Orion ORION mPulse 30 User manual

Orion Welders
Orion Pulse Arc Welding Workbook
Introduction
ank you for choosing Orion and congratulations on your purchase!
You are now the proud owner of an Orion system. Please read and follow all safety precautions and before proceeding with
setup.
Sunstone Engineering is the parent company of Orion Welders. At Sunstone & Orion 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 Welders, a Subsidiary of
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Payson, UT 84651
Email: [e-mail]
Voice: 801-658-0015
Fax: [phone]
Go to - http://orionwelders.com/resources/ for additional product specific resources.
OrionWelders.com
Table of Contents
Introduction ..................................................... 1
Warranty Information .......................................... 2
Welding safety Precautions .................................... 2
Chapter 1: Pulse Arc Welding ................................... 5
Chapter 2: Resistance Welding (Tack Mode) ................... 8
Chapter 3: Tungsten Electrodes ................................ 11
Chapter 4: Techniques, Tips, & Tricks ........................... 15
Chapter 5: Metals ............................................... 20
Chapter 6: FAQ / Troubleshooting / Glossary ................. 27
Chapter 7: Cleaning ............................................. 31

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Warranty
RETURNS:
Orion offers a 30-day return policy on all products. Before sending a product back please contact Orion to receive an RMA
number. e RMA number should appear clearly on the outside of the package. Customers are refunded via check. Please
note that a 10% restocking fee will apply to all returns. A 30% restocking fee will apply to all 3rd party products. Additionally,
all 3rd party products must be insured when sent back to Orion at the buyers expense. In some cases, a merchant fee may
apply. Equipment damaged by improper use or insufficient shipping precautions will be charged additional fees.
REPAIRS:
All Orion LZR series, c series, s series, and i series welders come with a 2 year repair warranty. e Orion mPulse welders
carry a 90 day warranty. Orion Welders will repair all defects in craftsmanship without charge during this time period
(excluding the cost of shipping). is warranty does not cover damage caused by improper use of Orion products. is
warranty does not include consumable items, such as welding electrodes or flash lamps. Orion Welders is dedicated to
keeping our products operating at peak performance for years to come. Any repairs needed after the warranty period are
performed at cost.
INTERNATIONAL ORDERS:
Orion Welders is happy to ship products internationally. International customers should be prepared to pay their country’s
customs, duties, and taxes. Also, international customers should be prepared to pay all shipping costs on any returns and
repairs.
Welding Safety Precautions
READ BEFORE WELDING
e following safety advice is generalized advice for the arc-welding industry. ese safety precautions are not all
inclusive. All users should exercise reasonable caution while using this device. e following group of symbols are warning
symbols:
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.
READ INSTRUCTIONS
• Read 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. e flying sparks, hot workpiece, and hot 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.

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• 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. e input 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. is 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.
• 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 when 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 Personal Protection Equipment. Often
sparks fly off from the weld joint area; therefore, take the necessary precautions to avoid trapping a spark within your own
clothing. Also arc welding gives off infrared and UV rays that can burn the retinal tissues within the eyes and cause surface
burns to exposed skin, similar to a sun burn.
• e 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 a cap. 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.
• Use a sunscreen of SPF 30 or high if welding for extended periods of time.
SAFETY PRECAUTIONS FOR HOT METAL
• Welding material that has a high thermal conductivity will cause metal to heat rapidly.

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• 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.
SAFETY PRECAUTIONS FOR FUMES AND GASES
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. e Orion
produces minimal fumes and gases when compared to large-scale arc welders. ough 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. e 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. e 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 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.
• 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 Engineering Documents (phone: 1-877-

