3: Just high voltage start.

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  7. Hi Fritz , do you have drawings from the stylus so i could start making that part already ,, of cours i pay no problem :-)
    grtz
    rik the Belgian

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  8. Rik, I have a drawing but the stylus is just a prototype and I am going to make some changes to it. I want to make the distance that the electrode move better adjustable and the front end thinner to save argon. I will make the drawing available when I done.

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  9. Hi Fritz , all , thanks for the info
    Wish you and family good health and succes in 2013
    Grtz
    rik

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  10. Nello everyone any news?
    I hope it's still in progres
    grtz
    rik

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    1. hello to all,this is such a wonderful project.Does anybody tried to do the same?

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  11. Hello to all, Please see the attached YouTube video link which is showing what I am looking for. It is not a sparkling or discharge spot welding typical machine but just a two electrodes type of machine that just heat up the two working pieces to be joined until its temperature will turn them to an incandecent red color, without melting them at all, but just to get enough temperature so the adding soldering will melt and easily run between the working pieces. Anybody who can help out on this, I wil appreciate very much. In summary I would like to get a DIY material information to solve. It is very important that the maximum right temperature can be keep it constant for a few seconds, so I can have enough time to add the soldering to be melt. The flux must be applied before apply the current through the working pieces, in other words, before the heat. http://www.youtube.com/watch?v=0Z3qW--p2uA

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    1. Search for a DIY Spot Welder in Youtube - Plenty of Microwave transformer spot welders there.

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    2. Hi , this is a completely different welding methode surch PUK welding , see it like a micro tig welder
      I don't know why Fritz stopt it was almoust don
      Grtz
      rik

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  12. best wishes of prosperity for the new year 2015. And that brings us new information about the sodador we expect

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  13. Love this concept! As a hobbyist and a Ham radio operator (KC9UVB) I can see huge potentials for this if it is affordable even in kit form.

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  15. Is it possible to buy Pulse arc welder from you? email wrota@wp.pl

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  16. Will this welder be too robust for building battery packs?

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