Published by Lee Garbutt | April 2, 2018 | Editorial | 23
Well, say I'm crazy (you won't be the first) but this is something I have wanted to try for years, and I bet I am not the only one. Whenever a new power supply with increasing output capacity appeared on the laboratory bench, I would find myself thinking: "I can use this beast for welding." Well, the AX1600i pushed me to the limit, I decided to give it a try ; What could go wrong?
The 12V output is 133.3 amps!
The Corsair AX1600i digital power supply can provide up to 133 amperes of current on the combined 12V rail, which is sufficient for welding amperage. There are dozens of PC power supplies on the market today that can provide 100 amps or higher at 12V output, but the AX1600i has another feature that may help the project succeed, that is, the ability to manually set the 12V current limit output. Since the AX1600i is a digital power supply, it allows to manually set the current limit of the 12V output through the Corsair Link data acquisition and control software, so I can add the function of selecting the required amperage for welding. Yes!
Just because the AX1600i "can" provide 133A current does not mean that I need so much current for welding. When I use a ¼” electrode to weld heavy steel parts, I usually only use that much power. For this experiment, I hope to start with a lower amperage, and I hope the Corsair Link software can provide this capability.
Use PC power supply for bar welding!
My first idea was to try to use TIG (tungsten inert gas) welding machine with AX1600i. I think using a TIG torch (a tungsten electrode covered with argon rather than a flux-coated rod) might provide better control, especially at the lower voltages and currents I plan to start testing. TIG welding machines are usually used for welding small stainless steel parts and metal plates. But then I remembered that the TIG welding machine power supply has a built-in high voltage pulse to start the plasma arc. Without additional activation, it may be difficult to generate an arc without damaging the fine tip of the tungsten electrode. So I decided to just use the traditional bar welding setup. The fact that the PC power supply outputs a DC voltage will have an advantage over the more common AC beehive arc welding machine, which can achieve better stability and produce higher quality welds.
Obviously, trying to convert a PC power supply to an arc welding power supply requires some modifications. The following is a quick list of the main challenges that I think we must overcome.
• Higher capacity fan for better cooling • Terminate all PSU 12V cables to welding leads • Disable short circuit protection function • Implement the current output required for selection • Use only 12 volts to trigger and maintain a stable arc
More airflow: AX1600i is designed for relatively quiet operation, which is not a problem during arc welding. To ensure that we have good cooling air flowing through the power supply, I took out a huge Delta fan, which I left over from the old water-cooled radiator test system.
This fan is a bit thicker than ordinary fans (38mm vs. 25mm), so I will install it on the outside of the PSU case. The large Delta air turbine spins at a constant speed of 8,000 rpm. It sounds like a hair dryer, but it moves a lot of air, which will keep all internal components cool. It's better to be safe than regret.
Terminating cables: I decided to use all 8 PCI-E cables and two 8-pin CPU cables to provide 12V output for the solder leads. The 24-pin ATX connector will be inserted into the control panel with the On-Off switch to power our PC welding machine, and one of the 4-pin peripheral cables will be used to power the backpack-mounted Delta fan.
I plan to start using positive polarity when welding, which means sending the positive output to the ground clip and the negative output to the stinger lead. Use 12 heavy-duty terminals for conversion. So far so good.
Disable SC protection: This caused me some troubles, but in the end, with the help of Corsair insiders (no promised name), I was able to identify and very carefully disable the security protection circuit chip on the digital control board.
The digital control board is located in the upper left corner of the figure above. This is by far the most difficult task to complete. An incorrect operation here may damage one of the DSP (digital signal processor) chips, which will cause the Corsair Link interface to fail and the PSU cannot be used.
Achieving the over-current set point: Being able to select the multi-rail output mode for the 12V power rail and manually setting the over-current limit via the included Corsair Link software is a huge help. I didn't realize it at the time, but by disabling the safety protection circuit, we also eliminated the problem that might trigger an overcurrent shutdown. Yes, this does bring some additional risks, but we know to enter this project. With security protection disabled, the power supply should now only limit the current supplied to each 12V power rail to the set point input through the Corsair Link, instead of shutting down.
