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The CMT Process

Fronius International GmbH


Welding Technology Division
Buxbaumstrasse 2
4600 Wels, Austria

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - History
CMT process
2002 onwards - series development
1999 onwards - development of basics

Steel SFI Demand for


Aluminium Spatter-Free micro-welds
Ignition

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - History

 36 developers from all sectors

 Development effort for CMT standard equipment: 39 man-years

 Submission of 21 patents to safeguard proprietary rights

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process

 CMT stands for Cold Metal Transfer

 Short-circuit arc process with totally new method of droplet detachment

 Relatively cold material transfer compared with conventional GMAW


process

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
Differences compared with conventional gas metal arc welding

 Material transfer takes place with virtually no current


 For the first time, wire movement is directly incorporated into the
process control
 The backwards movement of the wire assists droplet detachment

t = 0 ms t = 4.59 ms t = 6.21ms t = 7.56 ms t = 11.34 ms t = 13.23 ms t = 13.77 ms t = 14.31 ms

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Short circuit arc

Short circuit
Arc time

vD

t
IS

t
US

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process

vD

Short circuit Separation Arc time


IS

t
US

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Comparison

Conventional gas metal arc welding


 Measuring and setting of arc length by voltage Disadvantage:
workpiece surface and welding speed influence the voltage

CMT
 Measuring and setting of arc length are done mechanically

Advantage: Arc length is not influenced by the workpiece surface or


welding speed

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Arc length

CMT MIG pulsed arc

IS= 81 A AlSi5 1.2 mm IS= 111 A


US=11.2 V wfs = 5 m/min US=17.87 V

 Precise control of arc length


 Virtually spatter-free
 Very high arc stability

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Arc length

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Arc length

Extremely tolerant welding process with a large process window –


e.g. in terms of welding speed

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Arc length

Stickout change with CMT

Avg. wfs

dl
t
act. wfs

US

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Arc length

Stickout change with pulsed arc

wfs

dl
t

IS

t
T

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Combination

 CMT process combined with


pulsed arc to influence heat
input and seam geometry

 Important for gap bridging and to


increase welding speed

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Combination
CMT cycle Pulse cycle
Short circuit phase 1

Short circuit phase 2


Plasma phase

Boost phase

Arc phase

wfs

IS

t
US

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Limit
 The pure CMT process is limited by the start of the intermediate arc
 Lower power correction limit of the CMT process determined by the
required seam formation.
 With CMT pulse it is possible to reach the performance range of the
pulsed arc

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system
Equipment for automated applications

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Wire buffer

Robacta Drive CMT

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

 Decouples the main motor in the VR


7000 CMT from the AC servo motor in
the torch

 Can be installed up to 1.8 m behind


the CMT drive unit
Positioned on the balancer or on the
robot's 3rd shaft

Note: a greater distance has an


adverse effect on the wirefeeding
properties!

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Wire buffer set CMT variable

 A variable wirefeeding hose is included in this set


 The length of the robot arm between the wire buffer and welding torch
varies depending on the robot.
 This set enables the wire buffer and the wirefeeding hose to be adapted
to the length of the robot arm.

Variable CMT wirefeeding hose


Length: min. 1.05 m - max. 1.8 m

Customer Service
Information no. 0820-
111

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

 Highly dynamic AC servo motor


 Gearless motor for longer service life
 Wire contact pressure can be
reproduced and adjusted
 Precise wirefeed through digital speed
control
 Controls on electronics box
 Weight 1.6 kg
 IP23 electronic protection

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system
TPS 3200 / 4000 / 5000 CMT
TPS 3200 / 4000 / 5000 CMT MV

 With integral CMT package consisting of


both hardware and software

 Fully digital and microprocessor-


controlled

 3 operating modes: Standard / Pulse /


CMT

 Existing power sources can be


retrofitted

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

VR 7000 CMT

 LHSB connection from wire-feed


unit to drive unit

 Control of AC servo motor

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

FK 4000R

• For optimum cooling of the


robot welding torch

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

RCU5000i remote control unit

 Program selection
 Optimising and managing jobs
 Optimising synergic lines
 QMaster
 Documentation
 3 operating modes:
Standard / Pulse / CMT

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system
Hosepack from wire-feed unit  drive unit
 Robacta Drive CMT 4.25m / 6.25m / 8.25m F++/ G

