/ Battery Charging Systems / Welding Technology / Solar Electronics

S H I F T I N G T H E L I MI T S
E WELDING. HIGH PERFORMA
/ The CMT Twin, Time, LaserHybrid and TimeTwin technologies.
2 / About us

WEL
D
JOINT
S
POSSIBLE
/ Ever since 1950, we've been developing innovative comprehensive solutions for arc welding and
resistance spot-welding. Both of them weld processes that stand out for very high speed and
deposition rates. Our Cold Metal Transfer process has swept away one old prejudice: that you can't
weld aluminium and steel to one another. Day-in, day-out, we're working on our vision: to decode
the DNA of the arc. No wonder that we're the welding-sector's technological leader worldwide, as
well as being the European market leader.
B
E
C
A
U
S
E

WE KEEP GOING
WHERE OTHERS QUIT.
High-performance welding / 3

INNOVATIVE TECHNOLOGY
/ Products from Fronius are characterised by their high- performing,
rugged technology and stable wire guidance. Even at the highest speeds,
these ensure 100 % reproducible, visually immaculate weld-seams.
SYSTEM SOLUTIONS
/ If youre serious about exploiting the scope of excellent welding
properties and functions to the full, you have to think in terms of systems.
In conjunction with our peripherals, the digital power sources constitute
thoroughly co-ordinated and extremely innovative high-performance
welding systems that cater to every possible wish.
TECHNICAL KNOW-HOW AND MECHANICAL SKILL
/ Perfect welding solutions result from the interplay of several factors:
For a start, the welding systems themselves have to be top-class. As well
as this, users need to have excellent technical know-how and mechanical
skill. We make sure this is the case by giving welders thorough practical
training on their new welding systems, on their own premises.
HIGH PROCESS STABILITY
/ Our welding systems have above-averagely long service lives. This is
because their high-quality components are all superbly well made and
designed for optimum interoperability. Much to the welders benefit,
thanks to the high process stability which is essential for achieving the
desired speed and deposition rates.
SERVICE THAT'S NEVER FAR FROM THE CUSTOMER
/ Just like our welding systems, our service staff are high- performers too,
with capable teams of applications and service technicians delivering fast,
expert 'on-the-spot advice and support, 24 hours a day, 365 days a year.
TO MANY PEOPLE, HIGH PERFORMANCE
WELDING IS ONLY ABOUT SPEED. WE' VE
ADDED SUPERIOR PRODUCTIVITY.
/ Wherever light-gauge sheets need to be welded together at high speed, welding systems from
Fronius play an outstanding role. With wirefeed speeds of over 15 metres per minute and
deposition rates of up to 8 kilograms per hour in single-wire processes, they meet all possible
requirements regarding productivity and precision. What is more, Fronius tandem systems achieve
wirefeed speeds of over 30 metres per minute, and deposition rates of up to 20 kilograms per hour.
And when it comes to welding thick sheets and plates, Fronius welding systems really flex their
muscles, catering to every possible wish regarding cost-effective performance.
4 / Overview of weld processes
WE OFFER YOU WELDING SOLUTIONS THAT ARE
ALWAYS A STEP AHEAD.
/ The utmost in product quality, economy and energy efficiency - that's what Fronius stands for.
We have mastery of the entire welding spectrum and can guarantee a perfect interplay between all
the components of our welding systems. See for yourself!
/ /
/ A modified MAG process in which
optimisation of the shielding gas and of the
stick-out allows the deposition rate to be
increased by up to 30 %. The power-source
technology has been specifically tailored to
the demands of the TIME Process.
/ I
/ / /
CMT TWIN
/ A simplified system configuration and
synchronised start-up of two separately controllable
power sources, two wire electrodes and a gas
nozzle, combined with the tried-and-tested CMT
process. Unbeatable arc stability coupled with deep
penetration, optimum wetting to sidewalls, and low-
spatter welding.
/ CMT Twin weld process
6 / Application overview(s
APPLICATION MODULE CMT TWIN



































MAX. WELDING SPEED IN PB
POSITION
/ No undercutting / Reliable penetration / Virtually
spatter-free
(610.0 in/min)
407 A 196 A
28.5 V 15.0
V
Vwehi = 300 cm/min (118.09 in/m)
V . , = 15.5 m/min V . = 6.2 m/min
wireL ' wire! '
(236.14 in/min)
/ Steel, 3 mm (0.12 in)
BIGGEST 'a' DIMENSION IN PB
POSITION
/ No weldment manipulation needed / Ideal weld-
seam position (at 45)
/ Optimised wetting to sidewalls

