200i2 FAQ

What is Internal Weld Monitoring?

This new feature found exclusively on the Orion 200i² monitors welds as they are happening to ensure they’re consistent with the weld parameters selected. The welder makes slight adjustments as needed during the welding process to assure that welds are guaranteed to be consistent and repeatable every time. With this feature users can be confident their welder is yielding the best results.

What are Waveforms?

Waveforms control how weld energy is released. Multiple waveforms open the door to faster, easier methods of welding your work pieces. The new wave forms (Triangle and Square) found exclusively on the Orion 200i² allow users to weld difficult metals better than before. Welding silver is now easier with these new options offered by Orion. If users don’t know which waveform to select, don’t worry, we give the best waveform suggestion on the “Metals” screen.

General

Why Should I Buy an Orion?

We are the micro welding experts. Orion Welders, a Sunstone Engineering company, is dedicated to providing innovative and versatile products at affordable prices. We specialize in designing, engineering and manufacturing fine spot micro welding solutions. Our product line includes Capacitive Discharge, AC, Pulse Arc, and Micro TIG welding systems that are used in a variety of research and manufacturing fields and industries.

Over the years, our areas of expertise have grown substantially. The need for micro welding has steadily grown thanks to product and technology innovations that seem to constantly be pushing the limits of how small we make things. As this trend continues to progress, Orion Welders/Sunstone Engineering will continue to be the micro welding experts.

Metals FAQ

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.

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.

Micro Welding FAQ

Defining ‘Micro’

“Micro” is different for everyone. Orion Welders (a Sunstone Engineering company) specializes in “micro” welding, as I am sure you have read. We have many types of welding systems the range from pulse arc welders, to laser welders, to capacitive discharge welders. How about we tell you the smallest and largest applications we’ve welded, then you give us a call and tell us what you would like to weld. We’ll give you our recommendations form our various line of welding systems that we offer.

Smallest:

Largest:

Which welder is right for me?

This answer comes down to two main questions that you need to ask yourself. 1. What are my main uses for the machine? and 2. What is my budget? Here are some example scenarios – (1. I am only working with silver and only doing repairs and I have a very strict budget. 2. I will be using this for all metals and all types of repairs and maybe do some sculpting and random jewelry design on the side and I do have a pretty strict budget. 3. I will be using this for all metals and all types of repairs and maybe do some sculpting and random jewelry design on the side and I do not have a strict budget). If you are the first person then we recommend starting with a basic pulse arc welder like a 100c or an mPulse. Let these machine pay for themselves through the work you are able to do and then decide if you need one of our more advanced machines that will provide greater precision and efficiency. If you decide you want a more advanced machine trade your old one in for a credit to one of our more advanced systems. If you are person 2 then we would recommend you do the same thing but start with a 150s or a 200i2 and allow yourself to have me versatility and precision now. You can also trade your unit in for a credit to a more advanced system if you decide to in the future. If you are person 3 then we would suggest that you get a laser and a pulse arc welder. Its kind of like how you diversify your financial portfolio. Its good to have stocks, mutual funds, real-estate, etc because you never know what is going to come up and by having everything you need in your portfolio, you are always ready for any situation. By having a laser and a pulse arc welder you are also ready for any situation, you will literally have a complete workshop with a solution to every application, design, repair, creation, invention, you name it!

 

Did that answer your question?

Welding vs. Soldering

Pulse arc welding performs metal to metal fusion and provides stronger weld joints. No flux or prep work is needed when pulse arc welding. Users can simply weld the to work pieces together (even when they are dissimilar metals) and then bough and polish them. No pickling or acid baths required when pulse arc or laser welding.

 

Pulse arc and laser welders provide a very small and localized heat affected zone, giving users the ability to weld areas without removing precious stones, rubies, pearls, etc.

 

Pulse arc and laser welders will weld all metals, including Titanium.

 

Pulse arc and laser welders require no flames or flammable gases.

Pulse Arc (micro TIG) vs. Laser

Pulse arc and Laser welders produce very similar results. However, the way the pieces are fused together is very different. Lasers use a light beam and pulse arc welders use electricity and an arc to fuse the metal together. Lasers can control their weld spot size and the amount of energy that is discharged into the weld independently while pulse arc welders can only control the energy. More energy equals a larger spot size on a pulse arc welder and less energy equals a smaller weld spot size.

Pulse arc welding systems allow users to achieve deeper penetration, especially on silver. Sometimes the light beam on a laser will reflect off of silver and not penetrate the metal as well as a pulse arc system. Pulse arc systems are known for being the welder of choice when working with silver.

Lasers can be used to smooth out and polish areas that have been welded together that are rough by widening the laser beam and turning the energy down. Pulse arc welders can be used to smooth weld areas as well but can take a bit more time then on a laser. The only exception being on silver.

Pulse arc welders will only weld conductive materials. This can be nice when diamonds, rubies, or pearls are close to the welding area. If a laser beam accidentally touches one of these items it will weld it. If the tungsten electrode of a pulse arc welder touches a diamond, ruby, or pearls a weld will not occur. Both systems can control their energy to lower levels in order to work close to diamonds, rubies and pearls without damaging them.

Pulse arc welding systems require that the user attaches a grounding clip to the work piece and must touch the work piece to the tungsten welding electrode in order for a weld to occur. Lasers do not require a grounding clip and will weld anytime the user presses the foot pedal.

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 0.05 mm and up to 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 2 mm can be achieved.

Can I build-up or add material to a weld location?

Yes, Orion systems are very versatile. 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 1mm 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, 1mm steel wire may be more suitable. Orion systems have 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.