The CMT Process A Revolution in Materials-Joining Technology

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

The CMT Process and Its History CMT Process

from 2002 series development from 1999 basic development

Steel Aluminium

SFI Spatter-free ignition

Demand for micro-welds

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

The Developers

Project members Core team consisting of 21 developers Intensive support from 15 further developers plus employees from materials management, tool-making, production ... Development costs for CMT series production: 39 man-years Submission of 21 patents to secure industrial property rights

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

The Drive Unit An Innovative Solution

Innovative motor construction motor housing = torch body Small size and low weight due to lightweight construction concept (1.6 kg) Improved heat dissipation Electronic in own electronics box safety class IP23
The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

CMT Process

CMT is short for Cold Metal Transfer Dip arc process with completely new method of droplet detachment Metal transfer relatively cold compared with conventional GMA process

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Striking Differences Define a New Process

(1) Wire movement is incorporated directly in the process control for the first time.
Remote controller Serial data bus Wire drive Wire buffer

Control, monitoring

AC-Servomotor

Digital actual value

Process control

Actual value (U/I)

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Striking Differences Define a New Process

(2) Metal transfer is almost zero current.

t = 0 ms

t = 4.59 ms

t = 6.21 ms

t = 7.56 ms

t = 11.34 ms t = 13.23 ms t = 13.77 ms t = 14.31 ms

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Striking Differences Define a New Process

(3) The backward movement of the wire assists droplet detachment.

t = 0 ms

t = 4.59 ms

t = 6.21 ms

t = 7.56 ms

t = 11.34 ms t = 13.23 ms t = 13.77 ms t = 14.31 ms

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Weld Appearance

Practically spatter-free welded and brazed seams due to the three striking differences of the CMT process Isolated spatter particles possible for e.g. with extreme torch tilt angles

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Arc Length

Accurate control of arc length Conventional GMA welding Detection of arc length via voltage Disadvantage: influence on voltage of workpiece surface and welding speed, etc. CMT Mechanical detection and adjustment of arc length Advantage: arc length not subject to influence of workpiece surface and welding speed

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Arc Length

Extremely tolerant welding process with large process window e.g. in respect of welding speed Ignition sequence approx. twice as fast as hitherto Melting of the base metal in a very short time Combination of CMT process with pulsed arc To influence thermal input and weld geometry Important for gap bridging and increasing the welding speed

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Combinations

Combination of CMT process with pulsed arc

0 Pulse

1 Pulse

3 Pulses

5 Pulses

7 Pulses

0 Pulse

1 Pulse

3 Pulses

5 Pulses

7 Pulses

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Gap Bridging Ability

Lower thermal input results in less distortion and high gap bridging ability

Base metal

Sheet thickness Filler metal Shielding gas Welding speed

DC01 electrolytically galvanised 0.8 / 1.5 mm CuSi3 / 1.0 mm Argon 1,0 m/min (39.37/min)

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Limits

Upper output limit of the pure CMT process determined by the start of the intermediate dip arc. Lower output limit of the CMT process determined by weld formation required.

Rotating arc Pulsed arc Dip arc

Spray arc

CMT arc

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Revolutionary Characteristics of the CMT Process Limits

Narrow and high weld cross-sections with pure CMT process due to low thermal input.

Dip arc Wire feed speed Welding curent Welding voltage CMT Wire feed speed Welding current Welding current

5.0 m/min 96 A 17.0 V

5.0 m/min 84 A 13.5 V

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

Conclusions

CMT is a completely new, revolutionary welding process Precise control of the arc length due to a mechanical cycle High process-stability, e.g. when changing the torch orientation or varying the welding speed Practically spatterfree welding and brazing seams High flexibility influencing the penetration Good gap bridgability, also with thin sheets

The CMT Process A Revolution in Materials-Joining Technology Fronius 01/2004

PERFECT WELDING