/ Steel, 10 mm (0.39 in), a = 6
EXTREMELY HIGH PROCESS STABILITY
/ No need for any additional grinding off of the
primer coating / No weld-seam porosity / Virtually
spatter-free

/ Primered steel, 8 mm (0.31 in), a = 3
PERFECT ROOT
FORMATION
/ Homogeneous weld interface /
Reliable sidewall fusion / No weld-
pool backing needed
374 A 268 A
16.2 V 17.3 V
Vweid = 120 cm/min (47.2 in/min)
V . , = 7.1 m/min V . = 7.5 m/min
wireL ' wire! '
(275.49 in/min) (295.49 in/min)
/ Steel, 8 mm (0.31 in)
APPLICATION MODULE TIMETWIN



































HIGHEST-QUALITY METALLURGICAL
JOINS
/ Tightly controlled thermal input / Low thermal load /
Extremely low spattering
= 180 cm/min (70.75 in/min)
V . , = 9.2 m/min V . = 8.0 m/min
wireL ' wire! '
(354.19 in/min) (314.84 in/min)
230 A 200 A
21.4 V 20.4 V

/ CrNi, 2 mm (0.08 in)
HIGH SEAM QUALITY = 200 cm/min (78.61 in/min)
/ On many different thicknesses of metal V . , = 12.5 m/min V ^ = 11.3 m/min
wireL ' wire! '
/ Reliable root fusion (492.24 in/m) (432.89
in/min)
/ Very low pore formation 235 A 213 A
21.1 V 20.3 V

/Aluminium, 3 mm (0.12 in)
EXTREMELY HIGH DEPOSITION
RATE
/ Wirefeed speeds up to 30 m/min / Deposition
rates up to 22 kg/h / Extremely stable arc
achieved by fully digitised power-source know-
how
350 A 340 A
31.9 V 31.7 V
Vweid = 80 cm/min (31.45 in/min)
V . , = 15.5 m/min V . = 15.0 m/min
wireL ' wire1 '
(610.29 in/min) (590.29 in/min)
/ Steel, 8 mm (0.31 in)
MULTI-PASS WELD
/ Perfect welding properties in PF / Only
small included angle needed / Higher
productivity, as fewer passes are needed
Includes welding parameters from the root, filler and
top passes
Vwdd = 15 - 20 cm/min (5.9 - 7.9 in/min)
VwireL = 8 - 10 m/min Vwi T = 5 - 8 m/min
(314.84 - 393.54 in/min) (196.79 - 314.84 in/min)
200 - 250 A 120 - 200 A
17.3 - 17.8 V 15.8 - 17.3 V

/Aluminium, 40 mm (1.57 in), PF
APPLICATION MODULE TIME


/ Steel, 15 mm (0.59 in), 3 passes, PF, a = 12
NARROW-GAP WELDING
/ Good accessibility / Reliable
sidewall fusion / Highly economical,
thanks to lower number of passes
compared to MAG

/Steel, 12 mm on 25 mm (0.47 in on 0.98)
Beads 1 and 2:
Deposition rate
6.4 8.5 kg/h (14.1-18.7 Ib/h)
Vweld = 47/60 cm/min (18.5/23.6
in/min)
Vwire = 12/16 m/min
(472.24/629.64 in/min) 210/310 A
34/37 V
Beads 3/4/5/6:
Deposition rate
11-12.3 kg/h (24.3-27.11 Ib/h)
Vweld = 30 - 46 cm/min (11.8 - 18.11
in/min)
Vwi = 20 - 23 m/min (787.04 -
905.09 in/min)
390 - 420 A 42 - 46 V

/ Steel, 10 mm (0.39 in), a = 5
Deposition rate 16.2 kg/h (35.7 Ib/h) VwM
= 45 cm/min (17.72 in/min)
V_ = 30 m/min (1180.54 in/min) 520 A 51
V
/ Steel, 20 mm (0.79 in), PA, a = 8
ECONOMICAL Deposition rate 9.6 kg/h (21.16 Ib/h)
/ Large 'a dimension with small numbers of VwM = 37 cm/min (14.6 in/min)
passes Vwire = 18 m/min (708.34 in/min)
/ Reliable penetration behaviour 360 A
/ Minimal distortion 40 V
POSITIONAL WELDING
/ High weld-metal deposition, even in overhead position / Fine wetting to sidewalls / Reliable
fusion of the root edge
EXTREMELY HIGH DEPOSITION
RATE
/ Perfect penetration cross-section / No
undercutting
/ Distortion minimised by low thermal input
Application overview(s) / 9
APPLICATION MODULE
LASERHYBRID


