Single Pulse vs Double Pulse MIG Welding - What's the difference?

Pulse MIG Welding

Pulse MIG welding is a machine function that alternates between high and low amperage. This functionality reduces heat which in turn minimises spatter, while having no impact on the penetration quality of the weld, making it a great solution for thinner or soft materials.

WECO welders with pulse functionality offer both single and double pulse functions.


Single pulse MIG welding may sound quite similar to AC TIG welding functions i.e. emitting a constant high pitch buzzing however unlike AC TIG welding, Single pulse MIG welding is more like a spray transfer, this generally results in spatter free results as the MIG wire never actually touches the materials surface.

Instead droplets of the MIG wire are sprayed onto the materials surface during the high amperage part of the pulse cycle, making the weld process much faster, without any affect to the penetration or unnecessary transfer of excess heat.

Double Pulse MIG Welding


Double pulse MIG Welding is just the addition of a second pulse the above single pulse process. The second pulse process allows for the arc to remain on, however there is no transfer of wire and the temperature is so low that during this second pulse there is no welding function taking place

This changes the final weld result from more of a seamless and consistent weld, to something that looks much like a TIG weld, but with double the execution speed and no splatter to clean up again with absolutely no compromise on the penetration quality of the weld!

Double pulse MIG welding allows for some customisation that Single pulse MIG welding cannot accommodate, this is primarily the temperature (hotter or colder) during the second pulse, allowing the material a brief moment to cool down - however it is recommended that you leave the base amps low/cool.



Benefits to Pulse MIG Welding

Pulse MIG welding creates a smaller bead, keeping the weld in place and maximising control while still getting superior penetration. Benefits include; less heat = less distortion = great for thinner materials, hole filling = perfect fill at low heat without increasing the hole, no spatter = no need to apply antispatter + no need for cleanup after welding, great for heat sink metals = cooler welding = perfect penetration without blasting the material with heat.

Looking for more information on Pulse Welders >>CLICK HERE<< to see MACRO’s range of MIG Pulse Welders.