Whether you are using MIG, TIG or electrode processes - whether your operation is automated or manual: Fronius power sources are in a class of their own. Each system has been developed and produced by Fronius using state-of-the-art technology. See for yourself!
Whether you are using MIG, TIG or electrode processes - whether your operation is automated or manual: Fronius power sources are in a class of their own. Each system has been developed and produced by Fronius using state-of-the-art technology. See for yourself!
Metal Inert Gas welding and Metal Active Gas welding are the most widely used welding processes in the world today. The range of possible uses is especially wide in the case of the versatile MAG process, which is suitable for unalloyed, low-alloy and high-alloy base metals.This makes it ideal for use in both the production field and for repair welding. The MIG process, on the other hand, is used for aluminum and copper materials. All in all, then, a highly versatile welding process.
The TPS/i is a universal genius. It was conceived and designed from first principles, from the ground up. As a result, it has decisively improved the welding properties, optimised the communication between man and machine, and perfected the handling. Its modular design concept makes it easy to adapt it to users' individual welding-needs. With the TPS/i, we have already arrived in the future of welding. A perfect welded joint requires skill and a reliable welding system. The pursuit of quality has increased the demands on the welder exponentially. He is the human link between two materials, and the modern welding system is the amplifier of his senses.
The TransPuls Synergic 3200 for short circuit, spray and pulsed arcs is a fully digitized and microprocessor-controlled MIG power source with an output of 320 A. The power source gives the best weld properties in every respect, and reproducible results time and time again. The multiprocess power source is suitable for MIG, TIG and electrode welding, as well as manual or robotic applications.
The main advantage of Tungsten Inert Gas welding is the huge range of different materials that it can be used to weld. These materials can be welded from thicknesses of only 0.6 mm upwards, and include unalloyed and alloyed steels, aluminium, magnesium, copper, grey cast iron, bronze, nickel, silver, titanium, lead and many others beside. The principal area of use is for welding thin and medium thicknesses of material, and for welding root passes on joints with thicker cross-sections.
Manual Metal Arc welding, also known as manual electrode welding, is a process with which virtually all metals can be welded. This process is also excellent for outdoor use.Incidentally, most of our MMA machines also permit TIG welding. Manual electrode welding is a very widely practised and easy-to-use welding process.
/ compact - lightweight and portable/ battery powered/ mobile and cable-less welding AccuPocket welds all types of electrode (rutile, basic, CEL and special purpose electrodes) up to a diameter of 3.25 mm (0.13"). Steel, high alloy steels and aluminum are all suitable base metals.A fully charged battery is enough to weld up to six 3.25 mm (0.13"). electrodes or up to eighteen 2.5 mm (0.1")ones. AccuBoost Technology ensures that the power needed for perfect ignition and weld properties is permanently at hand.
Fronius's proven digital resonance concept has been refined to give even more precise and faster control of the welding current. Based on the presence of constant power reserves, there is an instant response to every minute change in the arc. This enables an ideal starting characteristic. A consistently perfect arc with minimum spatter leads to the best weld properties.
/ Perfect ignition: the reduced short circuit current on contact with the workpiece prevents the electrode from sticking. The current then increases to ensure that the arc does not break. The device then reaches the main, SoftStart or HotStart current, which the user can set precisely.
/ The new device series can be used with all electrodes. Rod electrodes with diameters up to ⁵⁄₃₂ inch and cellulose electrodes (CEL) give perfect welding results thanks to a special operating mode. New infinitely adjustable dynamic settings enable the user to adjust the ignition precisely to the electrodes being used. The HotStart function makes it easier to ignite CEL and rutile electrodes, while the SoftStart function enables a stable arc for basic electrodes, which ignite at a low welding current.
The plasma process is basically very similar to the TIG process but has a number of critical advantages. These make it an interesting alternative to laser welding where tough quality demands have to be met, especially on sheets and other components with a sheet thickness of up to 8 mm (0.31 in.).
In plasma welding, the arc is constricted by a cooled gas nozzle. The powerfully bunched arc that results does away with the need for time-consuming weld preparation work such as V- or U-type joint preparation. This saves as much as 30 % of the fi ller metal. In turn, the higher welding speed – around 20 % faster in soft-plasma welding, for example – saves time and costs at the same time as ensuring deeper penetration. Also, being enveloped in plasma gas, the tungsten electrode has a much longer service life.
Very often there is more to the welding processes than connecting two pieces of material. In many instances multiple welds are necessary, have to be coordinated, need to be brought into logical order. Fronius offers a wide range of mechanised welding systems - from pre-developed standard components to complex system solutions specially matched to your applications.