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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: [phone]) (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: [phone], 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: [phone] 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: [phone], website: www.ansi.org).
CE TESTED AND CERTIFIED
Welder tested for electrostatic discharge immunity up to 2kV for CE compliance
Chapter 1: Pulse Arc Welding
Welding Basics
e Orion is a pulse-arc welder and a capacitive discharge resistance welder in one. is combination of abilities allows
for infinite creative possibilities. In its Resistance Welder Mode (Tack) the Orion can be used to temporarily position parts
before welding or soldering. By increasing the energy output in Tack Mode it can also be used as a permanent fusion welder
(resistance welder, spot welder). In its Pulse Arc Mode (Arc), the Orion can be used to perform permanent welds, add metal,
and do a variety of other time-saving metal fusing 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. is
plasma arc is used as a heat source to melt the workpiece 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. e 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. is 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. e high temperature plasma in turn melts metal
in a small spot. is process takes place in milliseconds. e process is clean, and very controllable – perfect for intricate
and minute welding applications.
e Orion’s welding process:
1. e user touches the electrode to the surface with very
light pressure. 2. e Orion turns on the shielding gas (argon).
3. e 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 workpiece surface – therefore it is important to use very light pressure.

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*Remember that the weld is created only when the electrode lifts from the workpiece surface. is means that using too much
pressure will prevent a weld from taking place and will also damage your electrode.
e penetration of your weld spot depends on many different factors. However, as a rule
of thumb you can expect the penetration of the weld spot to be approximately ¼ 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 workpiece 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 actions 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. e 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.
e Orion welder uses the same high temperature plasma that can be found on the surface
of the sun. e sun creates this plasma via internal fusion reactions and the plasma
temperature measures about 5,500 deg C at the sun’s surface. e Orion creates it’s plasma
via electrical discharge and can generate temperatures of 5,500 – 8,000 deg C in 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 your
Orion. Your Orion is very easy-to-use and you will be making quality welds within minutes. e purpose of this section is to
help you to better understand some of the fundamental welding principles, to utilize all of the functions of your Orion, and to
adapt this knowledge to specific applications.
As you can see from this example, Orion welding machines offer a lot of energy. Higher energies are perfect for larger/thicker
pieces, deeper weld penetration and for welding highly conductive metals like silver.

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Hands On: Try welding on a flat plate with 30, 50, 75, 100, and 150 Ws of energy. Stay at max
length, and make sure you have a sharp welding electrode. (Orion 150s was used here)
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.
Hands On: Try welding at 3, 10, 25 Ws of energy. Stay at max length, and make sure you have a
sharp welding electrode. (Orion 150s was used here)
WELD ENERGY VS. WELD LENGTH OR TIME
What happens if the length (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 a smaller 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 length at the max time for most applications. e left image
was welded at 25 Ws with 3, 7, 11, and 15ms weld length. e right image was welded at 75 Ws with 20, 40, and 60ms weld
length.
e two weld parameters (energy and length) can be understood with the following analogies. Consider your Orion welder
to be like a water tower. e 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. e 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.
e actual weld puddle can be understood better using the following analogy. ink of the metal surface as a pool of
water in its frozen state. Your welder’s arc discharge impacts the “water” causing it to melt. e 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 slowly, the ripples have a chance to dissipate and go away completely before the water’s surface refreezes.
is is why short weld length causes the weld spot to look rippled. Keeping the weld length at its max will leave the weld
looking smooth and clean.

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Using a more technical description – during the welding process the weld spot becomes a liquid
pool of metal. e impact of the welding plasma causes vibrations on the molten pool’s surface,
much like a stone causes ripples on the surface of a still body of water. When in the arc screen,
your Orion gives you the freedom to ramp down the weld energy at the length you desire. We
recommend that when you are starting out that you keep the length at its max time for most
welding applications. is gives the molten metal vibrations time to smooth out before the
metal re-solidifies. After you feel comfortable welding we suggest you experiment welding
some applications with different length settings.
In addition, a longer weld length will also help prevent cracking in some metals as the extended time and longer
discharge curve allows the molten pool to cool slower. When the energy is cut off suddenly (by shortening the time
setting) the liquid metal “freezes” in place. is rapid freezing can cause micro stresses in the weld spot and may make
the metal more prone to cracks under additional stress such as hammering.
In most cases it is recommended to leave the weld length at max time 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 length. By turning down the length 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. e
larger weld in this image was done at 5 Ws for energy and 15ms for length. e smaller weld on the right was done at 5
Ws and 3ms.
Alternatively, you can sharpen the welding tip to a very fine point to help ignite the welding arc at very low energy
levels.
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.
You will see different results with each method. Take note of the results in order to help you when you begin work on
your own applications.
Chapter 2: Resistance Welding (Tack Mode)
is section applies to Orion welders that have the Tack welding feature. If you do not have the Tack feature this is still good
welding knowledge to have.
What is Resistance Welding (Tack Welding)?
Resistance welding, often called tack or fusion welding , takes place using a very different
process from that of Pulse Arc (TIG) welding. In resistance welding a large electrical current
is passed through two workpieces 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 workpieces, the temperature (especially at the interface between
the two pieces) can become hot enough to melt the metal in a spot. e 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 called
a “tack” weld. It provides the ability to temporarily position a part before permanent welding. is ability opens a multitude

