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Orion 100c User Manual

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1. p 67 orion FOREWORD Thank You for Choosing Orion Welders and congratulations on your purchase You are now the proud owner of an Orion 100c Welder The Orion has pulse arc fine spot resistance and tack welding capabilities This manual was designed to have you welding safely within minutes of unpacking your new welder Please read and follow all safety precautions before proceeding with the welding process Sunstone Engineering is the parent company of Orion Jewelry Welders At Sunstone 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 Orion Jewelry Welders a Subsidiary of Sunstone Engineering R amp D Corp 1691 American Way Suite 5 Payson UT 84651 Email sales orionjewelrywelders com Voice 801 658 0015 Fax 866 701 1209 Welding Safety Precautions READ BEFORE WELDING The following safety advice is generalized advice for the arc welding industry These safety precautions are not all inclusive All users should exercise reasonable caution while using this device The following group of symbols are warning symbols a CAUTION ELECTRIC SHOCK HAZARD EYE PROTECTION REQUIRED Consult these symbols and the related instructions listed next to the symbols for proper action when dealing with these hazards OrionWelders com 100c User Manual READ INSTRUCTIONS Re
2. vii LY NGS we a orion C SERIES DIIP 33773733737 power O 100c User Manual 100c User Manual Table of Contents 5 2 p 5 Manufacturer s Contact Information p 5 Welding safety Precautions p 5 Chapter 1 setup and Assembly p 10 Welder p 10 M CroScCOpe p 11 Microscope Arm Upgrade p 13 Shielding Gas Setup p 14 PICCINOGOS cucnenescucaesntuseceseeaaeteg hia p 16 Chapter 2 Welder Overview p 17 Chapter Pulse Arc Welding p 23 Chapter 4 Tack Resistance Welding p 28 Chapter 5 Tungsten Electrodes p 52 Chapter 6 Metals p 58 Chapter 7 Orion Techniques Tips and Tricks p 4 Chapter 8 Maintenance oivcicssevacetaversiaahactaxes D57 Chapter 9 Updating Welder Software p 59 Chapter 10 Technical Specification p 59 Chapter 11 Troubleshooting FAQ p 60 Warranty Information
3. HANDS ON Try making a small weld spot using 5 Ws of energy and maximum length and then 5 Ws of energy and minimum length Now with a very sharp electrode try making a weld spot at 1 3 Ws of energy and maximum length ch 4 100c User Manual CHAPTER 4 RESISTANCE WELDING The Orion 100c does not contain resistance tack welding capabilities but our other Orion welders do This section is to provide users with knowledge about resistance tack welding If this technology interests you please contact us for more information on trading in or upgrading to an Orion Welder with resistance tack welding capabilities What is Resistance Welding Tack Welding Resistance welding often called tack or fusion welding takes place using a very different process from that of TIG welding In resistance welding a large electrical current is passed through two work pieces to join them together At the contact point between the two materials there is a resistance to the flow of the electrical current As electrical current is passed through this contact point resistive heating takes place When enough current passes through the work pieces the temperature especially at the interface between the two pieces can become hot enough to melt the metalin a spot The terms resistance welder and spot welder are descriptive of this process If you limit the amount of energy and electrical current going into the weld you can create a temporary or weak weld ca
4. You are welcome to make your own pulse arc and tack fusion welding attachments NOTE 10 AWG is the largest cable that should be used with your Orion welder The 10 AWG cable should not be shorter than 3 5 feet 1m CAN I MAKE PERMANENT WELDS IN TACK MODE Yes the Orion has been designed with Sunstone Engineering s industrial spot welding resistance welding technology By turning up the energy and using tack welding attachments the Orion is a fully fledged resistance welder often called a fusion welder Alternatively by using low energy orion ch or small cabling the Orion will act as a temporary tack welder This temporary tacking allows positioning of a weld piece before permanent welding in Pulse Arc Mode WHAT MATERIALS CAN YOU WELD WITH THE ORION The Orion can weld a wide variety of materials Some examples include gold silver platinum steel stainless steel titanium and virtually all other precious metals In addition cobalt alloys aluminum tin brass and EVEN copper can be welded with the Orion Even with an ideal welder some materials and alloys will be difficult to weld Furthermore some materials such as zinc should not be welded because they may produce fumes that will make the welding technician sick Pulse arc welding of solder is also not advised because of its low melting temperature Solder will vaporize easily and leave your workpiece looking blackened or burnt CAN I BUILD UP OR ADD MATERIA
5. is very small Alternatively it may only melt the wire causing it to ball as shown here orion 6 A final scenario can occur when the electrode is placed on top of a 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 HANDS ON Try adding fill wire using the top placement method Build up a small mound of material As arule of thumb it is always best to use the side electrode placement This is especially true of larger fill wire diameters If it is essential for a top placement weld the process will be improved by using very fine laser wire to ensure full wire melting Choosing the correct wire gauge for your application is very important For example micro scale applications it is important to select the smallest fill wire available If a wire is selected that is similar in size to the base metal there is a good chance that the energy setting required to melt the wire will also melt the base metal Alternatively if the wire is small relative to the base metal the wire can be melted adding material to the base metal without any damage or warping to the base metal For larger features select a wire size that will allow you to perform your task efficiently For example filling a large pore should not be done with ultra fine wire but instead with wire of approximately
6. near the welding area 2 Adjust the regulator Knob fully COUNTER CLOCKWISE closed to prevent over pressurization of the line 3 Screw the gas regulator onto the argon tank 4 Connect one end of the gas tubing to the argon regulator Insert the other end of the gas tube about 1 4 inch into the Orion s gas connector on the back of the welder It will stop when it is fully connected Tug gently on the tube to verify a tight fit 5 Open the argon tank slowly to pressurize the regulator The dial on the left should pressurize and the dial on the right should remain at zero when the regulator knob is fully backed out 6 6 Set the gas pressure between 5 10 psi by slowly turning the regulator Knob CLOCKWISE This will adjust the dial on the right of the regulator 6 Set the gas pressure between 5 10 psi by Slowly turning the regulator knob CLOCKWISE This will adjust the dial on the right of the regulator Between 5 10 psi Regulator Knob OrionWelders com 100c User Manual Electrodes THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE The Orion welder comes standard with 5 0 5mm and 5 1 0mm electrodes The 1 0mm electrodes are a good all around electrode while the 0 5mm electrode is excellent for very small projects It is recommended that the user pay close attention to the electrode condition A contaminated electrode can lead to inconsistent welds and poor arc starting Only light pr
7. remain small or the work piece thickness is very thick additional weld joint preparation may be necessary The Y joint is the simplest joint to prepare Use fill wire of an appropriate diameter to build up material in the joint Weld with no fill material for the first pass to increase the weld penetration into the joint Then add fill wire to build up material in the top of the Y until the material is flush with the top surface Other joint preparations like X V etc are possible and the welding procedure is similar Pulse Arc Welding Warping In some specialized applications precise positioning of the work piece relative to a modelis very important However during the melting process the weld pool will expand and shrink asymmetrically meaning that the expansion during melting is less than the shrinkage during cooling This asymmetric expansion can warp the work piece The warping can be used to one s advantage if done correctly Often the user can simply observe the natural warp in the work piece and place welds to warp the part back into proper alignment Even if warping is not desired there are steps to avoid this problem To do this start with lower Energy settings This will minimize the initial warping as you stabilize the work piece Always alternate sides during the welding process several welds in a row on one side can exaggerate the warping while alternating welds will pull the part back and forth elimi
8. the protective gas acts as a barrier to prevent oxygen from entering the weld zone After the weld has occurred the protective gas is turned off shielding gas is necessary to produce clean and repeatable pulse arc welds Orion Welders recommends high purity argon This can be purchased at your local welding supply shop PRESSURIZED GAS SAFETY There are several important rules that should be followed when using a compressed shielding orion cht gas such as argon 1 Always secure the pressurized gas tank to a fixed location such as a sturdy table leg If the pressurized gas cylinder were to tip and become damaged there is possibility that the tank could become rocket like expelling the high pressure shielding gas as propellant 2 If you experience a large shielding gas leak open all of the doors and windows in the room Remember some welding gasses like argon are heavier than regular air and will sink to the floor of the room 3 ALWAYS TURN OFF THE SHIELDING GAS AT THE MAIN VALVE AND THE REGULATOR WHEN FINISHED This will help your shielding gas supply last longer if there is a small leak in the tubing and is also a good Safety practice If the tube becomes dislodged shielding gas could fill the room displacing needed breathing oxygen Argon is heavier than air and will fill the room from the bottom upward SETUP INSTRUCTIONS 1 Ensure that your argon or other inert gas tank is securely fastened to a stationary point
9. Defaults This will reset all Energy Trigger Type Agitation Interface Tab Gas Tab and Timing Tab settings back to their factory default settings Clear All Memory This button will erase all the Save and Load settings This can take up to 45 seconds after touching the ok button Cancel Save over 51 0 Ws 68 0 Ws 14 0 Ws Empty Slot CAVE CCREEN SAV SCREEN The 100c allows users to easily save weld parameter settings by simply touching the save tab at the top of the screen To save the setting touch any one of the five empty slots then touch the save button in the top right corner This feature will save the users current Weld Energy Trigger Type Agitation On or Off Gas Pre flow and Post flow Delays and Weld Time parameters that will not be saved are Accelerator On or Off Pre Weld time and Retract Delay If all five slots have a saved setting users can save over one of the five they no longer want by touching the setting they wish to save over then touching the save over button in the top right corner Cancel Empty Slot Empty Slot Empty Slot Empty Slot To access a Saved setting users can touch the load button at the top of the screen To load a saved setting simply touch the desired setting from the five available options then touch the load button in the top right corner This will load the users saved setting which includes Weld Energy Trigger Type
10. It is recommended that you use a resistive touch screen stylus or even the edge of your fingernail when making adjustments on the touch screen ARCSCR Pulse 7501 Spot Size amp Spot Depth This section of the touch screen interface shows the user the estimated weld spot size and weld spot depth based on the energy selection that will occur when a weld is made Energy Selection Bar Selecting the weld energy is accomplished by touching the energy selection bar This bar ranges from 3 100 joules Watt Seconds Users can also touch the power up and down buttons on either side of the energy selection bar 80 0 Ws m Trigger Options Users can choose Auto Trigger or Foot Pedal to initiate a weld When using Auto Trigger recommended the unit will automatically fire once the work piece is touched to the electrode tip When using Foot Pedal the weld will initiate when the foot pedal is pressed Agitation Option Agitation can improve weld formation and strength Note Agitation can produce loud high pitched sounds please take precaution if ears are sensitive Agitation Off This is the standard weld discharge with a smooth slope and is good for most metals Agitation On This function is only active in the 3 66 Ws range With agitation on additional energy is added periodically on top of or in addition to the standard primary weld discharge This energy improves the strength of the spot increases the weld penetrati
11. LONG WILL ELECTRODES LAST Under normal use electrodes will last for approximately 8 000 welds To ensure that you get the most life out of your electrodes use argon gas for pulse arc welding and maintain a sharpened cht 100c User Manual electrode tip during the welding process ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WHEN PULSE ARC WELDING Pulse arc joint preparation is very similar to that of general tungsten inert gas TIG welding Some different types of weld preparation include the simple I seam but joint X Y and V joints named for the way they look The I seam may require no filler material while the 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 4 to of the way through the material an I seam may be appropriate The weld location should be cleared of solder as this will reduce weld quality ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WITH TACK FUSION WELDING Just as in pulse arc welding all solder should be removed if a strong metal to metal tack fusion weld is desired Tacking can be used to weld solder in place or to temporarily tack a work piece to a solder layer CAN I USE TACK MODE TO PLACE SOLDER GRANULES OR PIECES BEFORE A SOLDERING TORCH IS USED Yes this is a very simple process A variety of hand pieces are available Trouble Shooting Solution s My welder won t Veri
