WB-W400 New AC-MIG Welding Power Source

„Welbee W400“ ideal for precise control of heat input to the base, in combination with welding wire inlet.

The latest addition in OTC DAIHEN EUROPE GmbH product range for the AC/MIG process of is the new Welding Power Source, Welbee W400, which is responsible for optimal control of the energy input, the high shrinkage rate and the firing control. It replaces the previous model, DW300 +. While the arc is burning, the Welbee W400 can alternatively switch the welding processes to either AC pulse, DC pulse, AC wave-pulse MIG or DC wave-pulse, during the welding process.

– Improved welding support for thin plate aluminum via improved AC welding mode
– Synchro-MIG function allows for optimized welding of different plate thicknesses
– AC Pulse and Wave Pulse modes provide beautiful welds with reduced soot
– Standard Aluminum & Stainless Steel welding modes
– 80 kHz Digital Inverter
– Control the weld current via a torch switch
– Crater Fill Function prevents crater oxidation
– 3 phase primary (460 Volts)
– 100 job memory storage for semi-automatic use


Automation processes for the processing of aluminum alloys are regularly tested. Conventional welding methods frequently fail because of the fact that during the welding process, warping or inadequate gap bridging occurs. In recent years, OTC’s pulsed MIG AC welding process (abbreviated as AC/MIG) has been used to improve the quality of the arc welding process. Using the so-called wave-pulse function, the control of the welding current is precisely synchronized with the wire feed speed in the AC/MIG welding process, in order to optimally control the weld pool.

Synchronized with the wire feed speed in the AC/MIG welding process, in order to optimally control the weld pool.




What is the difference from conventional methods? In DC pulse welding, a drop from the wire end is released synchronously with the pulse, which transitions into the weld pool without short-circuit. This form of material transfer is also called "one-pulse" or "one-drop" transition.

The low penetration depth at a high EN2 rate is particularly beneficial for the processing of thin sheets. For example, aluminum sheets with a thickness of 0.5 mm can be welded at a speed of 100 cm/min. The warping usually presents a further quality problem when welding thin sheets, which is largely prevented by the AC/MIG process. The temperature and the applied energy decrease with increasing EN rate. For example, the maximum temperature in 8 mm depth at an EN rate of 40% is 140K lower than that in the DC pulse method.

The AC/MIG alternating current welding process of OTCDAIHEN is different: a droplet is released by electromagnetic impingement forces (pinch effect) of the pulse peak, which is in the EP1 phase. This is referred to as the "one-cycle, one-drop transition" - the separation from the wire is short-circuits-free, in synchronization with the AC frequency and corresponding transmission into the weld pool. As the EN2 rate increases, the energy flows into the wire, resulting in said droplet, which can increase in the EP1, phase to up to 2.5 times the diameter of the wire. As a result, at the same wire transport rate, the welding current during the AC/MIG welding process is 30-40% below the welding current of the DC pulse welding process.

Since these effects can be influenced by the change in the EN2 rate, it is possible to control the heat input into the workpiece. This is the essential prerequisite for a low penetration depth.

The smaller deformation in thin sheets is due in all cases to the increasing EN2 rate. The reduced energy input not only reduces the melting of the cover plate, but also prevents an enlargement of the gap during the welding process. In all cases, the AC / MIG process provides a perfect welding seam, which is in no way inferior to the weld seam scaling during TIG welding.