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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 workpiece parts. As we zoom in on a cross sectional view of the workpiece 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 workpieces. is 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 workpiece causing rapid
heating and melting at the electrode location.
Left: On the micro scale all surfaces have a degree of surface roughness. is roughness causes the workpieces to only
contact 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 electricity to heat and melt the part via a large electrical current. is
contact point is where the highest heat is generated. Light pressure between the parts means less 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.
Sometimes it can be helpful to focus the energy of a resistance weld for larger parts. is can be done by using
a weldment, or bump between the parts to be welded. is bump forces the electrical current to pass through a
concentrated point (especially important for thicker parts). e smaller the bump tip diameter the more heat that can
be generated at that point. is technique is also very helpful for welding dissimilar, conductive metals. For example,
resistance welding silver to gold can be difficult, however, if I 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 bump 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.) e weldment or bump will fuse into the other part
making a resistance weld that cannot be seen on an edge.

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TIPS WHEN RESISTANCE WELDING
With the above in mind there are several different helpful recommendations to use when resistance (Tack) welding.
• e 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.
• High pressure will create a cool weld.
• Light pressure will create a hot weld.
• No pressure will produce an arc!!
• Placing a small bump or weldment between difficult to weld parts can simplify the welding process.
If using tools to hold the workpieces remember that firm pressure between the tool and the workpiece is important to
prevent welding the tool to the workpiece (e.g. brass lined pliers). en apply the correct pressure between the workpieces
to achieve your weld.
HANDS ON: Try turning the Tack Mode energy to a middle setting and make a weld:
1. First weld with very firm pressure between the parts. e 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). e result will be a very large spark, or at least a much better weld.
3. Practice at different energies and pressures until you feel comfortable with the process and results.
e pressure between the tool holding the part is 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
workpiece. 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 workpiece together remember that firm pressure between the tool and
the workpiece is important to prevent welding the tool to the workpiece (e.g. brass lined pliers). en apply the correct
pressure between the workpieces to achieve your weld. is will help to ensure the resistance between the tool and the
part is very low and no weld is made at this location.
Typically, steel is not used for resistance welding because of steel’s high internal resistance. is high resistance means
that a great deal of energy is dropped in the tool before even making it to the weld location. e tool can easily fuse to the
workpiece. e exception to making a resistance welding tool from steel is when only a small amount of energy is needed.
is 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. e Orion is capable
of transferring over 3000 amperes to the weld location.
TO ENABLE THIS FULL ENERGY TRANSFER:
1. e 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).

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*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 workpieces 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. 1mm spot size or less is typical). Remember that when using an
electrode to perform the welding process, the pressure 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).
Chapter 3: Tungsten Electrodes
THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE. e Orion welder comes
standard with (5) 0.5mm and (5) 1.0mm electrodes. e 1.0mm electrodes are a good all around electrode while the 0.5mm
electrode is excellent for very small projects. e larger 1mm electrode allows more energy to come out at one time. e
smaller 0.5mm electrode is better for applications where less energy is being used.
HANDS ON: Make a weld using 10 Ws and a sharp 1.0mm electrode. Now make a weld using the same settings with a
sharp 0.5mm electrode.
In the ‘HANDS ON’ examples above, more energy was transferred from the Orion into the workpiece for the same setting
using the 1mm electrode. For very small parts, using the small electrode is sufficient. is 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 1mm electrode.
e 1mm electrode is used when needing additional
weld current (more melting for same energy). e larger
electrode is recommended for metals such as silver, due
to higher welding energy requirements of such metals.
*Note: e 0.5mm electrode will “burn” or oxidize at
higher energy settings. As a general suggestion, the 1mm
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 welding process.
2. Tungsten’s melting temperature is much higher than most other metals. is means the metals being welded will
melt before the tungsten.

