Fronius iWave

for automated welding solutions

Multiprocess

Fronius iWave

Intelligent automation for stable TIG processes

Stable process, consistent results. The iWave has been designed for automated applications in which the welding system itself makes constant adjustments. Parameters for heat input, ignition behavior, and arc guidance are automatically controlled within defined limits.

DynamicWire complements this approach in cold-wire TIG welding by continuously adjusting the wire feed to the current process conditions.

At the same time, the iWave is a multiprocess platform that permits TIG, plasma, and MIG/MAG welding with just a single, automated system.

iWave Automated highlights
Dynamic wire feeding
Gap bridging of up to 30% possible: The DynamicWire dynamic wire feeding system automatically adjusts the wire speed to the current conditions during welding. The wire is always supplied in the exact quantity required, allowing air gaps of up to 30%* to be compensated for and welded. * In relation to the material thickness
Targeted heat input
Maximum control of the weld pool: CycleTIG allows you to regulate the arc, in turn giving you maximum control over heat input. Short welding times help you keep the weld pool safely and easily under control, making it simple to weld even the thinnest materials.
Reproducible ignition
Reduce ignition delays by up to 71%: Our intelligent RPI auto ignition function delivers fast and, above all, reproducible ignition behavior without any manual adjustment of the parameters and with any material properties.
Multiprozess PRO
One machine for every process iWave Multiprocess PRO gives you complete freedom in automated welding. You can use all MIG/MAG process variants in addition to all TIG and plasma functions with a single machine. The modular concept allows you to expand your high-tech welding machine platform as you see fit with the Standard, Pulse, PMC, LSC, or CMT welding packages.
Spring-loaded CrashBox
Z-triggering in the minus direction: Improved seals on the new CrashBox prevent dirt from entering, meaning that this has no influence on the accuracy of the TCP (Tool Center Point). In the event of collisions, the option of Z-triggering in the minus direction is also advantageous.
Interfacing
One interface for every process and a uniform process image Thanks to the standard high frequency resistance, all existing interfaces of the TPS/i welding systems can now also be used for iWave or TIG welding without additional hardware. There is now one interface for every process, including a uniform process image.
Dynamic wire feeding
Gap bridging of up to 30% possible: The DynamicWire dynamic wire feeding system automatically adjusts the wire speed to the current conditions during welding. The wire is always supplied in the exact quantity required, allowing air gaps of up to 30%* to be compensated for and welded. * In relation to the material thickness
Targeted heat input
Maximum control of the weld pool: CycleTIG allows you to regulate the arc, in turn giving you maximum control over heat input. Short welding times help you keep the weld pool safely and easily under control, making it simple to weld even the thinnest materials.
Reproducible ignition
Reduce ignition delays by up to 71%: Our intelligent RPI auto ignition function delivers fast and, above all, reproducible ignition behavior without any manual adjustment of the parameters and with any material properties.
Multiprozess PRO
One machine for every process iWave Multiprocess PRO gives you complete freedom in automated welding. You can use all MIG/MAG process variants in addition to all TIG and plasma functions with a single machine. The modular concept allows you to expand your high-tech welding machine platform as you see fit with the Standard, Pulse, PMC, LSC, or CMT welding packages.
Spring-loaded CrashBox
Z-triggering in the minus direction: Improved seals on the new CrashBox prevent dirt from entering, meaning that this has no influence on the accuracy of the TCP (Tool Center Point). In the event of collisions, the option of Z-triggering in the minus direction is also advantageous.
Interfacing
One interface for every process and a uniform process image Thanks to the standard high frequency resistance, all existing interfaces of the TPS/i welding systems can now also be used for iWave or TIG welding without additional hardware. There is now one interface for every process, including a uniform process image.

System overview and design

Top quality for every weld and every materialthanks to new technologies. iWave offers more targeted heat input,significantly improved ignition, and therefore maximum control over the arc.
iWave Automated Visual

TIG processes & functions

CycleTIG

TIG welding made easier thanks to the CycleTIG function. Based on the principle of stitch welding, this function offers additional setting options and new parameter combinations for improved welding results.

Targeted heat input
Very targeted heat input can be generated by means of a short interval time, a low or no base current, and a long interval pause time. Applications include edge application or repair work on die-cast parts.
Outstanding weld seam appearance
Combined with the tacking function, CycleTIG enables the welder to achieve an excellent seam appearance.
Fewer temper colors
The use of CycleTIG reduces temper colors and therefore keeps the need for rework to a minimum.
Easy control of the weld pool
Thanks to the short welding time, the weld pool can be well-controlled with ease. This prevents burn-through, particularly in corner and butt welds.
Targeted heat input
Very targeted heat input can be generated by means of a short interval time, a low or no base current, and a long interval pause time. Applications include edge application or repair work on die-cast parts.
Outstanding weld seam appearance
Combined with the tacking function, CycleTIG enables the welder to achieve an excellent seam appearance.
Fewer temper colors
The use of CycleTIG reduces temper colors and therefore keeps the need for rework to a minimum.
Easy control of the weld pool
Thanks to the short welding time, the weld pool can be well-controlled with ease. This prevents burn-through, particularly in corner and butt welds.

