Perfect Welding

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Perfect Welding

Efficient manufacturing of large components new high performance welding systems ensure

High performance welding requires a wire feed of more than 15 meters per minute or more than 8 kilograms of wire to be melted per hour. No problem with the TPS 600i. The TPS/i TWIN Push system saves users even more time.

Solid and flux core wires are used in these processes. Consistent wirefeeding is key to ensuring that the process remains stable, which is guaranteed by a four-roller drive. A push-pull system with multiple drive units is recommended for wires with low rigidity or long hosepacks. The welding torch also plays an important role; during high performance welding, the welding torch is subjected to high temperatures from the weld pool on one side and the high current density between the contact tip and the wire on the other. For this reason, water-cooled welding torches must be used during this type of welding process. Cooling is also of utmost importance when it comes to ensuring a long duty cycle at a high power level.


With high performance welding, the duty cycle in particular needs to be as long as possible. One of the advantages of the TPS 600i is that, in comparison to other devices in the TPS/i series, it has a more powerful power module. As a result, the system is able to weld continuously at an amperage of up to 500 A. The high power also leads to short cycle times and increased productivity. At the point at which other welding systems would have reached their limit, the TPS 600i still has more to give. The power source is even able to offer reliable continuous operation in high ambient temperatures. It can achieve a maximum welding current of 600 A and thus allows for a deposition rate of up to 13 kilograms per hour. Two devices can be combined and used as a tandem system in order to increase the power even further.

The TPS/i TWIN Push welding system consists of two powerful TPS/i welding systems (1), the TWIN Controller (2), a compact wirefeeder (3), a cooling system (4), hosepacks (5), and the TWIN welding torch (6). The Robacta TSS/i TorchServiceStation (7) for cleaning welding torches and the TX TWIN welding torch change station (8) complete the System.


During the TWIN process, two wire electrodes are fed into a welding torch with a single gas nozzle. However, the two electrodes remain electrically isolated from one another. As a result, the arcs can be controlled independently and, despite differing outputs, can be precisely coordinated. In addition to two high-performance power sources, the TWIN Push system also requires a TWIN Controller, which synchronizes the welding process and acts as a robot interface. A compact wirefeeder, cooling system, hosepack, and TWIN welding torch complete the welding system.

The TWIN Push process is also now available for the current TPS/i system platform. The powerful processor in the power source makes the synchronized process considerably more stable and reliable. Good gap-bridging ability saves the user a lot of time at the component preparation stage. The amount of rework can also be reduced, since precise control of the welding process enables controlled droplet detachment and low heat input into the component, minimizing spatter and distortion. Thanks to the TPS/i TWIN Push, users can achieve higher deposition rates and faster welding Speeds.

In addition, a wide variety of process variants are available for the TPS/i. PMC (Pulse Multi Control) TWIN, with its short, focused pulsed arc, ensures improved penetration and a higher welding speed. New control mechanisms provide the welder with the right support: the arc length and penetration stabilizers improve process stability and make it easier to configure parameters. If the position of the interface changes due to component tolerances that are too large, automatic seam tracking is here to help. During welding, the system sends a signal to the robot, which is used to adjust the weaving width as necessary

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