Society of American Silversmiths - PUK Pulse Arc Welders Reviewed, PUK04 Review

30/11/2017 Society of American Silversmiths - PUK Pulse Arc Welders Reviewed, PUK04 Review
Review & Usage of Lampert's Pulse Arc Welders

© Jeffrey Herman
Jeffrey Herman disclaims any responsibility or liability for damages or injuries as a result of
advice contained on this Web site.
Overview
(updated 5/16/2016)
Lampert Technical Papers

(updated 9.9.2016)
PUK04 Welder Settings

Download settings here
(updated 8/25/2014)
PUK Blog
(updated 11/29/2017)
Troubleshooting NEW
(updated 9/1/2015
Avoiding Pain When Welding for Long Periods

(updated 3/16/2014)
http://www.silversmithing.com/puk.htm#Settings 1/120
Overview
As any silversmith knows, silver solder is the ideal material to use when joining sterling pieces by the
traditional method of brazing. Sometimes I will receive an object which has been lead-soldered in the
area in need of repair (or re-repair). Sometimes the joined area is not visually accessible, and I don't
know if lead has been used.
In either case, I cannot use silver solder because the high temperature required will melt any lead in the
joint and allow it to form its own alloy with the silver. Not pretty! And, using a low temperature tin/silver
solder won't give me a sound joint or good silver color. For this reason, I had been exploring newer
technologies for joining metals. I tested laser welders from a few manufacturers, but found that their
compartments are too small for working on holloware. In addition, they are expensive to buy and
notoriously expensive to repair, and the down-time for repairs can be substantial. I also tested the Mini
Pulse III (an arc welder) from Aelectronic Bonding, which had too few welding power options and didn't
allow me to get into tight spaces.
I tested a friend's Lampert PUK2 pulse arc welder for a few months, and refined my technique to the
point where I felt confident to purchase Lampert's PUK3s Professional, which was developed to weld
silver more successfully. I was so impressed that I soon purchased the PUK3s Professional Plus which
had a broader power range, additional impulse settings, and five programmable settings.
PUK 3s Professional PUK 3s Professional Plus
Since I use the PUK on a daily basis, it was only natural to upgrade again to Lampert's latest model: the
PUK04, which has the following advances over the previous models I've owned. Features in bold were
the most important to me:
• Touch-screen programming.
• Smaller footprint;
• Exclusive "soft start" pulse for even cleaner welds and less electrode tip embedment;
• Substantially less cracking when welding and using filler wire for an even stronger weld;
• Minimum impulse setting: .5 milliseconds – critical for ultra-thin metal (the PUK 3s Plus: 3ms);
• 33 programmable settings (the PUK 3s Plus: 5);

• Three LED intensity settings.
PUK04
Above: As with every PUK I've owned, this latest model also sits to the right of my main bench where I
can pivot left to get access to my abrasive and burnishing tools. I set up ventilating behind the welding
area to capture all metal fumes. Venting or using the optional smoke absorber is a necessity, as with all
other forms of welding which produce metal fumes.
The electrodes
The 10 electrodes come pre-sharpened on both ends. I wait until I have used all 10 electrodes (20 tips)
before sharpening them at the same time with the supplied mandrelled diamond disk. This saves time. I
mount the disk in my Foredom handpiece and secure it to the bench over the dust collecting vent. The
recommended tip angle is 15%. Electrode replacement in the PUK handpiece can be accomplished
within five seconds.
Advice on welding larger objects
Whether it be pulse arc or laser, welding isn't meant to substitute for brazing large objects. Welding long
seams (e.g., on coffeepots or candlesticks) is more time-consuming than simply using the welder to tack
a seam in preparation for brazing.
If attaching parts to large bearing surfaces (e.g., a large finial to a coffeepot cover), it's best to tack the
part in place, then use the capillary action of torch-brazing to fill the void. Always consider the time it will
take to weld or braze and the subsequent clean-up.
The handpiece can be removed in three seconds for welding freehand.
PUK04
Lampert pulse arc welder highlights
Uses the same alloy as the piece being created or repaired (no color issues as with solder);
Tacking eliminates the shifting of joints and the time involved in wiring-up an object;
Repair objects without harm to stones or patinas;
Attach findings without losing metal hardness;
Work on material as this as .001";
No firescale or firestain due of argon protective atmosphere;
Localized heat won't melt nearby joints or damage stones;
Fill in porosity with the same alloy;

Simple and intuitive to operate;
Certified product safety: GS & CE marks;
DIN CERTCO certified eye protection in the microscope lens;
Maintenance-free;
Small footprint - fits into every workshop;
Very low cost of consumer materials (electrodes);
Extremely low argon consumption compared to other systems (I use only 1.5 lpm);
Touch-screen operation;
Easy-on, easy-off handpiece nozzle when changing electrodes;
Built in Germany with attention to the minutest detail - you can see and feel the quality;
3-year warranty!
Lampert Workshop Papers (Subcribe to their workshop series here.)

PUK3 settings: Papers #1-16
PUK04 & PUK5 settings: Papers #17-30
30 Welding duration http://bit.ly/2c56cGZ

29 Reattaching ear clip wires http://bit.ly/1gDSRT9
28 Using masking tape http://www.lampert.info/nl/workshop/Lampert_workshop_28.e.pdf
27 Repair of aluminum http://www.lampert.info/nl/workshop/Lampert_workshop_27.e.pdf
26 Repairs on hollow jewelry http://www.lampert.info/nl/workshop/Lampert_workshop_26.e.pdf
25 Removal of engraving http://www.lampert.info/nl/workshop/Lampert_workshop_25.e.pdf
24 Strengething prongs http://www.lampert.info/nl/workshop/Lampert_workshop_24.e.pdf
23 Contact tools http://www.lampert.info/nl/workshop/Lampert_workshop_23.e.pdf
22 PIN module http://www.lampert.info/nl/workshop/Lampert_workshop_22.e.pdf
21 Findings http://www.lampert.info/nl/workshop/Lampert_workshop_21.e.pdf
20 Repairing a bracelet http://www.lampert.info/nl/workshop/Lampert_workshop_20.e.pdf
19 Cuff links http://www.lampert.info/nl/workshop/Lampert_workshop_19.e.pdf
18 Designing a basket setting http://www.lampert.info/nl/workshop/Lampert_workshop_18.e.pdf
17 Repairing prongs & bezels http://www.lampert.info/nl/workshop/Lampert_workshop_17.e.pdf
16 Ring with bezel setting http://www.lampert.info/nl/workshop/Lampert_workshop_16.e.pdf
15 Impulse times http://www.lampert.info/nl/workshop/Lampert_workshop_15.e.pdf
14 Protective gas http://www.lampert.info/nl/workshop/Lampert_workshop_14.e.pdf
13 Joints and seams http://www.lampert.info/nl/workshop/Lampert_workshop_13.e.pdf
12 Welding pores http://www.lampert.info/nl/workshop/Lampert_workshop_12.e.pdf

11 Costume jewelery http://www.lampert.info/nl/workshop/Lampert_workshop_11.e.pdf
10 Silver http://www.lampert.info/nl/workshop/Lampert_workshop_10.e.pdf
9 PUK3 introduction http://www.lampert.info/nl/workshop/Lampert_workshop_09.e.pdf
8 Tacking bezels http://www.lampert.info/nl/workshop/Lampert_workshop_08.e.pdf
7 Tacking techniques http://www.lampert.info/nl/workshop/Lampert_workshop_07.e.pdf
6 Wires and prongs http://www.lampert.info/nl/workshop/Lampert_workshop_06.e.pdf
5 Ring-sizing http://www.lampert.info/nl/workshop/Lampert_workshop_05.e.pdf
4 Welding a loop http://www.lampert.info/nl/workshop/Lampert_workshop_04.e.pdf
3 Welding an ear post http://www.lampert.info/nl/workshop/Lampert_workshop_03.e.pdf
2 Adding metal http://www.lampert.info/nl/workshop/Lampert_workshop_02.e.pdf
1 The PUK principle http://www.lampert.info/nl/workshop/Lampert_workshop_01.e.pdf
Lampert Workshop Videos: http://www.youtube.com/user/LampertWelding/
Unit cost
The basic cost for the PUK04 is $5,295. It includes:
• PUK unit and microscope;