/Steel, 12 mm (0.47 in)

/ Steel, 2.7 mm (0.1 in)

/Steel, 2 mm (0.08 in)

/ Steel, 12.3 mm (0.48 in)
/ Steel, 16 mm (0.63 in)
10 kW WELDING HEAD
/ New design for a focal length of 300 mm (11.8 in) and 10
kW of laser power
4 kW WELDING HEAD
/ 10-year track record of successful deployment in the
automobile industry.
90 4 kW WELDING HEAD
/ Angled design for optimum accessibility, e.g. in
automotive axle production
90 8 kW WELDING HEAD
/ Ensures optimum accessibility in pipeline-construction projects
10 kW WELDING HEAD
/ Optimum head-geometry for single-sided root fusion on steel sheets
up to 10 mm (0.39 in) thick.

Overview of weld processes / 5
1
jU'
TIMETWIN
/ Is the name of a tandem process in which the weld
process is synchronously controlled between two
separately adjustable power sources. The two
mutually insulated wire electrodes are routed
through a single gas nozzle, thereby achieving
perfect welding results.
/ TimeTwin welding process
LASERHYBRID
/ This combination of laser and GMA welding
makes it possible to exploit the advantages of
each process to the full, and to create synergies.
The high welding speed and concentrated energy
of the laser can be combined with the GMA arc
to achieve either of two possible benefits:
maximum welding speed on light-gauge sheets,
or maximum weld penetration depth on thicker
materials.
10 / CMT Twin - the technology

CMT TWIN: THE THRIFTIEST WAY TO
WELD.
WIREFEED SPEED
/ VR 1550 wirefeeder with 4-roller
drive for smooth, precision feeding of
the filler metal - regardless of where
the wire is being fed from (bulk wire
container or wire-spool).
DIGITALLY CONTROLLED MIG/MAG WELDING
POWER SOURCES
/ The two digitally controlled CMT welding power sources
are perfectly attuned to one another by the unique
system/process technology of CMT Twin. They come with a
package of ideal characteristics covering every possible
application.
COOLING UNIT
/ The rugged and reliable FK 4000-R
cooling unit is designed to dovetail with
the modular concept of the welding system
as a whole.
CMT Twin - the technology / 11

/ Developed specifically for CMT Twin,
the torch holder allows the two CMT
Drive motors to be arranged in a way
that minimises the obstacle contours.
/ CMT Twin is based on the same set-up as the tried-and-tested TimeTwin process: two power
sources, one torch and two mutually insulated contact tips ('Lead' and 'Trail'). To which have been
added the outstanding welding properties of CMT. CMT Twin scores top marks for its high
welding speeds and
easy-to-use process
control
.
T
ORCH HOLDER
WELDING TORCH
/ A tandem torch optimised for the
high-performance power range, the
new Twin Compact Pro is highly
versatile. This is made possible by
the perfectly matched torch
packages. The compact design of this
water-cooled torch, with its two
mutually insulated electrodes,
provides very good weld
accessibility.
12 / LaserHybrid - the technology

LASERHYBRID: THE ADVANTAGES OF THE
FULLY DIGITISED MIG PROCESS COMBINED
WITH THE BENEFITS OF LASER WELDING.
LaserHybrid - the technology / 13

DIGITALLY CONTROLLED POWER SOURCE
/ LaserHybrid functions with a TPS 5000 welding power source. In order to fulfil the special requirements of LaserHybrid, the TPS 5000 comes equipped with a package of
special characteristics.
12 / LaserHybrid - the technology

