Power Sources Constant Voltage Power Supply

Power sources can be:  Most commonly used.

 Transformers for AC.  Can be mechanised or automatic welding.
 Transformer-rectifiers for DC.  Self-regulating arc so simple WFS control.
 WFS controls current, power supply controls
Static characteristic can be: voltage.
 Constant Voltage (flat) – most popular.  DC limited to 1000A by severe arc blow.
 Constant Current (drooping) – used for high
current.

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Constant Current Power Wire

 Preferred >1000A.  Usually 2 to 6mm diameter.

 Can be mechanised or automatic welding.  Copper coated to avoid rusting.
 Not self-regulating arc so must have voltage-  25 or 30kg coils.
sensing WFS control.  Can be supplied in bulk 300 to 2000kg.
 More expensive.
 Voltage from WFS control, power source
controls current.
 Not for high-speed welding of thin steel.

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Fused Fluxes Bonded or Agglomerated Flux

 Original Unionmelt design – manganese,  Powdered minerals pelletised with silicate.

aluminium and calcium silicates.
 Non-hygroscopic, no need to bake.
 Good for recycling, composition doesn’t vary.
 Some can accept up to 2000A.
 Very limited alloying and property control.
 Cannot make basic fused flux.
 Baked to high temperature but hygroscopic.
 Flexible composition, can alloy, make basic.
 Can add de oxidants for good properties.
 Composition can vary as particle breakdown.
 Needs to be filtered when recycling.
 Can add Mn and Si flux.

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