High-performance welding

High-performance welding
LaserHybrid, TimeTwin Digital, strip-wire,
large-diameter wires
The kingly discipline
of welding.
GENERAL REMARKS
It’s all about speed
And a lot more besides
High-performance welding processes. At first glance, it’s
It’s just like this with high-performance welding, too.
all a matter of boosting the welding speed or – to put it
Which is why the epithet “kingly discipline” is so well-
another way – of increasing the deposition rate. Look
deserved. In high-performance welding processes, a very
closer, however, and you’ll see that what it’s really about
great deal is demanded of the welding system: High
is higher productivity. And higher productivity calls for
availability, a stable process, precision working, reliability,
perfection, and for the utmost precision in the process.
robustness, long service life – to name only a few of the
Just imagine you had to take your car up to 250 km/h.
Not many cars would be up to the job! The only cars to
manage this feat would be ones in top condition, and with
a top-rate engine. What’s more, not every road can cope
with speeds like this, either.
properties desired. These are the overall requirements –
all of which must be met, 100 %. For Fronius, too. If you
want to have high-performance welding, there simply is
no other way of going about it. For the goal is, and
remains: higher productivity. And it’s only then that faster
really does mean better.
System supplier for automated
and robot welding
The four processes that we’ll be introducing to you here
This means that when a new component is being
are intended for use in robot welding and automated
developed, for instance, the relevant high-performance
welding. This also makes them suitable for all customary
process can also be taken into consideration right from
robots, irrespective of whether these are addressed
a very early stage. Working together right from the outset
digitally, in analogue or via field-bus. Fronius is a
is an excellent way of pooling and synergising both
“full-liner”, meaning that as well as all the application
partners’ knowledge, and makes for superlative results.
know-how, we can also supply all accessories; indeed,
we also see ourselves as having overall responsibility
for the process as a whole.
Fronius currently offers four different high-performance
welding processes:
diverse applications. Each of these processes can be
used just as effectively for light-gauge sheets as for
plates, and for steel as for chrome-nickel or aluminium.
- LaserHybrid
- TimeTwin Digital
- Strip-wire
- Large-diameter wires
[m/min]
10
8
Welding Speed *
High-performance welding is possible for many very
6
4
2
[kg/h]
0
10
20
Deposition Rate *
30
* Approximate figures
LaserHybrid
Large Diameter Wires
TimeTwin Digital
Strip-wire
Single Wire: conventional
Classification of high-performance welding processes with reference
to deposition rate and welding speed.
LaserHybrid
The most economical process to deliver 9m/min
Metal transfer in the LaserHybrid welding process.
OVERVIEW
Optimum efficiency and optimum quality
Cost comparison for Audi A2
How to reach peak performance – at the speed of light!
Total costs in € / m
The LaserHybrid process is the most economical variant
of high-performance welding, and also the one that
delivers the best quality: As measured by the actual costs
per metre of weld-seam, as well as by criteria such as
.
weld-seam quality, post-weld machining and
mechanical/technological values.
LaserHybrid is the “state of the art” in the field of
.
.
.
LaserHybrid
Punch riveting
MIG
.
materials-joining technology. Essentially, two welding
processes have been amalgamated here in such a way as
to exploit each of their advantages – the processes in
question being the conventional laser-beam process and
classic MIG welding. Some welcome synergies result,
such as a smaller weld-pool (meaning less thermal input),
higher availability, very low costs per metre of weld-seam,
and shorter fabrication times.
Aluminium
vs = 8.1 m/min
Aluminium
vs = 4.2 m/min
Savings on shielding-gas: Factor 18
Filler: AlMg4.5Mn
Thickness of material: 2 mm
Shielding gas: 100 % Ar
Cost of shielding gas: 6 €/m3
Aluminium
vs = 2.1 m/min
LaserHybrid
vs: 6 m/min
Q: 5 l/min
Mig
1 m/min
15 l/min
CrNi
vs = 2.7 m/min
Galvanised steel (laser brazed)
vs = 3 m/min
Steel
vs = 4.2 m/min
Aluminium
vs = 4.5 m/min
CrNi
vs = 3.6 m/min
BASIC PRINCIPLE OF THE PROCESS
Reconciling opposites
A special variant: Laser brazing
A new process: as fast as laser, and as good as MIG.