12. Manual Go to http www OrionWelders com 100c tutorials for full video tutorials Orion Jewelry Welders 1691 American Way Unit 5 Payson UT 84651 USA 1 801 658 0015
13. The user touches the electrode to the surface with very light pressure 2 The Orion turns on the shielding gas argon 3 The Orion retracts the electrode and sends a burst of electrical energy forming a plasma arc Please note that the weld is only made after the electrode lifts from the work piece surface therefore it is important to use very light pressure 100c User Manual Remember that the weld is created only when the electrode lifts from the work piece surface This means that using too much pressure will prevent a weld from taking place and will also damage your electrode The penetration of your weld spot depends on many different factors However as arule of thumb you can expect the penetration of the weld spot to be approximately 4 of the diameter of the weld spot Factors like electrode shape and condition also effect the weld penetration and will be discussed in more detail later PULSE ARC VS LASER Laser welding and pulse arc welding technologies are designed to create high quality welds in precious and non precious metals Laser welding uses collimated or focused light to add energy to the metal and melt it at a single location Pulse Arc welding uses electricity specifically electrons to add energy to the work piece 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 a
14. by following these set up instructions 1 Adjust the clamp height The microscope arm table clamp has two heights available Remove the allen head screws attaching the adjuster knob to the arm to adjust the height For thicker bench tops attach the allen screws in the lower holes For thinner bench tops attach the allen screws in the upper holes x a OrionWelders com 100c User Manual 2 Attach the microscope arm table clamp to your bench top Position the mount where you want it on the table then tighten the knob underneath with your hand until the clamp is very snug 3 Insert the microscope arm into the table clamp Secure the microscope arm by tightening the setscrew at the top of the table clamp 4 Insert the stylus into the holster under the microscope The stylus holsters adjustability allows for custom stylus placement and electrode angle to meet user preferences Shielding Gas Setup During the pulse arc welding process high temperature plasma quickly melts metal into a molten pool at the weld location If room air is allowed to come into contact with the molten metal oxygen from the air will quickly react with the hot metal The result is a metal oxide that is brittle porous and burnt looking Protective shielding gas is used such as 99 996 pure Argon Argon 4 6 or higher to prevent these effects The shielding gas is used to displace any oxygen at the weld location As the arcis performed
15. com 100c User Manual ports Connecting them to other devices may damage the welder and or the other devices ADJUSTING THE MICROSCOPE CONFIGURATION a Adjust the magnification between 5x and 10x b Adjust the focus c Adjust the height of the microscope head ko i e ee _ E hi iP j ee l l Lf When adjusting the microscope focus place your finger Oma 7 next to the welding electrode to help judge the correct T Oo focus location Focus the microscope till the texture on lk the skin of your finger is clearly visible a The microscope can be configured in many different ways to suit your individual preference Orion highly recommends configuration 3 as the simplest to use and implement In this configuration the user has an unobstructed space for hand and part placement This configuration also allows the welding stylus to easily be adjusted to different angles A The microscope and welding stylus can be configured to meet the user s work preference 1 Microscope facing forward work brought to stylus from front 2 Microscope head rotated 90deg from body work piece drawn toward user to touch the stylus 3 Microscope head rotated 90deg from body work piece lifted away from the user toward the back to touch the stylus HANDS ON Please take amoment to configure the Orion to one of the three configurations shown It is helpful to pract
16. 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 Keep your head out of the fumes Do not breathe the fumes Ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDS and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Welding in confined spaces requires good ventilation or an air Supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air Supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded SAFETY PRECAUTIONS FOR FALLING EQUIPMENT Use a working surface of adequate physical strength to support the welding
17. have many features available to them including high frequency agitation for added penetration and weld strength customizable save settings for fast and easy switching between weld settings and fully updateable and upgradeable software options As with other Orion welders the Orion 100c utilizes Pulse Arc technology This welding technology consists of two distinct energy ranges Micro and Ultra The Ultra energy range uses 30 to 100 joules of energy for projects that require deeper penetration or a larger spot size The Micro energy range uses 3 to 30 joules of energy and is perfect for smaller and more delicate pieces The Orion 100c offers a compact and affordable welding system in an easy to use package How to Setup the Welder The Orion has an internal switching power supply that can accept both 120 and 240VAC ASSEMBLY STEPS 1 Push the power cord firmly into the power receptacle 2 Push the argon gas tube 1 4 firmly into the tube receptacle until it seats firmly into the connector 3 Attach the microscope connector by pushing it into the Foot Pedal Microscope port Orion HDMI ports are not compatible with any other HDMI ports Connecting them to other devices may damage the welder and or the other devices 4 Connect the foot pedal by pushing it into the Foot Pedal Microscope port Orion HDMI ports are not compatible with any other HDMI ports Connecting them to other devices may damage the welder and
18. important aspect to consider and has a significant impact when welding various metals The shape of the electrode will greatly affect the welding plasma created during the arc Poor electrode shape will lead to plasma arcs that are not repeatable while good electrode shape will help the plasma arc to discharge smoothly from the welding tip The grinding direction to sharpen the electrode is very important When grinding make sure that grind marks run parallel to the electrode shaft Parallel grind marks will allow the plasma to discharge uniformly and smoothly from the electrode Grinding the electrode such that circular rings or marks show up will lead to a poor plasma arc affecting weld quality The plasma will discharge inconsistently from the electrode ridges and may become unstable oscillating in time Bad nr f chs 100c User Manual As arule of thumb the electrode should be ground so that the taper is approximately 2 5x the diameter The resulting electrode shape is a good general shape for easy arc ignition and excellent weld spots Always grind the welding electrode so that grind marks run parallel to the electrode shaft Placing the electrode incorrectly on the diamond wheel will produce circular grind marks and poor weld results Bosition HANDS ON Grind your electrode so that grind marks run parallel to the electrode shaft Verify by looking under the microscope Try to produce a taper that
19. in a limited number of locations Middle Applying more pressure will cause more surface contact less resistance and less resistive heating Right Applying less pressure will cause less surface contact more resistance for better resistive heating A resistance welder uses the resistance to the flow of Copper Electrode electricity to heat and melt the part via a large electrical current This contact point is where the highest heat is 3 generated Light pressure between the parts means less Metal Plate contact between the two surfaces more resistance and hence more heating and melting Heavy pressure between the parts translates to more contact between the two surfaces less resistance and less heating Copper Electrode Sometimes it can be helpful to focus the energy of aresistance weld for larger parts This can be done by using a weldment or bump between the parts to be welded This bump forces the electrical current to pass through a concentrated point especially important for thicker parts The smaller the bump tip diameter the more heat that can be generated at that point This technique is also very helpful for welding dissimilar conductive metals For example resistance welding silver to gold can be difficult however if place a gold weldment on the silver part the gold to gold resistance weld become very simple To aid in resistance welding difficult thicknesses or material combinations 1 Place a weldment or bu
20. is approximately 2 5x the electrode diameter ELECTRODE SHAPING EFFECTS There are two main electrode shape configurations that Orion users should consider when preparing for a new project The first is the sharp electrode which is the best for most applications and metals A sharp electrode is also the easiest to ignite and typically produces a good weld spot A sharp electrode is especially important for small parts where fine control is essential The second electrode shape is a flat ended tip This tip helps spread the energy more uniformly and is better suited for difficult metals like silver A combination of a pointed electrode with a small flat tip can also be useful for a variety of metals This configuration will help improve arc properties for silver and like metals while still allowing smaller parts to be welded As a general rule of thumb you can think of a sharp tip as a weld focuser while a blunted or truncated tip is a weld un focuser The tip shape changes the energy focus and weld penetration The weld spot on the left was formed with a blunt electrode while the spot on the right was made using a sharp electrode 15 Small Truncated The shape of the electrode will influence the shape and penetration of the weld spot There are advantages and disadvantages to each electrode shape As shown in the illustration above the electrode shape greatly influences the weld spot s shape and penetrat
21. or the other devices 5 The Pulse Arc welding stylus must be screwed in securely to insure no oxygen is entrained into the weld This may require pushing in and screwing down the connector several times pushing it in further each time until feeling the rubber O ring seal against the Orion connector Ho IOTI cht 6 Place a welding attachment into the positive receptacle on the front panel e g the pulse arc alligator clip Remember The pulse arc welding stylus requires the most attention during setup Since the argon gas will flow through the hand piece a tight fit between the power supply and the hand piece is necessary To accomplish this push the connector onto the Orion s front panel and screw it down Next push in the connector again and continue to screw it down Finally push in the connector unit you feel it bottom out then screw the connector in unit it is firmly seated How to Setup and Use the Microscope THE SHUTTER SYSTEM The Orion s microscope shutter system is more advanced than other welding systems The shutter allows an unobstructed working view before welding and completely protects the user s eyes during the welding process The Orion will not allow a weld to take place if the shutter does not completely shut Ensure the microscope cable is plugged into the microscope light ring then to the back of the welder in the Foot Pedal Microscope port one FO0t p De on OrionWelders
22. out of the weld joint Please see the previous discussion on overcoming porosity In short welding over the location with porosity again will help remove the porosity A fresh sharp electrode will help with this process Sometimes adding pure laser wire will also help in removing porosity In general gold welds easily Here are some tips when working with gold 1 Typically a sharp electrode is preferred when welding gold 2 Gold can easily accept small or large weld spots 3 Itis often typical that gold will look black surrounding the weld location This black layer is easily removed with steam cleaning clean rag or a small glass brush 4 Goldcan easily be added to almost any other metal 5 Very interesting welding combinations are possible 100c User Manual Platinum Pt Platinum Pt has a melting temperature that is similar to stainless steel but a density that is 3 times higher In addition the specific heat of Pt is lower by a factor of 4 than stainless steel This means that it takes less energy to raise the temperature of Pt to its melting temperature The end result is that Pt is a little more difficult than stainless steel to weld but very similar in overall behavior One important consideration when welding Pt is its high boiling temperature 3827 deg C relative to tungsten s melting temperature 3410 deg C What this means if the tungsten electrode is contaminated with Pt metal the Pt metal ma
