Perfect Welding

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Perfect Welding
SpeedClad 2.0

Cladding

Chemical load, wear and corrosion cause problems for metal components. Using overlay welding of additional special alloys, also known as cladding, however, components can be protected and therefore their service life can be increased. This is a technologically challenging process. Fronius offers modern systems and tailored welding processes for this purpose, which help the user to ensure the necessary high level of quality.

Compact Cladding Cell – Advantages

Ergonomic design

  • Welding torch – quick change system
  • Wirespool holder at operator height
  • Power sources on rail expansion device 

Compact and mobile

  • All components pre-assembled on a platform
  • Short commissioning times

Welding processes

  • TIG HD
  • SpeedClad 2.0

Area of application

  • Max. component diameter (external): 1 m
  • Max. component height: 1.4 m (1.9 m optional)
  • Max. bore depth: 1 m

HMI system controls

  • 21” touchscreen panel
  • Central control of all system components
  • Multi user management

System Overview – Compact Cladding Cell (CCC)
Inner overlay welding torch
  • TIG HD welding torch (from 25 mm bore diameter)
  • TWIN wire option
1
SpeedClad 2.0
  • Speedclad welding torch system for top overlay welding performance
2
Ring groove welding torch
  • SpeedClad welding torch system for top overlay welding performance
3
Wirefeeder
  • 4-roller drive
  • Wire speed monitoring
  • TWIN wire option
4
PowerLiner
  • Roller-guided wirefeeding hose for perfect wirefeeding
5
Ergonomics
  • Wirespool holder at operator height for easy changing of the wire spools
6
Stand
  • Highly precise welding torch positioning due to the use of servo motors and precision guides
  • Optimized cable guide management
7
Power source set
  • TransTig 5000 Job and TransTig 2200 Job – fully digital for optimum welding results
  • High performance cooler for SpeedClad
8
Rotary table
  • Servo drive with precision gearing for maximum positioning accuracy
  • Slip ring option for pre-heating unit
9
1
Inner overlay welding torch
  • TIG HD welding torch (from 25 mm bore diameter)
  • TWIN wire option
2
SpeedClad 2.0
  • Speedclad welding torch system for top overlay welding performance
3
Ring groove welding torch
  • SpeedClad welding torch system for top overlay welding performance
4
Wirefeeder
  • 4-roller drive
  • Wire speed monitoring
  • TWIN wire option
5
PowerLiner
  • Roller-guided wirefeeding hose for perfect wirefeeding
6
Ergonomics
  • Wirespool holder at operator height for easy changing of the wire spools
7
Stand
  • Highly precise welding torch positioning due to the use of servo motors and precision guides
  • Optimized cable guide management
8
Power source set
  • TransTig 5000 Job and TransTig 2200 Job – fully digital for optimum welding results
  • High performance cooler for SpeedClad
9
Rotary table
  • Servo drive with precision gearing for maximum positioning accuracy
  • Slip ring option for pre-heating unit

Applications

Bore to bore
Bore to bore advanced
Flange with bore
Straight/conical bore
Multi diameter
Ring groove
Cylindrical bore

ETR-S Advantages

ETR-S Advantage
  • Synchronized movement axes allow for the welding of complex component shapes
  • Considerably reduced setup times due to automatic determination of the component position in the 3D space
  • SpeedClad 2.0 compatible – up to three times better cladding performance in comparison with conventional TIG HD welding processes
  • HMI-T21 system controls – the new generation of control with an expanded scope of functions

System overview ETR-S HMI-T21
Column & boom

- Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides

 

- Vertical axis with travel distance of 3 to 5 m available

 

- selwing ring unit for 340° rotation

1
ETR head

- TWIN wirefeeder

 

- Motorized rotating and tilting

 

- Integrated oscillating unit

 

- Collision setup (electro-pneumatic)

 

- Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

2
HMI-T21 system controls

- 21” touch screen user interface

 

- CNC platform, STEP data import

 

- Autom. component position detection

 

- Real-time process visualization

3
Welding equipment

 - TransTig 5000 Job welding current source

 

- TransTig 2200 Job hot wire power source

 

- Power sources on telescopic extension devices for easy maintenance

 

- High performance cooler for SpeedClad 2.0

4
1
Column & boom

- Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides

 

- Vertical axis with travel distance of 3 to 5 m available

 

- selwing ring unit for 340° rotation

2
ETR head

- TWIN wirefeeder

 

- Motorized rotating and tilting

 

- Integrated oscillating unit

 

- Collision setup (electro-pneumatic)

 

- Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

3
HMI-T21 system controls

- 21” touch screen user interface

 

- CNC platform, STEP data import

 

- Autom. component position detection

 

- Real-time process visualization

4
Welding equipment

 - TransTig 5000 Job welding current source

 

- TransTig 2200 Job hot wire power source

 

- Power sources on telescopic extension devices for easy maintenance

 

- High performance cooler for SpeedClad 2.0

Applications

Usage ball NEW: Sphere*
Usage circle segment NEW: Circle segment*
Usage half ball NEW: Hemisphere*
NEW: Flange with bores*
Bore to bore
Bore to bore advanced
Straight/conical bore
Cylindrical bore
Multi diameter
Ring groove
Usage rectangular Rectangular
Usage race track Race track
* Only in combination with CAD import option