• Three different contacts (pliers, locking tweezers, and alligator clip) for attaching to your work;
• Handpiece;
• Welding mat;
• Microscope cover;
• 10 thorium-free electrodes with diamond disk sharpener;
• Metal compactor;
• Brass brush to remove any oxides or soot that may form on the piece you're welding. This will free-up
your flexshaft for other accessories.
WARNING! Shaded safety glasses and goggles made for oxy-acetylene brazing and welding are NOT
intended for arc welding. The flash that's produced when arc welding is much more intense and requires
the auto-darkening function found on PUK pulse arc welding microscopes and magnifiers.
Optional accessories I added:
This updated articulating arm ($575) allows me to work on larger objects underneath the microscope. It
swivels 360 degrees and secures with the twist of only one knob.
Precision regulator ($250). * This is now supplied with each welder and included in the final price.
When I was using the PUK 2, I tried a couple of different (and less expensive) argon regulators that
weren't nearly as accurate as the one from Lampert. Most argon regulators are made in China and have
graduated indicators that are too close together and/or have poor adjustment sensitivity, and very poorly
made (I returned two regulators before springing for the Lampert model). A regulator that doesn't give
accurate readings can lead to poor welds and wasted gas. The PUK regulator is very well made and has
more widely-spaced indicators to better indicate exactly how many liters per minute of gas is flowing.
Though it's priced at $135, it's a wise investment in German quality.
Argon gas, which protects the weld from developing oxides, is the other expense for running the PUK.
Without gas, the PUK won't run (and you would never produce a successful weld without it, regardless of
your chosen welding apparatus). To reduce the cost of argon, I would advise leasing a 300-cubic-foot
cylinder (5' tall x 10" diameter). I'm paying $125.50 per refill (includes hazmat & state tax) plus $50 for
the yearly lease. Argon purity of at least 99.97% is recommended by Lampert.
The industrial argon I'm using from my local Airgas company is 99.997% pure. These are the additional
specifications on my argon:
Carbon Dioxide: <1ppm

Nitrogen: <20ppm
Oxygen: <5ppm
THC: <1ppm
Water: <10.5ppm
Dew Point: -76F
I have been running the PUK on 1.5 liters of argon per minute regardless of the alloy I'm working with.
The headrest
* Available on PUK04 models manufactured BEFORE May 2013) $65.
* Available on PUK04 models manufactured AFTER May 2013) $77.
The PUK04 headrest allows relaxed and fatigue-free working with the welding microscope. It also helps
maintain concentration on the workpiece and eliminates fogging and the deposit of eyelash oils on the
microscope lens.
Additional electrodes – each set supplied with a diamond grinder and case ($45). See electrode
sharpening here.
Additional optional accessories
1. Pin module for welding ear studs

2. Welding wires
Gold Au 750/000 - 18K 500mm x 0,25mm (19,7" x 0,01")

old Au 585/000 - 14K 500mm x 0,25mm (19,7" x 0,01")|
Platinum Pt 960/000 500mm x 0,25mm (19,7" x 0,01")
Silver Ag 940/000 1000mm x 0,35mm (33,37" x 0,014")
Palladium-Silver PdAg 500/000 500mm x 0,40mm (19,7" x 0,016")
Pure-Titanium 1000mm x 0,30mm (39,37" x 0,012")
Tin - pewter 99.9% 100g x 0,75mm (3.52oz x 0.029")
Aluminum ALMG3 (for applications on AlMg alloys up to 3% Mg)
Aluminum ALSI (for applications on AlSi alloys up to 12% Si)
Stainless steel CMS
Steel GS2 (for hard facing applications 58 HRC)
Steel GS55 (for highly wear-resistant applications - 61 HRC)
3. Magnifying lens
4. Third hand
5. Welding smoke absorber (highly recommended if you have no localized ventilation)
6. Foot pedal
Catalog of PUK accessories.
Welding Wire Alloys
Rio Grande has an excellent selection. Below is a partial list:

Sterling / Argentium Sterling / Argentium Sterling Extra Hard / 14 Yellow Gold / 18 K Yellow Gold /
Platinum
Definitely purchase a Speedwire Welding Wire Dispenser (not a Lampert product).
Welding wire spooled in containers like the ones above make it difficult and time consuming to steady
thin wire exactly where you want it (it tends to flop around). The Speedwire Welding Wire Dispenser
makes thin wire much easier to weld since it puts it exactly where you want it – without movement.
Speedwire allows wire as this as .005" (.127mm) to be dispensed, though, you'll probably be using the
more widely available .010" (.25mm) wire. I bought the refillable Speedwire ($23) and coil the sterling
wire myself on steel rod in my lathe, then relax the coil by removing the wrapped rod from the lathe and
gently annealing it while still attached. Speedwire can also be supplied with pre-installed wire of
numerous precious metal alloys. See the Speedwire in use here, and see how the receptical can be
filled. For more information and purchasing from the inventor, go here. Speedwire can also be
purchased from: Hoover & Strong, Rio Grande, Stuller, among others.
Conclusion
Using this relatively new technology has broadened my scope of options when joining metals. I can mend
a pinhole with a dollop of sterling, dress it down, and give it a quick polish without disturbing the patina.
The end result: absolutely no indication the piece was repaired - the color is perfect! I can repair a bezel
surrounding a piece of glass without removing it. Normally I would be forced to unmount the glass,
possibly damaging it in the process. I even used the PUK to weld a steel wire to the end of a hardened
steel pin that was buried in a candelabra stem. I heated the stem, melting the lead solder, and pulled the
pin out. How slick is that?
When I say I use the PUK every day I'm working, I'm not exaggerating. It was the most prudent (and
expensive) purchase I've ever made for my shop, but it's already paid for itself. Once you own this little
gem, it will open a whole new world of possibilities. Oh, another plus: Lampert Tools USA offers up to
five hours of free training when you purchase a PUK welder. Simply contact owner and goldsmith Robert
Sepiashvili in Chicago to make an appointment.
Overall rating
Lampert PUK04: (excellent)
Additional information
Lampert's Web site (Germany)
Distributor
Lampert Tools USA

Robert Sepiashvili
67 East Madison #512
Chicago, IL 60603
866/4PU-K111 (866/478-5111)
Technical Support
Lampert Tools USA

Robert Sepiashvili
67 East Madison #512
Chicago, IL 60603
866/4PU-K111 (866/478-5111)
Suppliers
USA
A&A Jewelry Tool (Los Angeles, CA)

BTI/Landa (Miami, FL)
Gesswein (Bridgeport, CT)
Kassoy (New York, NY)
Otto Frei (San Francisco, CA)
Rio Grande (Albuquerque, NM)
SEP Jewelry Tools (Chicago, IL)
Uptown Material House (New York, NY)
Canada
Lacy West Supplies (Vancouver, Canada)

Nobel Packaging (Montreal, Canada)
PUK04 Welder Settings (Download settings here.)