DynamicWire

Active wire control for automated cold-wire TIG welding

Precise adjustment of the welding parameters is the foundation of a stable TIG process. DynamicWire significantly reduces the workload involved, as just one parameter has to be changed for all others to be adjusted automatically based on material-specific characteristics. 

The key difference from conventional cold-wire systems lies in their automatic self-regulation, whereby the wire speed continuously adjusts to the current process conditions to ensure a stable process.

iWave Automated Torch

How do I use TIG DynamicWire?
It’s quick and easy to add the TIG DynamicWire Welding Package to automated iWave systems with a cold-wire feed from 300i–500i by simply activating the software.

Your benefits::

  • The right wire speed every time
  • Gap bridging of up to 30%*
  • Set just one parameter to start welding

* In relation to the material thickness

More about TIG DynamicWire
iWave Automated DynamicWire
Hot wire
The targeted preheating of the filler wire enables significantly higher welding speeds. Dilution is simultaneously reduced, improving weld seam quality and minimizing the influence on the base material. For hot-wire welding, an additional iWave welding machine from 300 A is required to preheat the wire.
PushPull configuration
The PushPull configuration can be used universally for all welding processes, such as TIG, plasma, and ArcTig. It offers maximum flexibility thanks to perfectly synchronized wirefeeders, ensures stable wire feeding (even with special materials), works over ranges of up to 18 meters, and can be retrofitted to existing systems.
Precise and efficient plasma welding
iWave enables you to use higher welding speeds while eliminating the need for seam preparation. Thanks to the integrated plasma module, only a single welding machine is required.
Learn more about plasma welding
ArcTig—the revolution in TIG keyhole welding
iWave makes single-pass welding of materials up to 10 mm thick possible while maintaining high weld seam quality. In addition, the welding speed is significantly higher than with conventional TIG welding.
Learn more about ArcTig

Multiprozess PRO

Multiprocess PRO—one welding machine for every process

Combining the iWave 300i, 400i, or 500i with the Multiprocess PRO hardware option makes TIG, plasma, and MIG/MAG processes available (including all high-tech TIG functions as well as all MIG/MAG process variants), leaving you ready for any welding challenge. 

Thanks to the modular design, you can put together the exact functions you need by choosing compatible peripheral components, such as welding torches and wirefeeders, as well as custom welding packages. Choose from Standard, Pulse, PMC, LSC, CMT, PMC AC, and CMT AC. Additive manufacturing is also an option with the iWave.  

One device gives you countless possibilities, with the option of retrofitting process variants at any time. You can also add the appropriate equipment to make an automated process change from TIG to MIG/MAG possible. This significantly reduces space requirements as well as transport and maintenance costs.

More about iWave Multiprocess Pro
Multiprocess 3

CMT AC

CMT AC is the ideal solution for keeping the heat input remarkably low during MIG/MAG welding with the same deposition rate. The positive and negative components can be precisely adjusted by reversing the wire movement and the polarity of the wire electrode. This results in excellent gap-bridging ability, very low welding fume emissions, outstanding weld seams, and optimally controlled conditions for demanding additive manufacturing processes. 
More about CMT

Fronius Additive

Thanks to its revolutionary reversing wire movement, the CMT process is extremely stable, making it perfect for additive manufacturing. The layers are built up consistently, evenly, and spatter-free.

We developed the CMT Additive Pro characteristics specifically for this application. With the iWave 300i–500i series, the Multiprocess PRO option, and the CMT Welding Package, we offer the ideal complete solution for additive manufacturing. The perfectly coordinated equipment is compatible with all conventional robot systems thanks to its dedicated interfaces.   

More about Fronius Additive

Other topics

TIG robot welding torches
Designed for automated applications, our TIG robot welding torches can easily be adapted to meet a variety of production requirements.
Choose from a variety of torch bodies in different lengths and angles for complex component geometries and hard-to-reach welding positions.
Ready for the future of industry
The iWave provides the technological basis for interconnected, secure, and efficient welding processes, ranging from connectivity and data documentation to user and job management. All functions are either directly integrated into the welding system or can be added using modular components to ensure your system remains future-proof.
More about digital solutions
iWave manual
Our high-performance TIG technology ensures maximum precision and ease of use. It is particularly well-suited for both manual and automated welding, offering full control and flexibility.
More about iWave

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