Synergic Welding Machine Setup — Complete Parameter Guide
Introduction
Synergic welding machines represent the technological evolution of the MIG/MAG (135/131) process. Unlike conventional machines where the welder independently adjusts voltage, wire feed speed and inductance, a synergic machine automatically adjusts all parameters together from a single main variable: the wire feed speed.
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What is a Synergic Curve?
A synergic curve is a manufacturer-programmed relationship between wire feed speed, voltage, current and other parameters. Each curve is optimised for a specific combination of wire, shielding gas and transfer mode.
Leading manufacturers: Fronius (TPS/i, PMC, CMT), Kemppi (Wise, MasterMig), Lincoln Electric (Power Wave), ESAB (Aristo, SuperPulse) and Miller (Auto-Set).
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Transfer Modes
| Mode | Current | Thickness | Positions | Feature |
|---|---|---|---|---|
| Short circuit (Dip) | 50-180 A | 0.8-4 mm | All | Low heat input, thin sheets |
| Globular | 180-250 A | 4-8 mm | PA, PB | Unstable — generally avoided |
| Spray Arc | 250-500 A | >6 mm | PA, PB | Maximum penetration, high deposition |
| Pulsed | 50-400 A | 1-30 mm | All | Precise control, fewer spatters |
| CMT (Cold Metal Transfer) | 30-200 A | 0.3-3 mm | All | Zero spatter, ultra-thin sheets |
| Double Pulse | 100-400 A | 2-20 mm | All | TIG-like aesthetic appearance |
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Fine-Tuning Parameters
Arc Length
Voltage correction over the base synergic curve. +: wider flatter bead (capping, flat). 0: optimum point. -: greater penetration, concentrated arc (root, vertical, overhead).
Pre Flow (Gas Pre-Flow)
Gas flow time before arc ignition. Steel: 0.2s, Stainless: 0.5s, Aluminium: 0.5-1.0s, Titanium: 1.0-2.0s.
Post Flow (Gas Post-Flow)
Gas flow after arc extinction. Steel: 0.5-1.0s, Stainless: 2.0-3.0s, Aluminium: 3.0-5.0s, Titanium: 5.0-15.0s.
Soft Start
Wire advances at low speed until it touches the workpiece. Hot Start: +10-20% current for 0.3-1.0s for cold or thick workpieces.
Burn Back
Controls wire tip shape when trigger is released. Low: pointed tip (sticks). Correct: rounded ball. High: wire melts into contact tip.
Inductance
Controls current rise speed during short-circuit transfer. Low: more penetration, more spatter. High: smoother arc, less spatter, flatter bead.
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Summary Table
| Parameter | Steel+CO₂ | Steel+Ar/CO₂ | Stainless+Ar/CO₂ 2% | Aluminium+Ar |
|---|---|---|---|---|
| Arc Length | 0 to +2 | 0 | 0 to -2 | 0 to +2 |
| Pre Flow | 0.2s | 0.2s | 0.5s | 0.5-1.0s |
| Post Flow | 0.5-1.0s | 0.5-1.0s | 2.0-3.0s | 3.0-5.0s |
| Inductance | High | Medium | Medium-high | N/A (pulsed) |
| Mode | Short circuit/Spray | Short circuit/Pulsed | Pulsed | Pulsed/CMT |
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Troubleshooting
| Problem | Cause | Solution |
|---|---|---|
| Porosity at start | Pre Flow too short | Increase Pre Flow |
| Oxidised crater | Post Flow too short | Increase Post Flow |
| Wire sticks | Burn Back too low | Increase Burn Back |
| Excessive spatter | Inductance too low | Increase Inductance |
| Lack of penetration | Arc Length or Inductance too high | Reduce both |
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*Article based on Fronius TPS/i, Kemppi MasterMig, Lincoln Power Wave manuals, AWS Welding Handbook Vol. 2. Published at WeldFC Academy.*