This specialty joining process was developed for coated
Yes, a contradiction. But that was just what the Fronius
sheets. Only the filler metal is fused here, not the base
developers wanted. They wanted the high welding speed
metal – this is brazed instead. The result is an extremely
of the classic laser-beam process, at the same time as
narrow seam, entirely without distortion and without any
the superior gap bridgeability of the well-established MIG
weld inhomogeneities such as pores.
welding process. It took three years of ultra-intensive
research work. Today, we have the solution: a hybrid
process that unites both processes and exploits the
Light-years ahead
positive synergies between them. The laser beam and the
The LaserHybrid process represents the future of
arc act jointly in one welding zone, influencing and
materials-joining technology and is probably the most
supporting one another. The laser beam feeds heat to the
advanced welding process in existence today. Fronius
weld metal in addition to the heat from the arc. This
developed this process, was the “first mover” and so is a
causes the processes to influence one another, to a
long way ahead with its know-how. A very long way, in
different extent and in different ways.
fact. Incidentally, with LaserHybrid productivity
Several things result from this: Process stabilisation, for
improvements of up to 400 % are possible, depending
example, permitting virtually spatter-free welding. Or the
on the application!
very low thermal input and thus a smaller heat-affected
zone, leading in turn to an extremely small seam, which
together mean less weldment distortion and reduced
filler-metal consumption. Or, again, the completely
homogeneous seam that can be obtained with aluminium,
from beginning to end, owing to the 100 % elimination of
fusion defects at the start of welding in LaserHybrid.
LASER
PL : 2000W
Vd : –
LASERHYBRID
PL : 1500W
Vd : 5.5m/min
Gas nozzle
Laser beam
Electrode
Pulsed arc
Fusion zone
Schematic representation of LaserHybrid welding process.
Comparison of weld-seam geometry
PL : Laser power, Vd : Wirefeed speed
MSG
PL : –
Vd : 11m/min
1
3
4
2
Four different processes realised with one system
(1. Laser, 2. LaserHybrid, 3. GMA,
4. GMA tacking)
SYSTEM
FACTS
The LaserHybrid welding system is robot-enabled, flexible, mobile,
The LaserHybrid process offers the following
advantages over the laser or MIG welding
processes used on their own:
and compactly built – and thus ensures maximum fabrication
efficiency.
– Shorter fabrication times and lower costs;
higher productivity
– Welding speeds of up to 9 m/min
Sample LaserHybrid configuration
1. Power source: totally digitised, microprocessor-controlled
inverter power source, unrivalled precision in the welding process,
exact reproducibility, outstanding welding properties
2. VR 1500 wirefeeder: small, lightweight, digitally controlled with
4-roller drive, suitable for mounting on the 3rd axis of the robot
3. FK 4000 cooling unit: rugged and reliable, ensures optimum
– No fusion defects at the beginning of the seam
when working with aluminium
– Deeper penetration and narrow seams, yet less
thermal input
– Higher weld-seam ductility, joint strength and
scope for influencing the structure by means of
the filler metal
cooling of the welding torch
– Greater gap bridgeability, at the same time as
very much higher joining rates
4. RCU 5000i remote-control: remote-control unit with full-text
– Higher process stability and system availability
display, weld-data monitoring by Q-Master, straightforward user
– Greater scope for improving weld appearance
(design)
guidance, systematic menu structure, user administration
5. Robot interface: suitable for all customary robots, irrespective
of whether these are addressed digitally, in analogue or via
field-bus
UTILISATION
6. LaserHybrid welding head: great flexibility in terms of its
manoeuvrability, compact constructional design, integrated
Materials
crash-box (for collision protection), integrated cross-jet with
fume-extractor device, fume-extraction duct.
LaserHybrid welding is suitable for welding lightgauge sheets made of the following materials:
7. Wire supply
– Coated and uncoated steel materials
8. Laser-beam source
– High-alloy steels
– Aluminium materials
Applications
– Construction of plant, containers, machinery &
structural steel
– Automobile & allied vendor industries
– Aerospace
– Construction of rail vehicles & rolling stock
– Shipbuilding
TimeTwin Digital
Maximum deposition rate of up to 30 kg/h
Metal transfer in 180° phase-displaced pulsed arcs using the “TimeTwin Digital” welding system.
