Orion mPulse 30 Manual
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Orion mPulse 30 Manual

Pulse arc welding workbook
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Introduction

Thank you for choosing Orion and congratulations on your purchase!
You are now the proud owner of an Orion system. Please read and follow all safety precautions and before proceeding with
setup.
Sunstone Engineering is the parent company of Orion Welders. At Sunstone & Orion we are committed to producing quality
products and ensuring complete owner satisfaction. If you require assistance after reading this manual please contact us
with the information provided below.
Go to -
http://orionwelders.com/resources/

Table of Contents

Orion Welders, a Subsidiary of
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Email: sales@orionwelders.com
Voice: 801-658-0015
Fax: 866-701-1209
for additional product specific resources.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1: Pulse Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2: Resistance Welding (Tack Mode) . . . . . . . . . . . . . . . . . . .
Chapter 3: Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4: Techniques, Tips, & Tricks . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5: Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 6: FAQ / Troubleshooting / Glossary . . . . . . . . . . . . . . . . .
Chapter 7: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Orion Pulse Arc Welding Workbook
Payson, UT 84651
OrionWelders.com
Orion Welders
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Summary of Contents for Orion ORION mPulse 30

  • Page 1: Table Of Contents

    Introduction Thank you for choosing Orion and congratulations on your purchase! You are now the proud owner of an Orion system. Please read and follow all safety precautions and before proceeding with setup. Sunstone Engineering is the parent company of Orion Welders. At Sunstone & Orion we are committed to producing quality products and ensuring complete owner satisfaction.

  • Page 2: Warranty Information

    10% restocking fee will apply to all returns. A 30% restocking fee will apply to all 3rd party products. Additionally, all 3rd party products must be insured when sent back to Orion at the buyers expense. In some cases, a merchant fee may apply.
  • Page 3 Touching live electrical parts can cause fatal shocks or severe burns. The input power circuit and the internal circuits of the Orion welder are live when the power switch is turned on. Additionally the internal capacitors remain charged for a period of time after the Orion is turned off and/or power is disconnected.
  • Page 4 SAFETY PRECAUTIONS FOR FUMES AND GASES Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. The Orion produces minimal fumes and gases when compared to large-scale arc welders. Though not required, some form of ventilation is recommended.

  • Page 5: Chapter 1: Pulse Arc Welding

    By increasing the energy output in Tack Mode it can also be used as a permanent fusion welder (resistance welder, spot welder). In its Pulse Arc Mode (Arc), the Orion can be used to perform permanent welds, add metal, and do a variety of other time-saving metal fusing applications.
  • Page 6 (specifically electrons) to add energy to the workpiece and melt the metal in a spot. Although laser welding devices are good welding tools, the Orion can perform many of the same functions of a laser and in some cases can even perform actions that lasers cannot.
  • Page 7 The two weld parameters (energy and length) can be understood with the following analogies. Consider your Orion welder to be like a water tower. The amount of water in the tower is like the energy stored in the welder. Firing the welder is like opening a large valve to let water out.

  • Page 8: Chapter 2: Resistance Welding (Tack Mode)

    Chapter 2: Resistance Welding (Tack Mode) This section applies to Orion welders that have the Tack welding feature. If you do not have the Tack feature this is still good welding knowledge to have. What is Resistance Welding (Tack Welding)? Resistance welding, often called tack or fusion welding , takes place using a very different process from that of Pulse Arc (TIG) welding.
  • Page 9 It also helps eliminate the need for complicated binding or clamping of parts before permanent welding or soldering. Because the heart of the Orion is an industrial capacitive resistance welder, everything from one time custom pieces to production welding is possible.
  • Page 10 This may happen when only a light tack weld is needed before pulse arc welding. CABLES FOR RESISTANCE WELDING A true resistance welding hand piece should transfer as much energy to the weld location as possible. The Orion is capable of transferring over 3000 amperes to the weld location.

  • Page 11: Chapter 3: Tungsten Electrodes

    0.5mm electrode. In the ‘HANDS ON’ examples above, more energy was transferred from the Orion into the workpiece for the same setting using the 1mm electrode. For very small parts, using the small electrode is sufficient. This option reduces the peak weld current versus using the large electrode and can also allow for a smaller weld spot.
  • Page 12 Orion Pulse Arc Welding Workbook MELTING TEMPERATURES OF SELECTED METALS: Material Melting Point (deg C) The table shows a variety of metals and their corresponding melting Zinc temperatures. Note that tungsten has a significantly higher melting Aluminum temperature than the other metals. This is an important attribute of Silver tungsten that aids the welding process.
  • Page 13 There are several considerations that can be helpful when selecting electrode shape (e.g. sharp, blunt, or a sharp tip with a small flatted end). The most helpful of these is to spend time on your Orion and get to know how it responds to different electrode shapes and metals.
  • Page 14 Orion Pulse Arc Welding Workbook Left Image: A blunt electrode tip can be helpful when making more powerful welds in silver to help overcome silver’s high liquid mobility by “un-focusing” the plasma over the entire flattened area. Right Image: A sharp electrode will help place the weld into tight geometries, a blunt electrode can spread the energy and prevent weld formation.

