Lincoln Electric's HyperFill: Higher Deposition, Strong Welds

Lincoln Electric is a known stand out in the welding industry, for their quality, durability, and innovation. They offer tons of solutions that enhance productivity and results, but one you may not have heard of yet is HyperFill!

HyperFill is an advanced welding solution that uses twin-wire technology to achieve greater control, higher deposition rates, and increased weld quality compared to traditional single-wire MIG welding. Unlike conventional methods, HyperFill allows for a higher deposition area while still remaining stable, which means faster welding with fewer passes. This technology is compatible with a variety of Lincoln Electric's existing power sources, making it an easily integratable solution for various applications.

It’s just one power source, one wire feeder, one tip, but twin wire: achieving amazing deposition rates with a wide, smooth arc cone and no added complexity!

​When working with single wire, the arc shape tends to be a deep, narrow cone. As you work at a faster speed, your wire feed speed causes arc stability to deteriorate, making the process more difficult. As you can see, you end up with a narrow arc cone and narrow penetration profile that produces a less robust weld and increases the risk of weld defects at higher deposition rates.

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​But with Lincoln Electric's Twin Wire HyperFill you’re able to generates a wide, evenly- distributed arc cone.  This creates a smooth, stable puddle, making this process considerably easier to handle at higher deposition rates! The wider arc cone means you’ll end up with a robust penetration profile, as clearly seen, and it helps to improve weld quality at high deposition rates!

HyperFill offers quite the list of benefits that make it a standout choice for improving welding efficiency and quality. It delivers better penetration and a more controllable arc, which leads to cleaner work with less spatter and cleanup. And not only does it produce significantly lower fume emissions per pound of deposit, but it also requires less heat input. This reduction in heat contributes to fewer passes needed during welding, resulting in less distortion of the materials and better mechanical properties overall. At the end of the day, it is hard to pass up on HyperFill's impressive increase in deposition rates, from 12 to 20 lbs. per hour, making it a highly efficient solution for various welding needs!

HYPERFILL GMAW

HYPERFILL GMAW

Power Sources:
Power Wave S500
PIPEFAB (Process Pipe)
Cool Arc 55 or 55S

The standard HyperFill GMAW solution is highlighted by its ability to maintain high deposition rates (up to 18 lbs/hr manually and 24 lbs/hr robotically) while ensuring smooth arc stability and puddle control. This system simplifies the welding setup using a single power source, wire feeder, and contact tip, designed to deliver a wide and stable arc that improves weld quality at high deposition rates. It's especially effective in applications that call for speed and efficiency in metal transfer, making it ideal for general fabrication and heavy industrial applications. The system integrates seamlessly with existing Lincoln Electric setups, emphasizing ease of use and operational flexibility.

HYPERFILL FCAW

HYPERFILL FCAW

Power Sources:
Power Wave S500
Power Wave S700
PIPEFAB (Process Pipe)
Cool Arc 55S
​Cool Wave 20S

The same HyperFill twin-wire technology with a single power source and feeder has been expanded to include FCAW applications! Supporting high deposition rates using a flux-cored wire, this significantly enhances productivity. It achieves deposition rates above 15 lbs/hr (6.8 kg/hr), meaning better productivity in flat and horizontal positions. Plus, the patented FCAW HyperFill Tip ensures easy use even in out-of-position applications like vertical and overhead welding​​. Best suited for environments where higher penetration and faster travel speeds are necessary, like heavy fabrication and construction.

HYPERFILL RA

HYPERFILL RA

Power Sources:
Power Wave S700 Advanced Process Welder
with AutoDrive 4R220 Wire Drive
and Magnum PRO Water Cooled Robotic Torch

HyperFill RA is tailored for robotic welding in heavy fabrication applications, offering a 58% increase in travel speeds and deposition rates up to 23 lbs/hr without added system complexity! It allows for greater arc control and efficiency, leveraging the twin-wire system to increase deposition rates in thick-section welding. This setup would work best for making large, heavy-duty welds where depth of penetration and weld quality are paramount.

HyperFILL STT

HYPERFILL STT

Power Sources:
Power Wave with Power Feed 25M Portable Wire Feeders
PIPEFAB Ready Pak
Power Wave S500 with STT Process Module

The HyperFill STT is specifically designed for MIG with a focus on optimizing pipe root pass welding. Combining Lincoln Electric's Surface Tension Transfer (STT) process with their twin-wire GMAW solution, leading to increased welding productivity and efficiency- particularly for challenging pipe welding applications. Dramatically increasing travel speeds, especially in root pass welding, from 7in/min (single wire STT setup) to up to 11 in./min- a 57% increase in travel speed! This is a powerful solution for industries where pipe fabrication and maintenance are regular tasks.

Lincoln Electric's experts stopped by Earlbeck recently to show us the ropes and after seeing it in action, we’re all about HyperFill for its transformative impact on welding operations! It really represents a significant leap forward in welding technology. It's an ideal choice for businesses aiming to improve their operational throughput and save on their bottom line. For those seeking to stay ahead in a competitive market, adopting HyperFill could be the key to achieving superior welding results.

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HyperFill is a game changer that boosts efficiency and ensures top-notch results with great support from Lincoln Electric every step of the way. So if you're curious about how it can change the game for you, reach out today! Let us help you make the switch to more efficient, cost-effective welding solutions!