Advanced Process Welders

Discover the difference

Industry-Proven Equipment.
Industry-Leading Technology.

Lincoln Electric’s Power Wave®advanced welding platform was built to perform – period. With its robust design and leading-edge weld technology, the Power Wave® platform delivers weld performance and quality you can count on; day-in and day-out.

Reliability Redefined

When you are facing demanding production schedules, you need a welding power source you can rely on. The Power Wave® advanced welding platform delivers just that. From semiautomatic welding applications to complete robotic welding systems, the Power Wave® platform has you covered – day after day, shift after shift.

Intelligent Process Control

The Power Wave® platform is more than just a power source, it’s a complete welding process control system. Designed around three principles of process control, the Power Wave® advanced welding platform allows you to standardize your entire welding operation for optimized performance and reduced waste.

Three Principles of Welding Process Control

Implement – Optimized arc performance with Waveform Control Technology®.

Control – Process standardization with Power Wave® Manager and Weld Sequencer® Software.

Verify – Productivity and quality monitoring with CheckPoint® Production Monitoring.

Industry 4.0 Ready

By combining the latest IoT innovations with decades of welding expertise, the Power Wave® platform delivers a truly intelligent welding system designed to keep pace with the factory of 
the future and provide a TRUE picture of your entire welding operation.

Product Line

Explore Power Wave® Systems

Intelligent, robust power sources that are not only built to last, but built to lead.

I'm looking for...

C300

5 - 300A

Output range

250A

at 100% Duty Cycle

Integrated 
user interface 
and wire feeder

S350

5 - 350A

Output range

300A

at 100% Duty Cycle

Compact Multi-Process Capability

S500

5 -550A

Output range

450A

at 100% Duty Cycle

Powerful Multi-Process Capability

S700

20-900A

Output range

700A

at 100% Duty Cycle

High Amperage. High Duty Cycle

i400

5-420A

Output range

350A

at 100% Duty Cycle

R450

5-550A

Output range

450A

at 100% Duty Cycle

High Performance Robotic Welding

Plug and Play Capability

AC/DC 1000

100-1000A

Output range

1000A

at 100% Duty Cycle

submerged-icon-01

Advanced Submerged Arc

Weld Technology

Explore Waveform Innovations

Easily select and optimize the ideal arc characteristics with Waveform Control Technology®

I'm looking for...

High Deposition, Low Difficulty

High Deposition, Low Difficulty

2F Heavy Plate Fillet Welds

18lbs/hr

(8.16 kg/hr)

2F Heavy Plate Fillet Welds

5/16″ (8mm) weld size with SuperArc®.040 wire
Test Disclaimer

HyperFill

Bigger Welds - Faster. Easier

+50%

Increase in Usable Deposition

Improved Operator Ease-of-Use

2F Tube to Flange Flare Bevel

70IPM

(178 cm/min)

2F Tube to Flange Flare Bevel

1.4mm high-strength steel tube to 1.0mm high-strength steel plate.

2F 15<sup>°</sup> Lap Weld

95IPM

(241 cm/min)

2F 15° Lap Weld

1.5mm carbon steel
Test Disclaimer

Rapid Arc®

Maximizing weld travel speeds with the industry's premier waveform for high-speed welding.

50%

Increase in travel speeds

15%

Reduction in spatter

5F Tube Through Plate Fillet

65IPM

(165 cm/min)

5F Tube Through Plate Fillet

1.4mm carbon steel tube to 1.2mm steel plate

1G Double Flare Groove Weld

65IPM

(165 cm/min)

1G Double Flare Groove Weld

1.5mm carbon steel
Test Disclaimer

Rapid X

High speed, low spatter, low heat input, no trade-offs.

40%

Increase in travel speeds

30%

Reduction in spatter

2F Galvanized Lap Weld

85%

Reduction in porosity

2F Galvanized Lap Weld

1.2mm DP980 galvanized ASTM A653 60G/60G
Best results achieved with MetalShield® Z consumables

2F Galvanized Lap Weld

96%

Reduction in porosity

2F Galvanized Lap Weld

2.0mm DP980 galvanized ASTM A653 60G/60G
Best results achieved with MetalShield® Z consumables
Test Disclaimer

Rapid Z

Fast welds, low porosity on coated materials.

Reduced internal and external porosity

Improved bead appearance

Typical STT<small><sup>®</sup></small>Root Pass

Typical STT®Root Pass

Process Comparison

Process Comparison

Bead appearance and productivity

Test Disclaimer

STT®

Industry-proven root pass welding solution.

