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High Performance Welding with Greater Efficiency

Synchronized welding with two individually controllable arcs is easier with the TPS/iTWIN systems and the PMC TWIN and CMT TWIN welding processes.

Posted: May 23, 2022

The Fronius TPS/i TWIN enables 100% control of two perfect arcs. These can also be set to different performance levels, depending on the desired end result.
The TPS/i TWIN series is now even more versatile. Not only steel, but also aluminum, nickel-base alloys, and high-strength steels can now be welded at high speed and at an extremely high deposition rate.

Fronius is adding to its range of smart, high-end TPS/i TWIN tandem welding systems. Synchronized welding with two individually controllable arcs has never been so easy as with the new TPS/i TWIN systems and the PMC TWIN and CMT TWIN welding processes. Both systems boast stable penetration and help save time thanks to their high speed and impressive deposition rate.

When it comes to high performance tandem welding, the main challenge is successfully controlling both arcs. Achieving this allows operators in the container, vehicle, and wagon construction industries to easily perform multi-layered or long welds in order to produce top-quality large-scale components. The TPS/i TWIN Push system, which is already well established on the market, is now joined by TWIN Push-Pull systems including the CMT TWIN process, which is well equipped to deal with such challenges. From now on, it will be possible to use tandem welding systems to join aluminum as well as steel.

Two Versatile Powerhouses

The TPS/i TWIN Push-Pull solution is designed for use in motor vehicle and railway vehicle construction, and is used to weld aluminum profiles or pressure containers using the PMC (Pulse Multi Control) process. In addition to the PMC process, the new TPS/i CMT TWIN system also uses the CMT (Cold Metal Transfer) process, thereby also enabling welding of aluminum, nickel-base alloys, and high-strength steels. The controlled heat input provided by the Cold Metal Transfer process is also particularly well suited for thin sheet applications. Penetration and weld profile can be further optimized if each TWIN arc is set to a different performance level.

High Speed and 25 kg Deposition Rate

In practice, the benefits of tandem welding compared to single wire welding are particularly apparent in cases where a perfect result needs to be produced at high speed. With a deposition rate of up to 25 kilograms per hour and a speed of up to 4 meters per minute, the Fronius TPS/i TWIN systems are quite the workhorses. This is made possible thanks to a wire speed performance of around 30 meters per minute for each processing line. Despite this speed, a flawless finish is achieved with reliable penetration quality and no weld-seam porosity. This reduces both the number of layers and the production time.

Exceptional Weld Quality – Achievable at Any Time

The integrated self-regulating TWIN process ensures optimal results and high efficiency, with only the essential settings needing to be adjusted. In the background, the system independently controls the welding parameters and variables to ensure the arcs are always precise. In order to ensure completely stable welding, a high level of process reliability is required, and this is guaranteed by the combination of PMC and CMT. Innovative solutions for optimal wire feeding such as the TWIN Drive or the wire buffer component ensure a steady supply of wire, thereby increasing the reliability of the welding process and taking process stability to another level. This cuts reworking and production errors to a minimum, thus saving time and resources.

Rapid and Precise Thanks to Smart Assistance Systems

The Fronius TWIN series offers a range of different functions and robot assistance systems that help welders to automate the production process as efficiently as possible. For example, SFI (spatter-free ignition) prevents spatter during ignition and the innovative chipping hammer removes previously formed slag by way of reversing the wire movement to ensure a clean start to the weld. SeamTracking automatically compensates for deviations, and TouchSense equips the robot with a positioning sensor that it can then use to compensate for clamping and component tolerances. WireSense measures these tolerances and transmits them directly to the robot. All this reduces welding errors, reworking time, and even discards, which directly contributes to increasing efficiency in high performance welding.

Business Unit Perfect Welding

Fronius Perfect Welding is an innovation leader for arc welding and a global market leader for robot-assisted welding. As a systems provider, the Fronius Welding Automation division also implements customized automated complete welding solutions, for the construction of containers or offshore cladding for example. The range is rounded off by power sources for manual applications, welding accessories, and a broad spectrum of services. With more than 1000 sales partners worldwide, Fronius Perfect Welding has great customer proximity.

Fronius International GmbH

Fronius International GmbH is an Austrian company with headquarters in Pettenbach and other sites in Wels, Thalheim, Steinhaus and Sattledt. With 5,660 employees worldwide, the company is active in the fields of welding technology, photovoltaics and battery charging technology. 92% of its products are exported through 36 international Fronius subsidiaries and sales partners/representatives in over 60 countries. With its innovative products and services and 1.321 granted patents, Fronius is the global innovation leader.

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