OVERVIEW
Performance x 2 = perfection and speed
In conventional single-wire processes, deposition rates of
digitised – and then the result is not only twice the speed,
up to 6 kg/h can be obtained. So it is only logical that if
but also an extraordinarily high degree of perfection.
you use two wires instead of one, you can achieve twice
Like with TimeTwin Digital. Which demonstrates the
as much. And this is just the way it is with the tandem
whole point of high-performance welding: The clever
process, except that this is better still – giving you
thing about it is not so much that it welds fast, but that
deposition rates of up to 30 kg/h. Let’s now also assume
it welds both fast and perfectly.
that the power sources being used here are totally
The TimeTwin Digital welding system achieves the very highest
economic efficiency in automated welding of low-alloy or high-alloy
steels and aluminium materials.
The system "TimeTwin Digital" reduces the welding time for pipeline
welding from four hours to only twenty minutes per joint; the
automatic system of Fronius welds high-tensile X-100 steels with
four "tandem heads".
Shipbuilding, steel
vs = 150 cm/min
Truck rim/steel
vs = 155 cm/min
Boiler, steel
vs = 350 cm/min
Fillet weld, aluminium
vs = 200 cm/min
BASIC PRINCIPLE OF THE PROCESS
The high-achieving duo
Expert know-how comes built-in
TimeTwin Digital is a tandem-based GMA welding
Fronius digital systems’ lead in terms of ease of
process that has already stood the test of time, and
operation is all to do with their integrated expert
passed with flying colours. In this process, two separately
knowledge: For the most varied applications, there are
controllable TPS 4000 or TPS 5000 power sources work
optimised parameter records which are stored in synergic
with two insulated wire electrodes in one single gas
characteristics and can be utilised at any time.
nozzle and in a shared weld-pool. What is new about this
Time-wasting “hunting around” for parameters is now a
welding process is the fact that it is completely digitised,
thing of the past – and results are now 100 %
resulting not only in hitherto unequalled precision and
reproducible.
perfection, but also in vastly easier handling.
A synchronisation unit mediates between the two power
optimum results. In this way, the metal-transfer processes
Forward, back, single, double –
everything is possible
from both wire electrodes can be timed to co-ordinate
Automated applications, where every second counts, call
with one another. This is the fundamental precondition for
for great flexibility. TimeTwin Digital answers this call in
a stable, low-spatter tandem process. Another factor
several ways. However, particular mention should be
which is equally important for the overall sequence is the
made of the facility which TimeTwin Digital gives you to
ignition. In TimeTwin Digital, this is guaranteed to be
alternate between the leading and trailing wire electrode –
jerk- and spatter-free, thanks to SFI ignition.
meaning there is no need to reorientate at the end of the
sources, harmonising the two wire electrodes so as to get
seam in multi-pass welding. This shortens cycle times
and improves accessibility. Also, there are jobs that can
only be welded with one wire, e.g. smaller round wires. In
cases like this, it is very easy to switch off the second
Two insulated wire electrodes work in one single gas nozzle, and in a
shared weld-pold.
installation.
SYSTEM
Two completely separate – and individually controllable –
power sources work with two insulated wire electrodes in
one single gas nozzle, and in a shared weld-pool. This
shortens the cycle times and enhances both welding
quality and profitability.
Container, aluminium
vs = 180 cm/min
FACTS
Sample TimeTwin Digital configuration
1. TimeTwin Digital power sources: consisting of two totally
digitised customary TPS 4000’s or TPS 5000’s linked via a digital
data interface
2. FK 9000 cooling unit: ensures optimum cooling; comes as
standard with thermostat, rate-of-flow watchdog and water filter
3. VR 1500 wirefeeders: small, lightweight, digitally controlled with
4-roller drive, suitable for mounting on the 3rd axis of the robot
4. VR 1500 PD unreeling unit: unreeling unit with a planetary
drive, for ensuring highly constant wirefeed even when using long
hosepacks
TimeTwin Digital: A decisive advance – made
possible by digital technology.