23. surface tension when compared to other metals Because of these properties how the weld energy is applied to silver is important 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 a very sharp electrode tip point However as the desired spot size gets larger bigger arc mode welds and almost all pulse arc mode welds the liquid silver is easily pushed around by the welding pulse This will lead to large blobs of material being displaced from the weld site resulting in a noticeable hole To avoid this problem simply un focus the weld energy by creating a truncated electrode tip flat The size of the flat depends on the size of the weld For relatively small welds a small flat is all that is required For very high energy welds the electrode may be completely flat Imm diameter Resistance welding silver in tack mode is very difficult because of silver s high electrical conductivity Sterling silver has a high electrical conductivity very similar to that of copper However Argentium silver is approximately 30 less conductive This means that more heat can be generated during the spot welding process due to the additional material resistance Use Argentium silver if your applicati
24. to titanium welds are simple to perform and are strong Titanium welded to other metals can have a variety of results For example Ti to Gold Au results in a clean looking but brittle weld Copper to Ti has similar results Silver to Ti is relatively strong When welding Ti to other materials remember to test the weld strength with scrap pieces before welding the final work piece One important consideration when welding Nb is it s high boiling temperature 4742 deg C relative to tungsten s melting temperature 3410 deg C What this means if the tungsten electrode is contaminated with Nb metal the Nb metal may superheat and start to boil right on the electrode This boiling of the Nb will in turn melt the tungsten electrode causing it to lose its sharp shape Yellow White Gold Au Yellow gold is a relatively simple material to weld Typically it will produce a strong and symmetric weld spot and resulting welds are smooth and require little cleanup This is true for even lower Karat golds however please note that weld results will improve with higher gold content Typically the different metals added to gold are used to change its wear characteristics and color The more additional metal added not gold the lower the karat value Lower karat golds that contain copper and silver etc can produce a black coating around the weld s surface This can easily be steam cleaned wiped off with a clean rag or taken off with a glass
25. 2 45 Thermal fae ow fs so a fine se me Conductivity Some Values may be approximate Melting Point The temperature at which the metal will begin to melt The molten metal of the weld pool will be at this temperature during the welding process Boiling Point If enough energy is added to the weld joint and heat is removed slowly by the surrounding solid metal the weld puddle can begin to boil Liquid metal will be turned into gaseous metal Specific Heat The energy required to raise the temperature of the metal per unit mass 100c User Manual Think of this number as how much metal will melt for a given weld energy melting point also is important A larger specific heat means more energy is required to melt the metal Electrical Resistivity This number represents the resistance to the flow of electrons in a metal This property is especially important during a resistance or tack weld The more resistive the metal is the more easily it will resistance weld e g stainless steels the smaller this number is the more difficult it will be to weld the material e g silver especially in tack mode Density how much of the metal atoms mass is in a given volume of space This property will also influence how large the weld spot is for a given metal All other things being equal a lower density metal will have a larger weld spot than a higher density metal for the same wel
26. Agitation On or Off Gas Pre flow and Post flow Delays and Weld Time After selecting the saved setting remember to verify the spot size and depth before welding anew piece Also remember to go to the settings tab and touch Restore All Defaults before welding a new work piece that will require different parameters 100c User Manual Making a Weld 1 Use the provided stylus to select 25ws energy no agitation trigger on auto then hit play 2 Lightly touch the electrode in the 25ws box on the provided weld plate Maintain contact amp keep hands steady by resting them on the table 3 Use the provided stainless steel weld plate as a guide to try different settings Make several welds on the weld plate to get comfortable with the stylus and settings 4 More advanced weld control options can be found by touching the settings tab See pages 14 16 for more details For immediate access to videos tutorials and other Orion related material scan this QR code with any smart phone or go to www OrionWelders com orion CHAPTER 3 PULSE ARC WELDING Welding Basics The Orion is a pulse arc welder and a capacitive discharge resistance welder in one This combination of abilities allows for infinite creative possibilities In its Tack Mode the Orion can be used to temporarily position parts before welding or soldering By increasing the energy output it can also be used as a permanent fusion welde
27. L 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 Imm in diameter can be added However the user should select wire diameters that match the size of the feature being welded Users should also select wire with similar material to that of their workpiece For example when re tipping a gold ring 0 25mm gold filler wire is an excellent choice If filling a large gap in a steel workpiece Imm steel wire may be more suitable The Orion has the energy and versatility to weld both of these and many more applications with ease CAN THE ORION WELD SILVER Yes the Orion has been specifically designed with the more difficult to weld materials in mind Silver requires appreciable energy for a sustained period of time The Orion has enough energy and capacity to make quick work of your silver applications CAN I WELD DIFFERENT DISSIMILAR METALS TOGETHER Yes in many instances different metals can be welded easily together with the Orion In pulse arc welding the weld spot location becomes a new alloy of the two primary metals this new alloy will adopt new properties that may be better or worse than the primary materials Dissimilar metals can also be joined in Tack Fusion Mode Again weld strength and properties will depend on alloy properties
28. This will also lead to the molten weld puddle being exposed to oxygen PROTECTIVE GAS RULES OF THUMB 1 5 10 PSI is a good shielding gas rate 2 The shorter the electrode is the less gas flow is necessary 3 Gas flow may need to be increased if the electrode is lengthened Any discolorations that shows in titanium is an indication of poor shield gas coverage For this reason it may be helpful to practice on titanium to make sure your gas flow is correct Adjust your gas to ensure no discoloration in a small titanium weld spot This will give you confidence of proper argon shielding for other materials orion CHAPTER 7 METALS Weldability of Common Metals One very important aspect of Pulse Arc welding is a working Knowledge of material properties This knowledge will help you understand why various metals will react differently during the welding process Shown below is a table of properties 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 tainless 304 Ee Carbon Steel alladium Ei Cobalt Chrome N gt Z A 1064 1081 1300 1500 1772 3410 5 555 555 Electrical ER Aluminum EY Platinum Ex Tungsten uta 27 1 6 22 10 6 10 8 Resistivity 475 4 Thermal 54 10 6 5 5 3 Expansion 1 23 5 19 1 14 1 17 11 10 18 12 8 9 9 T
29. With extensive use the internal parts and especially the electrode WILL BE HOT Allow them to cool before attempting to change electrodes As an added safety precaution it is recommended to put the Orion in Stop Mode To change the electrode first remove the stylus hull by pulling on it Then loosen the collet cap by twisting it counter clockwise Grasp the electrode and push it into the collet to free it and then pull it out to remove it If changing electrode sizes the collet must also be swapped out To do this remove the collet cap by continuing to twist it counter clockwise The collet should be loose and will remain in the stylus shaft If it is not loose gently tap it out with a screwdriver or other small tool Replace the collet with the desired one Replace the collet cap but do not tighten yet Insert the fresh electrode into the collet and lock it into place by hand tightening the collet cap in a clockwise direction Finally replace the stylus hull by pushing it snuggly back into place See below for an exploded view of the stylus Stylus Shaft Collet Collet Cap Electrode Stylus Hull OrionWelders com 100c User Manual When sharpening electrodes be sure to remove them from the stylus first Use the included diamond wheelin a rotary tool to reshape the tips Be sure to follow all safety instructions provided by the rotary tool manufacturer When grinding down the tips attempt to create a 15 angle
30. ad the owner s manual before using the Orion Only personnel trained and certified by the manufacturer should service the unit Use only genuine replacement parts from the manufacturer SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION Sparks can fly off from the welding arc The flying sparks hot work piece and hot A equipment can cause fires and burns Ensure that your work area is clean and safe for welding before starting any weld job Do not install or operate unit near combustible surfaces Do not install or operate unit near flammables Do not overload your building s electrical wiring be sure the power distribution system is properly sized rated and protected to handle this unit Remove all flammable materials from the welding area If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Watch for fire and keep a fire extinguisher nearby Do not weld where the atmosphere may contain flammable dust gas or liquid vapors Remove any combustibles such as butane lighters or matches from your person before doing any welding Do not exceed the equipment s rated capacity Use only correct fuses or circuit breakers Do not oversize or bypass them SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK Touching live electrical parts can cause fatal shocks or severe burns The in
31. al may contain zinc and Often welding over the same boil during the welding pro location two or three times will cess e g white gold smooth the weld spot Sharp electrode in a mobile Truncate the end of the elec metal such as silver trode to help un focus the weld energy 1 During the ignition process the electrode is touching the work piece surface when the weld current begins to flow The metal contaminate may form a liquid metal electrical conduction bridge During the weld ignition process the electrode will retract and this may lead to the vaporization of the liquid metal bridge as it is necked down during the electrode retraction process This vaporization process can be explosive on a very small scale and leaves a crater in the metal s surface The result will be a small pock mark in the metal s surface The electrode must be reground before reliable welding can continue at this setting At lower energies this resurfacing re tipping may be very important to get the welder to ignite reliably At higher energies the welding process may proceed virtually unhindered even with a metal contaminated electrode To remove the small crater weld over the crater with a newly ground electrode 2 The electrode may stick to the metal s surface This happens as the liquid metal bridge cools before the electrode tip has retracted sufficiently to leave the surface of the work piece Anow Solid metal to metal weld has taken place at the ele
32. arc more easily 5 Flattened tips provide arc stability at higher energies 6 At high energies a sharp tip may melt off during the welding process and contaminate the work piece 7 Alarge flat or completely blunt electrode tip for some metals is desirable e g silver aluminum WG OrionWelders com chs 100c User Manual 8 Alarge flat can be helpful on all metals depending on the desired weld puddle and the work piece geometry 9 Truncating the electrode helps to un focus the weld energy and prevents burrowing in mobile metals like silver 10 How large you make the tip flat e g a very small flat vs a completely blunt electrode is determined by the amount of energy the Orion will deliver At low energies no flat is needed where at maximum energy the tip can if desired be completely blunt Remember the smaller the flat the easier the weld ignition 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 A sharp electrode will help place the weld into tight geometries left a blunt electrode can spread the energy and prevent weld formation right As discussed above silver is really the major exception to having a sharp tip Because of silver s high liquid mobility a sharp electrode with a focused arc at the very tip will actually burrow a hole in the center of the weld sp
33. brush Please also note that sometimes during the welding process a small amount of the welded metal will evaporate Different metals will evaporate at different rates from the weld pool The orion evaporated metal can deposit around the weld location in a very thin layer that can look black This type of deposit can typically be removed by steam cleaning wiping with a clean rag or witha glass brush Please also note that some gold alloys can contain small amounts of zinc 0 5 1 0 This zinc addition is used as a deoxidizer during casting and can improve the fluidity of the molten metal As discussed above zinc can cause porosity and will contribute to a black film that must be removed via glass brush or clean rag Yellow gold physical properties and composition one possible 58 75 gold 12 27 silver 9 15 copper and some zinc White Gold White gold is also a relatively simple metal to work with There are two main types of white golds palladium white gold and nickel white gold Palladium white gold composition one possible 58 5 gold 10 palladium 28 5 silver 2 5 copper nickel zinc Nickel white gold composition 14k one possible 58 5 gold 25 8 copper 15 5 nickel 0 4 zinc Gold color can be changed with the following alloying show alloy chart by composition and color Note the zinc content of white gold High zinc content can lead to weld defects like porosity etc as the zinc boils