 Torch hosepack can be decoupled from drive unit

 External wirefeeding hose for rapid liner change

Power source  wire-feed unit hosepack


 Interconnecting cable 1.7m / 4m / 8m – 95mm²

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Gas-cooled Robacta Drive


CMT
Welding current at Duty cycle
CO2 ArCO2
320A 260A 60%
250A 200A 100%

Hosepacks
Robacta Drive CMT G F/4.25m
Robacta Drive CMT G F/6.25m
Robacta Drive CMT G F/8.25m Torch neck interface No water hoses on
wire-feed unit connection

Customer Service
Information no. 0832-79

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Gas-cooled Robacta Drive CMT

 Can only be used with torch necks


MTG 2500 and MTG 4000, 22° and 36° gas-cooled

 Other TCP such as Robacta Drive CMT


W

gas-cooled

TCP comparison, gas-/water-cooled, 22° and 36°

Customer Service
Information no. 0832-79

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Robacta Drive CMT Pro


Gas nozzle connections O-rings Sensor cable

Blade terminal on housing

 Equipped with gas nozzle touch sensor as standard


 Gas nozzle touching the workpiece is detected
 The signal is transmitted via a sensor cable from the gas nozzle to the
blade terminal on the housing
Customer Service
Information no. 0802-
103

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Robacta Drive CMT Pro

Advantages

 Gas nozzle touch sensor installation kit on the wire-feed unit is no


longer needed
 Gas nozzle positioning kit is suitable for all Robacta torch necks
 The gas nozzle positioning kit is available separately as a spare part

Requirement
 The CMT wire-feed unit requires firmware OFFICIAL SR43 V1.02.41 or
higher

Customer Service
Information no. 0802-
103

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

CMT mounting bracket and base plate

(1) Mounting bracket CMT 22°


(2) Mounting bracket CMT 36°
(3) Mounting bracket CMT flex (22°/36°)
(4) Clamp
(5) Clamp extension
(6) New base plate
(7) Robacta Drive CMT

Application examples

Tightening torque: 3.0 Nm

Customer Service
Information no. 0542-75

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

New original equipment kits for CMT

Steel / CuSi Bronze Steel Teflon Steel


Graphite (with Graphite Teflon Graphite
sliding end piece)
Bronze Graphite Teflon Graphite

 The new, material-specific CMT original equipment sets differ through


the use of the included wire inner liners and wire guides

Advantages
 Less wear
 Longer service life of wire liners and guides

Customer Service
Information no. 0712-98

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - The system

Robacta Drive CMT PAP G/W

Gas-cooled and water-cooled available end of Q2/2009

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

Power source with integrated


wire feed
PullMig torch integrated in
hosepack

Wire buffer integrated in


hosepack

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

 Wire buffer is protected


from damage by a leather 2 m length
pouch

 Suspension device in wire


buffer

 2 m free length from wire


buffer to PullMig torch

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

 Torch has integral AC servo


motor

 300 g lighter than a standard


PullMIG torch (approx. 1.9
kg)

 Integral potentiometer

 Wirefeeding system is easy


to adjust

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

Push-pull adjustment

 PPU 28
Current is checked via
potentiometer

 PPU 29
Current is checked with the
Synergic button on the Comfort
panel

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

Easy to use

 Synergic Mode

 CMT pulse / CMT Synergic line

 No RCU 5000i required

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

PullMig CMT G

4,047,469 PullMig CMT G/F/4m


4,047,470 PullMig CMT G/F/6m
4,047,471 PullMig CMT G/F/8m

Advantages

 Simple design of the CMT welding system (no cooling unit


required)

 Also suitable for pulsed and standard applications


Customer Service
Information no. 0823-112

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration

PullMig CMT with up/down

Up/down button for gas-cooled and water-


cooled PullMig CMT is available now

Advantages
 Up/down button allows targeted and precise adjustment of welding
current during the welding process.
 The up/down button also allows you to switch over to pre-
programmed jobs in job mode.