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MELTING TEMPERATURES OF SELECTED METALS:
e table shows a variety of metals and their corresponding melting
temperatures. Note that tungsten has a significantly higher melting
temperature than the other metals. is is an important attribute of
tungsten that aids the welding process. While welding, electrons from
the weld plasma impact the workpiece 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 workpiece than the atoms striking the
electrode.
ELECTRODE SHAPE
e electrode shape is a very important aspect to consider and has a significant impact when welding various metals.
e 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.
e grinding direction to sharpen the electrode is very important. Top Image:
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. Bottom image: Grinding the electrode such that circular
rings or marks show up will lead to a poor plasma arc, affecting weld quality. e
plasma will discharge inconsistently from the electrode ridges and may become
unstable, oscillating in time. e weld spot will not be repeatable.
As a rule of thumb the electrode should be ground so that the taper is approximately
2.5x the diameter. e 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.
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 is approximately 2.5x the electrode diameter.
ELECTRODE SHAPING EFFECTS
ere are two main electrode shape configurations that you should consider when preparing for a new project. e first is
the sharp electrode, which is the best for most applications and metals. A sharp electrode is also the easiest to ignite and
Material Melting Point (deg C)
Zinc 420
Aluminum 660
Silver 962
Gold 1064
Copper 1083
Stainless 304 1450
Carbon Steel 1500
Titanium 1660
Platinum 1772
Niobium 2468
Tungsten 3410

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typically produces a good weld spot. A sharp electrode is especially important for small parts
where fine control is essential.
e second electrode shape is a flat ended tip. is 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. is 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.
e tip shape changes the energy focus and weld penetration.
e weld spot on the left was formed with a blunt electrode,
while the spot on the right was made using a sharp electrode.
e shape of the electrode
will influence the shape
and penetration of the weld
spot. ere 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 penetration. 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. is 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.
ere are several considerations that can be helpful when selecting electrode shape (e.g. sharp, blunt, or a sharp tip with
a small flatted end). e most helpful of these is to spend time on your Orion and get to know how it responds to different
electrode shapes and metals.
CONSIDERATIONS FOR ELECTRODE SHAPE:
• When welding very small features, under about 1mm, the electrode should be sharp to help focus the weld energy.
• When welding with less than 20-30 Ws the electrode will typically be sharp.
• Some materials weld better with a sharp electrode (e.g. Stainless Steel).
• When welding at very low energy settings a sharp electrode will help ignite the arc more easily.
• Flattened tips provide arc stability at higher energies
• At high energies a sharp tip may melt off during the welding process and contaminate the workpiece.
• A large flat or completely blunt electrode tip for some metals is desirable (e.g. silver, aluminum at energies >16 Ws).
• A large flat can be helpful on all metals depending on the desired weld puddle and the workpiece geometry.
• Truncating the electrode helps to un-focus the weld energy and prevents “burrowing” in mobile metals like silver.
• 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.