34. chit 100c User Manual HOW DO I DETERMINE THE BEST ENERGY SETTINGS FOR MY APPLICATION In Arc Mode metals will weld according to thermal conductivity and melting point For example a metal with lower thermal conductivity e g stainless steel titanium cobalt alloys will weld easily because the weld heat stays concentrated in the spot Therefore less energy is required to weld one of these metals than other metals of the same thickness that have a higher thermal conductivity Metals with higher thermal conductivity e g copper silver gold will require more energy to create the same spot because much of the heat is conducted away quickly The melting temperature of the metal is also very important when determining the necessary energy setting for a weld Knowing the approximate or relative melting temperature of your working metal will enable you to estimate the amount of energy required to create a spot High melting temperature translates to a large amount of energy required Low melting temperature translates into a smaller amount of energy required to make the weld In Tack Mode energy is important but there are two other important factors that need to be remembered These factors are electrical conductivity and contact pressure In Tack Mode the Orion is a full fledged resistance welder This means that the Orion uses a metal s electrical resistance to create the weld heat Metals that conduct electricity well e g copper are more
35. cing the electrode between a high and low spot the melting process will try and flatten the two taking material from the high area and moving it toward the low area 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 Please note that various metals will react differently to pushing and surface tension smoothing For example silver has a relatively low surface tension while in a liquid state This means that the plasma push method may be more successful than it would be with stainless steel with a much higher surface tension On the other hand because of the high surface tension of stainless steel the surface tension smoothing method will proceed quickly Pushing metal is especially helpful if one of the parts to be joined is J heat sensitive In this example the horizontal member is more heat sensitive or is thinner than the vertical member Material is pushed from the vertical member onto the horizontal member to prevent part damage In this example the vertical member is more heat sensitive or is thinner than the horizontal member Material is pushed from the horizontal member onto the vertical member to prevent part damage Pulse Arc Welding Weld Cracking Some materials are pron
36. ctions that lasers cannot For example welding silver is difficult for laser light because of silver s highly reflective properties However the Orion does not have this limitation because electrons are electrically attracted to the surface of silver The Orion also has the advantage of only welding on metal Lasers can strike precious stones or other nonmetals and can even crack or evaporate the target Because the Orion is electrically driven it requires a conductor such as a metal to allow the welding process to take place R Collimated Laser Light orion The Orion welder uses the same high temperature plasma that can be found on the surface of the sun The sun creates this plasma via internal fusion reactions and the plasma temperature measures about 5 500 deg C at the sun s surface The Orion creates it s plasma via electrical discharge and can generate temperatures of 5 500 8 000 deg Cin very controlled small bursts START WELDING To become an expert and to really learn how to maximize the capabilities of the Orion we recommend that you dedicate time for real hands on experience We recommend that you read and complete the following sections while you are in front of the Orion The Orion is very easy to use and many users will be making quality welds within minutes The purpose of this section is to help the user to better understand some of the fundamental welding principles to utilize all of th
37. ctrode tip preventing chs 100c User Manual retraction and arc ignition This is often referred to as electrode sticking 3 What can be done if the weld spot doesn t look good asymmetric for example This may mean the electrode may be damaged sharp tips or jagged edges or strange shape due to contamination Poor tip condition can also lead to porosity small holes in the work piece Electrode condition greatly affects energy transfer and also weld properties see above discussions Left A perfect electrode Right An electrode in poor condition with metal contamination Electrode contamination can lead to small explosions that create craters in the work piece All four welds were made at the same setting Metal contamination on the electrode caused one weld to create a crater It is recommended that the user pay close attention to the electrode condition see additional discussion A contaminated electrode can lead to inconsistent welds and poor arc starting Only light pressure is needed to start the welding process too much pressure will interfere with the welding process lead to electrode metal contamination and will shorten the amount of time you can weld before re sharpening or replacing the electrode CHAPTER 6 TECHNIQUES TIPS amp TRICKS Pulse Arc Welding Adding Material Typically material is added with a small laser wire one weld at a time However there are many additional options to a
38. d energy Thermal Expansion When a metal is heated it will expand or elongate slightly In some situations especially during resistance welding metal can expand quickly and spill out of the weld joint Thermal Conductivity This is a measure of how fast the metal conducts heat Metals that are good conductors of heat e g copper will dispel the heat away from the weld location quickly during the welding process This action reduces the size of the weld spot Metals that are poor conductors of heat e g titanium are slow to conduct heat away from the weld location and the weld energy has a greater affect on the weld size etc z E E z E 5 gt 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 Please note that some metals may have properties not accounted for in this chart that may make welding more difficult than indicated e g palladium orion ch 7 Titanium and Niobium Some metals may react easily with oxygen and even other gases like nitrogen Titanium Ti reacts with both oxygen and nitrogen at elevated temperatures Ti burns to form 1102 in air at 1200deg C Ti will also burn in pure N2 gas at 800deg C
39. dd material One for example is instead of using small laser wire the Orion can weld a much larger wire or rod to fillin more metal in a single weld 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 orion SIDE PLACEMENT Placing the electrode on the side of the wire is generally the best method of adding fill wire As shown below place the electrode at an approximate 45 degree angle between the wire and the base material As the electrode pulls away from the base material and the arc ignition happens the base material will melt first and then the wire will be melted and pushed or pulled by surface tension into the base material This is an excellent method to produce a uniform molten pool of metal and ensure the proper mixing of the base material and the fill wire The electrode may also be placed at a 45 degree angle in front of the wire However less material will be added with every weld and a portion of the wire will typically ball up in the process Bectrode Base Material Fill Wire AN Fill Wire Fill Wire Fill Wir Weld Spa Base Material Remember that for a larger fill wire the energy must be increased to completely melt the wire If there is insufficient energy there may only be partial melting of the wire However in some situa
40. difficult to weld in Tack Mode and require special Tack attachments to obtain a proper weld The second important factor when in Tack Mode is the weld contact pressure The weld contact pressure can be controlled by how much force you apply to the two pieces that are being welded together The harder you push the pieces together the lower you make the electrical contact resistance between them and the lower the created heat Conversely light pressure will result in high contact resistance and high heat For all welds the size and thickness of the metal will play a significant role in the energy settings that you choose Orion recommends that users start at a low energy and work upwards until an appropriate energy setting is found WILL CONTAMINATE MY BASE MATERIAL WITH THE TUNGSTEN ELECTRODE There is a possibility of tungsten contamination when the Orion user forces the welding electrode into the weld material However with proper practice using the pulse arc welding stylus contamination is very unlikely orion ch DO I NEED TO USE ARGON TO WELD Argon is necessary to produce a clean and repeatable pulse arc weld Without protective argon oxygen may combine with the weld metal to produce brittle and porous welds In Tack Mode however protective argon is not necessary Other protective gases can also be used such as pure nitrogen However Orion recommends high purity argon This can be purchased at your local welding supply s
41. e Very low energy settings will require extremely little pressure on the electrode Increase the energy slightly to add more energy to the arc Verify that the work piece is clipped to or touching an attachment that is securely plugged intothe Arc terminal Verify that the play button is green Verify that the stylus connector is completely inserted into the stylus receiver on the front panel Disconnect and reconnect it following the procedure given in the Setup Instructions The work piece is not conductive and cannot be arc welded with the Orion Change the flow rate of the shielding gas Between 5 10 PSlis recommended Decrease the length of exposed electrode to bring the work piece 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 Even though the tank s valve has been shut there may still be residual pressure in the gas tube After the pressure is released the Orion will display the gas connectivity status correctly ch 100c User Manual Glossary Capacitive Discharge CD An effective resistance welding technology that stores energy in capacitors in order to release a consistent amount of energy in every weld Orion uses this technology to produce clean and smooth welds Custom Setti
42. e Orion the stylus is the main hand piece used for arc welding It safely encloses the electrode and directs the shielding gas to the weld area Tack Fusion Welding Tack welding can refer to a semi permanent weld to place parts prior to permanent pulse arc welding Fusion welding can also refer to a permanent resistance weld See Resistance Welding TIG Welding Also Known as Tungsten Inert Gas Welding is an arc welding process that uses anon consumable tungsten electrode to produce a weld The weld area is protected from atmospheric contamination by an inert gas such as argon Trigger When using the Orion welder the term trigger is used to denote what method the operator is using to initiate the welding cycle When the trigger is set to Automatic the Orion will automatically detect the contact between the tungsten electrode and the workpiece Once contact is made the weld sequence will initiate automatically When the trigger is set to Foot orion ch 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 Watt Second Ws The reference for weld energy A Watt second is the same as a Joule 1 Ws 1 Workpiece In this manual workpiece refers to anything being welded or worked on WARRANTY AND CONTACT INFORMATION All Orion products come with a 2 year limited repair warranty Orion Jewelry Welders will repair all defects in craf
43. e functions of the Orion and to adapt this knowledge to specific applications As you can see from this example the Orion s Arc Mode offers a lot of energy At higher energies this mode is perfect for larger thicker pieces deeper weld penetration and for welding highly conductive metals like silver Hands on Try welding in Arc Mode on a flat plate with 30 50 75 and 100 Ws of energy Stay at max length and make sure you have a sharp welding electrode The Orion s Arc Mode can also be very refined and controlled Lower energy settings allow for welds on small parts and delicate features Having both power and precision allows users to have maximum versatility Selecting the proper weld setting is a matter of user preference and application necessity oa 29 r7 1 Sapte aa gt gt 100c User Manual ENERGY VS TIME What happens if the time duration of the weld is adjusted As can be seen in the figures below the weld time controls the size of the pulse to asmaller extent then the energy It also controls the smoothness of the weld puddle Because the smoothness of the weld spot is also related to the internal stress of the weld joint a smoother weld will have less stress It is recommended that the user keep the weld time at max time for most applications The top image was welded at 25 Ws with 0 2 4 8ms weld time The bottom image was welded at 75 Ws with 10 20 50ms weld length The tw