Revised 4/11/2014
The below settings have worked successfully on numerous pieces I have worked on in my workshop.
They should be used as guidelines only. MS = Milliseconds
Welding Sterling (updated 4/9/2014)

w/Sterling Filler Wire (.010"/.25mm)
MS Mode Power Deposit
1.5 Sterling (Thick) 26% Very Light
1.5 Sterling (Thick) 45% Light
2 Sterling (Thick) 50% Medium (I personally use this setting most often.)
3 Sterling (Thick) 50% Heavy
s
Welding Sterling
w/Sterling Filler Wire (.005"/.127mm - .010"/.25mm)
MS Mode Power Object Thickness
.5 Sterling (Thick) 22% .001 - .003 (.025 - .076mm)
1 Sterling (Thick) 30% .004 - .025 (.102 - .635mm)
s
Welding Sterling (updated 4/9/2014)
3 Sterling (Thick) 55% Very Light

5 Sterling (Thick) 60% Light
9 Sterling (Thick) 65% Medium (Warning: burn hazard - hold with insulated pliers.)
16 Sterling (Thick) 65% Heavy (Warning: burn hazard - hold with insulated pliers.)
s
Welding Sterling (for depositing filler wire on an extreme angle)
MS Mode Power Electrode Tip
1 Sterling (Thick) 30% Sharp
s
Welding Sterling (that has been plated with fine silver)
1.5 2 (Expert) 45% Medium
Welding Sterling
w/Palladium/Silver Filler Wire (.010"/.25mm)
3 Sterling (Thick) 50% Medium
s
Welding 14K Yellow Gold
w/14K Yellow Gold Filler Wire (.010"/.25mm)
1.5 Gold (Thick) 45% Medium
s
Welding Copper
w/Copper Filler Wire (.010"/.25mm) Below settings are guideline as there are many copper alloys.
MS Mode Power Electrode Tip
3 8 (Expert) 55% Sharp
3 8 (Expert) 65% Dull
s
Welding Brass (updated 4/11/2014)
w/Brass Filler Wire (.010"/.25mm) Below settings are guideline as there are many brass alloys.
Brass (Thick) 50% Medium
2
s
Welding White Metal
w/Pewter Filler Wire (cut thin strips from .010"/.25mm sheet stock)
1.5 Sterling (Thick) 45% Medium
PUK Blog
11/29/2017: Welding thin silver
This sterling coffeepot cover had chased beads that were over polished leaving voids. The image on the
right shows those voids filled. I used the prong setting feature with 30% power, 1.5 ms, and smoothing
mode for speed. After filling the holes from the top, I flattened the resulting weld nodules on the inside
using the same settings.
10/5/2017: When a pulse arc welder is your

absolute BEST choice for a restoration
The cherub of this sterling bell had broken off at

its left toes and right ankle. Since it was
originally brazed to the top of the bell, the welder
was my only consideration. I was able to make a
seamless mend using Argentium welding wire
topped with sterling for a perfect color match.
Since the cherub was cast, Argentium produced

a much stronger join.
9/16/2017: When color is EVERYTHING!
The sugar shaker on the left lost its top and the collector requested that I create a new sterling piece
using the salt top as an example. I made tubing and raised in the top then welded a cap in place with
sterling for a perfect color match. I brazed half-round wire to the tubing and drilled the holes before
polishing.
9/12/2017: Filling engraving on a sterling Montblanc pen
PUK 5 Settings:
Alloy: Silver
Mode: Prong Tipping (This was a sterling barrel with plastic insert which required a delicate setting).
Power: 30%
MS: 2
Questions? Feel free to e-mail me here.
6/23/2017: Argentium welding wire
What I especially appreciate about the Argentium welding wire is that successful welds without center-
line cracking can be accomplished with blunt electrodes, saving time. And as I mentioned previously, this
alloy offers impressive results when welding hardened sterling and other silver alloys. And if you're
lacking brass welding wire, the Argentium works equally well when welding brass objects. Did you find
yourself short of stainless welding wire? Another reason to have Argentium on hand!
6/17/2017: Gap-free ring shank seams
One method of welding ring shanks so there are no gaps on the back side is to attach a very thin strip of
metal to the back of the seam. Run your electrode into the v-groove over the entire length of the seam,
melding the strip to the shank. Then fill the groove with your welding wire. You'll notice there will be no
gaps after grinding away the strip after welding.
2/26/2017: Closing a ring shank

This sterling ring had been cut open and expanded for a larger finger. I first closed the separation (left)
and used a triangular file to form a "V." I then welded the bottom of the V in order to close the split. I filled
the V with sterling using .010" in the bottom half and .017" wire to the top, adding extra for burnishing.
The reason I used the larger diameter wire was to fill the void more quickly. I filed the seam until there
was a paper thickness of metal from the shank. Next came light burnishing of the top and underside to
compress the silver. I finished with 2000-grit silicon carbide paper and bronze wool as a final finish to
blend with the rest of the ring.
2/4/2017: Filling large splits
The sterling match safe below required the striker split to be filled with sterling. The thinnest material was
.005" while the primary body thickness was .015". I used .017" wire and placed it on a slight angle over
the void then positioned the electrode directly over it, pulsing the wire into the approximate .040" wide
opening. The wire spread (sprayed) over the entire void. The reason the thinnest material didn't vaporize
was because the wire temperature had lowered by the time it attached to those areas.
Before attempting this technique, experiment on a piece of scrap silver to make certain you calibrate the
proper settings.
11/19/2016: Pressure splits
Sterling belt buckle splits aren't unusual because of the pressure exerted upon them when securing the
belt. This was the case below; in fact there were breaks on both sides. I opened the splits with a v-
shaped graver and filled 3/4 depth with Argentium welding wire which made the repaired area much
stronger than using straight sterling. I then topped it off with sterling for a perfect color match. And since
the hinge pin was a bit loose I decided to tack it in place so it wouldn't come out.
10/21/2016: Why are my electrodes moving into the chuck as I weld?
1. Your chuck isn't tight enough. Apply more HAND PRESSURE when tightening;
2. You're using the larger chuck jaws which won't secure the smaller diameter electrodes;
3. When installing electrodes, the oils in your fingers have been deposited in the chuck jaws making
them slippery. Remove the chuck jaws and degrease them.
7/15/2016: Welding objects that have been hardened from stamping or forging
This wrought sterling butter spreader snapped in two probably because it was too brittle. This is another
case where Argentium silver welding wire had to be used because of the object's hardened state. I filed
all the edges of the break (front and back) to a point and welded the blade to the handle with the
Argentium. I continued filling the gap until it was about 2/3 filled. Because the Argentium color doesn't
quite match that of standard sterling, I pulsed sterling in the remaining 1/3 of the void then finished it with
2,000-grit paper and 0000 steel wool to match the rest of the piece.
6/8/2016: Do you miss the versatility of the three outlets you had on the PUK04?
Don't worry, on the PUK5 you can piggyback the connectors...
5/15/2016: Testing the new PUK5: Welding Argentium Sterling 935 with Argentium silver welding wire
Two pieces of sheet were angled and tacked-welded at the top and bottom corners prior to flooding the
v-groove with the welding wire. The sheet was then folded. (The line along the left edge of the weld is not
a crack.)
As with the previous test welding Argentium using the PUK04, this test was also successful using the
PUK5 and it's programmed welding wire setting of 4ms and 45% power.
5/2/2016: Testing the new PUK5
Last week I started testing the new PUK5 and comparing it to the PUK04. The PUK5 sits to the right.
Preliminary testing compared to the PUK04...
* Smaller footprint;
* Simpler display;
* Single button control;
* Faster welding speeds;
* New "smoothing" feature flattens your welds for quicker finishing;
* More comfortable rubber eyepieces on the microscope (crucial for long periods of welding);
* More affordable: $4,795 (regulator included!). The PUK04 base price was $5,295 not including
regulator.
PUK price list of equipment and accessories.
4/9/2016: Brazing to a convex surface.
This Tiffany sterling ladle handle was missing its bird finial. My
customer found one that closely matched the original. Normally I
would have had to pin the bird in place, but all I had to do with the
PUK was tack it in a couple of spots then braze it and apply a