– The shorter cycle times and higher welding
quality boost profitability: 5 times the welding
speed of MIG/MAG single-wire welding, and
deposition rates of up to 30 kg/h
– The digitisation results in very stable arcs,
perfect droplet detachment and low thermal
input
– The perfect start-up and crater-filling phases
lead to identical properties and weld-seam
appearance along the entire length of the seam;
5. RCU 5000i remote control units: remote-control unit with
this has particularly favourable effects with
full-text display, weld-data monitoring by Q-Master, straightforward
joints that are subject to high dynamic stressing
user guidance, systematic menu structure, user administration
– Improved accessibility, as it is possible to
6. Robot interface: suitable for all customary robots, irrespective
alternate between the leading and trailing wire
of whether these are addressed digitally, in analogue or via
electrodes; this does away with the need for
field-bus
reorientation at the end of the seam in
7. Robacta Twin Compact welding torch: for improved ease of
access, separate cooling of gas nozzle and torch body, suitable for
multi-pass welding
– Built-in applications know-how: over 60 welding
both welding directions, and with Fronius forced-contacting
programs are available for various base metals
arrangement for defined current transfer
and filler metals
8. Robacta TC Twin cleaning system: uses electromagnetic forces
for touchless, cost-saving removal of the welding spatter that
UTILISATION
accumulates in the gas-nozzle zone during steel welding
9. Wire supply
Materials
– The TimeTwin Digital welding system has a
huge spectrum of applications. The specific
know-how can be used for all materials.
Applications
– Construction of plant, containers, machinery
& structural steel
– Automobile & allied vendor industries
– Pipeline construction
– Construction of rail vehicles & rolling stock
– Shipbuilding
– Construction of special vehicles and
construction machinery
Strip-wire,
large-diameter wires
High-deposition single-wire process
Longitudinal view of a metal transfer from AlSi5 strip-wire in a pulsed arc.
OVERVIEW
Special wires call for
special technology
Special applications, such as extra-thick plates on
earthmoving machinery, call for unconventional solutions.
Like wires with diameters of up to 3.2 mm, or wires with a
rectangular cross-section of approx. 4.5 x 0.5 mm. While
- Strip-wire: over 11 kg/h on steel, up to 4 kg/h on
aluminium
- Large-diameter wires: over 25 kg/h on steel, up to
5 kg/h on aluminium
wires like these certainly have definite advantages for the
intended area of use, they do make very special demands
Welding speeds on steel can be as much as 165 cm/min,
of the welding system. Of the wirefeed, for instance, and
and even more on aluminium. For classic GMA
in terms of performance and reliability. Fronius’ response
single-wire processes, these are extraordinary figures!
to these demands is a technology that makes possible
Intended for fully automated applications, incidentally.
high deposition rates:
The TPS 9000 welding system consists of two TPS 5000’s and
comes with a robust VR 1500 wirefeeder. Designed for e.g. welding
large diameters of wire.
The Robacta Drive Flat welding torch, with a water-cooled gas
nozzle, ensures exact wirefeed and a high deposition rate.
Left:
Strip-wire, 4.0 x 0.6 mm
Sheet thickness: 3 mm
Filler metal: AlSi5
Welding speed: 3 m/min
Deposition rate: 2.4 kg/h
Right:
Strip-wire, 2.4 mm
Sheet thickness: 8 mm
Filler metal: AlMg4.5Mn
Welding speed: 0.8 m/min
Deposition rate: 5.2 kg/h
BASIC PRINCIPLE OF THE PROCESS
SYSTEM
Know-how is the whole secret
The special rectangular shape of the strip-wire results in
A system will only function properly if there is perfect
an oval weld-pool. This leads to low arc-pressure,
interplay between all the components.
meaning better control of the weld-pool. In turn, this
results in the above-mentioned advantages of
significantly higher deposition rates and/or welding
Sample strip-wire configuration
speeds.
1. TPS 5000 / 7200 / 9000 power source: totally
Owing to the special geometry of the wire, the preferred
digitised, microprocessor-controlled inverter power
area of application for strip-wire welding is with weldment
source, unrivalled precision in the welding process, exact
handling systems or on longitudinal travel carriages. In
reproducibility, outstanding welding properties
this case, the weldment is moved beneath the welding
2. FK 4000 cooling unit: rugged and reliable, ensures
torch. For special applications, the wire may also be
optimum cooling of the welding torch
turned perpendicular to the welding direction, so that the
gaps can be bridged better. Depending on the
application, either the TPS 5000, TPS 7200 or TPS 9000
welding system can be used.
