Pulsed MIG is a beginner-friendly welding process that reduces burn through rate and produces better quality weld.
It is specially invented for beginners to weld aluminum, stainless steel, nickel, and non-ferrous like thin materials.
In this process, you won't need a degree to be a hobby welder if you had practiced well.
There are only a few welders which are responsibly capable of pulse MIG welding.
No talk further, let's dive right in...
What is pulse MIG welding?
Pulse MIG welding is an arc welding procedure in which the wire electrode not ever touches the weld puddle.
In Pulse MIG welding,
The fusing power source quickly and automatically switches among a high peak current (confirming good fusion) plus a low background current (drops heat input and decreases distortion).
You can easily recognize a quality machine if you learn the basics of pulse MIG welding.
5 Best pulse MIG welders
1. HTP Pro Pulse 220 MIG Welder - TOP PICK
The pulse pro is not planned for factories or large construction projects needing constant up-time.
It is a great choice for modest repair jobs plus numerous small scale construction projects.
It delivers the great output with an input voltage of 208 - 240V 1PH, Max 35 Amps.
Attractive Key Features:
The Pro Pulse proffers ST-arc, a function that reads welding factors back to the welding mechanism live, checking the arc length and keeping the arc length continuous, while permitting the stick-out to vary.
Lightweight design creates the Pro Pulse as the perfect MIG for using both in the workshop and on the job site.
The multi-process nature of the machine offers closely endless options when welding.
The output range is from 20 to 200 amps, on full burn, the duty cycle is restricted to 20 percent.
The uptime plus power output is not that remarkable.
Still, there aren't the numerous boxes priced similarly that are advertised for 200 amp operation which will offer additional features that this MIG machine is proficient of.
The synergic function works in both pulsed and non-pulsed settings.
Factor selection on pulsed process welders could be complex.
Nonetheless, synergic technology makes factor selection more instinctive and automatic.
A classy choice for small project works with lots of functions and affordability.
Synergic technology makes it even better. It helps to put up all the efforts of different parameters to get the best possible output.
2. Millermatic 255 Pulsed MIG Welder - RUNNER UP
The Millermatic 255 MIG welder is a comprehensive 250 amp welding package that derives standard through pulsed MIG welding ability.
The design of the inverter means the Millermatic 255 is less than half the weight of its prevalent predecessor, the Millermatic 252.
You can moreover set your voltage and wire feed speed manually, for a custom welding arc.
Attractive Key features:
Easy-to-understand interfaces through 7-inch color LCD confirm appropriate machine setup and factor selection, dropping setup time, and growing weld time as well.
Quick-access backlit Auto-Set and Pulse buttons above the LCD illumine when activated.
An Auto-Set Elite proffer predefined weld settings to upsurge ease of use and confirms that the job is done correctly for workers of all skill levels.
It is accessible for MIG and pulsed MIG procedures with the capability to fine-tune your settings.
Set weld parameters through selecting wire and gas kind, wire diameter, and material thickness.
The machine is way more productive compared to the competitors.
They have been more convenient by removing the need to set the factors manually.
Moreover, they used to deliver reliable and compatible quality by welders of all skill levels through using pre-qualified weld settings.
What is the fundamental parameter that you would notice of power tools at a very first glance?
It must be – How powerful they are.
Here you go!
It is a superior welder with a great machine set up which has good potential for productivity.
This welder can be your most favorite without any doubt.
3. Everlast Power MTS 251Si Pulse MIG Welder - Budget-Friendly
The Everlast Power MTS 251 SI is a flexible welding machine that offers unbelievable abilities with a multi-process mechanism.
Also, it is one of the cheapest pulse MIG welder with high quality performance.
Attractive Key Features:
Easy user control:
This dynamic welder derives with automated control which is appropriate for a beginner.
Everlast 251 includes all controls are grouped according to its function with an easy to understand format.
Furthermore, the hassle-free series makes this welder toward user-friendly and more convenient.
So, it is very compatible with the novice.
This stuff of Everlast family is a very compacted multi-process welder through pulse MIG/TIG features.
It is a digitally-organized 3-in-1 inverter welding mechanism capable of MIG, TIG, in addition to Stick welding.
The Everlast Power MTS 251 SI included so many features that make it a multi-purpose welder.