patina to give it an aged appearance. Prior to brazing, I drilled a
small hole in the ball to let out any moisture that may have
remained inside. After the brazing I welded the hole closed.
3/29/2016: Edging
This fused plate finial support was in two pieces and crushed. Being sterling fused to a copper core
meant that I had to add sterling to the edge when reassembling. Normally, the sterling on the top edge
would have been burnished over the copper concealing it. The welded sterling accomplished the same
thing. Here the welding is in its raw state prior to burnishing and finishing.
3/18/2016: Adding to a compressed casting
This is the top portion of an enormous cast sterling candlestick. It had been dropped on its edge and
dented. If I hadn't had my welder, I would have had to cut sterling sheet and brazed it in place. Being able
to fill-in the dent went much faster. Since this was a substantial dent, I used .020" (.51mm) dead-soft
sterling wire with settings of 9ms, the "thick" setting mode, and 65% power. Welding time was
approximately five minutes. All that's left to do is blend the weld with the rest of the rim and polish.
1/29/2016: When there's no other alternative
The customer of this sterling inkwell wanted major dents removed but didn't want to go to the expense of
having me remove the plaster and push them out. Not a problem, I just filled them in with sterling!
1/27/2016: The PUK5 makes its debut!
Get all the details here on what makes this PUK even simpler to use.
1/5/2016: Make your electrodes last longer!
Are you looking to use your electrodes longer between changes? Try grinding a longer taper and don't
put a definite point on the end. If you leave a flat that's .001" - .002" in diameter it won't be blown off and
you'll be able to use that point for a longer period.
12/30/2015: Welding Vermeil Filigree
This Chinese vermeil and enamel container cover came to me very sad looking. The best way to repair it
was to push up the right side of the finial then cut the soldered connections around the middle. I then
reformed each "cup" over a dapping punch and welded the connections with 14K yellow gold. Using any
method other than pulse arc welding would have been problematic because I would have had to remove
the finial stone and the plating would be destroyed from the heat.
This was one of those "make it salable" jobs for an antique dealer, so I made it look presentable without
doing a full restoration which would have been very costly.
10/9/2015: Welding sterling with inlaid enamel
This type of restoration was always tricky prior to pulse arc welding since I would have had to use a low-
flo lead solder.. The key fob – which was only about two inches in diameter – had its shield reattached
twice with laser welders. The customer noticed that I offered a different technology and asked if I would
try it. Upon receiving the fob, I removed the previous welded material on the contact points so I could
start fresh. I then angled the bottoms of the feet so I could weld into and out of the bottoms, making a
complete connection to the ring. I gave the customer a on-year warranty against the shield falling off
under normal handling conditions.
10/6/2015: Another instance where tacking saved time
The plain portion of the handle on this 13" punch bowl (not including the handles) had to be removed and
dents filled with sterling. (It was a casting that was too heavy to pull out the dents.) Reattaching it required
no binding wire or other holding device, only four pulses with the welder to secure it in place. I removed
the handpiece from its holder and did the welding freehand while looking away when I heard the "beep"
– the indicator when the capacitors are about to discharge. A liquid flux was then applied to the seams
and the bowl sprayed with liquid flux via a Badger airbrush to prevent firestain.
8/11/2015: New alloy for welding standard sterling and Argentium sterling.
Sterling test: There are instances when putting a weld under stress is better handled by using a
different alloy than what's being welded. In this experiment, I beveled the edges of two flat sheets of
standard sterling. The starting dimensions of the sheets butted together were .450" x 1.5" long x .038"
thick. I deposited Argentium laser and arc welding solder (76% fine silver) into the "V." The sheet was
bent on the weld to the form what you see below, then polished along the welded seam. I found that the
solder performed at least as well as Lampert's palladium/silver welding wire – with a better color and at
a substantially reduced cost. Remember, you can always leave a few thousanths on an inch in the weld
area in order to layer sterling on top for a perfect color match. If you are interested in purchasing the
solder, it's currently only available from Cookson Gold in the UK. Their wire is 1.44mm square and will
have to be drawn into thinner round wire. The material will soon be available as actual welding wire from
Rio Grande.
Argentium Sterling test: I used the same technique using the Argentium laser and arc welding solder
on 935 Argentium sterling sheet (below), but this piece was hammered flat after bending. Impressive.
7/72015: Working on objects containing lead solder and lacquer
There are times when no other method of restoration is practical other than pulse arc welding. The piece
below is a detail of the Hartford Bishop's crozier. It came to me containing lead solder from a previous
repair and poorly applied lacquer. Two thistle elements had become detached. I was asked to remove
all traces of lead that was used to solder the elements in place. The heat of the torch also discolored the
lacquer - what a mess. I was able to reattach the thistles without further damaging the lacquer and
coated those areas with Renaissance wax. The crozier will have its lacquer stripped and hand polished
at a later date.
The image below shows the reattached thistles.
3/28/2015: Welding when contaminants are present on a piece
There are times when welding that no matter what you do, the weld fails. Perhaps there are minute
amounts of dirt on the inside of an object that you can't see or remove. Maybe the inside of a piece was
never cleaned after brazing and corrosion developed. There may also be areas that were repaired with
unknown solders. Whatever the case, here's a technique I developed when I had this very problem. I was
working on a double-walled sterling oil lamp which developed a small hole allowing vegetable oil to leak
into the basin. I removed over two cups of oil, but was unable to remove the basin cover to thoroughly
remove the residue. A solder seam had opened and needed to be welded closed. I removed the solder
in the seam and hoped the oil residue wouldn't contaminate the joint while welding. It did. Whatever
setting I used would allow the oil to migrate to the surface. I decided to try something radical. I ramped up
the milliseconds to 20, chose the thick setting, and cranked the power to 60%. What happened, I
believe, was the seam and surrounding area was cauterized from the extreme blast. Whatever
contamination was on the inside of the basin disintegrated and the seam closed. I was now able to
continue welding with sterling wire on top of this clean material.
I would never recommend to a beginning welder to attempt such a major step up in milliseconds and
power, especially when working with material thinner than .032" (.811 mm). I had been using 2
milliseconds with 50% power prior to the experiment. I would recommend ramping the welding
milliseconds and power gradually to see how the metal reacts. What you want to avoid, at all cost, is
blowing a huge hole in your piece that will require a major repair.
2/7/2015: Refilling a Speedwire
I have provided a video on making your own coiled sterling wire for Glenn Manning's Speedwire.
1/9/2014: Using prongs to hold pieces together
The piece below is part of a candelabra. A candle cup broke off of one of the arms and had to be
reattached. In this case, I didn't tack-weld both pieces together because soot may have been deposited
inside the seam making it more difficult for the solder to flow. I devised a method to hold the pieces
together by tacking four wires (prongs) to the bottom of the candle cup. I applied flux inside the seam,
assembled both pieces, then pushed the prongs over, securing the arm. This enabled me to rest the tip
of the solder wire against each prong when the cup and arm came up to temperature, allowing the
capillary action to carry the solder around the seam. After removing the flux I filed off the prongs.
12/17/2014: Extended use for Lampert's welding spool
Some of you may be using Lampert's welding wires. I generally use their palladium/silver wire as they're
the only company making it. If you're drawing your own wire that's too thick for the Speedwire system, re-
use Lamper't spool! I ground away the tabs that hold both plates together, drilled a hole through the inner
walls so the wire will stay still while winding, then installed a nylon 1/4" hex head bolt, two washers, and a
nut. Voila, a stable method for holding your wire (in my case, below, it's .020"). The nylon components
are substantially lighter than steel.
11/23/2014: New Option for Attaching PUK's Flexible Contact Strip
The candlestick below had a stem that was too large for the flexible contact strip to fit around and the
other contacts would have left a light mark on this new candlestick. I decided to use aluminum tape to
fasten the strip, eliminating the need to refinish the contact area.
10/19/2014: Tool repair. Have you ever dropped a cast iron tool on a
cement floor? I have. You cry a little then you reshape it. Or, you braze
some brass rod or silver solder to rebuild the tool. Or, you can use your
PUK! This cast iron spoon stake chipped when it fell on my cement
floor. I used the stainless steel setting on the PUK and rebuilt the
missing piece with some heavy mild steel wire, then reshaped the
repaired area. (Shown is the welded area prior to finishing). There's no
messy flux clean-up and you'll maintain the finish on the rest of your tool
– no repolishing. If you have a very heavy T-stake with some porosity,
welding will take much less time and without heating a large area with
your torch.
10/19/2014: This money clip broke on its spine from too much stress. It was welded back together with
palladium/silver wire and built up around the break, adding strength. Welding was the only practical
option for this repair because of the inlaid stones. Because of the tension exerted on the spring, silver
sheet was welded to the spine for extra support and tapered around the back for a more appealing
appearance
8/25/2014: Welding Objects With Hard Fired Enamel
If you ever repaired an object containing enamel, you know how difficult it can be, especially if the object
requires soldering. You can't use silver solder because of the danger of damaging the enamel. And lead
solder won't give you a secure or attractive result, but that's the only method available in your workshop.
If you create or restore enameled objects, you may want to consider a pulse arc welder since the heat is
so localized no harm will come to the enamel. This pot needed its handle secured and its dents removed
from the single-walled body, double-walled cover, and removeable tea strainer that sits under the cover.
There had been a rod extending through both ivory insulators. One end was hard soldered to the handle
and the other was peined over on the inside of the pot. Over time, this assembly loosened. I removed
both rods then welded new ones to the body, covering the holes. I then drilled holes through the handle
for the rods to extend and countersunk the holes. After I reinstalled the insulators over the rods, I attached
the handle with the rods protruding through the holes. I then pulsed down over the rods, spreading the
silver into the countersinks and securing all parts for an undetectable repair (below).
7/25/2014: Welding Stress Cracks

