For those who need enhanced multi-process welding capabilities and portability in harsh industrial environments, ESAB Welding & Cutting Products has introduced its Aristo 500ix inverter-based welding power source and Robust Feed Pulse and Robust Feed U6 wire feed systems. The Aristo 500ix provides outputs for MIG/MAG, flux cored, MMA and TIG welding, offering maximum output of 500A/39V at 60 percent duty cycle and a 100 percent duty cycle rating at 400A/39V. When paired with Robust Feed Pulse or U6, users can weld with solid wire up to 2.0 mm and cored wire up to 2.4 mm. These feeders offer a 50 mm dinse terminal on the back for connecting an MMA electrode holder, while the Robust Feed U6 also enables gouging from the wire feeder.

“Many fabricators want the benefits of pulsed MIG welding and advanced wire control, but they hesitate because of harsh welding conditions,” says Arne Lagerkvist, Global Product Manager, Heavy Industry Welding Equipment, ESAB. “The Aristo 500ix and Robust Feed system puts those fears to rest. They are fiercely tested and ready for any job site where fabricators want to reach the next level of productivity improvements or help less experienced welders produce better results.”

Built Tough
Housed in a weather-protected IP23-rated case, the Aristo 500ix has a cooling design that isolates electronics from dust, oil, metal shavings and other airborne contaminants. Thick, double bent metal side panels provide impact protection, yet the design enables easy access for service and maintenance. Its ergonomic handles are crane rated. The optional trolley also features dedicated crane lifting points, as well as a torch holder and large cable holders for better organisation.
Robust Feed Pulse and Robust Feed U6 feature the industry’s only IP44 rating to protect the unit against dirt, mud, splashes and even heavy rain. The primary power cable secures to the rear of the unit with a twist lock connection that eliminates stress on the positive power terminal and gas connections inside the case. There is no strain or risk from shearing off a cable or hose connection if an operator drags the feeder by the cables between the feeder and power source.
A heat kit inside Robust Feed wards off condensation and keeps the wire dry, while a cooling fan manages heat in operating conditions up to 55o C without the need for cooling vents. Robust Feed also offers best-in-class ergonomics, crane-rated lifting options and an optional wheel that affixes to either the bottom or side of the unit to provide a very stable wheeled solution. The digital display can be rotated 90 degrees for a vertical or horizontal orientation so operators can read parameters without straining.

Enhanced Performance
Robust Feed Pulse/U6 accept wire spools up to 300 mm, measure 595 x 250 x 430 mm and weigh 18.3 kg. The precisely crafted 4-roll drive stand accommodates 38 mm drive rolls and feeds wire at speeds of 0.8-25.0 m/min. The design improves accuracy at lower speeds, has the power to feed cored wires and the high speeds necessary for smaller diameter hard wires. These feeders offer all the benefits of a premium workshop wire feeder for controlling MIG/MAG functions, including synergic pulse, amperage target setting, 2/4-stroke trigger control, creep start, hot start, crater filling, adjustable burn-back time, gas pre- and post-flow time, gas purge/wire inching and more.
Robust Feed Pulse control functions are easy to find, set and fine-tune, while the Robust Feed U6 offers the ultimate combination durability and advanced functionality, including parameter limits and parameter lock for better repeatability. Both panels feature QSet, which automatically optimises the short circuit arc for the gas/wire combination installed and then adapts welding parameters to match an operator’s individual welding style.
Icons, push buttons and digital displays simplify use and eliminate language barriers. To begin pulsed welding, operators simply select the synergic line. The system then provides optimum dynamic arc control to maintain consistent penetration and weld bead appearance, automatically adjusting for variations in arc length and wire feed speed. Robust Feed Pulse offers 93 synergic lines and Robust Feed U6 offers 92 synergic lines to address a wide variety of steel, aluminium, stainless steel and high alloy solid and cored wires.

Pulsed MIG Benefits
Pulsed MIG welding provides numerous benefits. Depending on the application, it may enable users to:
•Greatly reduce or eliminate weld spatter and post-weld clean-up.
•Control bead appearance and profile, an important factor when customers value good-looking weld beads.
•Enable all-position welding while maintaining reasonably high deposition rates and travel speeds.
•Weld thinner materials without burn-through or warping, increasing first-pass yield and reducing scrap rates.
•Standardise on a single, larger diameter aluminium wire for welding a broad range of metal thicknesses.
•Better manage heat input to preserve mechanical properties while also increasing travel speed, especially on stainless steel.