  • Page 15: Chapter 4: Techniques, Tips, & Tricks

    Typically material is added with a small “laser” wire, one weld at a time. However, there are many additional options to add material. One for example is, instead of using small “laser wire” the Orion can weld a much larger wire or rod to fill in more metal in a single weld.
  • Page 16 Orion Pulse Arc Welding Workbook There are several methods to aid in the addition of fill wire, which are mentioned below. The placement of the electrode relative to the wire is very important and will influence how the material behaves during the addition process.
  • Page 17 A final scenario can occur when the electrode is placed on top of large wire being welded to a base material at a high weld energy setting. In this case the plasma can push the wire metal down to the base metal surface but there may be no penetration into the base material.
  • Page 18 Orion Pulse Arc Welding Workbook Placing the weld electrode on the edge of a bump will smooth away the bump as surface tension spreads the metal over the molten base material. HANDS ON: Use your electrode with several different materials to push metal around, or to use surface tension to smooth a metal mound out.
  • Page 19 If only one weld spot is made, cracking will typically not occur unless the weld joint is stressed by hammering etc. This means that welding over porosity in a Pd piece can be accomplished with the Orion (or laser) to help clean up a ring during the finishing process.

  • Page 20: Chapter 5: Metals

    Remember that finger oils, etc. will cause blackening around the weld spot. This blackening can easily be wiped away with a clean rag or taken off with a glass brush (one is included with your Orion system), sand blaster or steam cleaner.
  • Page 21 of some common metals. These metals have been arranged by melting temperature for convenience. Each of the properties listed below will have an effect of the weldability of the metals. Melting Point 1064 1083 1200 1300 1450 1500 1660 1772 2468 3410 Boiling Point...
  • Page 22 Orion Pulse Arc Welding Workbook This measure of weldability comes from properties of the metal like melting point, thermal conductivity, density etc., and is intended as a relative reference between the different metals. It can be thought of as how much spot size and penetration a given amount of weld energy will have on the metal.
  • Page 23 Using the following can help reduce oxide formation on the back of the workpiece: 1. Argon flood on both sides of the workpiece during the welding process. This is the best method but can use a lot of gas and requires additional setup. 2.
  • Page 24 This means that welding over porosity in a (Pd) piece can be accomplished with the Orion to help clean up the metal during the finishing process.
  • Page 25 When welding silver it is important to understand the concentration of your weld energy relative to the size of the silver being welded. For very small welds, a sharp electrode poses no problem. This means that in the Orion’s arc mode, silver will typically behave well even with a concentrated, focused beam of energy (i.e.
  • Page 26 For best results select a low carbon steel without a zinc coating. Make sure the steel is free from other contaminates such as rust or oil. Remember that if using the Orion to produce welds in very thick pieces the weld joint may need to be prepared as discussed previously.

  • Page 27: Chapter 6: Faq / Troubleshooting / Glossary

    I WANT TO GET THE MOST POWER POSSIBLE OUT OF THE ORION. WHAT CAN I DO? The Orion is designed to deliver a tremendous amount of energy in Tack Mode. You can use up to 10AWG cabling to deliver more energy to the work area. NOTE: Using larger cabling (ex. 8 AWG or larger) may damage the welder and will void your warranty.
  • Page 28 CAN I BUILD-UP OR ADD MATERIAL TO A WELD LOCATION? Yes, the Orion is very versatile. In Pulse Arc Mode, filler wire can be used to add metal to a weld location. In Tack Mode, filler wire or sheet filler can be permanently affixed to a location. Wire sizes up to and greater than 1mm in diameter can be added.
  • Page 29 X, Y and V require filler material and may require successive layers of material to be added to the joint. For joints were the Orion can penetrate approximately ½ to ¾ of the way through the material an “I”...
  • Page 30 • Decrease the length of exposed electrode to bring the workpiece closer to the stylus nozzle. • Verify that there are no gas leaks at the gas receiver on the rear panel of the Orion and also at the stylus connector on the front panel. Note: Gas cannot leak from the stylus connector except during a weld.

  • Page 31: Chapter 7: Cleaning

    Once contact is made the weld sequence will initiate automatically. When the trigger is set to “Foot Pedal” the Orion will not initiate the weld sequence until the foot pedal is depressed and there is contact between the tungsten electrode and the workpiece.
  • Page 32 Be sure to only perform cleaning on the Orion when it is switched off and unplugged. Never use abrasive cleaning implements on any part of the Orion. Do not blow compressed air into any part of the Orion as this may damage the internal components. Never use any chemicals besides mild detergents on any part of the Orion.

This manual is also suitable for:

Welder orion 150sOrion 100cTw150sTw1mTw100m

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