What is a Synergic MIG Welder or Welding machine?

Types of polarity in SMAW, MIG, MAG...
Types of polarity in SMAW, MIG, MAG, FCAW, TIG and SAW

Synergic Welding Power Source (Synergic MIG Welder)

A Synergic MIG Welder or welding power source or let’s say a welding machine is called to be Synergic when a single setting (either current, arc length or material thickness, etc.) is adjusted on the machine panel and the other settings (current, or wire speed, stick out) will change automatically to give a stable welding arc.

The latest synergic MIG welder contains a number of stored welding programs with linked wire diameter, welding filler wire & arc length adjustment to suit welding needs for different materials such as carbon steel, stainless steel, and aluminum.

As shown in the below figure, changing any value on the power source will adjust the other parameters automatically due to the inbuilt algorithm in the synergic welder or welding machine.

Synergic MIG welder

Synergic MIG Welder Working

All parameters depend directly on each other:

  • Wire feeding speed
  • Current strength
  • Voltage
  • Arc length
  • Inductance
  • Pulse height

If one of these parameters changes, the other ones will change in a special created Synergic-line too.

Synergic MIG Welder Front Panel
Synergic MIG Welder Front Panel

What is Synergic MIG

In a normal MIG/MAG welding power source, the welder is required to set the wire feed speed (Current) and select an appropriate voltage. The two variables are dependent on the wire diameter and gas used. This requires the welder/operator to have knowledge of the relationship between current and voltage for having good welding results.

Synergic MIG welder

In a synergic (non-pulse) MIG/ MAG welding set, there is a one-knob dial that defines the wire feed speed. The microprocessor within the equipment will select the optimum voltage from a look-up table (a synergic curve) to match the given current. The synergic curve has been developed to give the best possible settings for a particular current/wire feed speed.

So, now the welder is not responsible to select the right voltage. A trim button can be used, which allows the user to decrease or increase the voltage by a small percentage. The trim action allows the welder to make small corrections in voltage to suit the variables at the workpiece.

Advantages of Synergic MIG Power source

  • Save time with ‘One knob’ operation.
  • User friendly interface- save money on training.
  • Pulse parameters are selected automatically .
  • Get the consistent welding results each and every time.
  • Ability to store the program in the machine & recall anytime.

Synergic welder vs. pulse welder

Synergic is a feature of a welder/ welding machine that enables an inbuilt program in the machine algorithm. This brings comfort for the welder to set a single value on the machine and the other parameters get adjusted automatically. Pulse welder on the other hand relates to the metal transfer mode feature of a welder/ welding machine.

A pulse welding machine works on pre-defined welding programming to ensure low heat input, efficient wire melt-off rate, and good quality welds with minimal spatters. A pulse welder can be programmed to include the synergic feature too.