Fronius welders can seem expensive – until you add up all the costs of your operation.
Why the biggest and the best use Fronius welders:
Downtime can be extremely expensive, especially in automated welding and large scale projects. Fronius welding equipment is renowned for it’s reliability and longevity and will save you money in the long term.
We also offer local support and servicing of the welders we sell. In the unlikely event you do have a problem with one of our welders we have qualified and certified Fronius technicians to repair them and get you back up and running ASAP.
We will give you the confidence to expect a high quality weld first time, every time.
Variation in weld quality is unacceptable in automation – just imagine the extra work involved with checking and fixing poor quality welds. However it’s also essential for pipe-welding and general repairs.
By design Fronius welders are straight-forward to use and programmed with an extensive range of specialized welding processes.
Time is money and in order to be the best in automated welding Fronius welders are designed to put down a lot of wire very quickly. Rather than simply using more wire Fronius welders ensure they don’t use any more wire than we absolutely have to.
That commitment to efficiency extends across the entire Fronius brand so you benefit from their decades of expertise in automation – even if you are using an hand-held welder.
Fronius TPSI is an all new MIG/MAG welding appliance platform – leading the industry into a new era. The TPS/i transcends or shifts the boundaries that previously applied.
With it, users benefit from using individually customisable appliances that can also be subsequently upgraded and that stand out for their high intelligence and extensive communications functions.
This makes the appliances easier to operate, multi-functional and able to deliver virtually limitless performance.
As a versatile and simple process, MMA welding has become established in many steel processing sectors. Due to its minimal equipment requirements, the process speaks for itself thanks to the fact that it is highly portable, especially on building sites. That wind-sensitive shielding gas is not required, is a further point in its favour. Despite its low-cost applicability, high-quality results can be achieved. Innovations in power source technology mean a stable arc, even in unfavourable conditions or when the mains cable is long.
Basic system principle
As with MIG/MAG welding, so too in MMA welding the electrode fulfils a dual function of arc carrier and consumable filler material. In MMA welding, the electrode is referred to as filler rod or rod electrode. The heat from the arc melts the core wire of the filler rod and the base metal. At the same time, the filler rod casing acts as bell jar and layer of slag to protect the heated workpiece surface from chemical reactions with the surrounding air. This maintains the strength and durability of the weld metal. The filler rod is connected to one pole on the power source via the welding cable and electrode holder. The earth connection runs via the workpiece terminal and earthing cable to the other pole on the power source. The pole that represents the welding potential depends on the type of rod electrode being used. Rutile electrodes are mostly welded at the power source?s negative pole, whereas basic electrodes are mainly used at the positive pole. Under certain conditions, rutile electrodes are also suitable for alternate current welding with simple welding transformers and no current rectifier. Other characteristics of basic electrodes include easy weldability, even weld seam and spray transfer. In addition to large drop transfer, basic electrodes on the other appear to incorporate moisture, thereby causing pores in the weld metal in its undried state. Advantages include weldability in several positions and good mechanical properties of the weld. A further type of electrode is the cellulose electrode. In addition to spray transfer, cellulose electrodes have a very deep fusion penetration, good mechanical strength, and are suited to all welding positions, including vertical down seam. Disadvantages include difficult weldability and the generation of a substantial amount of smoke. Furthermore, these electrodes are not suitable for all types of power source.
Most recently, the TIG welding process has been facing greater and greater competition from the ever-perfected MIG/MAG process and its related processes. These processes drastically increase productivity without concessions to quality. Despite its slower welding speed and lower deposition rate, the TIG process has been and still is for many applications the best guarantee for the highest quality results. Last but not least, innovations in the power source sector ensure a sustained future for TIG welding. The following comments are meant as a more detailed discussion of the basics.
The core of a TIG welding torch is a non-consumable, temperature-resistant tungsten electrode. The arc that proceeds from it heats and melts the material. As required, a filler wire is fed in manually or with a wire-feed unit. In many cases, a narrow gap needs no filler material at all when being welded. Ignition of the electrode normally takes place without the tungsten electrode touching the workpiece. This requires a high-voltage source that temporarily switches on during ignition. For the majority of metals, welding itself takes place using direct current. Aluminium, however, is welded using alternate current.
The nozzle for shielding gas is fitted around the tungsten electrode. The gas that flows out protects the heated material from chemical reactions with the surrounding air, thereby ensuring the required strength and durability of the weld metal. Inert gases such as argon, helium or their compounds are used as shielding gases. Even hydrogen is used occasionally. All these gases are inactive, which is what the specialist term “inert”, taken from the Greek, refers to. The term used to describe the process, “tungsten inert gas” (TIG) welding, comes from the type of shielding gas and the electrode material used.
The most-used shielding gas for TIG welding is argon. It optimises the ignition properties, as well as the stability of the arc, and helps obtain a better cleaning zone than helium. This in turn ensures an especially wide and deep fusion penetration, thanks to its thermal conductivity, which is nine times higher than that of argon. Used in conjunction with aluminium, pore formation is less pronounced. Furthermore, hydrogen is also sometimes used for austenitic steels, the percentage often only 2 to 5 %, the rest consisting of argon. The heat conductivity of hydrogen is even eleven times greater than argon, leading to a very deep fusion penetration and extremely effective outgassing.
When welding corrosion-resistant materials, for example stainless steels, the heated edges oxidise because of contact with oxygen in the air, which cannot always be completely avoided. The so-called annealing colours appear. These can be removed by rework, which restores corrosion resistance. It is preferable however to prevent the annealing colours from forming in the first place. This happens by using so-called forming gases. Forming gases keep the air away from the edges of the weld seam and in some cases even influence the root formation of the seam. Forming gases are primarily compounds of hydrogen and nitrogen, but argon is also used.