One of the many strengths of pulse arc welding is the ability to correct mistakes. For instance: you're at
the final stage of checking (thickening) the edge of a vase you just spent weeks raising and planishing.
Suddenly you discover a stress crack that formed down the side of the piece because the metal became
too hard. What do you normally do to repair the crack after you're done swearing? That's right, you solder
it or start over with a new piece of metal. The problem is if you use solder, the color difference will stand
out like a soar thumb. And this is where welding will save the day. You file a v-groove into the crack and
use a wire of the same alloy as the piece itself and fill it in. You've not only saved hours of production
time, you've corrected a mistake that will never be detected.
As a restoration specialist, I have been confronted numerous times with this issue. A bracelet or sugar
tongs that were flexed so many times a crack developed. Or a spun bowl that wasn't properly annealed
when made and cracked on its edge after hitting a tile floor. And that flimsy 18th century goblet that was
torqued when hand polishing and cracks opened around its stem. It's very satisfying returning a piece to
a customer knowing that a new technology produced a better result.
5/20/2014: Welding results in brittleness in sterling
Are you about to size a ring? Be aware that if you're filling the "V" you made with filler wire will be more
brittle than the rest of the ring. And I'm using a ring shank only as an example. On a hardened shank,
pulse a couple of layers of sterling in the bottom of the "V" using 2-3ms, thick mode, and 50% power.
Add a couple of layers of palladium/silver wire for a stronger connection to the shank and finish off with a
thick layer of sterling for a perfect color match.If you find that after welding you have to size up a quarter
to one half you should concentrate any hammer blows away from the weld. This will insure that the weld
will not split.
4/11/2014
2/28/2014: Welding a snuffbox hinge knuckle
Three-knuckle hinges should be easy to make, right? So why do I constantly see them with the center
knuckle smaller than the other two? Strange. That center tube MUST be longer than the others so it won't
take added abuse.
This 2.75" sterling snuffbox is a case in point. That cover was torn from the hinge. Removing the tight
hinge pin would have damaged the outsides of the outer two knuckles. This is where the PUK excels in
its duties. Using a triangular graver, I dug a groove between the knuckle and cover on the top and
underside. This allowed me to fuse more material between the two components. I wanted to duplicate
what would have naturally occurred with silver solder's capillary action drawing the solder between the
two components. I fused one thick layer of palladium/silver into the crevices since this alloy would
provide a stronger join than sterling. I finished by filling the rest of the crevasse with sterling for a perfect
color match to the snuffbox. The images below show the deposited sterling prior to leveling the area.
Below is the polished underside of the cover/hinge connection.
1/31/2014: Welding over multiple alloys (silver, copper, and lead)
Below is a fused plate cover to a Matthew Boulton urn. Fused plate (commonly called Sheffield plate),
was sterling sheet "sandwiching" a sheet of copper. This was the precursor to electroplating. In order for
the cover and rim edges to be connected, a very thin piece of sterling sheet (evident in the image) was
lead soldered to the edges, hiding the copper. If I used the same technique to close those edges, the
remaining strip may have pulled away from the edge, so welding was the safest and most logical
technique to use. I cleaned the area missing this thin sheet and proceeded to reconnect the cover and
rim split with palladium/silver wire. It worked brilliantly, as illustrated below. I will top the filler with a heavy
thickness of sterling for a perfect color match. This is just one more reason I enjoy using the PUK.
1/15/2014: This money clip developed a stress crack then broke from many years of use. It was welded
back together with palladium/silver wire. Removing the coin could have damaged it and brazing the split
would have softened the metal with no way to harden the overall clip. Because of the tension exerted on
the spring, silver sheet was added to the spine for extra support.
12/27/2013: The PUK04 comes through again with a sensitive weld