3. VR 4000 wirefeeder: 4-roller drive with superb
wirefeed properties, also suitable for long hosepacks
4. Robot interface: suitable for all customary robots,
irrespective of whether these are addressed digitally, in
analogue or via field-bus
Big capabilities for big diameters
5. Robacta Drive Flat welding torch: digitally controlled
Wires with large diameters (up to 3.2 mm) are welded
push-pull drive with integral wire-drive; external wire
with the MIG/MAG process – at considerably higher
guidance for optimum strip-wire travel, separately from
power, however. And when the output power can rise as
the other welding media, and Fronius forced-contacting
high as 900 A, a welding system has to meet far tougher
arrangement for defined current transfer
requirements. What this means is that all the equipment,
from the wirefeeder unit all the way through to the torch
6. Wire supply
cooling system, must be designed for this high output
7. Robots or longitudinal travel carriage for
power.
weldment-handling
FACTS
Sample “large-diameter wires”
configuration
1. TPS 9000 power source: power-scalable by means of two
completely digitised customary TPS 4000’s or TPS 5000’s, linked
via a digital data interface
2. FK 9000 cooling unit: ensures optimum cooling; comes as
standard with thermostat, rate-of-flow watchdog and water filter
3. VR 1500-11 wirefeeder: small, lightweight, digitally controlled
– Welding system (power source, wirefeeder,
cooling unit and torch) specially developed for
processing strip-wires and large-diameter wires
– To deliver the high welding current of e.g. 900 A
that is required, two scalable power sources
work in parallel, jointly creating a single arc
– Scalable power sources make possible welding
currents of 900 A with a duty cycle of 100 %
(at 25°C) or 60% (at 40°C)
with 4-roller drive, suitable for mounting on the 3rd axis of the
robot.
4. Digital Gas Control: The gas-flow rate is pre-set for the
welding task in hand, stored with the respective job, and digitally
controlled. This makes it possible to reduce the gas
consumption – and thus to cut costs – by between 5 and 20 %.
– Strip-wire welding is particularly economical
for mechanised or automated welding of
longitudinal seams, or where the workpiece is
moved by a handling robot
– Shallower penetration in overlay welding, as the
oval weld-pool in strip-wire welding results in
lower arc pressure
5. Robot interface: suitable for all customary robots,
irrespective of whether these are addressed digitally, in
analogue or via field-bus
6. Robacta welding torch: high-performance welding torch with
water-cooled gas nozzle for long service life, digitally controlled
– Deposition rates in strip-wire welding: over
11 kg/h on steel, up to 4 kg/h on aluminium
– Deposition rates when welding large-diameter
wires: over 25 kg/h on steel, up to 5 kg/h on
aluminium
wirefeed speed, Fronius forced-contacting arrangement for
defined current transfer
UTILISATION
7. Robacta TC cleaning system: uses electromagnetic forces
for touchless, cost-saving removal of the welding spatter that
accumulates in the gas-nozzle zone during steel welding
8. Wire supply
Materials
– Coated and uncoated steel materials
– High-alloy steels
– Aluminium materials
Applications
– Construction of plant, containers, machinery
& structural steel
– Automobile & allied vendor industries
– Pipeline construction
– Construction of rail vehicles & rolling stock
– Shipbuilding
– Construction of special vehicles and
construction machinery
FRONIUS USA LLC
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Brighton, Michigan 48116, USA
Tel: +1 810 220 4414
Fax: +1 810 220 4424
E-Mail: sales.usa@fronius.com
FRONIUS INTERNATIONAL GMBH
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A 4602 Wels, Austria
Tel: +43 7242 241-0, Fax: +43 7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
FRONIUS CANADA LTD
2875 Argentia Road, Units 4,5 & 6
Mississauga, ON L5N 8G6, Canada
Tel: +1/905-288-2100
Fax: +1/905-288-2101
E-Mail: sales.canada@fronius.com
40,0006,2305 v01 2008 aw 02
UralMash
Text and illustrations technically correct at time of going to print. We reserve the right to make modifications.
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