As you can see in the screenshot above the Corsair Link Home tab, Multi-Rail operation is enabled, and all ten 12V outputs of the PCI-E and CPU cables have been set to 6A (6A x 10 = 60A combined 12V Output). This seems to be a good starting point. I can go back anytime and try different settings as needed.
As mentioned above, all 10 12V outputs have been wired and terminated in the two welding cables connecting the ground clamp and the stinger.
By changing the overcurrent limit of the 12V output, I hope to be able to select the available output capacity for the PC welder. When you trigger an arc, it will show that the PSU is completely short-circuited, which is why we must disable the short-circuit protection. By setting a current limiter on each 12V output, the PSU should basically be in constant current mode. Unfortunately, I can only change the settings when the PSU is actually connected to the computer to run the Corsair Link software. But to be safe, I disconnected the computer before entering "welding mode". I may be a little crazy, but I am not stupid!
Okay, we have already considered... the modification is complete... the AX1600i has been tested and it seems to be still working!
I will start using a 1/8” 6010 DC stick and see what happens.
Turn on... the fan is screaming... it's time to light up...
It is indeed a challenge to start an arc and maintain stability with only 12 volts, even if there is enough amperage available. The current limiter is set to provide only 60A (just sticking to the rod all the time when the arc is not established), and I have no luck. Usually this amperage is fine for a 1/8-inch rod, but I found that I need more amperage to generate more heat to maintain a sustainable plasma arc. There is nothing I can do about this other than working on my technology.
The main goal is to see if we can run a short bead and glue two steel plates together. It's not pretty, but...
Bottom line, this is crazy. You can buy a relatively inexpensive rod welder or MIG welder for light household use for less money than the Corsair AX1600i digital power supply.
I hope you like our little experiment, but please don't try it at home.
Note: During this experiment, no PC power supply was permanently damaged or damaged.
This is not for what! This is not for what! 😀
This makes you worse than a cryptocurrency miner! ! ! 😀😀😀😀
Oh come on jon, this is ok
Oh Jon, this could become a huge new market for pirate ships. Think about the possibilities!
There are some problems now. Now I will ask questions for every power review in the future... But can it be welded?
I know it was mentioned jokingly for a few years at least during the power review.
It's fun to see it put into actual use!
I have seen a technology. It means I have seen a technology. The Linear Power car audio representative bridged one of its 2 ohm stable mono amplifiers from hell to the fuse, then proceeded to "weld" some metal plates with the output, then reconnected it to the fuse system and pumped it Give a pair of Fosgate Punch Pro 12-inch DVCs all the way up... it sounds perfect. Back in the day, the linear power supply has surpassed the engineering amplifier...exp is also terrible. All power circuits use mil. Specifications TO-3 packaged transistors are flush mounted on a large amount of alum. Radiator with active cooling setting in 2 fan push/pull cofigs. I have a 2x250w RMS 2 ohm stabilized LP amplifier, rated for 4 ohm stability in mono mode, and rated power of 600W RMS.
Would love to use the old high-end amplifier with a modern 1200-1500 watt PSU to power the amplifier stage itself with Frankenstein. Not too thick... ATX PSU and car audio systems are mostly 12VDC systems. Oohahahaha...
Say I'm crazy, but I say I'm crazy, but I'm pretty sure this will invalidate the Corsair's warranty 🙂
If someone tries to obtain the warranty for this power supply due to a welding problem, I would love to hear a conversation with a Corsair representative.
Hey, I saw MacGyver soldering. Hey, I saw MacGyver soldering on a TV with a 12V car battery, so I knew it was possible! Very well written, guys-this is great!
The amperage provided by the car battery is several times that of this PSU.