44. e to crack because of their metal properties For example High Carbon steel Palladium Pd and some silver alloys Why does the cracking take place With some metals it is the new crystal structure created during the welding process e g palladium and high carbon steel However another cracking process often called hot cracking can occur when the cooling process and the resulting thermal shrinkage create high stresses in the work piece Hot cracking is very geometry dependent and can be avoided by carefully considering the weld joint before welding Ideas to overcome hot cracking 1 Keep joint gaps as small as possible 2 Keep the Weld Time Duration at Long to help ramp down the heat more gradually Improper joint preparation or geometry can lead to uneven weld puddle cooling If the puddle cools in such a way to create a hot center section the hot section will be pulled apart by the stresses from the cooling out metal 100c User Manual A proper weld joint will help the weld puddle cool uniformly This will allow even stresses within the weld puddle and prevent weld cracking Palladium and high carbon steel cracking is a special case and is difficult to overcome when laser or Pulse Arc welding 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 r
45. eering Documents phone 1 877 413 5184 website www global ihs com OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 5250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov National Electrical Code NFPA Standard 70 from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org onWeld 100c User Manual CHAPTER 1 WELDER SETUP amp ASSEMBLY The Orion 100c is a powerful addition to the Orion line of pulse arc welding technology Like all Orion welders the 100c features a touch screen interface that streamlines and simplifies the welding process allowing users to do more and to work more efficiently Users
46. elding energy requirements of such metals Note The 0 5mm small electrode will burn or oxidize at higher energy settings As a general suggestion the Imm electrode is a good choice for most applications even very small ones Left Using too much energy with the 0 5mm electrode will cause it to overheat and reduce its life Right A 1 0mm electrode can weld at a variety of energies without overheating Why Use Tungsten Electrodes 1 Hardness tungsten is extremely hard and is therefore able to hold its shape during the orion welding process 2 Tungsten s melting temperature is much higher than most other metals This means the metals being welded will melt before the tungsten Melting temperatures of selected metals Material Melting Point deg C Zinc 420 C mnn 660 Silver 962 1064 Gold ELECTRODE SHAPE The table shows a variety of metals and their corresponding melting temperatures Note that tungsten has a significantly higher melting temperature than the other metals This is an important attribute of tungsten that aids the welding process While welding electrons from the weld plasma impact the work piece and form a weld spot At the same time positively charged gas atoms impact the electrode Both of these processes create heat However more heat is generated by the electrons impacting the work piece than the atoms striking the electrode The electrode shape is a very
47. epe o gt i ii Titanium and Niobium metals will oxidize readily at elevated temperatures and voltages The charts show Ti and Nb painting with electricity showing the voltage at which the color will appear However similar colors will appear due to heat if welding without sufficient shield gas These colors during welding need to be avoided Picture courtesy of Reactive Metals 100c User Manual How to avoid oxide and nitride formation these will work for other metals as well In many situations this is not an issue because the argon Ar coming from the welding stylus completely covers the molten weld pool However in some situations this is not the case For example welding on a thin material the back of the material is unshielded from oxygen and the exposed metal will react with oxygen Using the following can help reduce oxide formation on the back of the work piece 1 Argon flood on both sides of the work piece during the welding process This is the best method but can use a lot of gas and requires additional setup 2 Solder flux A thick layer of solder flux can help reduce oxide formation Place the flux on the back side of the work piece The flux should be as viscous and thick as possible Some fluxes may work better than others After saying all of the above it should be noted that titanium is very simple to weld With proper gas Shielding the weld looks bright and clean Titanium
48. essure applied by the electrode tip determines the weld pressure and the heat generated A weldment or bump between the two parts to be welded can still be used to focus the energy Place the electrode directly over the weldment location remember the weldment is actually between the two sheets etc not on the electrode ch 5 100c User Manual CHAPTER 5 TUNGSTEN ELECTRODES THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE The Orion welder comes standard with 5 0 5mm and 5 1 0mm electrodes The 1 0mm electrodes are a good all around electrode while the 0 5mm electrode is excellent for very small projects The larger 1mm electrode allows more energy to come out at one time The smaller 0 5mm electrode may be better for cases when less energy is desired HANDS ON Make a weld using 15 Ws and 8ms using a sharp 1 0mm electrode Now make a weld using the same settings using a sharp 0 5mm tip In the HANDS ON examples above more energy was transferred from the Orion into the piece for the same setting using the Imm 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 For larger parts use the Imm electrode The Imm electrode is used when needing additional weld current more melting for same energy The larger electrode is recommended for metals such as silver due to higher w
49. essure is needed to start the welding process too much pressure will interfere with the welding process lead to electrode metal contamination and will shorten the amount of time you can weld before re sharpening or replacing the electrode Before welding for the first time follow these steps to get your electrode properly installed and setup 1 Remove the stylus hull by gently pulling it away from the stylus 2 Loosen the collet cap by twisting it counter clockwise 3 Verify that the collet has a small hole in the center to allow for the Imm electrodes 4 Insert the electrode into the collet Leave between 0 6 0 7 inches of the electrode protruding from the stylus shaft This will allow the electrode enough room to stick out from the stylus once the stylus hullis in place Lock the electrode into place by hand tightening the collet cap in a clockwise direction Replace the stylus hull by pushing it snuggly back into place the electrode should stick out about a 1 4 in after the stylus hull is snapped back into place nu Exploded view of the stylus components lt gt Stylus Shaft Collet Collet Cap Electrode Stylus Hull orion CHAPTER 2 WELDER OVERVIEW User Interface The Orion 100c offers a simplified and streamlined interface for ease of use and one touch access to every welding parameter The Orion touchscreen is a resistive touchscreen which requires users to use pressure
50. fy that the power cord is plugged into the rear panel of the Orion turn on and also into a power outlet Do NOT use an extension cord with the Orion Check the circuit breaker for that particular power receptacle Check and replace any blown fuses in the Orion s Fuse Bay My electrode keeps Clean the work piece at the weld site sticking before Clean or sharpen the electrode even weld Increase the energy slightly to add more energy to the arc Solution s can trigger a weld but it always aborts and does nothing My electrode keeps sticking when weld I m set to Auto Trigger Touch Detect but noth ing ever happens when touch the electrode to my work piece My welds look dirty or blackened The Orion still shows that have gas connected even after I ve turned my tank off Hold the stylus steady so that the electrode continuously contacts the work piece If contact is lost even for an instant the weld will abort Verify that the attachment plugged into the terminal is making constant contact with the work piece Clean the surface of the work piece at the weld site Oil carbon deposits and other residue can cause continuity to be lost Verify that the electrode is sharp and not deformed at its tip Replace or sharpen the electrode as necessary Verify that the current mode is not Tack Mode Hold the stylus so that there is less pressure on the electrod
51. hen not in use Use only well maintained equipment and repair or replace damaged parts at once PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND ARC RAYS It is essential for every person in the immediate work area to wear utilize proper pE Personal Protection Equipment Arc welding gives off infrared and UV rays that can AT burn the retinal tissues within the eyes and cause surface burns to exposed skin similar to a sun burn Very often sparks fly off from the weld joint area therefore take the necessary precautions to avoid trapping a spark within your own clothing The stereo microscope provides proper eye protection when pulse arc welding No additional protection is necessary Wear protective garments such as oil free flame resistant leather gloves heavy shirt cuff less trousers high shoes and acap Avoid synthetic fibers as they melt easily Use an approved face shield or safety goggles with side shields when tack welding or when observing others performing pulse arc and tack welds SAFETY PRECAUTIONS FOR HOT METAL Welding material that has a high thermal conductivity will cause metal to heat rapidly Repetitive welds in the same location can cause metal to become hot Do not touch hot weld areas bare handed Allow sufficient cooling time before handling welded pieces OrionWelders com 100c User Manual SAFETY PRECAUTIONS FOR FUMES AND GASES Welding produces fumes and
52. hop HOW DO CONTROL WELD SPOT SIZE AND WELD DEPTH Simplified answer Energy adjusts your spot size while your weld time controls penetration In reality both of these factors energy and time influence both welding characteristics spot size and weld depth However the above rule of thumb will allow good and intuitive control of your welding parameters It is also important to keep your tungsten electrode sharp to maintain precise control over the characteristics of the weld spot size and weld depth HOW MUCH HEAT IS ADDED TO MY WORKPIECE The Orion is capable of extremely fine welds In low energy settings small amounts of energy are added and cause virtually no heat to be added to the workpiece During small welds involving little energy it is possible to hold the work piece in hand For applications that require higher energy the Orion is capable of adding up to 100 Joules Ws of energy to a weld Until the user is familiar with the welding characteristics of the Orion we recommend holding all parts with the pulse arc attachments e g alligator clip and not with your fingers WHAT IS THE SMALLEST AND LARGEST SPOT SIZE ACHIEVABLE The answer to this question depends greatly on the material being welded However spot sizes of down to 0 75 mm and up to 3 5 mm are typical and simple to implement HOW DEEP CAN MY PULSE ARC WELD PENETRATE Depends on the material being welded however spot depth of down to 1mm can be achieved HOW
53. ice using the microscope before welding One challenge that is easy to overcome is the eye hand coordination of bringing the work piece to the welding electrode while looking through the microscope Practice your eye hand coordination while the welder is in pause or until you feel confident in your electrode to part placement when the welder is in pause an audible beep will sound every time the work piece is touched to the electrode tip to remind you to place the welder in play As will be discussed the angle of the electrode tip relative to the work piece surface is very important and will take practice Practice placing the work piece such that it is always perpendicular to the point of electrode contact To Help You Become Familiar with the Microscope 1 Rest your hands on the microscope table and position the work piece close to the welding electrode before looking into the microscope 2 Make sure your focus is at the tip of the electrode 3 Use slow controlled movements 4 Itis helpful to have your hands resting and to only use your fingers to move the work piece 5 Place the work piece surface perpendicular to the point to make electrode contact HANDS ON Practice setting up your hands close to the welding electrode and then looking into the scope Practice placing the work piece perpendicular to the point of the electrode 100c Plus Microscope Arm Upgrade MICROSCOPE ARM INSTALLATION Attach the microscope arm to any bench
54. ill often come with a coating of zinc The zinc coating will cause the metal to appear more white or lustrous than typical steel As discussed above welding on zinc will cause many issues to consider The zinc will evaporate quickly from the weld area causing a black coat to spread to the surrounding metal including the welding stylus The zinc evaporation may also cause strange weld behavior etc 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 High Carbon Steels Spring Steel Tool Steel High carbon steel welds easily but may become brittle after the welding process To avoid weld failure the part must be heat treated after the welding process Cobalt Chrome Alloys Cobalt Chrome is very sensitive to oxygen contamination If there is insufficient argon coverage or oxygen present in the argon gas this alloy will crack Once oxygen embrittlement has occurred the weld area must be removed via grinding etc to prevent future cracking over the same area Copper Copper is one of the more difficult alloys to weld because of its high heat capacity and high thermal conductivity These factors make it even more difficult to weld than silver Copper also requires more energy than silver for the weld to take place about 30 m
