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For many years, manufacturers working with complex projects or thin materials would have raised an eyebrow at the thought of switching from TIG (Tungsten Inert Gas) welding to MIG (Metal Inert Gas) welding.
TIG welding, while more time-consuming, costly and difficult to learn, was the only welding process that produced that high-quality, precise, aesthetically pleasing weld they needed. MIG welding, while faster and not as costly, was only good for thick materials where an aesthetic weld wasn’t critical.
But that all changed with the introduction of robotic welding technology, and leading the pack in this technology is OTC DAIHEN’s Synchro Feed Evolution.
Synchro Feed Evolution is a robotic MIG welding technology that is proven to create a similar welding bead as TIG, allowing manufacturers to switch from a manual TIG process to a much-faster robotic MIG process.
The Pros and Cons of TIG
TIG welding is renowned for producing impeccable welds, especially in critical welding tasks where precision is non-negotiable.
The TIG process involves using a non-consumable tungsten electrode to create an arc that melts the base material and a separate filler material if needed. This method delivers aesthetically pleasing, clean and high-quality welds, making it suitable for applications like aerospace and medical equipment, and for applications using thin materials, such as electric vehicle components.
However, TIG welding comes with its challenges.
Learning the TIG technique demands time and dedication, as it requires intricate hand-eye coordination and expertise. Additionally, finding skilled TIG welders can be a considerable challenge, as the learning curve is steep, and the pool of qualified personnel is limited. Moreover, TIG welding is time-consuming, creating longer lead times, affecting production rates and potentially increasing costs.
Move Over TIG, This MIG’s Got You Beat
OTC DAIHEN’s rollout of Synchro Feed Evolution has become a game changer for manufacturers using TIG welding. It can match the precision and aesthetics of TIG welding while beating it in efficiency and consistency. 
Typical robotic MIG welding employs a welding robot equipped with a MIG welding torch that deposits a consumable wire electrode onto the workpiece. OTC DAIHEN’s Synchro Feed Evolution technology combines a revolutionary wire retraction system in the torch with a high-speed processor in the power source that together creates ultra-low spatter welding with a stable arc.
It also includes advanced operating modes to expand its capabilities even further than your typical MIG. In Push Arc Mode, weld beads are 30-40% wider and flatter to alleviate issues caused by gaps, poor fit and part deviation. In Pulse Mode, a rippled wave weld is created, ideal for aluminum and thin materials, with precision pulsing between ultra-low spatter and Pulse transfer modes.
Traditional MIG welding has long been thought of as not the best choice for all materials, especially non-ferrous metals like aluminum. Synchro Feed Evolution brings versatility, overcoming material challenges such as:
- Reducing blow holes when welding zinc plate.
- Reducing burn-through when welding aluminum.
- Preventing pitting and formation of blow holes when welding zinc-plated steel.
Synchro Feed Evolution: The Baddest MIG on the Market
Making the switch from TIG to robotic MIG welding without compromising weld aesthetics or quality is now an option with Synchro Feed Evolution. The benefits are many:
- Enhanced Efficiency – reduce cycle times, leading to increased production rates and faster project completion.
- Skilled Labor Savings – lower reliance on finding skilled TIG welders.
- Consistency – eliminate the variability introduced by human factors in manual TIG welding.
- Cost Savings – gain long-term cost savings from increased productivity and reduced labor costs.
As the manufacturing industry continues to evolve, the choice between manual TIG welding and robotic MIG welding with a proven technology such as Synchro Feed Evolution becomes not just a matter of quality, but also one of strategic competitiveness.
Learn more about OTC DAIHEN arc welding robots.
