Welding Automation
Solution provider for automated welding
Welding Automation at a glance
Fronius Welding Automation stands for:
Your solution provider for automated welding systems
From single piece to series production. We offer automated welding solutions ranging from mechanized and robotic systems to collaborative welding cells. Our high-performance systems can be flexibly integrated into existing production lines thanks to modern sensor technology, offline programming, simulation software, and welding data management.
Scalable solutions (ranging from single-piece to mass production) make automation a viable option even for small and medium-sized enterprises.
The right welding automation solution for your needs
Mechanized welding systems
Mechanized welding systems automate the torch guidance without using robotics, such as through boiler welding systems or rail-guided welding carriages.
Circumferential welding
Compact circumferential seam welding systems enable cylindrical components to be welded automatically. The combination of two welding heads, a rotary unit, and a tailstock creates a stable workpiece guidance system that ensures consistent weld quality and high process reliability.
Areas of application:
- Circumferential seams on vessels and pipe sections
- Flange connections
- Mass-produced and custom parts
Materials:
Steel, chromium-nickel, aluminum, duplex, nickel-based
Process:
MIG/MAG (CMT), TIG (cold and hot wire, ArcTig), plasma
Longitudinal welding
Mechanized longitudinal seam welding systems are designed for welding the inner and outer surfaces of large-diameter cylindrical components. A clamping system secures the component in place, while a welding carriage moves steadily along the seam, ensuring precise, repeatable seam quality.
Areas of application:
- Container shells
- Tank and machine construction
- Large components with long seams
Materials:
Steel, chromium-nickel, aluminum, duplex, nickel-based
Process:
MIG/MAG (CMT), TIG, plasma
Robotic welding
Robotic welding is a type of welding where the welding torch is precisely guided by industrial robots. This makes it possible to automate even complex tasks on a variety of components while maintaining a consistently high level of quality. Offline programming and simulation software make it a cost-effective option even for small batch sizes.
Smart robotic welding
Robotic welding systems enable a stable and automated process control, even with varying components and frequently changing requirements.
Areas of application:
- Housing, flange, and frame constructions
- Thin and thick-walled sheets
- Individual parts and small batches
Materials:
Steel, chromium-nickel, aluminum, duplex
Process:
MIG/MAG (e.g., CMT, PMC), TIG, plasma
Cobot welding
Collaborative welding cells (cobots) offer an easy introduction to robotic welding and effectively complement manual welding processes. Particularly well-suited for small production runs and changing components, their strengths are best demonstrated in flexible manufacturing environments as they can be set up quickly and are easy to operate.
Typical applications:
- Small production runs and frequently changing components
- Support for manual welding processes
- Flexible manufacturing environments
Materials & processes:
Depending on the application and configuration, comparable to traditional robotic systems
Additive manufacturing
The additive manufacturing process for metal 3D printing enables fast, cost-effective, and precise component production.
The wire-based, arc-driven CMT process offers considerable design flexibility and the ability to produce complex component geometries, all while delivering high deposition rates.
Typical applications:
- From prototyping to mass production
- Component optimization and modification
- Repair and reverse engineering
Materials:
Steel, aluminum, nickel-based alloys, and virtually all weldable materials
Process:
MIG/MAG (CMT)
Overlay welding (cladding)
Overlay welding protects components against wear and corrosion. It is used in a variety sectors, such as for risers or valves in the oil and gas industry or membrane walls in power plants and waste incinerators.
Even complex geometries can be reliably clad with specialized overlay welding systems. Continuously rotating torches ensure a uniform application, even in internal contours and hard-to-reach areas.
Overlay welding of complex geometries
Typical applications:
- Valve blocks with intersecting bores (bore-to-bore)
- Components with complex geometries, such as seat pockets, race tracks, or circular segments
- Flanges with and without bores
Special features:
- Continuously rotating torch
- Suitable for automated mass production and single-piece applications
- Repair welding of damaged components
Materials:
Steel
Process:
TIG hot wire and SpeedClad 2.0
Customer solutions
Cost-effective welding solutions for efficient production
Consistently high weld quality and cost-effective processes throughout the entire product life cycle are key requirements for modern welding systems. That’s why we employ feasibility studies, simulations, and welding tests as early as the engineering phase.