Fronius cladding systems are vertically designed and manufactured - welding power supplies, wire feeders, torches, controls and motion equipment. Benefit to user is maximum design flexibility and system productivity.
Fronius cladding systems are vertically designed and manufactured - welding power supplies, wire feeders, torches, controls and motion equipment. Benefit to user is maximum design flexibility and system productivity.
Fronius cladding systems are vertically designed and manufactured - welding power supplies, wire feeders, torches, controls and motion equipment. Benefit to user is maximum design flexibility and system productivity.
Fronius cladding systems are vertically designed and manufactured - welding power supplies, wire feeders, torches, controls and motion equipment. Benefit to user is maximum design flexibility and system productivity.
Fronius cladding systems are vertically designed and manufactured - welding power supplies, wire feeders, torches, controls and motion equipment. Benefit to user is maximum design flexibility and system productivity.
This modern joining method satisfies increasingly stringent demands,.some of the most important of which are process stability, reproducibility and cost-effectiveness. The bundling together of specific material properties opens up a number of interesting possibilities. Material compounds impart to a component or product the desirable properties of the constituent materials. Previously, such results could only be achieved by mechanical means or by bonding. Of much greater interest, however, is the ability to use heat to join materials with differing properties. The main focus in this respect is on the joining of steel and aluminium, as this will be of particular interest to the automotive sector, where it could spawn a whole range of previously undreamt of innovations.
The joining of dissimilar materials requires precise knowledge of the properties of each material. Aluminium is highly regarded due to its low specific weight and its excellent usability and processing characteristics. On the other hand, its strength and low cost make steel indispensable in many areas of industry. Other requirements primarily address anti-corrosion features, thermal expansion coefficient, and atomic properties. When joining steel and aluminium under the influence of heat, what is known as an intermetallic phase is created at the interface between the two materials. The more heat that is applied, the more extensive the intermetallic phase and the poorer the mechanical properties of the join will be. However, the chemical and physical properties also require appropriate measures to be taken. The different thermal expansion coefficients of the two materials create a stress field around the join. There is also a marked tendency for corrosion to form as a result of the large electrochemical potential difference of steel compared with aluminium. All the technologies that have been used to join steel and aluminium in the past have only been able to deal with certain geometries or have required extensive control inputs. Although the perceived wisdom among many metallurgists was that steel and aluminium could not be welded together, extensive research in the field of MIG/MAG welding indicated that arc welding was indeed a potential way of joining the two materials. The CMT process evolved from the continuous adaptation of the MIG/MAG process to resolve the problems posed by the joining of steel and aluminium. CMT is a controlled process and allows the material transfer to take place with barely any flow of current. The aluminium base material melts together with the aluminium filler material, with the melt wetting the galvanised steel. The filler wire is constantly retracted at very short intervals. The precisely defined retraction of the wire facilitates controlled droplet detachment to give a clean, spatter-free material transfer. The wire movement takes place at a very high frequency and requires a quick-response, gearless wire drive directly on the torch. Obviously the main wirefeeder will not be able to keep up with these movements. The wirefeeding hose is therefore provided with a wire buffer that compensates for the additional forward and backward movement of the wire.
CMT welding is carried out exclusively using digital inverter power sources. The welding system basically uses the same latest state-of-the-art hardware as a MIG/MAG system, while at the same time taking certain specific requirements into account. Particularly noteworthy is the highly-dynamic wirefeeder mounted directly on the welding torch. The moment the power source detects a short circuit, the welding current drops and the filler wire starts to retract. Exactly one droplet is detached, with no spatter whatsoever. The filler wire then moves forwards again and the cycle is repeated. High frequency and extreme precision are the basic requirements for carefully controlled material transfer. The wire drive on the welding torch is designed for speed, not high tractive forces. The wire is therefore fed by a more powerful but, due to the above, slower main wirefeeder. A wire buffer on the wirefeeding hose is used to convert the superimposed, high-frequency wire movement into a linear wirefeed.
The highlight of the CMT process is without doubt its ability to join steel and aluminium. Although the steel base material is only wetted during this brazing process and does not melt, numerous trials always resulted in a break in the aluminium base material, not in the weld seam. In addition to the joining of steel and aluminium, the CMT process is also highly suitable for a number of other applications. There is undoubtedly a great deal of interest in the almost spatter-free brazing of hot galvanised and electrolytically galvanised sheets using a filler wire made from an alloy of copper and silicon. Ongoing trials are examining the joining of galvanised sheet (0.8 mm) and black material (5 mm), with extremely low levels of distortion of the galvanised sheet. Light-gauge welding (0.3 – 0.8 mm) of aluminium sheets is also perfectly feasible. The low level of heat insertion in the CMT process means that a weld pool is not required; even then there is no risk of weld drop-through. The results of welds performed on stainless steels and magnesium are also first class.