Reduced burn-through & lack of fusion

Improved operator appeal and bead appearance

2F Ultra-Thin Lap Weld

35IPM

(89 cm/min)

2F Ultra-Thin Lap Weld

0.6mm to 0.6mm carbon steel

2F Ultra-Thin Lap Weld

0.6mm

Material & Gap

2F Ultra-Thin Lap Weld

0.6mm to 0.6mm carbon steel with 0.6mm gap

Test Disclaimer

AC-STT®

The ultimate in welding precision and performance – designed specifically for thin gauge materials

Reduced burn-through & spatter

Improved gap-bridging capabilities

High Performance MIG Brazing

High Performance MIG Brazing

2F Galvanized Fillet Weld

40ipm

(102 cm/min)

2F Galvanized Fillet Weld

0.8mm to 0.8mm galvanized ASTM 60G/60G
Best results achieved with SuperGlaze SiBR consumables.
Test Disclaimer

STT® Braze

Redefining MIG brazing performance.

Reduced Spatter

Improved Travel Speeds

CV vs. Low Fume Pulse<sup><small>™</small></sup>

CV vs. Low Fume Pulse

Process Comparison

Process Comparison

Fume generation rates [ .052 – 400 WFS ]
Test Disclaimer

Low Fume Pulse

A better weld. A better work environment.

up to 66%

Reduction in fume generation

Improved arc stability and operator appeal

Bead Appearance

Bead Appearance

Traditional Pulse compared to Precision Pulse
Test Disclaimer

Precision Pulse

Enhanced puddle control specifically designed for out-of-position welding.

Improved arc focused and stability at lower voltages

Improved operator appeal and puddle control

Lower Welding Distortion

Lower Welding Distortion

Traditional GMAW compared to Pulse-on-Pulse
Test Disclaimer

Pulse-on-Pulse®

Patented aluminum welding solution for GTAW appearance with GMAW productivity.

Reduced distortion on thinner aluminum materials

Improved aluminum welding productivity

Process Control Technology

Take control – Every machine, Every weld.

With it’s embedded process control technology, the Power Wave® advanced welding platform allows you to easily standardize your welding process for reduced process variation and improved WPS compliance across your entire weld floor.

Process Control Technology

PowerFeed

Power Wave® Manager

    • Standardize your fleets welding procedures
    • Easily save & transfer machine settings
    • Easily configure and select procedure memories
    • Establish parameter range limits and lockouts
  • Allow operators to focus more on welding – less on settings

WeldSeq

Weld Sequencer

Utilizing the Power Wave advanced welding platform, Lincoln Electric’s patented Weld Sequencer software delivers an intelligent, visually-aided process control solution that optimizes welding performance and quality.

  • Visual work instructions clearly define each assembly step.
  • Continuous on-screen weld metrics & verification.
  • Automatically track weld count, cycle time and deposition.

Resources

Weld Sequencer Infographic


Weld Sequencer Success Story


Weld Sequencer
Automatic Procedure Adjustments


Weld Sequencer Smart Positioner

Production Monitoring

Information that leads to Solutions

CheckPoint® Production Monitoring technology changes the way you look at your welding operations. More than just a weld data collection tool, CheckPoint® is a full production monitoring solution that delivers the precise information you need for maximizing welding productivity and performance.

Production Monitoring

Powerful Data, Quick And Easy

 
CheckPoint® Production Monitoring provides full visibility of your welding operation faster, cleaner and more efficiently. From real-time dashboards to in-depth weld reports, the CheckPoint® framework was built to provide essential welding data the way you need it, when you need it.

Collect weld data on:

  • Operator Arc on Time
  • OEE Metrics
  • Material Consumption
  • Weld and Assembly Information

 


Secure Access-Any Where, Any Device

 
With secure, cloud-based access, CheckPoint® Production Monitoring allows key stakeholders to view and track welding data anywhere in the world, on any device.

  • No setup or software installation required
  • Track real-time weld production data 24/7
  • Create custom alerts and notifications
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polaris-logo
crown-logo

Success Stories and Articles

Video

Product Highlight:
Smart Positioner
Ultimate Weld Process Control

Success Story

Weld Sequencer Provides Production Efficiencies for Leading Forklift Manufacturer

Crown Equipment implements process control technology to help simplify, standardize and improve welding operations.
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Success Story

Weld Sequencer Provides Production Efficiencies for Leading Forklift Manufacturer

About Crown Equipment

For more than 50 years, Crown Equipment has been a leading manufacturer of world-class forklift and material handling equipment. With operations that span the globe, Crown designs, manufactures, distributes, services and supports products that revolutionize the material handling industry.