ETR Ultimate Advantages

ERT Ultimate

High-end cladding system

  • Expanded working area due to motorized track
  • Complex component shapes
  • Multi station operation (fully automated)
  • Synchronized movement axes
  • SpeedClad 2.0 compatible HMI-T21 system controller

System Overview ETR Ultimate
Column & boom

/ Servo motors, encoder, precision guides

/ Assembled on motorized track (“track motion”) 

1
ETR head

/ Twin wirefeeder

Motorized rotating and tilting

/ Integrated oscillating unit

/ Collision detection (electro-pneumatic)

/ Welding torch holder with clamp fasteners for new generation TTHW welding torches & SpeedClad 2.0

2
Welding equipment

TransTig 5000 Job

/ TransTig 2200 Job

/ Telescopic extension devices for welding current sources to allow for easier maintenance

/ High performance cooler for SpeedClad 2.0

3
Track motion

/ Motorized track

/ Platform for column & boom and welding equipment

4
HMI-T21 system controls

21” touch screen

CNC platform, STEP data import

Automatic component position detection

/ Real-time process visualization

5
1
Column & boom

/ Servo motors, encoder, precision guides

/ Assembled on motorized track (“track motion”) 

2
ETR head

/ Twin wirefeeder

Motorized rotating and tilting

/ Integrated oscillating unit

/ Collision detection (electro-pneumatic)

/ Welding torch holder with clamp fasteners for new generation TTHW welding torches & SpeedClad 2.0

3
Welding equipment

TransTig 5000 Job

/ TransTig 2200 Job

/ Telescopic extension devices for welding current sources to allow for easier maintenance

/ High performance cooler for SpeedClad 2.0

4
Track motion

/ Motorized track

/ Platform for column & boom and welding equipment

5
HMI-T21 system controls

21” touch screen

CNC platform, STEP data import

Automatic component position detection

/ Real-time process visualization

Applications

Bore to bore
Bore to bore advanced
Flange with bores
Straight/conical bore
Usage half ball Hemisphere*
Usage circle segment Circle segments*
Usage ball Sphere*
Multi diameter
Usage race track Race track
Usage rectangular Rectangular
Ring groove
* Only in combination with CAD import option

Conventional Cladding System Advantages

Conventional Cladding System

New control and drive technology for an even more precise cladding process

Motorized tiltable welding torch axis (up to 90°) to comply with the optimum weld layer

SpeedClad 2.0 compatible – up to three times better cladding performance in comparison with conventional TIG HD welding processes

HMI-T21 system controls – the new generation of control with an expanded scope of functions


System Overview Conventional Cladding System
Column & boom
  • Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides
  • selwing ring unit for 270° rotation
1
Welding equipment
  • TransTig 5000 Job welding current source
  • TransTig 2200 Job hot wire power source
  • Power sources on telescopic extension devices for easy maintenance
  • High performance cooler for SpeedClad 2.0
2
Welding head
  • Motorized tilting of the welding torch axis 0 - 90°
  • AVC/oscillating axes
  • Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0
3
HMI-T21 system controls
  • 21” touch screen user interface
  • STEP data import
  • Real-time process visualization
4
1
Column & boom
  • Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides
  • selwing ring unit for 270° rotation
2
Welding equipment
  • TransTig 5000 Job welding current source
  • TransTig 2200 Job hot wire power source
  • Power sources on telescopic extension devices for easy maintenance
  • High performance cooler for SpeedClad 2.0
3
Welding head
  • Motorized tilting of the welding torch axis 0 - 90°
  • AVC/oscillating axes
  • Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0
4
HMI-T21 system controls
  • 21” touch screen user interface
  • STEP data import
  • Real-time process visualization

Applications

Bore to bore
Bore to bore advanced
Straight/conical bore
Flange with bore
Cylindrical bore
Multi diameter
Ring groove

Ultra fast overlay welding SpeedClad 2.0

SpeedClad 2.0

A new dimension in cladding

In comparison with SpeedClad Twin, the new cladding process only requires one electrode and one wire for the same or quicker welding speeds. Considerably fewer wear parts and less maintenance work are clear benefits of this process.

In addition, the much slimmer welding torch allows for the cladding of small interior diameters.

Why is SpeedClad 2.0 worthwhile?

Waste 2 Energy



Membrane walls

Overlay welding to increase the corrosion resistance of membrane walls in power plants and waste incinerators. A special device is used to tension the component and bring it into a vertical position. The trolley, which is guided on a gear rack, moves the two CMT welding heads safely and precisely over the entire weld length. Each welding torch is located on a linear oscillating unit and can be positioned manually using motorized carriages and adjustment units. More about membrane walls


Heat exchanger pipes

Overlay welding system with HMI-T10 system controls for mechanized CMT exterior overlay welding of heat exchanger pipes, which are used in power plant construction and waste incinerators. A safety light grid guarantees optimum protection of personnel during the welding process. More about heat exchanger pipes
User Application Cladding

Customer solutions that are impressively cost effective

 

Our customers need systems that produce perfect welds throughout the entire product life cycle. They need to be efficient and as profitable as possible. During the engineering phase we therefore place great importance on feasibility studies, simulations and welding tests.

To our customer solutions

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