Course: Manufacturing Science

Lecture No.: 15
Arc Welding Power Source
Keywords: Welding power source, classification, basic characteristics of power
source, OCV, power factor, constant current and constant voltage power source,
self regulating arc, operating point

9.1 Introduction
One of the main requirements of a welding power source is to deliver controllable
current at a voltage desired according to the demands of the welding process.
Each welding process has distinct features from other processes in the form of
process controls required. Therefore, arc welding power sources play very
important role in successful welding. The conventional welding power sources
are:
Power Source Supply
(i) Welding Transformer AC
(ii) Welding Rectifier DC
(iii) Welding Generators AC/DC
(IV) Inverter type welding power source DC

Welding transformers, rectifiers and DC generators are used in shops while

engine coupled DC and AC generators are used at site where domestic line
supply is not available. Rectifiers and transformers are usually preferred
because of lower noise, higher efficiency and lower maintenance as
compared to generators. The inverter type welding power source first
transforms the AC into DC. The DC power is then fed into a step-down
transformer to produce the desired welding voltage/current. The pulse of high
voltage and high frequency DC is fed to the main step-down transformer and
 there it is transformed into low voltage and high frequency DC suitable for
welding. Finally, low voltage and high frequency DC is passed through filters
and for rectification. The switching on and off is performed by solid state
switches at frequencies above 10,000. The high switching frequency reduces
the volume of the step down transformer. The inverter type of power source
provides better features for power control and overload protection. These
systems are found more efficient and better in respect of control of welding
parameters than other welding system. The invertors with microcontrollers
allow changes in electrical characteristics of the welding power by software in
real time. This can be done even on a cycle by cycle basis so as to provide
features such as pulsing the welding current, variable ratios and current
densities, stepped variable frequencies.
Selection of a power source mainly depends on the welding process and
welding consumables to be used for arc welding. The open circuit voltage
normally ranges between 70-90 V in case of welding transformers while that
in case of rectifiers varies from 20-60 V. Moreover, welding arc voltage
becomes lower than open circuit voltage of the power source. Welding power
sources can be classified based on different parameters related with them as
under:
 Type of current: A.C., D.C. or both.
 Cooling medium: Air, water, oil cooled.
 Cooling system: Forced or natural cooling
 Static characteristics: Constant current, constant voltage, rising
characteristics.
9.2 Characteristics of power source
Each welding power source has set of characteristics indicating the capability
and quality of the power source. These characteristics help in selection of
suitable welding power source for a given welding condition. Basic characteristics
of a welding power source are given below:
 Open circuit voltage (OCV)
 Power factor (pf)
 Static characteristics
 Dynamic characteristics
 Current rating and duty cycle
 Class of Insulation
9.2.1 Open circuit voltage (OCV)
OCV shows the potential difference between the two terminals of the power
source when there is no load. Setting up of correct open circuit voltage is
important for stability of welding arc especially when AC is used. The selection of
an optimum value of OCV (50-100V) depends on the type of base metal,
composition of electrode coating, type of welding current and polarity, type of
welding process etc. Base metal of low ionization potential (indicating ease of
emitting free of electrons) needs lower OCV than that of high ionization potential
metal. Presence of low ionization potential elements such as K, Na and Ca in
electrode coating/flux in optimum amount reduces OCV setting required for
welding. AC welding needs higher OCV compared with DC owing to problem of
arc stability as in case of AC welding current continuously changes its direction
and magnitude while in case DC it remains constant. In the same line, GTAW
needs lower OCV than GMAW and other welding processes like SMAW and
SAW because GTAW uses tungsten electrode which has good free electron
emitting capability by thermal and field emission mechanism. Abundance of free
electron in GTAW under welding conditions lowers the OCV needed for having
stable welding arc.
Too high OCV may cause electric shock. OCV is generally found to be
different from arc voltage. Arc voltage is potential difference between the
electrode tip and work piece surface when there is flow of current. Any fluctuation
in arc length affects the resistance to flow of current through plasma and hence
arc voltage is also affected. Increase in arc length or electrode extension
increases the arc voltage. Further, electrical Electrical resistance heating of
electrode increases with electrode extension for given welding parameters.
9.2.2 Power factor (pf)
Power factor of a power source is defined as a ratio of actual power (KW) used to
produce the rated load (which is registered on the power meter) and apparent
power drawn from the supply line (KVA) during welding. It is always desired to
have high power factor (pf). Low power factor indicates unnecessary wastage of
power and less efficient utilization of power for welding. Welding transformers
usually offer higher power factor than other power sources. However, sometimes
low power factor is intentionally used with welding transformers to increase the
stability of AC welding arc. The basic principle of using low power factor for better
arc stability has been explained in section 6.2.2. Application of a welding power
source with high power factor offers many advantages such as:
Reduction of the reactive power in a system, which in turn reduces the
power consumption and so drop in cost of power
More economic operations at an electrical installation (higher effective
power for the same apparent power)
Improved voltage quality and fewer voltage
drops Use of low cable cross-section
Smaller transmission losses
9.2.3 Static Characteristic of power source
Static characteristic of a welding source exhibits the trend of variation in voltage
with current when power source is connected to pure resistive load. This
variation may be of three types, namely constant current (CC), constant voltage
(CV), rising voltage (RV).
Constant current power source
The volt ampere output curves for constant current power source are called
‘drooper’ because of substantial downward or negative slope of the curves. With
a change in arc voltage, the variation in welding current is small and, therefore,
with a consumable electrode welding process, electrode melting rate remains
fairly constant even with a minor change in arc length (Fig. 9.1). These power
sources are required for processes that use relatively thicker consumable
electrodes which may sometimes get stuck to workpiece or with non-consumable
tungsten electrode where touching of electrode with base metal for starting of arc
may lead to damage of electrode if current is unlimited. Under these conditions,
 the short circuiting current shall be limited which would provide safety to power
source and the electrode.