55. ill wire when welding If regular low carbon steel is used the weld joint will eventually rust over time Austenitic stainless steels 304 for example weld easily However hot cracking is a possibility with this material To help avoid any cracking it is helpful to weld using an alloy that will produce a small amount of ferritic crystal structure in the weld joint The addition of the ferritic crystal structure will help suppress cracking For example when welding 304 stainless a 308 stainless fill wire can be used Not all situations will require crack suppression techniques Smaller parts like those typically welded using the Orion do not require these procedures 201 202 205 216 301 302 303 304 305 308 309 310 312 314 316 317 321 329 330 332 547 548 384 385 stainless steels Martensitic stainless steels 410 for example have a high carbon content This high carbon content increases the risk of cracking To decrease the risk of cracking it may be helpful to increase the work piece temperature to between 200 300 deg C Often material thinner than 3mm can be welded successfully without heat treatment provided that pure argon is used during the welding process 403 410 414 416 418 420 422 431 440 501 502 503 504 stainless steels Low Carbon Steels Mild Steel Low carbon steels typically weld easily with no major cautions Please be advised that low carbon orion ch 7 steel will rust and w
56. ing during the finishing process However welding more than one overlapping weld will inevitably lead to cracking laser or Pulse Arc welder Palladium cracking be thought of as a combination of hot cracking and a new weld puddle crystal structure problem After a weld the molten Pd re crystallizes typically forming a large and weak metal grain structure When welds overlap the new crystal structure in the previous weld the new puddle will be weak compared to the original metal The result is a crack will start at the edge of the new weld where it overlaps with the old weld joint The crack will then run along the middle of the weld puddle in the direction of the overlapping joints This is due to the stresses created during the weld puddle cooling process as described above with hot cracking However this time instead of geometry causing cracking a rip starts in the old crystal structure and propagates during the cooling process much like ripping a piece of paper The result Pdis difficult to weld successfully without breakage Typically with Pd single spots of porosity can be welded and fixed but overlapping welds will crack Pulse Arc Welding Joint Preparation The Orion 100c can be adjusted to a weld penetration of up to approximately 0 66 mm in depth depending on the material However deeper penetration usually also means large spot size around 1 5 to 2 mm When deep penetration is desired but the weld spot size needs to
57. ion By looking at the figure one might assume that the 180 degree shape is the best electrode configuration to achieve an optimal weld spot However the 15 degree electrode shape has the advantage of easy weld ignition at lower energy levels In some situations it is advantageous to place a small flat on the end of the sharper tip or truncate the weld tip This has a Stabilizing effect on the arc and also allows deeper weld penetration Even a small flat on an otherwise sharp electrode can be helpful in making repeatable welds while still allowing easy arc ignition For the smaller energy settings an extremely sharp electrode is essential Remember the size of the truncation flat is related to the energy setting Use smaller flats for lower energy larger flats for high energy 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 with the Orion and get to know how it responds to different electrode shapes and metals CONSIDERATIONS FOR ELECTRODE SHAPE 1 When welding very small features under about 1mm the electrode should be sharp to help focus the weld energy 2 When welding with less than 20 30 Joules Ws the electrode will typically be sharp Some materials weld better with a sharp electrode e g Stainless Steel 4 When welding at very low energy settings a sharp electrode will help ignite the
58. ion The exception to making a resistance welding tool from steel is when only a small amount of energy is needed 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 To enable this full energy transfer 1 The welding attachment should use 3 5ft 1m of 10AWG cable 2 IMPORTANT the cable should be no larger than 10 AWG or damage to the welder may occur e g 8AWG is a larger cable Not all tack welds require this amount of energy Smaller cabled pulse arc attachments can be used for simple tack welds that require lower energy CUSTOM RESISTANCE WELDING TOOLS It may be helpful to shape the tool for the application Tools that clamp the parts e g brass lined pliers should have as much surface as possible in contact with the part to allow more energy to transfer to the weld location Remember that the area between the work pieces should be small to focus the energy if a strong weld is desired A weldment or bump can be used to help focus the energy if desired If you are shaping an electrode to actually perform the weld then the tip should be as small as is reasonable for the desired weld size e g Imm spot size or less is typical Remember that when using an electrode to perform the welding process the pr
59. ion on our website As Orion engineers develop new software with more efficient settings and or features to help users have the very best welding experience they will place the update on the Orion website for user to download 1 Download update ZIP file from website or email 2 Unzip file which produces a file called Update bin 3 Plug USB into computer then Place the Update bin file in the root directory of the USB thumb drive Do not place the file into any subdirectory or folder on the USB drive and do not rename the update file or the welder will not be able to perform the update 4 Turn welder off then plug the USB thumb drive into the USB port on the side of the welder 5 Turn the welder on Update will run automatically 6 Once the update process is complete and reaches 100 the system may reboot itself into the main home screen Depending on the update it may not automatically reboot but wait at the 100 mark for the operator to manually reboot Either way it is important that the operator turns the welder off removes the USB drive and turns it back on at least once before using CHAPTER 10 TECHNICAL SPECIFICATIONS Welder Type Pulse Arc Weld Modes 2 Pre Programmed Metal Settings 5 Customizable Save Settings 5 Languages Multiple Display 4 4 Touch Screen Energy ws 5 100 ws Switching Power Supply 110 240VAC Auto Detected Weld Spot Diameter 0 75 2 5mm Footpri
60. l and a uniform new alloy In most cases this is not necessary for a strong joint and the first weld will be sufficient 3 Some material combinations may benefit from a third metal at the joint which forms a better stronger alloy with the two primary metals An example of titanium welded to gold and silver The gold to titanium weld looks clean but is brittle The silver to titanium weld also looks good and is strong The Silver to gold weld looks good andis strong orion ch 8 CHAPTER 8 MAINTENANCE Changing and Sharpening Electrodes As electrodes wear they will become dull and result in lower quality and less attractive welds Sharpening or changing them out periodically is important to maintain weld consistency The Orion s electrodes are made of lanthanated tungsten The small amounts of lanthinum found in the electrodes help the tips stay sharp and help improve weld performance The electrodes are also double ended meaning that either end can be used for welding The 1mm electrodes require the included collet with the small hole in the center This collet is pre installed in the stylus when shipped The 1mm electrodes cannot be used with the other zero clearance collet and similarly the 0 5mm electrodes cannot be used in the collet designed for the Imm electrodes Inserting and tightening electrodes into the wrong collet can damage the stylus When swapping electrodes use caution when touching any part internal to the stylus
61. lled a tack weld It provides the ability to temporarily position a part before permanent welding This ability opens a multitude of creative possibilities 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 Left A typical industrial welding configuration Right A close up zoom of the weld showing the electrical resistances that are used to create the weld spot As shown in the figure above a typical weld configuration requires a positive and negative electrode with pressure applied to the work piece parts As we zoom in on a cross sectional view of the work piece parts we can identify the electrical resistance locations where heat is generated For fine spot or small scale resistance welding most of the heat is generated at the contact point between the two work pieces This has been identified on the figure as the largest resistance point During the weld a large pulse of electrical current is dumped quickly through the work piece causing rapid heating and melting at the electrode location p Contact t t J tessut oi Resistance Pressure C ontact Resista ine 4 4 T i Left On the micro scale all surfaces have a degree of surface roughness This roughness causes the work pieces to only contact
62. mp on one side to focus the energy 2 Use an electrode configuration that is simple and has as much contact area as possible on the outside of the parts 3 The weldment or bump will fuse into the other part making a resistance weld that cannot be seen on an edge ch 4 100c User Manual TIPS WHEN RESISTANCE WELDING With the above in mind there are several different helpful recommendations to use when resistance welding 1 The pressure between the two parts is the most important variable in resistance welding even the amount of energy being used for the weld plays to a degree a lesser role 2 High pressure will create a cool weld 3 Light pressure will create a hot weld 4 No pressure will produce an arc 5 Placing a small bump or weldment between difficult to weld parts can simplify the welding process If using tools to hold the work pieces remember that firm pressure between the tool and the work piece is important to prevent welding the tool to the work piece e g brass lined pliers Then apply the correct pressure between the work pieces to achieve your weld HANDS ON Try turning the Tack Mode energy to 50 Ws and make a weld 1 First weld with very firm pressure between the parts The result may be little or no weld 2 Next clamp the parts firmly in the tool but apply virtually no pressure between the parts make sure these are parts you no longer need The result will be a very large spark or at least a much be
63. nating most warping After the smaller stabilizing welds have been placed you can turn up the energy and make the larger welds alternating sides as done with the lower Energy welds Pulse Arc Welding Weld Cleaning For many applications the weld joint will require very little preparation Keep the weld area clean and free from debris 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 During the welding process small amounts of metal will be vaporized from the weld joint and can ch 6 100c User Manual be deposited elsewhere on the work piece Typically this thin film of metal will look black and can easily be cleaned off with a glass brush ultrasonic cleaner etc If the welds themselves look black or discolored it may be an indication of oxidation and can come as a result of too little or too much argon gas flow If the part is too hot some metals will readily react with oxygen to form oxide layers If gas flow is insufficient the weld spot may be poorly covered and oxygen may be present during the weld On the other hand if the protective gas flow is too high the gas may exit the stylus nozzle in a turbulent state When the gas flow is turbulent it will grab oxygen and other atmospheric gases and bring them inside the protective argon gas Shield
64. ng The available slots for settings that a user may customize and then save Factory Preset Setting Refers to the settings that have been pre programmed into the Orion Hand Attachment The Orion comes with a variety of hand attachments that can serve 85 a positive or negative electrode depending on the circumstances Joule See Watt Second Liters Per Minute lpm Used to reference a gas flow rate for shielding gas argon Millisecond Ms One thousandth of a second 001 Used to reference the Weld Time or length of a weld pulse Plasma Plasma is an ionized high temperature gas in which a certain proportion of electrons are free rather than being bound to an atom or molecule The ability of the positive and negative charges to move somewhat independently makes the plasma electrically conductive The Orion s pulsed arc uses this high temperature plasma to create a weld Pulse Arc Welder Arc Welding uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point Pulse refers to the intermittent nature of the weld arc produced Resistance Welding A process that uses the electrical resistance properties of ametalasa method of welding Shielding Gas Argon or other inert gas is used while welding to displace the regular atmosphere from the weld location This drastically reduces oxidation and carbonization of the metals increasing the weld quality Stylus On th
