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Linear DC welding power supplies, also referred to as transistor direct current power supplies, use a high number of power transistors as the direct energy source to generate welding current. This technology produces clean, square waveforms with extremely fast rise times, delivering performance comparable to high frequency inverter systems in specific applications.
Linear DC welders are commonly used in constant voltage feedback control and are especially effective for thin foils, fine wire welding, and extremely short weld pulses where precise energy delivery is required.
Linear DC welders use transistor-controlled feedback with total response times of less than 5 microseconds (μS). The name “Linear DC” refers to the square waveform output generated directly from the power transistors. Unlike inverter technologies, no transformer is utilized in the power conversion process.
These systems are typically operated using constant voltage feedback in conjunction with short weld pulses. The rapid feedback response allows high-energy welds of extremely short duration to be applied without weld splash or arcing.
Because pulse duration is short, heat stress and the size of the heat-affected zone are limited. This supports:
Constant voltage feedback is often selected for two primary reasons:
If weldments collapse faster than the weld head can follow, arcing can occur. With Linear DC welding, the extremely fast feedback response minimizes this condition and stabilizes the weld process.
Linear DC welding power supplies are characterized by:
The primary limitation of Linear DC technology is low duty cycle capability, typically much less than one weld per second at less than rated output.
Transistor DC units also tend to be larger and heavier than other resistance welding power supply technologies.
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