50
Increasing
arc length
40
Arc voltage [V]
3
30
2
1

20

10
0 50 100 150 200 250 300 350 400 Current [A]

Fig. 9.1 Static characteristics of constant current welding power source

In constant current power source, variation in welding current with arc voltage
(due to fluctuations in arc length) is very small therefore welding current remains
more or less constant despite of fluctuations in arc voltage / length. Hence, this
type of power source is also found suitable for all those welding processes where
large fluctuation in arc length is likely to take place e.g., MMA and TIG welding.
Constant voltage power source
In CV power sources, a small variation in arc voltage (due to fluctuations in arc
length) causes significant change in welding current. Since arc voltage remains
almost constant during welding despite of fluctuations in arc length therefore this
type of power source is called constant voltage type. Moreover, the constant
voltage power sources do not offer true constant voltage output as current-
voltage relationship curve shows slightly downward or negative slope. This
negative slope is attributed to internal electrical resistance and inductance in the
welding circuit that causes a minor droop in the output volt-ampere
characteristics of the power source (Fig. 9.2). This type of power sources is
found more suitable for all those welding processes where fluctuations in arc
length during welding is limited like in semiautomatic welding process MIG, SAW
and PAW. The power sou rce shall su pply neces sary current to melt t he electrode
at the rate req uired to m aintain the preset vol tage or arc length. The speed of
electrode drive is used to control feed rate of th e electrod e which in turns affec s

the arc gap/voltage. The variation arc voltage changes the aver age welding
curr nt. The u se of such power source in conjunction with a constant speed
electrode wire feed drive esults in a self regul ting or self adjusting arc system .
Due to some i ternal or xternal fluctuation if the chang e in arc le ngth occur s,
then it regulates the electrode melti g rate MR (by regul ating curre nt) to regain
the d esired arc length.

Fig. 9.2 Static characteristics of constant voltag e welding p ower sour e

Self regulating arc

In s emiautomatic welding processes where c onstant voltage pow er source is used
in association with automati ally fed (constant s peed) sm all diamet er consumable
electrode, arc length is maintai ned by self-regulating arc. Self-regulating arc i s one,
which governs the melting /burn off r ate of the e lectrode (b y
changing the current) so that feed rate becomes equal to melting rate for
maintaining the arc length. For example, increase in arc length due to any reason
shifts the operating point from 2 to 3 thus increases the arc voltage (Fig. 9.3).
Operating point is the point of intersection of power source characteristics with
arc characteristics. Rise in arc voltage decreases the welding current
significantly. Decrease in welding current lowers the melting rate (see melting
rate equation) of the electrode thus decreases the arc gap if electrode is fed at
constant speed. Reverse phenomenon happens if arc length decreases (shifting
the operating point from 2 to 1).

Static characteristics of constant voltage welding power showing operating points

with increasing arc length

Duty Cycle
Duty cycle is defined as ratio of arcing time to the weld cycle time multiplied by
100. Welding cycle time is either 5 minutes as per European standards or 10
minutes as per American standard and accordingly power sources are designed.
If arcing time is continuous for 5 minutes then as per European standard it is
considered as 100% duty cycle and that will be 50% duty cycle as per American
standard. At 100% duty cycle, minimum current is drawn from the welding power
source. Welding power source operating at low duty cycle allows high welding
current for welding purpose safely. The welding current which can be drawn at a
duty cycle can be evaluated from the following equation;
DR x IR 2 = I2 100 x D100……………………………………………..(equation)
Where I - Current at 100% duty cycle
D100 - 100% duty cycle
IR - Current at required duty cycle
DR - Required duty cycle
OCV [V]

Fig. 9.3