The perfect partner for overlay welding: Fronius Welding Automation

All parameters live and at a glance

The HMI-T21 system controls are ready for Industry 4.0 with a large, intuitive 21-inch touchscreen, multi-user accounts with individually assigned authorizations, process visualization in real time, on-the-fly parameter adjustments, and innovative functions such as X-Ray View, Component Editor, Bore-to-Bore Advanced, actual value monitoring in real time, and STEP file import. And, of course, the system offers remote maintenance capabilities. The X-Ray view provides a transparent outline of the component to give the operator an excellent overview. The Bore-to-Bore-Advanced function offers assistance when several offset transverse bores with non-90° angles or flanges with bores are to be surfaced. All relevant welding parameters are displayed live in the system-integrated actual value monitoring. 

A service that meets every need

The welding professional creates components step by step in the Component Editor via the HMI-T21 touchscreen. The height and diameter are defined by inputting the relevant dimensions, and the various components appear in real time as 3D graphics on the screen. In addition to cylindrical shapes, flat and conical shapes are also possible. There are also options to model bores and extensions, such as flanges. The CNC technology now integrated at Fronius creates scope for even more component geometries than before, including intersection bores on conical components.

The welding processes are programmed in the Program Editor. Operators select the individual sections of the components and define the welding sequence. One especially helpful aspect is that the welding torch can be shown at the starting point. 

All welding parameters are defined in the Weld Editor. The system offers a selection of jobs with fixed parameters that can be adjusted at any time—even on-the-fly—in the Weld Adjust menu. AVR (Actual Value Recording) records the actual values of the welding current, voltage, wire speed, gas quantity, and welding position during the welding processes in table form. The PC software packages Data Logger HMI and Data Viewer HMI are optionally available for graphical evaluations and analyses.

Once the home position of the welding torch has been calibrated, it moves independently to the starting point for each overlay welding application. Siegfried Wiesinger, overlay welding expert at Fronius, explains: “The remote control can be used to fine-tune a range of parameters even just before igniting the arc—for example, the AVC (Arc Voltage Control) function adjusts the starting point and distance of the welding torch to the component.“

SpeedClad 2.0—Award-winning and blazing fast

Faster, resource efficient, more economical—with SpeedClad 2.0, Fronius is setting new standards in overlay welding of valve components. SpeedClad 2.0 is much more cost-effective than the pulsed TIG hot wire processes. This innovation stands apart thanks to its high deposition rate, impressive speed, and low shielding gas consumption. In recognition of its exceptional results, the process was awarded the Excellence in Welding Award by the American Welding Society at FABTECH in Chicago on September 13, 2023. The jury was impressed by the deposition rate of the nickel-based alloy used in overlay welding being increased from 1.63 kg (3.59 lb) to up to 6 kg (13.23 lb)/h, with Fronius now using a 1.6 mm wire (0.063 in) in place of the 1.14 mm (0.045 in) wire. The welding speed rose from 33 cm (13 in)/min to 135 cm (53 in)/min, and the average pulsed current went from 240 amperes to 460 amperes. All Fronius customers are guaranteed the ideal heat input while simultaneously reducing argon gas consumption from 516 l/kg to as little as 140 l/kg. The fully re-developed welding torch system allows cladding of significantly narrower component diameters of 100 mm (3.94 in) instead of 150 mm (5.91 in). The heat input formula served as the starting point for the optimized cladding process: heat input = volts x amperes x 60 / welding speed. 

Sustainability is part of Fronius Welding Automation’s genetic makeup, which is why many of its innovations not only deliver technical improvements but also reduce consumables—just as the SpeedClad 2.0 process does.

Longitudinal and circumferential seam welding systems and robotic welding systems also in the range

As a solution provider, Fronius Welding Automation not only produces overlay welding systems but also mechanized welding systems and robotic welding systems for all industries.

These include longitudinal and circumferential seam welding systems, welding carriages, and handling-to-welding robotic welding systems. Collaborative systems, intelligent sensor technology, software solutions for data management, and offline programming including welding simulation open up profitable welding opportunities for metal processing companies starting with a single batch. The specific requirements for the welding technology are analyzed together with the customer. This is followed by the creation of an individual solution.

To do this, Fronius has a construction kit of standardized components at its disposal. Starting with the feasibility study and continuing with planning, engineering, manufacturing, and start-up, the sale of welding systems is handled as a project. Since 1975, more than 3,500 installed systems have been used across 45 different countries with over 2,000 customers. Covering an area of more than 11,000 square meters (118,400 sq. ft), around 150 employees take on the welding technology challenges presented by their customers. 

Take a look for yourself at the new and proven solutions for cladding and 3D metal printing. The Fronius team are looking forward to showing these innovations at the ADIPEC trade show in Abu Dhabi, on 4th to 7th of November 2024, Hall 14, Stand 14316.