The CMT process provides a straightforward way of joining steel and aluminium. Over and above this, CMT has a number of more than satisfactory mechanical and technological characteristics. Interest is not just confined to the joining of steel and aluminium. There are a number of other extremely interesting potential applications, including the spatter-free brazing of coated sheets, the light-gauge welding of aluminium and the welding of magnesium. A large number of trials are currently in progress. Which other applications the CMT process is suitable for remains to be seen.
The TransPuls Synergic 2700 for short circuit, spray and pulsed arcs is a fully digitised and microprocessor-controlled MIG/MAG power source with an output of 270 A. The power source gives the best weld properties in every respect, and reproducible results time and time again. The integral wire-feed unit guarantees portable use on construction sites, in workshops and for maintenance and repair activities. The multiprocess power source is suitable for MIG/MAG, TIG and electrode welding. CMT stands for Cold Metal Transfer. The wire movement is incorporated into the process control, where heat is inserted only very briefly. Metal transfer takes place with barely any flow of current. The result is spatter-free MIG/MAG welding and brazing of thin sheets (0.3 mm or thicker), MIG brazing of galvanised sheets and the joining of steel and aluminium.
| Mains voltage | 3 x 400 V |
| Mains voltage tolerance | + 15 % / - 15 % |
| Mains frequency | 50 / 60 Hz |
| Mains fuse protection | 16 A |
| Primary continuous current (100 %) | 6,6 A |
| Primary continuous power (kVA) | 4,5 - 8,7 kVA |
| Cos phi | 0,99 |
| Degree of efficiency | 87% |
| Welding current range MIG/MAG | 3 - 270 A |
| Welding current range TIG | 3 - 270 A |
| Welding current range, electrode | 10 - 270 A |
| Duty cycle at 10 min/40° C (104° F) | 40 % d.c. at 270 A |
| Duty cycle at 10 min/40° C (104° F) | 100 % d.c. at 170 A |
| Open-circuit voltage | 50 V |
| Working voltage MIG/MAG | 14,2 - 27,5 V |
| Working voltage TIG | 10,1 - 20,8 V |
| Working voltage Electrode | 20,4 - 30,8 V |
| Protection | IP 23 |
| Type of cooling | AF |
| Insulation class | B |
| Dimensions l/w/h mm | 625/290/475 |
| Dimensions l/w/h (inches) | 24.6/11.4/18.7 |
| Weight kg | 27 |
| Weight lb | 59.5 |
| Marks of conformity | CE |
| Marks of conformity | CSA |
| Safety | S |
• Pulse welding up to 320 A
• Welds sheets of 0,3 mm or thicker
• For manual and robot applications
The TransPuls Synergic 3200 for short circuit, spray and pulsed arcs is a fully digitised and microprocessor-controlled MIG/MAG power source with an output of 320 A. The power source gives the best weld properties in every respect, and reproducible results time and time again. The multiprocess power source is suitable for MIG/MAG, TIG and electrode welding, as well as manual or robotic applications.
CMT stands for Cold Metal Transfer. The wire movement is incorporated into the process control, where heat is inserted only very briefly. Metal transfer takes place with barely any flow of current. The result is spatter-free MIG/MAG welding and brazing of thin sheets (0.3 mm or thicker), MIG brazing of galvanised sheets and the joining of steel and aluminium.
| Mains voltage | 3 x 400 V |
| Mains voltage tolerance | + 15 % / - 15 % |
| Mains frequency | 50 / 60 Hz |
| Mains fuse protection | 35 A |
| Primary continuous current (100 %) | 12,6 - 16,7 A |
| Primary continuous power (kVA) | 8,7 - 11,5 kVA |
| Cos phi | 0,99 (320 A) |
| Degree of efficiency | 91% |
| Welding current range MIG/MAG | 3 - 320 A |
| Welding current range TIG | 3 - 320 A |
| Welding current range, electrode | 10 - 320 A |
| Duty cycle at 10 min/40° C (104° F) | 40 % d.c. at 320 A |
| Duty cycle at 10 min/40° C (104° F) | 100 % d.c. at 220 A |
| Open-circuit voltage | 65 V |
| Working voltage MIG/MAG | 14,2 - 30,0 V |
| Working voltage TIG | 10,1 - 22,8 V |
| Working voltage Electrode | 20,4 - 32,8 V |
| Protection | IP 23 |
| Type of cooling | AF |
| Insulation class | F |
| Dimensions l/w/h mm | 625/290/475 |
| Dimensions l/w/h (inches) | 24.6/11.4/18.7 |
| Weight kg | 35,6 |
| Weight lb | 78.6 |
| Marks of conformity | CE |
| Safety | S |
• Pulse welding up to 400 A
• Welds sheets of 0,3 mm or thicker
• For industrial use
The fully digitised and microprocessor-controlled MIG/MAG power source for short circuit, spray and pulsed arcs enables the best weld properties in every respect, and reproducible results time and time again. With an output of 400 A, the TransPuls Synergic 4000 meets the highest demands of the automobile and component supply industry, equipment construction, chemical plant construction, machine and tracked vehicle manufacturing, and in shipyards. The multiprocess power source is suitable for MIG/MAG, TIG and electrode welding, as well as manual or robotic applications.