Yes, you can actually use the battery, not just on MacGyver.
I think this is more common because I think it is more common to use two in series (I see ymmv), but this commenter is correct. People also use them with Fets for spot welding. According to the settings, this has some dangers, but it works
It reads great! ! ! I am a welder great reading! ! ! I am a welder and a computer enthusiast. It's so cool to see two worlds collide. I would suggest that you try again, but don't try to run 7018 with 6010. The arc produced by 7018 is less violent and easier on the welding machine, or in this case, PSU will make the arc more stable and easier to control.
yes, I agree. I usually use
yes, I agree. I usually use 7018 electrodes because they are easy to weld-perfect for people who only weld. Unfortunately, I went out and only had 6010 on hand. Maybe it should take time to buy some 7018 sticks. Thanks for your input!
Jarre finally did it! Did Jarre finally do it! Can't wait to hear this on the podcast.
E6010 poles need more. E6010 poles require more violent arcs than other poles. You should try E7018. Since there are fewer sporadic arcs, they may perform better. I would love to see what happens
130 amps won't run 1/4 inch 130 amps won't run 1/4 inch rod, haha, my Lincoln 300 advantage runs in the range of 280 to 350, depending on where I solder, but I do like this project Well planned! A new standard has been developed for each PSU, haha, but now it can be welded in all lists
It may be better to use several power supplies to connect them in series and parallel arc welding at the same time.
But then I remembered TIG
But then I remembered that the TIG welding machine power supply has a built-in high voltage pulse to start the plasma arc. Without additional activation, it may be difficult to generate an arc without damaging the fine tip of the tungsten electrode.
In fact, the damage is not that serious. When I started working at sea 25 years ago, the TIG welding machine finally started to become sturdy enough to be trusted for 99% of the working time.
We also have POWCON rod welding machines, those literally always working utensils, you can also use them for TIG welding, and a special TIG welding gun with a gas valve on it, so you can cold start/stop the air flow , And then you start welding by tapping tungsten on the metal.
Photo of the strike torch: http://gowelding.org/wp-content/uploads/tig-cup-sizes.jpg
Of course, a high-voltage pulse is a better way to start welding, but if needed, a torch can work well.
I've read that you need 16v to I've read that you need 16v to ionize argon
According to the Fronius website According to the Fronius website (IMHO, money can buy the best welding machine, after Corsair😉, one of the smaller TIG welding machines has a working voltage of 10,1-16,8V. https:/ /www.fronius.com/ en/welding-technology/products/manual-welding/tig/transtig/transtig-puls/transtig-1750-puls
The working voltage of larger machines is 10,1V – 46V https://www.fronius.com/en/welding-technology/products/manual-welding/tig/transtig/transtig/transtig-5000
So 12V should work normally.
So you just "carefully" so you just "carefully closed the safety protection circuit"? And the PSU will never run in constant current mode. I don't buy any of them.
Come on, illuminate people——
Come on, relax-check your calendar-what day is today? ? ?
The best article in years LOL The best article in years LOL
April Fool's Day. Love April Fools' Day. love it.
Hey Li, you really let me Hey Li, you really let me go there. You use a logical framework and enough technical details to write this story to make it so credible. Then completed the transaction with all the "staged" photos. well done! This should be one of the best April Fool's Day spoofs ever. Thank you everyone at PCPer for making this happen.
The article idea of 4-1-2019, the article idea of 4-1-2019, use Lincoln Welder to power your crypto mining equipment. 🙂
https://www.homedepot.com/p/Lincoln-Electric-225-Amp-Arc-Stick-Welder-AC225S-230V-K1170/100041326
By the way, you can isolate the PC power supply and run the three in series to obtain a maximum of 133A of 36V. A car audio 50F capacitor is connected in parallel to each PS to avoid OCP from ending your fun.
https://web.archive.org/web/20170902033627/http://ac8gy.com/pc_supplies.html
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