It includes Synergic MIG, Pulse MIG, as well as Pulse TIG also it has Stick welding, Standard DC MIG and TIG welding settings.
Double power input!
Everlast 251 has a standard double power input 110v/220v which makes it a home welder for DIY’ers and hobbyists.
If you are looking for one machine to rule in the workplace with a fair budget, the Everlast Power MTS 251Si is a perfect choice.
Considering the requirements, the manufacturer designed it with all adornment.
4. Topwell 250A Ture Pulse MIG Welder
This double pulse MIG welding mechanism by Topwell is the most useful one we had tested.
It offers four rollers for additional stability and it makes it more users friendly.
Moreover, the machine is decent for mild steel, stainless steel, as well as aluminum.
Attractive Key Features:
This model is appropriate for diverse wire ranges, from 0.8 to 1 mm.
It is furthermore good for 0.06 to 0.27 inches of aluminum plate.
This means that you could use this machine for 85% of all works connected to aluminum welding.
Excellent results with aluminum!
This machine might be the finest choice for aluminum welding as it does not create spatters, and you could get the stacked dime look.
Four rollers for additional stability...
This feature, in blend with the wire feeder system, confirms a steady wire speed, which is significant for quality output.
Synergic controls create operating this mechanism a piece of cake.
No matter you are a newbie or an expert, it will explode the best.
In conclusion, the main features of this MIG welder are pulsed plus double-pulsed mode, flexibility regarding kinds of materials it could be used for, and superiority while it derives to welding aluminum.
The collaboration of these three makes it an expert in the game of welding.
5. Lincoln Electric Power MIG 350 AMP MIG Welder - Multi-Purpose Uses
The Lincoln Electric Mig Welder is an entirely adjustable gas-free MIG welder.
The unit works on flux core, as well as is excellent for private uses.
This one is exceptionally adaptable and is free from any wire knots.
The cast aluminum body creates it widely firm and sturdy.
The welder is moveable, which makes it easier to carry to any place of work.
It works by a free speed control and has improved connectivity.
Attractive Key Features:
Lincoln Electric's Power MIG 350MP is the eventual choice for procedure versatility and arc performance, containing stick, TIG, MIG, and flux-cored abilities.
Advanced welding processes...
This multi-process wire feeder/welder moreover features advanced welding procedures, for example, Lincoln Electric's Pulsed MIG, Pulse-On-Pulse and Power Mode.
It makes the machine perfect for individuals intricate in light to heavy job shop construction and manufacturing, particularly involving aluminum application.
Robust output range!
This Power MIG model offers a robust output range from 5 to 350 amps for control thin DC TIG welding over industrial sheet metal and medium structural application.
The Power MIG 350MP is the single machine, outer the Power Wave family, toward feature Lincoln Electric's next weld procedures.
Waveform Control Technology:
The Waveform Control Technology conveys customized welding factors for every application through added welding waveforms for downloading straight to the machine for future applications.
Synergic control of voltage...
Synergic control of voltage through the wire feed speed permits users to set weld processes with only one control for painless.
Using Lincoln Electric's Chopper Technology, the Power MIG 350MP conveys high-quality welds through great arc control.
It delivers improved starts, low spatter levels, brilliant bead appearance, a wide functioning "sweet spot" and improved stainless steel with aluminum welding performance.
Considering the need for buying a pulsed MIG welder:
Buying a welder is always a tricky part.
You can’t just go and pick one from thousands.
The factors you should consider before buying a pulse MIG welder are given below:
Welders usually deal with a rough and robust opponent.
So, they should have that kind of caliber to stay strong.
You should look for strongly built welders that can fight for a long time.
Furthermore, they are quite expensive so before buying it you should make sure it won’t give up and will last for a longer time.
Otherwise, you have to spend money on a couple of times for no reason.
Accurate electric outlets installed:
The first thing you should look at the electric outlets.
There are different kinds of power sources available for different types of welders and works.
So, choosing the right power source is important as when you will have the perfect electric outlet installed only then the welder will run smoothly without any disruptions.
Convenient to use:
While you choose a pulse MIG welder to be sure it is easy to operate otherwise you have to suffer and regret later while using it.
