Synergic Control in MIG Welding: A Comprehensive Guide

Introduction: What Is Synergic Control?

Synergic control in a MIG welding machine refers to an advanced system that automatically adjusts welding parameters according to the wire type, diameter, and shielding gas. The user only has to select either the amperage, wire feed speed, or plate thickness with a single knob. The machine then automatically sets the welding voltage and wire feed speed to optimal levels, based on a pre-established “Synergic Curve” stored in the machine’s memory.

The Essence of Synergic Curve

A Synergic Curve is a graphical representation that plots the optimal and most efficient delivery of power for a specific welding task. The term “synergy” refers to the combined action of all involved parameters. Each synergic curve is unique for a specific combination of machine, wire type, and shielding gas. Manufacturers like LORCH have incorporated a range of digital control software programs in their MicorMIG welding machines, to facilitate optimal welding settings.

Digital Control and Software Programs

Advancements in digital control software have made it possible to develop specific programs aimed at achieving the best synergic curve for the selected combination of machine, wire, and gas. This ensures that as you adjust one setting, the machine automatically tweaks the other settings to maintain optimal welding conditions.

Practical Implications of Synergic Control

For Welders

In practical terms, a welder using a synergic controlled MIG machine only needs to set the wire diameter and shielding gas once for any given welding operation. After that, they simply adjust one control for the material thickness or according to a Welding Procedure Specification (WPS).

For Welding Supervisors

For those in supervisory roles, synergic control makes it significantly easier to set up machines for testing against weld specifications. Once set up, these configurations can be easily replicated across multiple machines of the same type.

Synergic MIG/MAG Welding: A Special Variant

Synergic MIG/MAG (GMAW) welding is an advanced form of pulsed MIG/MAG welding. It provides unit current pulses to detach identical molten droplets of predetermined volume from the electrode wire. These are programmed into the machine and are unique to the material and wire diameter being used.

Essential Characteristics

Automatic Pulse Parameters: The machine automatically selects pulse parameters.
Pulse Frequency/Duration: Directly related to wire feed rate.
Electronic Control: Ensures uniform penetration and a consistent weld bead profile.

Limitations and Adaptability

Not all MIG welding machines with synergic functionality offer the same level of flexibility. Some machines offer limited choices in terms of materials and gases, as well as wire diameters for each material type.

For Novice Welders

For beginners, the synergic functionality can yield excellent welding results after just a few practice runs.

For Experienced Welders

For seasoned professionals, synergic control can save substantial amounts of time, especially if they frequently switch between materials and thicknesses.

Customizable Settings and Material Compatibility

Here’s a general list of material, gas, and wire diameter settings commonly available:

Steel with CO2: 0.6mm-0.8mm-1.0mm or 1.2mm
Steel with CO2 + Argon: 0.6mm-0.8mm-1.0mm or 1.2mm
Stainless with CO2 + Argon: 0.6mm-0.8mm-1.0mm or 1.2mm
Aluminum with Argon: 0.8mm-1.0mm or 1.2mm
Flux-Cored Wire without Gas: 0.8mm-1.0mm or 1.2mm

Note: Machines with less than 250 amperes might not support wire of 1.2mm for some materials. Likewise, machines with less than 120 amperes may not work effectively with 1.0mm wire.

Conclusion

Synergic control offers a sophisticated yet user-friendly system for MIG welding. It caters to both novice and expert welders by providing an optimal balance of automation and customization. Whether you’re a welder or a welding supervisor, understanding and utilizing synergic control can lead to more efficient and higher-quality welding. This is one of the best MIG welding machine on the market with precision Synergic Control.

Feel free to reach out for any further clarifications or technical queries. Happy welding!

Benoit Fortin
Founder & Owner
BMOD INNOVATION INC.
Quebec City, Canada