WELDING HEAD
/ The integral wire straightener ensures
precision wire positioning in the Fronius 90
4kW welding head. Developed specially for axle
production, this welding head provides optimum
weld accessibility.
FRONIUS CROSSJET
/All Fronius LaserHybrid-welding heads come
with the patented enclosed CrossJet system. This
unique system reliably prevents soiling of the
protective optical glass, thereby ensuring
optimum system availability.
i
/
Fa
/ Fronius LaserHybrid, the laser-MIG process from Fronius, unites the advantages of the industrial-
scale MIG and laser-beam welding processes. And does so without taking on any of the
disadvantages of either process. Fronius LaserHybrid marries the excellent gap-bridging ability and
easy weld-seam preparation of MIG welding with the low thermal input, deep penetration and
speed of the laser process. With Fronius LaserHybrid, it is possible to carry out automated joining
of different aluminium and steel items at speeds of up to 8 metres per minute, in superlative
quality.
14 / TIME - the technology

TIME MANUAL WELDING TORCH
/ The 2-circuit cooling system ensures optimum
cooling. Thanks to the continuously adjustable contact
tip, this welding torch permits an extremely long stick-
out (of between 15 and 25 mm). The longer stick-out
means that the wire is heated up very strongly, allowing
extremely high wirefeed speeds to be achieved, yet at a
low amperage.
DIGITALLY CONTROLLED MIG/MAG-WELDING POWER SOURCE
/ Higher performance also means that more power is required from the
power source: The TIME 5000 Digital has an extremely long duty cycle, with
possible working voltages of up to 48 V and a wirefeed speed of 30 m/min.
COOLING UNIT
/ If you have more power, you need more cooling.
The rugged and reliable FK 4000 cooling unit is
designed to dovetail with the modular concept of
the welding system as a whole.
TIME: 30 % HI GHER DEPOSITION RATE
THAN CONVENTIONAL MAG WELDING.


3-PARAMETER CONTROL
/ The TIME Process is a technically more advanced version of the conventional MAG process. It
has a long and successful track record in industry, for both manual and mechanical applications.
The difference from conventional MAG welding is that the TIME Process has a longer wire stick-
out on the welding torch, and a higher wirespeed. As a rule, it is possible to work with 2-
component shielding gas. However, we recommend admixing helium for seams with an 'a'
dimension above 8 mm, for metal thicknesses from 25 mm upwards, and for penetration cross-
sections greater than 50 mm
2
.
/ The 3-parameter control makes for very easy handling of the entire welding process. This ensures that start-up, lowering to the required welding power and
end-crater filling are all carried out with complete
process-reliability.
TIME - the technology / 15










































HAVE THREE DIVISIONS AND ONE
PASSION: SHIFTING THE LIMITS.
/ What Gunter Fronius started in 1945 in Pettenbach, Austria, has now become a modern day
success story. Today, the company has around 3,000 employees worldwide and owns more than
850 active patents. Since the very beginning, our goal has not changed: to be the technology and
quality leader. We shift the limits of what's possible. While others progress step by step, we
innovate in leaps and bounds.
BATTERY CHARGING SYSTEMS
/ We started a technological revolution with
Active Inverter Technology and are now one of
the leading suppliers in Europe. We are driven
by the aim of providing intelligent energy
management systems that ensure mobility stays
as economically viable as possible in the
twenty-first century.
WELDING TECHNOLOGY
/ We develop welding technologies, such as
entire systems for arc and resistance spot
welding, and have set ourselves the task of
making impossible weld joints possible. Our
aim is to decode the arc welding's DNA. We
are the technology leader worldwide and the
market leader in Europe.
SOLAR ELECTRONICS
/ The greatest challenge of our time is to make
the leap to a regenerative energy supply. Our
vision is to use renewable energy to achieve
energy independence. With our mains-
connected inverters and products for monitoring
photovoltaic systems, we are now one of the
leading suppliers in solar electronics.
Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com
Fronius Canada Ltd.
2875 Argentia Road, Units 4,5 & 6
Mississauga, ON L5N 8G6 Canada
Telephone +1 905 288-2100 Fax +1 905
288-2101 [email protected]
www.fronius.ca
Fronius USA LLC
6796 Fronius Drive Portage, IN
46368 USA
Telephone +1 877 FRONIUS
[email protected]
www.fronius-usa.com
Fronius UK Limited
Maidstone Road, Kingston Milton
Keynes, MK10 0BD United
Kingdom Telephone +44 1908 512
300 Fax +44 1908 512 329
[email protected]
www.fronius.co.uk
Fronius International GmbH
Froniusplatz 1 4600 Wels Austria
Telephone +43 7242 241-0 Fax +43
7242 241-953940
[email protected]
www.fronius.com
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