The Challenge

During a recent round of new product releases, Crown engineers at the company’s facility in Greencastle, Indiana, needed a more efficient system to handle the extremely tight tolerances of their fabrication process. With new forklift frames requiring a variety of weld and assembly steps, Crown engineers needed a solution to help eliminate as much variation as possible.

The Answer

After a full demonstration of Lincoln Electric’s Weld Sequencer™ solution, Crown quickly realized that this technology provided the type of systematic process control required by these new additions to the product line. Integrated directly into the welding cell, the user-friendly graphic interface provides operators with step-by-step guidance for even the most complex weld assemblies.
Using a simple LCD monitor mounted near the workpiece, Crown implemented the Weld Sequencer software to visually guide their operators through each step of the fabrication process. In addition to providing visual verification of weld placement and part orientation, Weld Sequencer also automatically controlled the power source so the right settings were programmed for each weld.This helped to ensure that each and every weld was made in the proper sequence with the proper settings.

“The beauty of the Weld Sequencer is that it steps the operator through the entire process, making sure they stay on track with the sequence.”

Dan Miller, Crown Manufacturing Engineer

The Results

It didn’t take long for Crown to see the results. After implementing Weld Sequencer, the Greencastle team experienced process improvements and a boost in overall production efficiency, all very much valued by Crown’s engineering team. In addition to greatly improving product consistency, the Weld Sequencer has also proven helpful in training new operators—an important cost-saving factor.

“Before, when we were training a new operator, someone would have to mentor them for several weeks,” says Dan Miller, manufacturing engineer at Crown. “Now all we have to do is teach somebody to use a Weld Sequencer, and then provide support when it’s needed.”

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Reduced Operator Variation

Reduced Training Time & Cost

Success Story

Upgrade to Advance Welding Technology Contributes to Company’s Productivity

Long-Time Partnership and Power Wave® Advanced Welding Platform Contributes to Company’s Success
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Success Story

Upgrade to Advance Welding Technology Contributes to Company’s Productivity

About Morbark

Morbark, headquartered in Winn. Michigan, has been serving the forestry, recycling, and biomass industries for over 60 years. From its humble roots as a simple blacksmithshop to their current 1.1-million-square-foot manufacturing complex, Morbark has made a name for itself as a leading manufacturer of high-quality tree chippers, stump grinders and more.

The Challenge

With products weighing in at 56 tons, and fabrication schedules ranging anywhere from two hours up to four weeks, Morbark’s welding performance and efficiency are imperative to the company’s overall success. With an installation base of primarily older SCR (silicon -controlled rectifier) welding equipment, the company realized it was time to explore newer, more efficient welding technology as they continued to strive for maxim um production performance.

The Answer

Utilizing their long-time partnership, Morbark relied on local Lincol n Electric Sales Reps to introduce the latest technology that Lincoln Electric had to offer. After reviewing the late st Power Wave® advanced process welders, Morbark quickly realized upgrading their installation base with these advanced welders was the way to go.

The Results

It didn’t take long for the company to realize the considerable energy savings these new inverter-based powers sources provided. In addition to energy savings, Morbark experienced significant production improvements thanks to Power Wave’s Waveform Control Technology®, allowing them to use advance pulsed waveforms for improved heat input control – helping prevent distortion, as well as burn through on their thinner materials.

Morbark also quickly discovered the benefits Lincoln Electric’s CheckPoint® production monitoring technology – a standard feature on every Power Wave® system. This cloud-based production monitoring tool allowed key welding personnel to remotely monitor productivity of each machine, evaluate individual welder arc-on time andanalyze short- and long-term production stats.

We use more than 75 different welding procedure settings and the monitoring allows us to uniformly control the machines across the boards and create consistency between welders

Barry Sellers, Morbark Production Supervisor

78%

Energy Cost Savings

20%

Increase in Production

Case Study

Polaris Industries Switches to Advanced Welding Process for Reduction in Spatter, Distortion and Rework

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Case Study

Polaris Industries Switches to Advanced Welding Process for Reduction in Spatter, Distortion and Rework

About Polaris Industries

For more than 50 years, Polaris Industries, Inc., has manufactured snowmobiles, all-terrain vehicles, personal watercraft, off-road utility vehicles and Victory Motorcycles for customers who thrive on adventure. In addition to these popular recreational vehicles, Polaris also has a new line of commercial-grade utility vehicles and equipment.

The Challenge

For years, the 1,900-employee plant in Roseau, MN, used a conventional CV MIG process to weld chassis, steering and suspension components. The company wanted to reduce spatter, distortion and rework that was hurting productivity and profitability. The welding at Polaris is particularly challenging because of the limited weld lengths. With lengths of two inches or less on most parts, the arc is only on for a brief period and does not have much time to establish itself. This challenge requires a machine that can quickly provide arc stability.