65. nt 5 5 x 6 5 x 8 75 14x 16 5 x 22cm Weight 7 5 lbs 3 4kg Stereo Microscope Magnification 5x 10x Shutter Auto Darkening Shutter System cht 100c User Manual CHAPTER 11 FAQ TROUBLESHOOTING GLOSSARY Frequently Asked Questions CAN I USE ANY ATTACHMENT WHILE IN TACK MODE NO The pulse arc welding stylus should never be used while the Orion is in Tack Mode However any other attachment can be used Attachments sold as tack welding attachments have been designed to transfer more energy to the weld These attachments help the Orion work as not only a tack welder but as a permanent fusion resistance welder CAN ATTACHMENTS LABELED TACK BE USED WITH THE PULSE ARC WELDING STYLUS Yes The pulse arc welding stylus requires an electrical contact to the workpiece Tack welding attachments can be used for this purpose Please note that tack welding attachments will also transfer more energy to the arc when used for Pulse Arc Mode This means that you should use lower energy settings than you would need with pulse arc attachments 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 CAN MAKE MY OWN WELDING ATTACHMENTS Yes the Orion welder is very versatile
66. o weld parameters energy and time can be understood with the following analogies Consider the 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 The length parameter in the welder can be thought of as how long the valve is left open You can discharge a very small amount of water by only having the valve open a short time or you can allow all of the water out of the tower by leaving the valve open for a longer period of time The actual weld puddle can be understood better using the following analogy Think of the metal surface as a pool of water in its frozen state The welder s arc discharge impacts the water causing it to melt The arc discharge also causes the now liquid water to ripple similar to when a stone has been thrown into a body of tranquil water If the arc energy is removed quickly the water freezes instantly and the ripples remain frozen into the water s surface If the arc heat is removed more slowly the ripples have a chance to dissipate and go away completely before the water s surface refreezes This is why short weld time causes the weld spot to look rippled Keeping the weld time at its max will leave the weld looking smooth and clean orion ch 3 Using a more technical description during the welding process the weld spot becomes a liquid pool of metal The impact of the welding pla
67. on and will slightly increases the weld spot size The increase is relatively small compared to the total weld energy but it should be accounted for in high precision applications OrionWelders com 100c User Manual Undo Play Pause Sleep The four buttons displayed at the bottom of the screen are undo play pause and sleep In order to weld the play button must be touched If not welding users should touch the pause button to avoid accidental welds This will Keep the unit powered on but welding functions will be disabled The sleep button is a power saving option that will power down the unit without having to turn it off To wake the unit from sleep mode simply touch the screen Wait a second for the pop up message then touch the screen again The undo button will step backwards allowing users to undo the last 10 touch settings made on the touch screen The Interface Tab allows users to adjust the Screen Brightness Audio Volume and Microscope LED Ring brightness Simply slide your finger or atouch screen stylus left and right on the slider bar to change the setting Language Button Touching the Language Language button will open the following screen to allow users to select their desired language preference Calibrate Touchscreen Touching the Calibrate Touchscreen button will take the user to amenu explaining the calibration process Follow the instructions on these screens to calibra
68. on requires spot welding as opposed to pulse arc welding Even while pulse arc welding it may be desirable to use Argentium silver because of its superior tarnish resistance Thin Argentium silver parts can be welded directly using copper electrodes Thicker silver parts may require a weld projection or bump to focus the weld current This welding strategy is discussed in detail in Chapter 4 Tack Welding 100c User Manual Aluminum Al Aluminum behaves very much like silver during the pulse arc welding process Aluminum has a very low melting temperature 660 deg C and is very mobile when in a liquid phase This means that the same principles that apply to welding silver also apply to Aluminum Aluminum also has one additional complication that may make it difficult to work with in some situations This metal is very susceptible to hot cracking On occasion the weld parameters or geometry may be such that a crack may appear in the weld Always perform test welds for strength verification In general pulse arc welding in aluminum will produce a weaker weld than with other metals Stainless Steel Stainless steels are relatively simple to weld The weld puddle looks smooth and joins easily and the resulting weld joint is strong Because of the low thermal conductivity of stainless steel it is easy to hold the work piece in hand while welding without weld heat immediately making the work piece too hot to hold Use only stainless steel f
69. ore Thin copper however welds very easily and lower energy is typically sufficient to produce very strong welds For thicker copper similar techniques as those employed to weld silver must be used Brass Brass is a material that contains a large amount of zinc 30 37 zinc by composition The remaining material is copper As discussed previously zinc is ahard metal to pulse arc weld or resistance weld because of its low melting and boiling temperature 420 deg C 907 deg C During the melting process the low temperature zinc evaporates boils out of the brass alloy 100c User Manual For low energies this simply coats the surrounding material in a black zinc film that can easily be removed with a glass brush For larger pulse arc weld energies the black coat can cover larger areas and porosity can develop at the weld location as zinc boils from the weld Joining Different Metals Welding different metals together will produce a new alloy at the weld location The new alloy will have different properties although in many cases similar properties to the base metals Some metals combine well forming a strong and useful new alloy Other metal combinations are weak and brittle Helpful Hints for Combining Different Metals 1 Check the new alloy strength with scrap material to ensure the joint will turn out as expected 2 You may need to weld over the joint location several times to get complete mixing of the weld poo
70. ot at higher energies However for small spots a sharp tip is still recommended in silver By using a blunted or truncated tip the energy is effectively spread over the weld area and both the burrowing hole and the thin silver blow through can be largely avoided TROUBLESHOOTING THE ELECTRODE Poor weld results are most often traced back to electrode condition and shape Because the electrode condition is very important the following table will help troubleshoot problems quickly In the table below we see that trouble igniting the arc can be cause by several different reasons The most common is a contaminated electrode If the work piece metal contaminates the welding electrode the following may occur orion Symptom Possible Problem Possible Solution Trouble igniting the arc Contaminated electrode Re grind the electrode to remove contamination Electrode shape not conducive Shape the electrode to avery to ignition at low energy sharp tip Broken electrode jagged edges Re grind electrode to desired shape Cratering of the weld spot Electrode contamination lead Re grind the electrode ing to ametal bridge explosion see discussion Sharp electrode in a mobile Truncate the end of the elec metal such as silver trode to help un focus the weld energy Weld spot not symmetric Damaged or jagged electrode Re grind electrode Porosity in the work piece Damaged electrode with jag Re grind electrode ged tips Met
71. ow when welding For example the Accelerator will use standard gas flow delays for the first weld but decrease the gas flow time for subsequent welds that occur immediately after the first weld With the accelerator feature enabled an operator or system can weld more quickly in applications that require rapid back to back welds because the system does not need to clear a gas line that has recently been actively used e g seam welding or automated welding This feature can help save time and gas in back to back weld applications Purge Touching the purge button will send a shot of shielding gas through the gas flow system This is used to clear the gas line of any oxygen that may have entered before a weld to clear gas out of the line after the shielding gas tank has been turned off so user can remove the gas tubing from the back of the welder and to test if the gas is flowing through the system properly 100c User Manual Timing Tab The Timing Tab allows users to control the different weld duration parameters Pre Weld This delay is the time from the moment the weld is initiated either by compressing the foot pedal or touching the work piece to the electrode to the time the weld process begins Shorter time will cause the weld process to begin immediately Longer time will cause the weld to have a noticeably extended delay before it welds As such other factors add to this delay for a total time between trigger and
72. put 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 Incorrectly installed or improperly grounded equipment is a hazard This device was designed to operate indoors only Do not operate welder in a wet damp environment Holding the hand pieces connected to the front of the welder is okay and will not generate an electrical shock Remove personal jewelry before welding i e rings watches bracelets etc Do not touch live electrical parts Wear dry hole free insulating gloves and body protection orion Properly install and ground this equipment according to this manual and national state and local codes Do not weld with wet hands or wet clothing Always verify the supply ground check and be sure that the input power cord ground wire is properly connected to a ground terminal in the disconnect box or that the input power cord plug is connected to a properly grounded receptacle outlet Do not remove or bypass the ground prong Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect the input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill Check ground conductor for continuity Turn off all equipment w
73. r resistance welder spot welder In its Pulse Arc Mode the Orion can be used to perform permanent welds add metal and do a variety of other amazing and time saving applications WHAT IS A PULSE ARC WELDER A pulse arc welder is a specialized type of a Tungsten Inert Gas TIG welder In TIG welding a sharpened tungsten electrode is used in combination with electrical energy to start and sustain a high temperature plasma stream an arc This plasma arc is used as a heat source to melt the work piece metal Filler metal can also be added to build up joints and create strong and reliable weld beads or weld seams TIG welders can use AC alternating current or DC direct current energy to initiate the pulse arc weld The Orion uses industrial capacitive discharge technology to produce the pulse arc weld Because AC wall voltage can vary up to 20 during the day capacitive welders have the advantage over AC technologies of precisely storing energy before the welding process This means that the Orion will produce a repeatable weld independent of AC power fluctuations PULSE ARC WELDING FUNDAMENTALS Pulse Arc welding uses electrical energy to create a plasma discharge The high temperature plasma in turn melts metal in a small spot This process takes place in milliseconds The process is clean and very controllable perfect for intricate and minute welding applications The Orion s welding process See image on top of next page 1
74. sma causes vibrations on the molten pool s surface much like a stone causes ripples on the surface of a still body of water The Orion welder s energy discharge has been designed to ramp down the weld energy for longer weld time This gives the molten metal vibrations time to smooth out before the metal re solidifies It is recommended that the user keep the time at its max length for most welding applications In addition a longer weld time will also help prevent cracking in some metals as the extended time and longer discharge curve allows the molten pool to cool more slowly When the energy is cut off suddenly by shortening the time setting the liquid metal freezes in place This rapid freezing can cause micro stresses in the weld spot and may make the metal more prone to cracks under additional stress like hammering Time In most cases it is recommended to leave the weld time at max length with one important exception If welding a very small part at less than 5 Ws of energy it is very helpful to turn down the time By turning down the time the arc will still ignite easily but the energy that the welder allows out during the weld is limited by the shorter amount of time The larger weld in this image was done at 5 Ws and 15 Ms time The smaller weld on the right was done at 5 Ws and 3 Ms time Alternatively the user can sharpen the welding tip to a very fine point to help ignite the welding arc at very low energy levels
75. tart at the edge of the new weld where it overlaps with the old weld joint as the new weld cools and is stressed The crack will then run along the middle of the weld puddle in the direction of the overlapping joints This cracking is due to the stresses created during the weld puddle cooling process as described above with hot cracking However this time instead of geometry causing the cracking arip starts in the old crystal structure and propagates during the cooling process much like ripping a piece of paper The result Pd is difficult to weld successfully without breakage Typically single orion spots of porosity can be welded and fixed but overlapping welds will crack There is a welding solution that can stop this cracking process The addition of gold fill wire to the weld joint creates a new alloy and stronger crystal structure The gold can discolor the weld joint However by welding over the joint several times the gold will diffuse into the Pd Another possible solution is to use a high gold content white gold Pd alloy laser wire Silver Ag Silver is an interesting metal with several properties that must be considered during the welding process First silver is highly reflective over a large range of light wavelengths This metal characteristic makes welding silver difficult for a laser but poses no problems for a Pulse Arc welder Second silver is a very mobile metal when in a liquid state and has low