Some of the welders are very complex using the method.
So, before you buy the welder you should check that its dial system is not too much complicated and its functions are also adjustable.
The more the welder is user-friendly the greater the outcome will be.
Have you paid heed to the duty cycle while picking up the welder?
If not, you might have a bad time with it.
To make a perfect weld, the welder should have enough strength in it.
If you intend to buy a welder for heavy usage then make sure the duty cycle is at least 60% which means it can run non-stop for 6 minutes.
Regular MIG vs PULSE MIG
The regular MIG welding can be easily explained as joining two materials via a wire electrode that is solid and constant, while the gas passes through the gun.
This is the older, classic MIG welding technique.
Pulsed MIG is a type of classic MIG welding.
What is the key difference?
As you probably assume, the current of the pulse MIG welding is - pulsed.
It originated from the need to control the transfer of metal when it comes to low current.
Pulse transfer is primarily a kind of spray.
The arc is open, but instead of the axially small droplet current, the machine electronics control the axial firing of each drop separately or of a couple of drops per unit of time.
The size and velocity of a drop are also controlled.
In addition, the electronics control the period of time after which the next drop of wire is separated from the wire.
We’re not through yet...
Some sources say that the electronic experts must set 64 control parameters.
That’s why this technology is not done manually for decades.
This means that each parameter is not set in a separate way.
Instead, the so-called "synergic pulse lines" were designed.
What does this actually mean?
The user simply informs the machine on the type of the gas chosen, as well as the wire material, the diameter and chooses the material thickness.
Then, the computer calculates all the parameters (the above-mentioned 64 different control features) and gives you the result.
It gets better!
Pulse is an outstanding method of welding of the non-ferrous metals and stainless steel.
Therefore, it is the very first choice among them all.
Every expert will tell you that this is a supreme method of welding.
Pulse welding uses gases that develop spray transfer. For steel, Argon + 18% CO2 is used.
Also, you can choose Argon + 8% CO2 is the best option.
For stainless steel, you should use Argon + 2.5% CO2.
For aluminum, pure argon is the best option.
Once again, we want to point out that spray and pulse are not possible with pure CO2 gas.
High-speed pulse is a another type of pulse MIG welding.
We have already said that electronics control the separation of the drop in the unit of time in the classic pulse MIG welding mode.
The high-speed pulse implies control of a few drops (e.g. 3 drops) in the unit of time.
Benefits of pulse MIG welding:
Benefits of pulse MIG welding include:
- Significantly less or no spatter (when compared to other types of welding).
- Welding at 50-150 A current is possible.
- Pulsing extends the 180-220 A spray operation.
- Pulsing is the perfect choice for thinner materials.
- Working at higher deposition rates is possible thanks to the pulse.
- Good even for jobs where spray transfer is not possible.
Pulse MIG welding settings:
Knowing how to adjust the speed of the wire and the voltage is of the utmost importance when working with pulse MIG welders.
Some machines will resolve these issues by themselves based on pre-determined settings.
However, it is good to know the basics.
In addition, you must know some transfer settings too.
There is a new standard on welding attestation, the ISO 9606-1.
It specifies the transfers in detail.
"Transfer" is the way to transfer a molten drop from the wire across the port into the molten metal of the object to be welded.
Why is this important?
It is important because this standard refers to the pulse MIG welding as a type of transfer spray.
Therefore, we strongly recommend you to refer to the ISO 9606-1 standard to learn more about the specific settings and procedures.
When it comes to the hot start feature setting, there are a few parameters you should pay attention to. Those are:
- The setting of the time period (duration)
- Percentage of how much the initial amplitude is higher than the one determined by the wire speed and overhang.
For example, you can choose the following setting, during the first second, the amplitude is 40% higher than the one resulting from the pre-set wire speed and overhang.
Why is this important? It is sometimes difficult to obtain an impermeable welding result.
Therefore, we choose the higher current than the pre-set one during the first 1-2 seconds.
Then, the amperage returns by itself to the pre-set value.
Pulse MIG welding has been used in industrialized production for about 20 years, breaking into the handheld marketplace no more than years ago; it can be used for numerous things.
But to achieve a fast better outcome welding the stainless steel and aluminum, you have to choose the compatible welder very cleverly.