Osziloskop Lab

WELDING PROCESSES FROM FRONIUS INNOVATIVE AND EFFICIENT

THE PERFECT SOLUTION WHATEVER THE WELDING APPLICATION

At Fronius we have been working tirelessly for decades to decode the “DNA of the arc” so that you can achieve optimum welding results. As the global innovation leader and welding technology leader, we have mastered welding processes – from arc welding to resistance spot welding – to a tee. Our arcs and welding processes are constantly setting new standards in speed, efficiency and quality. Drawing on this expertise, we develop products and systems for all kinds of applications – from ultra-light gauge sheet welding and aluminium welding to high-performance welding, from manual welding or battery-powered power sources to robot welding systems.

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AN OVERVIEW OF FRONIUS WELDING PROCESSES

An arc in the lower power range with a consumable electrode. The dip transfer arc is ignited by the wire electrode briefly touching the workpiece. This creates a high, quickly increasing short circuit current. The heat liquidises the wire electrode and the droplet detaches. After the short-circuit bridge is broken, the arc ignites again. Dip transfer arc welding can be performed in practically any position.
When welding with a pulsed arc, the basic voltage is regularly superimposed with an increased pulse voltage. This causes a base current and pulsed current to alternate at a pre-set frequency and pulse time. The base current keeps the arc at a low power, melts the wire electrode and liquefies the weld pool. The increased pulse voltage liquefies the wire end and forms a large droplet, which is detached due to the magnetic forces. The process parameters are selected in such a way that a droplet detaches every time there is a current pulse, depending on the wire diameter and electrode material. The pulsed arc is especially suitable for welding thinner sheets.
The spray arc burns constantly without short-circuit interruption. The material is transferred to the weld pool in fine droplets at high speed. The high thermal energy ensures a larger heat-affected zone and thus greater workpiece distortion than with a dip transfer arc. This type of arc is particularly suited to welding thicker sheets.
High-performance welding process in which multiple wire electrodes are melted off at the same time. Two wire electrodes are usually used; however it is also possible to use three or more. These melt in separate arcs usually under one shared shielding gas cover and form a shared weld pool together with the material of the workpiece.
Hybrid processes combine conventional welding processes, such as MIG, MAG and TIG welding, with laser welding. A preliminary laser beam heats up the workpiece surface to vaporisation temperature and creates deep, narrow penetration. An arc follows forming a wide focal spot. Applications of this type of welding include welding components with large gap widths, which the laser alone cannot bridge. Hybrid processes enable high welding speeds and good weld seam quality to be achieved, thereby reducing the heat input and distortion.
Energy-efficient and productive welding process in which no shielding gas needs to be added. The two parts to be joined are laid on top of one another precisely. Two electrodes press the workpieces together mechanically and fix them in place. A strong voltage creates a current flow between the two electrodes. The workpieces exhibit a resistance which causes specific points of the metal to heat up considerably and become liquid. The mechanical pressure of the electrodes causes the two workpieces to fuse together, resulting in an inseparable joint once they have cooled down. Resistance spot welding is used to join sheets in bodywork and vehicle construction, and generally in sheet metal production. Materials that are not suited to welding can also be joined, with certain limited exceptions.

The plasma welding process is very similar to the TIG welding process, but has a number of key advantages. These make it an attractive alternative to laser welding, which demands high quality standards – in particular for sheets and other components with a thickness of up to 8 mm.