Hold point: 1 mm electro-galvanized, filler wire: CuSi3 1 mm, wire speed: 11.5 m/min, number of CMT cycles: 8Click image to enlarge

Fronius has introduced a new cycle step process variant for the CMT (Cold Metal Transfer) welding process that allows users to set both the number of individual droplets and the pause time between cycles.

The result is a heat-reduced bead with clear ripples and a high degree of reproducibility. The new process variant has a wide range of applications, from visible weld seams and additive applications to fixation points.

During MIG/MAG welding, a droplet melts at the end of the wire electrode and is transferred to the weld pool during the short circuit phase of the CMT process. Following this characteristic short circuit, the arc ignites again and a new welding cycle begins. With CMT Cycle Step, Fronius can control these individual cycles precisely so that the user can define the exact number of droplets per welding spot, thus representing a whole new level of control and reproducibility. The extent of the resulting material removal in a sequence can also be set.

Lap joint: 3 mm aluminum, filler wire: AlSi5 1.2 mm, number of CMT cycles: 18, pause time: 0.16 s, welding speed: 50 cm/min, wire speed in the CMT process phase: 7.7 m/min, average wire speed: 6.1 m/min. Note: The average value is lower than the set value.Click image to enlarge

With Cycle Step, the heat input into the workpiece is minimal and can be effectively controlled, which is particularly useful during position welding with gap tolerances. Another advantage is the clear rippling of the weld seam, making Cycle Step ideal for high-quality visible seams. CMT Cycle Step also enables the smallest fixation points to be welded and is therefore an alternative to spot welding guns. Furthermore, CMT Cycle Step can be used to weld galvanized sheets or to produce hold points for supporting bonded joints. Overlay welding and applications in additive manufacturing are also possible with Cycle Step.

The Cycle Step option is available as an upgrade from TPS/i firmware version 1.9.0. Following the upgrade, the function is available on TPS/i systems for all CMT characteristics.

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