This welder never ceases to amaze me! The perfume bottle top below (actual length 3") was originally a
button hook. My customer wanted to use this hook in place of the missing top. I cut the hook and inserted
a sterling ball over the rod, then welded it in place with sterling. Pretty straight forward, right? Well, not
entirely. You see, the handle was filled with pitch, so the challenge was to weld the ball to the handle
without any pitch melting and contaminating the joint. I used a very sharp electrode with a setting of 1ms,
thick mode, and 35% power. The heat was so localized that the welding went along flawlessly!
11/1/2013: Excellent source for .010 (.25mm) dead soft sterling wire
Rio Grande – Rio also carries other metals in the same form as above.
10/5/2013: Electrode sharpening
We all have our own techniques when sharpening tools. Below is an image of me sharpening electrodes
in a very safe manner. When it's time to sharpen my 80+ electrodes, I do so all at once. I cut a pipe hold-
down so I would need only one screw to secure it to my bench over the inset 4" galvanized elbow that
connects to my dust collector. I use the diamond sharpening wheel that comes in each package of PUK
electrodes. Using very little pressure from my forefinger on my left hand, I quickly "twirl" two electrodes
into (not away) the wheel with the thumb and middle fingers of my right hand. Since I'm primarily welding
silver and using very little power, I grind relatively slim tapers. Though I have ground as many as four
electrodes at once, grinding only two at a time will give you more uniform tips.
9/25/2013: Removal of solder and plating critical when welding
I mentioned in an earlier post regarding removing silver solder from a match safe before welding.
Though palladium/silver wire may sometimes fill without removing solder, the absolute best and easiest
welds are accomplished when solder is not present. Another issue is the presence of a coating over the
main alloy, whether it's fine silver or rhodium covering sterling, gold over sterling, and especially lacquer.
Always scrape, abrade, or chemically remove this surface in order to work successfully with the
underlying alloy.
9/16/2013: Removing a hand mirror handle dent
Today I'm working on a sterling hand mirror which has it mirror-holding bezel lead soldered in place. So,
how to remove a handle dent (the customer didn't want any other work done)? In this case, I drilled a hole
in the bottom of the handle large enough to insert a burnisher to pop out the dent in the middle of the
handle. I then pushed a no-hole sterling ball into the handle and had it drop to the handle bottom, tacking
it in place. Below you'll see the ball totally welded in place before I add additional material and blend the
handle into the ball.
7/12/2013: Burnishing over a cast iron head
On objects made of thinner material, it's always best to support the piece from underneath when
burnishing so the area won't dent.
6/26/2013: Welding over firestain
Pulse arc welders don't like firestain; it sees it as an oddball alloy and won't react well with it, producing
an unsuccessful weld. Remove all firestain from the welding area to expose the pure alloy prior to
welding, otherwise, it will be akin to trying to solder over dirty metal.
6/10/2013: Filling in knife handle dents
Here I had a Georg Jensen sterling dinner knife that had been dented on its tip. It was no problem filling
in with a .020" / .51mm wire. The resulting restoration is undetectable.
6/7/2013: Restoring internal threads
Yesterday I was working on a sterling candelabra that had a candle cup with its internal threads worn
down. I used Lampert's palladium/silver wire to fill in the threads and retap the hole. This saved
considerable time over brazing a wire into the hole, drilling, then tapping. The reason for using the
palladium/silver was because the threads had been hardened from numerous times screwing and
unscrewing the cup from its threaded rod. This alloy excels in fusing itself to hardened silver, more so
than standard sterling. I then removed the stripped sterling rod from its arm (the bobeche disk is free-
floating over the arm), drilled and tapped a hole, then screwed in a new threaded rod before welding it in
place with the palladium/silver wire.
5/23/2013: The beauty of tacking
The silver creamer below illustrates just how easy and clean it is to get parts ready to braze or solder. A
few pulses from the PUK will position the attachment without the fear of movement. No need to worry
about binding wire melting or a third hand moving the piece out of place. Tacking this leg in a few spots
took only 30 seconds.
4/12/2013: Engraving Cleaner
There are times when using a glass brush can be messy and even get in the way of a good weld. Plus,
the tiny fibers can get lodged in your skin and can be very difficult to find. Today I made this engraving
cleaner which will free-up your flexshaft for other accessories. The screw can be loosened and rotated to
expose new material.
As with soldering, welding also requires a clean surface. This is especially true with engraving, which
can be very deep. When I see oxide build-up (not soot), I reach for the cleaner. The cleaning will also aid
in void-free welds.
4/5/2013: Filling Engraving
This rare Jensen piece shows its chased lettering filled with sterling (left). The image on the right shows
the finished job. I used 2ms, thick mode, 50% power. The material on this tankard allowed me to use a
more powerful pulse. Remember to always start with a less powerful setting so not to blast through the
object.
4/2/2013: Filling Engraving
Below is the bottom of a sterling creamer – part of a five-piece teaset that had to have the monograms
filled in. The material was too thin to eradicate, and the customer wanted a replacement monogram
engraved. See more of monogram filling here.
Top left: I removed all oxide in the engraving with Wright's Silver Polish and a horsehair brush (a typical
flux brush). It's best to start with a clean surface. I used silver polish since it's less abrasive than a glass
brush or 0000 steel wool.
Top right: the engraving being over-filled with sterling wire (I used these settings: 2ms, thick mode, 50%
power).
Bottom left: the monogram totally filled.
Bottom right: no trace of the monogram after planishing, abrading, and polishing.
3/10/2013: Flattening filler wire
On my PUK bench sits a small anvil for flattening my .010" / .25mm filler wire which comes out of my
Speedwire dispenser. There are times when I need a thin piece of sheet to fill a narrow split.
3/9/2013: Skimming (my term)
There are times when you'll want to build a heavier thickness on top of what you're welding. Below is a
weighted candlestick with the pitch still inside. Previous welds on this piece had not yet been refined, as
I simply wanted to get all holes filled first.
I'm using a much heavier .020" / .51mm wire on the edge of <.005 / .127mm sterling. This is a fairly
advanced technique, for you'll want to position the electrode on the edge of the wire, pushing a small
amount onto the area beneath with a light setting. I'm using the thick sterling setting, 1ms, and 35%
power. This would never be enough power to melt the entire wire, but will melt a portion of it. This
technique is also allowing for a much thicker base to weld to without blowing through the thinner material
beneath. Using a heavier wire will cover the hole much quicker than using .005" / .127mm, and will give
me a much thicker base to add heavier amounts of silver. Later burnishing will also result in a smoother
surface. Another plus in using thicker material will be found in argon savings.
Below: The filled hole
2/21/2013: Smoothing deposited metal
I discovered this technique yesterday which allows me to free-up my flexible shaft for welding
accessories. This $20 Dremel electric engraver, with its 9 power settings, hammers down, massaging
the metal while giving a beautiful smooth finish for light filing and sanding. I removed the engraver point,
polished the other end, and reinstalled it. The engraver is very loud, so I wear earmuffs. I feel the
deposited metal is much less traumatized than when working with many rotary burnishers which "pull" the
metal instead of compressing it like a rolling mill.
The area in front of the deposited sterling was finished with a #4 pillar file then 1200-grit wet/dry paper,
ready for polishing.
I will start searching for a quieter electric engraver.
2/20/2013: Cast iron/sterling welding
Yesterday I made a hanger for my grinding wheels' truing device. This is an example of successfully
welding sterling to cast iron. It's not a pretty connection (I wasn't concerned with aesthetics), though the
weld is extremely strong even though there is very little contact between both materials. I used the
sterling mode with the thick preset. Periodically removing any soot from the welding area will guarantee
a homogeneous meld between weld layers.
2/7/2013: Stainless welding
I did some stainless welding today with no filler wire. The blade in a dinner knife snapped off its tang. I
removed the tang from the sterling handle, welded its circumference, and made it ready for reinsertion. If
I had silver-soldered the two pieces back together, there most certainly would have been some etching
to the blade from the flux. Cleaning of the tang and welding took all of three minutes!
1/8/2013: White metal welding
Up to now I've been demonstrating how fantastic the PUK is at welding silver. You may remember the
successful test I performed on pewter. Yesterday I was straightening, leveling, and polishing a white
metal sailing trophy. One additional repair was required: reattaching the ship's wheel. White metal
generally melts below 300 F (149 C). Since there was a large gap that required filling where the wheel
meets the handle, I used some higher temperature lead-free pewter which melts at approximately 450 F
(232 C). I used the sterling setting with a time of 1.5ms, thick mode, 35% power. The pewter performed
beautifully, filling the gap and leaving a brighter color than a traditional tin/lead solder. (I do no plating, so
the pewter color was a great substitute for a silverplated finish. Plus, this was a repair, not a restoration
project.) The pewter also gave me a considerably stronger join. Gently bending the wheel back and forth
proved the welded areas were successful.
11/20/2012: Void-free welding
Below is an image of a piece of .040" (1.02mm) sterling sheet that was built-up to a thickness of .105"
(2.67mm) using .020" (0.51mm) sterling wire. Notice the lack of voids do to successful melding of weld
deposits. I used a setting of 2.5ms / thick mode / 45% power, pulsing over and around the sides of the
wire. I then dropped the settings to 1.5ms / thick mode / 45% power, and placed the electrode at a 45-
degree angle where the partially melted wire meets the sheet. This allowed the wire to puddle, melding
with the sheet and leaving no voids. I then cut a cross-section with a sawblade and finished the face with
2000-grit silicon carbide paper.
When building upon melted wire, make certain that there are no voids underneath, otherwise, the area
(when cut on a profile like the piece below), will look like a sponge and will not have structural integrity.
I welded two pieces of .040" (1.02mm) sterling sheet together with .020" (0.51mm) sterling wire, allowing
voids (the dark areas of the weld) to develop in the process. I then split the seam by bending,
demonstrating what can happen to a joint when not totally filled. Insufficient power was used when the
electrode was positioned on top of the welding wire. The result was that portions of the underside of the
welding wire didn't fuse to the sheet.
10/22/2012: Using brass wire wheels
When using a typical 3/4" brass wire wheel in a flexible shaft to remove soot and oxide build-up, use very
little pressure and a slow speed. Not doing so may leave brass residue on the piece you're welding and
will lead to an unsuccessful weld. Welding doesn't like the presence of an addition metal which isn't part
of the alloy you're welding.
10/21/2012: Tools I use with the PUK
Front row, left to right...

Burnisher with slightly flat side, burnisher with slightly flat side, burnisher with slightly flat side, burnisher
with three sides, burnisher with three sides, burnisher with three sides,
Back row, left to right...
PUK compactor (teeth removed, slightly flattened side), flexshaft mandrel with four sides (not pretty, but
works well), 45-degree heart bur for cutting grooves, burnisher with slightly flat side, burnisher (top has a
slight angle for "massaging" the welded surface), graver for cutting grooves
8/21/2012: Welding a Japanese waste bowl containing lead solder
This is a double-walled fine silver waste bowl that had many dents. The handles had disconnected from
the rim because they were lead soldered. I had to disassemble the inner and outer bowls, remove the
dents, reassemble with lead solder, repatinate, and hand polish.
I decided to make a stronger connection where the handles meet the rim, so I welded the dragon toes
with sterling (silver soldering would have obviously melted the lead solder holding the two bowls
together).
8/9/2012: Welding extremely thin sterling
Below is a close-up of a weighted candlestick. The customer didn't want a complete restoration, but to
simply repair the stem-to-base connection without removing the dents. The candlestick material was only
about .004" (.1mm) thick. I was able to weld the split closed with .010" (.25mm) sterling filler wire using
the following settings:
Material: Sterling
Mode: Thick sheet (not gap mode)
Milliseconds: 1
Power: 30%
What's amazing is that I didn't have to empty the pitch to perform a successful repair. Upon completion of
the weld, I remelted the pitch which filled in any voids around the repair.
7/26/2012: Protect alligator teeth from marring your work.
1. Grind down the jaw teeth