CMT stands for Cold Metal Transfer. The wire movement is incorporated into the process control, where heat is inserted only very briefly. Metal transfer takes place with barely any flow of current. The result is spatter-free MIG/MAG welding and brazing of thin sheets (0.3 mm or thicker), MIG brazing of galvanised sheets and the joining of steel and aluminium.
| Mains voltage | 3 x 400 V |
| Mains voltage tolerance | + 15 % / - 15 % |
| Mains frequency | 50 / 60 Hz |
| Mains fuse protection | 35 A |
| Primary continuous current (100 %) | 12,2 kVA |
| Cos phi | 0,99 |
| Degree of efficiency | 88% |
| Welding current range MIG/MAG | 3 - 400 A |
| Welding current range TIG | 3 - 400 A |
| Welding current range, electrode | 10 - 400 A |
| Duty cycle at 10 min/40° C (104° F) | 50 % d.c. at 400 A |
| Duty cycle at 10 min/40° C (104° F) | 100 % d.c. at 320 A |
| Open-circuit voltage | 70 V |
| Working voltage MIG/MAG | 14,2 - 34,0 V |
| Working voltage TIG | 10,1 - 26,0 V |
| Working voltage Electrode | 20,4 - 36,0 V |
| Protection | IP 23 |
| Type of cooling | AF |
| Insulation class | F |
| Dimensions l/w/h mm | 625/290/475 |
| Dimensions l/w/h (inches) | 24.6/11.4/18.7 |
| Weight kg | 35,2 |
| Weight lb | 77.6 |
| Marks of conformity | CE |
| Marks of conformity | CSA |
| Safety | S |
• Pulse welding up to 500 A
• Welds sheets of 0,3 mm or thicker
• For industrial use
The fully digitised and microprocessor-controlled MIG/MAG power source for short circuit, spray and pulsed arcs enables the best weld properties in every respect, and reproducible results time and time again. With an output of 500 A, the TransPuls Synergic 5000 meets the highest demands of the automobile and component supply industry, equipment construction, chemical plant construction, machine and tracked vehicle manufacturing, and in shipyards. The multiprocess power source is suitable for MIG/MAG, TIG and electrode welding, as well as manual or robotic applications.
CMT stands for Cold Metal Transfer. The wire movement is incorporated into the process control, where heat is inserted only very briefly. Metal transfer takes place with barely any flow of current. The result is spatter-free MIG/MAG welding and brazing of thin sheets (0.3 mm or thicker), MIG brazing of galvanised sheets and the joining of steel and aluminium.
| Mains voltage | 3 x 400 V |
| Mains voltage tolerance | + 15 % / - 15 % |
| Mains frequency | 50 / 60 Hz |
| Mains fuse protection | 35 A |
| Primary continuous current (100 %) | 18 - 29,5 A |
| Primary continuous power (kVA) | 13,1 kVA |
| Cos phi | 0,99 |
| Degree of efficiency | 90% |
| Welding current range MIG/MAG | 3 - 500 A |
| Welding current range TIG | 3 - 500 A |
| Welding current range, electrode | 10 - 500 A |
| Duty cycle at 10 min/40° C (104° F) | 40 % d.c. at 500 A |
| Duty cycle at 10 min/40° C (104° F) | 100 % d.c. at 360 A |
| Open-circuit voltage | 70 V |
| Working voltage MIG/MAG | 14,2 - 39,0 V |
| Working voltage TIG | 10,1 - 30,0 V |
| Working voltage Electrode | 20,4 - 40,0 V |
| Protection | IP 23 |
| Type of cooling | AF |
| Insulation class | F |
| Dimensions l/w/h mm | 625/290/475 |
| Dimensions l/w/h (inches) | 24.6/11.4/18.7 |
| Weight kg | 35,2 |
| Weight lb | 78.5 |
| Marks of conformity | CE |
| Marks of conformity | CSA |
| Safety | S |