“Our operators were utilizing various modes of metal transfer depending on the particular preference of each operator. We were lacking repeatability from one operator to the next.”

Craig Cerminara, Welding Engineer

The Answer

Polaris converted to Lincoln Electric’s Power Wave® power source with Waveform Control Technology™. In making the switch, Polaris implemented the use of Rapid Arc™ – a high travel speed and low spatter pulsed spray transfer – that led to improvements in arc consistency, reduced weld spatter, and improved travel speeds.

“For Polaris there are numerous benefits with the Power Wave platform. It doesn’t matter what wire feed speed the operator sets; he or she will always run the same process and we will always get consistency in the welds,” said Cerminara. “With the Power Wave units, we provide a set range for our operators and then they can fine tune for their particular welding style.”

The Results

In just the first application where Polaris used Power Wave®, the company experienced a 35 percent increase in productivity, attributed to the elimination of post-weld clean-up operations and rework.

“The Rapid Arc™ process reduces the amount of heat input into the weld and therefore decreases distortion,” said Cerminara. “Spatter has also been reduced translating into a huge cost savings in labor and rework time.”

The improvements didn’t stop with the new equipment. Over a three-month period, Lincoln experts spent four days a week at Polaris training the company’s more than 250 operators on how to use the new machines and the nuances of the Pulsed MIG process.

“We’ve been absolutely pleased with the support we have received from Lincoln – everyone was professional and the response to issues was timely and useful,” said Cerminara. “I would not consider it a difficult transition moving from the CV to a Pulsed MIG process and attribute that mostly to the training provided.”

Success Story

MetalCraft Marine Charts a Course for Improved Productivity and 
Energy Efficiency

In a competitive global economy, efficiency reigns supreme on the shop floor, especially when it comes to overall equipment effectiveness.
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Success Story

MetalCraft Marine Charts a Course for Improved Productivity and 
Energy Efficiency

About MetalCraft Marine

MetalCraft Marine is a Kingston, Ontario-based integrated designer and builder of custom, high-performance aluminum work boats for government agencies in North America and globally. Customers include: the U.S. Navy, the U.S. Coast Guard, and various local and regional port authorities.

The Challenge

Five years ago, MetalCraft Marine needed a welding equipment upgrade. Old machines were failing and downtime was on the rise. In addition, inefficiencies in energy consumption forced the company to run nearly half the machines that their workload required.

The boat-building company wanted to increase reliability, lower operating costs and drive process efficiency. They also had to achieve all of this without disrupting service on its industry-leading 10-year warranty on hull seams.

The Answer

Lincoln Electric’s Power Wave® S350 welding power source, along with the Power Feed® 25M wire feeder, dramatically improved energy efficiency and production. Today, MetalCraft runs eight machines at a time rather than just four.

“We were able to double our weld output per day – or even tripled it in some cases – because the machines only drew between eight and 12 amps most of the time, so our house power didn’t need to be adjusted.”

Michael Allen – MetalCraft general manager

The improvements went beyond the new equipment. MetalCraft also benefited from Lincoln Electric’s technical welding support and onsite education.

“Lincoln spent a great deal of time with us, spec’ing out exactly what we needed,” said Allen. “And then when we brought the equipment on board, they spent four or five months returning periodically to work with our welders to bring them up to speed and identify any tweaks that could be made – both in terms of the equipment itself and the peripheral equipment, such as the welding guns. They worked very closely with us to redefine our welding procedures to take full advantage of the new and more advanced equipment.”

The Results

“The quantifiable and dramatic improvements were almost immediate,” said Allen. “The Lincoln equipment, and the consulting advice that came with it, probably enabled us to improve our aluminum welding efficiency by 20 percent. That’s a 20 percent reduction in the time it takes to build a boat. Those machines all paid for themselves in less than a year…The end result was less rework, better appearance, fewer quality inspections required, and improved efficiencies as well.”

The utility savings enabled MetalCraft to double its welding capacity. The increased capacity equated to an increase in sales by more than 300 percent over the past five years.

“We have good procedures identified in preset user memories, and that makes it easier,” said Allen. “You can program the setting you want. So, the guy just has to press a button or two and everything gets set up. He’s not tweaking the controls. Plus, it has a couple settings on it that make it easier for a relatively new person to use compared to an experienced person, and still get good results.”

3x

Daily Weld Production Output

Video

ACS Industries, Inc - Huge Gains with Robotic Welding

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