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Left Image: 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.
Right Image: A sharp electrode will help place the weld into tight
geometries, a blunt electrode can spread the energy and prevent weld
formation.
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 spot 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 information will help troubleshoot problems quickly.
• During the ignition process the electrode is touching the workpiece surface when the weld current begins to flow.
e 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. is vaporization process can be explosive (on a very small scale) and leaves a
crater in the metal’s surface. e result will be a small “pock” mark in the metal’s surface. e 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.
• e electrode may stick to the metal’s surface. is happens as the liquid metal bridge cools before the electrode tip
has retracted sufficiently to leave the surface of the workpiece. A now solid metal to metal weld has taken place at the
electrode tip preventing retraction and arc ignition. is is often referred to as electrode “sticking”.
• What can be done if the weld spot doesn’t look good, asymmetric for example? is 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 workpiece).
In the table below we see that trouble igniting the arc can be caused by several different reasons. e most common is a
contaminated electrode. If the workpiece’s metal contaminates the welding electrode the following may occur:
Symptom Possible Problem Possible Solution
1 Trouble igniting the arc Contaminated electrode Re-grind the electrode to remove contamination
Electrode shape not conducive
to ignition at low energy
Shape the electrode to a very sharp tip
Broken electrode, jagged edges Re-grind electrode to desired shape
2 Cratering of the weld
spot
Electrode contamination leading
to a metal bridge explosion (see
discussion)
Re-grind the electrode
Sharp electrode in a mobile
metal such as silver
Truncate the end of the electrode to help “un-
focus” the weld energy
3 Weld spot not sym-
metric
Damaged or jagged electrode Re-grind electrode

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Symptom Possible Problem Possible Solution
4 Porosity in the work-
piece
Damaged electrode with jagged
tips
Re-grind electrode
Metal may contain zinc and “boil”
during the welding process. (e.g.
white gold)
Often welding over the same location two or
three times will smooth the weld spot
Sharp electrode in a mobile
metal such as silver
Truncate the end of the electrode to help “un-
focus” the weld energy
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.
e Orion’s electrodes are made of lanthanated tungsten. e small amounts of lanthinum found in the electrodes help
the tips stay sharp and help improve weld performance. e electrodes are also double ended, meaning that either end
can be used for welding.
When swapping electrodes, use caution when touching any part internal to the stylus. 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.
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 workpiece. 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 you 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, leading to electrode metal contamination and will shorten the
amount of time you can weld before re-sharpening or replacing the electrode.
Chapter 4: Techniques, Tips, & 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 add
material. One for example is, instead of using small “laser wire” the Orion can weld a much larger wire or rod to fill in more
metal in a single weld.

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ere are several methods to aid in the addition of fill wire, which are mentioned below. e placement of the electrode
relative to the wire is very important and will influence how the material behaves during the addition process.
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. is 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. e 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 n the process.
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 situations this may
be advantageous.
HANDS ON: Try adding fill wire using the
side placement method. Build up a small
mound of material.
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. is 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
is very small. Alternatively, it may only melt the wire
causing it to ball as shown here.

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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 a rule of thumb it is always best to use the side electrode placement.
is 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, on 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 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
ere are two competing forces at work during the pulse arc welding process. e 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. e Second is the electrons from the plasma pushing the molten metal in the direction the electrode tip
points. e 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 workpiece surface with the electrode
tip on the edge or slightly interior to the edge of the metal mound. e 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.
By placing 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.

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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. is 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 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 prone 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 workpiece. 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 length/time at its max length setting 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.

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A proper weld joint will help the weld puddle cool
uniformly. is 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. is
means that welding over porosity in a Pd piece can be accomplished with the Orion (or laser) to help clean up a ring 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 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. e result is
a crack will start at the edge of the new weld where it overlaps with the old weld joint. e crack will then run along the
middle of the weld puddle in the direction of the overlapping joints. is 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. e
result – Pd is 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
Your Orion 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 remain small or the workpiece thickness is very thick, additional weld joint preparation may be
necessary.
e 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. en 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.

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Pulse Arc Welding: Warping
In some specialized applications, precise positioning of the workpiece relative to a model is 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. is asymmetric expansion can warp the workpiece.
e warping can be used to one’s advantage if done correctly. Often the user can simply observe the natural warp in the
workpiece 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. is will minimize the initial warping as you stabilize the workpiece. 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 eliminating 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. is 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 be deposited elsewhere
on the workpiece. 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. is
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. e 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. is will give you confidence of proper argon shielding for other materials.
Chapter 5: Metals
Weldability of Common Metals
One very important aspect of Pulse Arc welding is a working knowledge of material properties. is knowledge will help
you understand why various metals will react differently during the welding process. Shown below is a table of properties