2. Anneal appropriate diameter brass or copper tubing
3. Force-fit tubing over jaws
4. Use round nose pliers to crimp new non-marring teeth
5. Roll over tips so they touch
6. Flatten and weld corners of tips
7. Slightly round tip corners
8. Polish tips
7/19/2012: Wallace Sterling Golf Trophy – working large
Filling in dents and welding cracks. I have the trophy sitting on a rolling pneumatic table that can be
height-adjusted. I constructed the table out of an old office chair, removing the seat and replacing it with a
piece of plywood.
6/272012: 10" Tiffany Sterling Plate
This plate came to me with chased lettering that the customer wanted removed and the overall look
brought back to its original beauty. This job was going to very complex. The lower parts of the lettering
were very thin as it was chased on a steel form, and the slightly rounded corners would be more
difficult to level with the overall disk. These factors required numerous setting adjustments on the PUK.
Above, I'm flattening the over-filled sterling mounds with a special smoothing mode. This entire filling
and smoothing process was extremely time-consuming, requiring enormous concentration and
constant refocusing of the 10x microscope.
The lettering completely filled.
The deposited sterling was then planished over a slightly domed stake to remove any porosity left by
the welding. Then, 600-, 1200-, and 2000-grit silicon carbide wet/dry paper was used to remove any
high spots and prepare the surface for polishing.
The center disk shows no sign of ever having been chased.
The plate was repatinated and lightly polished, resulting in a dramatic transformation. The entire
restoration took over 14 hours!
5/30/2012: Sterling Kiddush Cup
This Kiddush cup was made from very thin material. I reshaped the torn area which extended 3/4 of the
way around the stem. I then brought together both sides of the split and welded them together. All voids
were filled by welding with sterling wire for a perfect color match. I straightened the stem and leveled the
bottom and top rims. I then removed the dried polish and performed a very light hand polishing.
5/10/2012: Welding Objects That Flex

I often receive broken sterling flatware for restoration. Welding these stamped (hardened) pieces back
together will result in cracking on either side of the weld due to the flexing of the utensil. This is due to
differences in grain structure of the stamped object and the welded filler wire. I recommend using a mini-
torch and annealing the very edges of the break. Then file a v-groove on the backside of the break and
use filler wire (e.g. sterling for a sterling fork) to fill the groove. This technique makes for a homogeneous
connection.
5/5/2012: Argon Consumption
There are many things about the PUK I enjoy. One of those features is the very low argon consumption
compared to other systems. I find that I can perform 99% of my welding using only 1.5 liters per minute
(lpm).
5/5/2012: Sterling & Amber Ring
This is going to blow you away! A friend came to me with an amber and sterling ring. The amber was
glued into the setting with decorative wires above, only 1/16" from the amber. As you can see below, the
wires had come apart. So, I couldn't remove the stone, and was forced to weld the wires back together (I
would have chosen to weld them regardless of whether or not the stone could be removed). If I had used
a laser welder and missed the mark, the stone would have fried. But first, I wanted to try the technique I
was about to use on a sterling jump ring surrounding a piece of plastic. It worked - no harm came to the
plastic. Here's the procedure I used...
The wires were pried open and the silver solder removed.
The wires were then sprung back together. As a precaution, I slipped four layers of index card stock
between the wires and the amber to prevent the stone from burning.
Below are the wires reattached with sterling filler wire. I used the filler setting with 1.5ms and 30% power.
4/16/2012: Sterling Box Cover
This box cover's four corners were all split. I used sterling filler wire on the inside and outside, then
compacted the material from the outside to remove any porosity. What appears to be a corner split in the
third image is actually a reflection
3/25/2012: Sterling Bracelet
This bracelet wasn't the thinnest piece I repaired with the PUK, but it did present a new issue: How would
pulse arc welding hold up to constant bending?
This was the procedure I used:
The split was thoroughly cleaned, then beveled on the back side. I used .010" sterling filler wire and over-
filled, spreading and smoothing material on either side of the break to strengthen the area. If I had not
added additional support, I would see this piece back in my shop in a short time. I didn't totally compact
the filler metal as it would have become too brittle with the possibility of the split re-opening. I decided to
simply burnish the surface to remove any surface porosity. This left the filler material a bit more flexible.
12/30/2011: Sterling Casters
Someone had the clever idea to engrave these 1730 caster bodies with "salt" and "pepper." (The tops
were left off to show a larger area of the engraving.) Engraving the function of these pieces is certainly
not something I would have done, but to each his own. Since the silver was too thin to remove by filing, I
used the PUK and sterling wire to fill it in. When I photographed the "after" image I had not yet polished
the bottom sections of the casters.
12/11/2011: Sterling Cut Glass Jar Cover
This 5½" Wallace sterling cut glass jar cover was stamped and spun out of extremely thin material. The
image on the left shows light coming through three areas of a flower as well as other areas on the piece.
These areas were worn through from over polishing. The edges of the open spaces were the
approximate thickness of a piece of tin foil (.001"). The PUK worked beautifully, and I used .25mm
sterling wire for a perfect color match.
11/18/2011: Heat-sensitive Stones
Question from jeweler: I recently purchased a PUK Pro welder and am contemplating a retipping of a
Tourmaline. I've completed several successful repairs upon Diamonds and Rubies but haven't worked on
softer, heat-sensitive gems. Can you share any advice or point me in the direction of any technical
material?
Answer: Tourmalines are inherently fragile stones. Having said this, there should be no problem
rebuilding a prong. Firstly, it is advisable to try this technique on a practice setting holding a faceted
glass "stone." Use 36-gauge annealed wire (.005") and the lowest possible power setting on your PUK
when welding. Welding from the outside of the setting (don't let the electrode pass over the glass), build
the prong straight up with the filler wire. When you're happy with the height of the prong, finish it and
gently push it over the glass.
11/4/2011: Standard Sterling & Argentium
I did a comparison test using .030" (0.76mm) sheet standard sterling and Argentium. I used the gap
mode with 6ms and 45% power for both alloys. The standard sterling (left) had smaller and slightly
rougher welds than the Argentium, and demonstrated more oxide formation. The actual weld diameter
sizes were .030" (0.76mm) for standard sterling, and .040" (1.02mm) for the Argentium. Dropping the
power to 30% when welding the Argentium gave the same size diameter weld as the standard sterling.
Conclusion: Argentium gave a cleaner and smoother weld with 30% less power consumption as
compared to standard sterling.
Standard sterling Argentium
11/2/2011: Pewter
Today I experimented with welding metals other than the sterling I normally work with. I cut some lead-
free pewter sheet that was .040" (1.02mm). I filed the edges of each sheet 90 degrees to make a butt
joint. I then used the PUK's gap filler mode with a setting of 6ms and 35% power, running down the
center of the joint and overlapping each weld 50% I welded the top and bottom of the joint, with sheet
penetration of over 50%. I then sawed through the joint and used 1200-grit silicon carbide paper to see if
there were any gaps and found none. I folded the sheet on the joint in half from front to back, then back to
front, and found no stress cracking. I continued the folding back and forth which eventually resulted in joint
failure. This was because the joint was more brittle than the rest of the sheet. The same failure would
have resulted if I had used pewter solder.
Since I was in an experimenting mood, I used the same PUK settings and welded the pewter to the
aluminum backing of a safety edge blade with excellent results. The aluminum was then welded to the
steel blade - this, too, was successful.
Two butt-welded pewter sheets (1.125" wide total)
10/15/2011: Gorham Sterling Match Safe (shown repairing the seam only)
The most tedious repair on this safe was closing the seam (or joint). The first order of business was to
open the seam to remove any solder. Ultra-fine 0000 steel wool was used inside to remove any grime
around the seam, making the surface smooth for burnishing.
Here I'm raising the seam past it's normal state,

enabling greater access for scraping the seam
walls.
This modified dental tool has a narrow triangular

scraper on its end. It is used to remove all solder
in the joint so the filler wire be welded to the
clean sterling. Pulse arc and laser technologies
will not fuse successfully to solder that previously
melted. The filler metal will combine with the
existing solder and produce a grainy alloy with a
color that doesn't match the surrounding
material.
Cleaning around the seam with a fine glass

brush will aid in successfully filling the joint.
The joint is now tapped closed using a rawhide