76. te If the touch screen is working correctly we recommend not accessing this function Cancel Gas Tab The Gas Tab allows users to control Pre flow Delay and Post flow Delays Users can also turn the Accelerator on or off and Purge the gas line Pre flow Delay Allows users to control the amount of shield gas released before the weld occurs This delay might want to be lengthened in applications that require the electrode tip to be further out from the Stylus Hull opening than is normal In this case an increased pre flow delay is recommended to allow for complete clearing of the gas line and good shielding at the weld spot The pre flow delay can be alternatively shortened for applications that don t require as pure of an environment for the weld spot or have a short distance from the electrode tip to the Stylus Hull opening Post flow Delay With post flow delay users are able to have control of the amount of shield gas released after the weld Materials that solidify quickly do not need the system to maintain an inert gas environment for as long while materials that remain in a molten state for an abnormally long time may require a longer post flow delay to maintain good shielding at the weld spot for extended times beyond the actual weld event Accelerator The Accelerator is an advanced feature that will automatically detect the time between the last weld and the current weld in order to determine how much gas to fl
77. the same diameter as the pore In this case the repair can be accomplished in literally one weld In comparison with the ultra fine wire the repair would take many welds Pulse Arc Welding Pushing Metal There are two competing forces at work during the pulse arc welding process The first is the surface tension of the molten metal Surface tension is a force between the metal atoms that is pulling the molten pool of metal flat during the metal s liquid phase The Second is the electrons from the plasma pushing the molten metal in the direction the electrode tip points The plasma tries to push the molten metal while the surface tension tries to keep it in place This means 1 Some metals with lower surface tension e g silver are easier to push around than metals with high surface tension e g Stainless 2 Surface tension itself can be used to move metals around By placing the electrode between a high and low spot the melting process will try and flatten the two stealing material from the high and moving it toward the low Pushing Metal is accomplished by placing the electrode at a 90 deg angle from the work piece surface with the electrode tip on the edge or slightly interior to the edge of the metal mound The welding process will then take material from the mound and spread it into the surrounding material One should repeat this process until the proper spread of material is achieved ch 6 100c User Manual 3 By pla
78. tions this may be advantageous HANDS ON Try adding fill wire using the side placement method Build up a small mound of material ch 6 100c User Manual TOP PLACEMENT With top placement the material addition process will depend a great deal on the wire size and the weld energy If the wire is very small the results will be similar to the side placement discussed above For a small wire welded with high weld energy relative to the wire size the weld plasma powers through the wire This technique melts the base metal and joins the melted wire to the base plane However if the wire is larger or the energy is set to produce only a small spot size the wire will typically fail to be added to the base material Instead the wire will ball and some melting of the base material will occur which is insufficient to add the wire Placing the weld electrode on top of the fill wire at a 90deg angle from the base material surface is typically not the preferred method of adding material If the wire is large compared to the energy setting the wire will ball due to surface tension and will not be added to the base material A top electrode placement can work if the wire diameter is small compared to the energy setting In this case there is enough plasma pressure to force the molten wire onto the base material Placement of the electrode directly on top of the fill wire can melt the wire into the base if the energy is sufficient or the wire
79. to form TiN Titanium nitride TiN is inherently brittle which will result in a weak weld joint Very light reaction mostly shielded may just include slight discoloration However a heavy reaction will cause absorption of gas and will cause a dark gray and porous result If the reaction is too heavy the weld location will become very weak and porous Niobium Nb reacts with both oxygen 02 and nitrogen N2 gas Niobium will oxidize react with oxygen at 200deg C The reaction with N2 starts at 400deg C As you can see niobium is even more reactive than titanium This means that greater care must be taken when welding Nb to ensure proper gas Shielding and clean welds For thin parts this is particularly difficult as heat is easily conducted to the opposite weld side the underside of the sheet for example This heat on the underside causes the Nb to absorb 02 and N2 gases resulting in brittle welds For both Ti and Nb the level of oxidation can be observed visually Heavy oxidation will cause a gray porous surface however oxidation or nitrogen absorption in smaller degrees will cause the surface of the metal to color This principle can be used to actually paint on oxide in different colors on Ti and Nb parts ra m r aE Pri a i gt 4 Fe ia e Sy ee 1 s T
80. to the tip as shown below A sharp tip welds better in much the same way that a sharp pencil writes better However grinding a very small flat surface on the tip of the electrode tip will improve the number of welds between tip sharpening Cleaning Guidelines Work pieces The included fiberglass brush can be used to clean off weld debris and discoloration from weld areas The bristles are extended and retracted by twisting the top General Cleaning Guidelines 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 Always clean the Orion s parts indirectly by moistening or spraying a soft cloth first and then use only the cloth to perform the cleaning Stylus and Hand Attachments If discoloration appears at the end of the stylus or hand attachment it can be wiped off using a moistened cloth Cables and Cords Detach cables and cords from the Orion and wipe them off using a moistened cloth Orion s Case andLCD Screen Wipe gently with a moistened cloth being careful not to let any moisture into the air vents orion CELO CHAPTER 9 UPDATING WELDER SOFTWARE Orion users are able to receive software and welder setting updates via email or through a software update download opt
81. tsmanship without charge during this time period excluding the cost of shipping This warranty does not cover damage caused by improper use of Orion Jewelry Welder products This warranty does not include consumable items such as welding electrodes or hand piece attachments Orion Jewelry Welders is dedicated to Keeping our products operating at peak performance for years to come Any repairs needed after the 2 year warranty period are performed at cost typically costing SO 100 USD Orion Jewelry Welders offers a 30 day money back guarantee on all of our products Before sending a product back please contact Orion Jewelry Welders to receive an RMA number The RMA number should appear clearly on the outside of the package Customer refunds are accomplished via check Please note that a 3 restocking fee will apply to all returns In some cases amerchant fee may apply Equipment damaged by improper use or insufficient shipping precautions will be charged additional fees Orion Jewelry Welders is dedicated to providing quality products and support Please feel free to call with any questions before or after purchasing our products Phone 1 801 658 0015 Toll free 1 877 786 9553 Fax 1 866 701 1209 E mail sales OrionJewelryWelders com Web www OrionJewelryWelders com Mail Orion Jewelry Welders a Subsidiary of Sunstone Engineering R amp D Corporation 1691 American Way Unit 5 Payson UT 84651 USA 100c User Manual Orion 100c User
82. tter weld 3 Practice at different energies and pressures until you feel comfortable with the process and results The pressure between the tool holding the partis also very important If insufficient pressure is applied between the tool and the part the weld may take place between the tool and the part Always grip the part firmly in the tool to reduce the contact resistance between the tool and work piece Doing this will reduce the amount of heat created where the tool and part meet RESISTANCE WELDING TOOLS It is always a good idea to have the resistance welding tool made from a material like copper when welding more resistive parts such as steels If using a tool to hold the work piece together remember that firm pressure between the tool and the work piece is important to orion ch 4 prevent welding the tool to the work piece e g brass lined pliers Then apply the correct pressure between the work pieces to achieve your weld This will help to ensure the resistance between the tool and the part is very low and no weld is made at this location Typically it is not good practice to use a set of steel pliers to hold a steel part for example during resistance welding The tool can easily fuse to the work piece Typically steel is not used for resistance welding because of steel s high internal resistance This high resistance means that a great deal of energy is dropped in the tool before even making it to the weld locat
83. unit during operation or storage Secure welding unit during transport so that it cannot tip or fall SAFETY PRECAUTIONS FOR HIGH FREQUENCY PITCH AND VOLUME Welding with high frequency pulse agitation can produce loud high pitched sounds It is recommended to use hearing protection when welding with agitation turned on MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES Wearers of pacemakers and other implanted medical devices should keep away orion Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations OVERUSE CAN CAUSE OVERHEATING Allow a cooling period between strenuous welding schedules follow rated duty cycle If overheating occurs often reduce duty cycle before starting to weld again OBSERVE ALL NECESSARY PRECAUTIONS ASSOCIATED WITH COMPRESSED GASES Use only compressed gas cylinders containing the correct shielding gas for the process used Always keep cylinders in an upright position and secured to a fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame PRINCIPAL SAFETY STANDARDS Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engin
84. weld energy release i e Retract Delay and gas Pre flow Delay Retract Delay The Retract Delay allows users to change the amount of time it takes for the electrode to fully retract to create the arc and weld Sliding the bar to the left will bring the delay time down and therefore make the arc and weld happen faster Sliding the bar to the right will add more time to the delay and make the arc and weld happen slower It is recommended for users to keep the Retract Delay at the factory setting if you do not know the factory setting go to the System Tab and touch the Restore All Defaults button Weld Time Duration The 100c will automatically change the Weld Time Duration based on the current Energy setting If the Energy is set between 3 Ws and 33 Ws the Weld Time Duration will be Short If the Energy is between 34 Ws and 100 Ws the Weld Time Duration will be Long The typical setting for Weld Time Duration is Long However lower Energy settings can be more difficult to get the plasma arc to ignite This is due to a lower initial peak energy output If the operator or application requires such low Energies that ignition becomes inconsistent the system can generate similar total energy output by increasing the initial energy but decreasing the Weld Time Duration of the weld The resulting weld will output more energy in a shorter period of time but the heat generated is the same as the low Energy setup System Tab Restore All
85. y superheat and start to boil right on the electrode This boiling of the Pt will in turn melt the tungsten electrode causing it to lose its sharp shape Palladium Pd Palladium Pd is a white lustrous metal that is typically a much lower cost than platinum Palladium is also much lighter having a density 4 that of platinum It would seem that Pd is the perfect metal Unfortunately Pd is generally difficult to work with and is somewhat difficult to weld in a jewelry setting This is mainly due to palladium cracking during the welding process Palladium can be welded using the Orion welder however cracking can occur Palladium cracking is an especially difficult phenomenon to overcome with laser or pulse arc welding 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 to help clean up the metal during the finishing process However welding more than one overlapping weld will inevitably lead to cracking laser or pulse arc welder Palladium cracking can be thought of as a combination of hot cracking and new weld puddle crystal structure problems After a weld the molten Pd re crystallizes typically forming a large and weak metal grain structure When welds overlap the new crystal structure in the last weld puddle is weak compared to the original metal The result a crack will s

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