mallet. There still exists a very slight taper from
the bottom of the seam to the top, which will
enable me to deposit sterling filler wire.
Here, a pulse arc welder is used to close the

seam. This technology enables me to use
.005"-.010" diameter sterling wire on this repair
as opposed to brazing with hard silver solder.
Silver soldering would have taken much longer:
fluxing the piece to prevent firestain, clean-up of
the solder joint around the chased detail, and
extensive repatination. Pulse arc welding
localizes the heat and surrounds the weld area
with argon gas. This gas totally eliminates
oxides from forming in the sterling.
The joint after welding.
A rotary compactor is used to hammer down

and compress the sterling wire that was used for
the weld.
A fine rubberized abrasive wheel removes any

compactor imperfections.
This is the result before repatinating.
PUK 3s Professional
Video of welding the match safe above.
Herman Silver Restoration: Gorham Match Safe
9/22/2011: Sterling Pie Server
This problem normally would require me to remove the plaster from the handle making sure it's perfectly
clean before brazing. I would then have to go in with a scraper and clean around the split to guarantee a
successful brazing job. Most handles I repair contain pitch which would have to be fully emptied so to not
contaminate the joint (Arc welding and laser welding would have produced enough localized heat to melt
the pitch, contaminating the seam.) For this handle, I experimented by removing only the plaster that was
attached to the underside of the ragged split (approximately 2" in length) and left the remaining plaster in
the handle. Also, I didn't remove the solder from the seam - arc welding and laser welding technology
normally wreak havoc when working with solders, but I was curious to see if the PUK would give me a
different outcome. I cut a piece of annealed .005" sterling sheet and used it as a shim in the split,
exposing about a 1/16" above and below the surface. I then clamped the two sides together and began
welding using the PUK's gap filler mode. Positioning the electrode on the top edge of the shim, I was
able to melt and "push" the sterling down into the split, successfully filling the most of the void. This
process is completed within milliseconds. I then used .010" annealed sterling wire to fill any remaining
voids. The end result displayed absolutely no porosity and was undetectable. There was no firescale or
firestain to remove, no patina to be reapplied, and a seam that would never split again.
Troubleshooting
Centerline cracking
This is one of the biggest problems you'll encounter if you don't program the proper settings. If this
occurs, try 1. using a sharper electrode, or 2. increasing the millisconds which will lengthen the cooling
time of the weld.
Additional trouble shooting questions are answered here.
Should you have any questions after reviewing the Welder Settings section, please e-mail me and I'll
do my best to help you.
Avoiding Pain When Welding for Long Periods

Les Hubert, Licensed Massage Therapist
The job of a silversmith or any other metal worker demands precision. And this comes with a price if the
artisan's hands and arms are called in to provide that precision. With the cooperation of silversmith Jeff
Herman, I was able to observe just such an occasion. Jeff informed me that he had been experiencing
forearm pain and that this occurred during and after intense concentration with the use of a pulse arc
welder. In order to use this device correctly, one has to hold the object being worked on prolonged
periods with micro movements. In the following photo, the red ellipse indicates where his pain is located.
This pain is caused by a condition called lateral epicondylitis, commonly referred to as tennis elbow.
In this particular case Jeff is asking his muscles to make constant micro movements, where they are at a
disadvantage after prolonged periods. Muscles need to adequately contract and elongate in order to
pump out fuel waste and bring in fresh fuel. When they are unable to do this, lactic acid builds up in the
muscles and connective tissues, creating micro tears. To illustrate, imagine an elastic band that has
been burned. Instead of elongating when stretched, its fibers will simply separate and tear.
Below is a video of welding a large object illustrating micro movements of the arm.
Micro Movements of the Arm
With this condition of tennis elbow, one can also find pain leading to the thumb because of the radial
nerve that lives in the area between the larger extensor muscles of the forearm (see diagram).
Treatment Suggestions
If you are already having problems with these areas, I

suggest getting treatment with a licensed professional
such as a massage or muscular therapist or physical
therapist as soon as possible. If that's not possible in
the immediate future, then ice should be applied to the
affected area for at least 20 minutes (see photo to
right).
Then remove the ice and move the forearm slowly in a

circular motion (demonstrated in the video below) for
one minute. Repeat this process two more times.
Cryotherapy or ice therapy can quickly help control

swelling and pain. Combined with movement it can aid
in removing some of the scar tissue in the affected
area, thus allowing the body to replace the scar tissue
with new and healthy fibers.
Moving the Forearm Slowly in a Circular Motion
How to Avoid this Condition
When your work demands a steady hand, give yourself plenty of stretch breaks. Every half hour isn't a
bad idea. Try mildly ringing out a towel, raising and lowering a weight (I used a sledge hammer that has
a hanging hole in the handle), or squeezing a soft ball to aid in lactic acid release.
Mildly Ringing out a Towel
Raising and Lowering a Weight
Try to keep in mind that your body has limits of endurance. It's an incredibly complex and beautiful
organism. With your help, as with any tool, if properly maintained, it will continue to serve you well for
many years.
Les Hubert is a licensed massage therapist for Michael K. Galvin & Gel Essentials in Cranston, RI.
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30/11/2017 Society of American Silversmiths - PUK Pulse Arc Welders Reviewed, PUK04 Review

Review & Usage of Lampert's Pulse Arc Welders

Lampert Technical Papers

PUK04 Welder Settings

Avoiding Pain When Welding for Long Periods

PUK 3s Professional PUK 3s Professional Plus

• 33 programmable settings (the PUK 3s Plus: 5);

Advice on welding larger objects

The handpiece can be removed in three seconds for welding freehand.

Lampert pulse arc welder highlights

Fill in porosity with the same alloy;

Lampert Workshop Papers (Subcribe to their workshop series here.)

30 Welding duration http://bit.ly/2c56cGZ

12 Welding pores http://www.lampert.info/nl/workshop/Lampert_workshop_12.e.pdf

Lampert Workshop Videos: http://www.youtube.com/user/LampertWelding/

The basic cost for the PUK04 is $5,295. It includes:

• PUK unit and microscope;

Optional accessories I added:

Carbon Dioxide: <1ppm

Additional optional accessories

1. Pin module for welding ear studs

Gold Au 750/000 - 18K 500mm x 0,25mm (19,7" x 0,01")

Catalog of PUK accessories.

Welding Wire Alloys

Rio Grande has an excellent selection. Below is a partial list:

Definitely purchase a Speedwire Welding Wire Dispenser (not a Lampert product).

Lampert PUK04: (excellent)

Lampert's Web site (Germany)

Lampert Tools USA

Lampert Tools USA

A&A Jewelry Tool (Los Angeles, CA)

Lacy West Supplies (Vancouver, Canada)

PUK04 Welder Settings (Download settings here.)

Welding Sterling (updated 4/9/2014)

3 Sterling (Thick) 55% Very Light

11/29/2017: Welding thin silver

10/5/2017: When a pulse arc welder is your

The cherub of this sterling bell had broken off at

Since the cherub was cast, Argentium produced

9/16/2017: When color is EVERYTHING!

9/12/2017: Filling engraving on a sterling Montblanc pen

Questions? Feel free to e-mail me here.

6/23/2017: Argentium welding wire

6/17/2017: Gap-free ring shank seams

2/26/2017: Closing a ring shank

2/4/2017: Filling large splits

11/19/2016: Pressure splits

10/21/2016: Why are my electrodes moving into the chuck as I weld?

Don't worry, on the PUK5 you can piggyback the connectors...

5/2/2016: Testing the new PUK5

PUK price list of equipment and accessories.

4/9/2016: Brazing to a convex surface.

PUK was tack it in a couple of spots then braze it and apply a

3/18/2016: Adding to a compressed casting

1/29/2016: When there's no other alternative

1/27/2016: The PUK5 makes its debut!

1/5/2016: Make your electrodes last longer!

12/30/2015: Welding Vermeil Filigree

10/9/2015: Welding sterling with inlaid enamel

10/6/2015: Another instance where tacking saved time

7/72015: Working on objects containing lead solder and lacquer

The image below shows the reattached thistles.

3/28/2015: Welding when contaminants are present on a piece

2/7/2015: Refilling a Speedwire