Customer Service
Information no. 0823-112

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Manual configuration
CMT Synergic lines that cannot be used with TPS 2700 CMT
(insufficient power)

 PGM 879 (CMT + P) AlMg 4.5 Mn 1.2


 PGM 883 (CMT + P) CuAl 8 1.0
 PGM 884 (CMT + P) CuSi 3 1.0
 PGM 923 (CMT) CuSi 3 1.0
 PGM 933 (CMT) CuNi 30 Fe 1.2
 PGM 970 (CMT) CuAl 8 1.2
 PGM 981 (CMT) G3Si1 1.2
 PGM 1011 (CMT +P) Ti6 Al 4 V 1.2
 PGM 1023 (CMT + P) CuAl 8 1.0
 PGM 1097 (CMT) G3Si 1 1.2
 PGM 1098 (CMT) G3Si 1 1.2
 PGM 1101 (CMT + P) (Mn E 21) 1.2

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Basic principle

Brazing
 Welded on aluminium side

 Brazed on steel side

Welding

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Aluminium

 Fillet weld
Aluminium

 Sheet thickness 1.5 mm

 Vs = 60 cm/min
Steel

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Main problems in this type of welding

 Formation of a brittle and very hard intermetallic phase of type Fe2Al5 ():
hardness~ 1050 HV, FeAl3 (): hardness ~ 900 HV

 Electrochemical potential E changes suddenly around the join (St - Al:


E ~ 1.22 V)

 Different thermal expansion coefficients , leading to stress fields


around the join

 Very different melting points Ts of the base materials

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Structure of the intermetallic phase (IMP)

Join Al content [at.-%] Structure Micro-hardness Density

Ordered bcc structure

Ordered bcc structure

Complex bcc structure not known

Complex rhombohedral structure

bcc orthorhombic structure

Very complex monoclinic bcc structure

Comparison:
Al 99.5: Hardness: ~ 40 HV
Fe: Hardness: >140 HV

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Aim of this type of join

 Formation of an IMP with thickness < 5 µm

 To influence the composition of the IMP ( phase preferred)

 IMP has only minimal influence on mechanical/technological behaviour


of the weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Formation of the IMP

Aluminium filler

IMP

Steel base material

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium
IMP characteristics

 Morphology

 Closed form, thickness 1.7 µm

 Tooth structure thickness 6 µm

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

 Behaviour under dynamic


stress

 Greatly influenced by seam


geometry

Lap joint DX 54 / AA
6016

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

"Break" occurs in the heat-affected


zone of the aluminium, and to some
extent in the aluminium base
material

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Corrosion behaviour

 120-hour salt spray test (SST)


– continuous exposure to
moisture, conforms to DIN
50021/SS

Rm [MPa] Rm [MPa]
Braze material without with
corrosion corrosion

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

 Sharp radii
 High dimensional stability
 Shape analysis
 Crash test on profiles

Shape analysis

Crash test

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Steel with aluminium

Joining on both sides with CMT

Joint geometry

Steel plate (1)


Brazing zone Welding zone

Joint zone
Brittle seam
due to IMP
<2µm
Aluminium plate (2)

Steel plate (1)

Detail

Al filler (3)

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2
Advantages
 Cheap gas
 Good penetration depth
 Available worldwide

Disadvantage
 Spatter ejection
 Oxidation of seam surface
 More slag and silicates on seam surface

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

Spatter ejection with conventional short circuit arc

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

Fillet weld in PA / s = 2 mm / Welding in short circuit arc

Welding parameters
Short circuit arc

Filler: G3Si-1 / ER70-S6 /


1.0mm

Gas: 100% CO2

Wire feed speed: 10m/min

Welding speed: 100cm/min

Current: 218 A

Voltage: 24 V

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

Fillet weld in PA / s = 2 mm / Welding in CMT arc

Welding parameters
Short circuit arc

Filler: G3Si-1 / ER70-S6 /


1.0mm

Gas: 100% CO2

Wire feed speed: 10m/min

Welding speed: 100cm/min

Current: 218 A

Voltage: 24 V

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

Seam surface comparison (100% CO2)

Standard MAG process

CMT process

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

CMT Conventional MAG


 Current reduction before
 Uncontrolled droplet growth
short-circuit
 Controlled particle transfer  Changing short-circuit frequency
 Extremely stable short-circuit
 Severe spattering
frequency

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2

Slag hammer function for removing slag

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process - Welding with CO2
Slag hammer function demonstration video

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications
Weld seam profiles

 Lap joint
 Butt weld
 Flanged weld
 Fillet weld
Main working positions for welding

Positions horizontal

 PA

falling
rising

 PB across

 PC overhead

 PG

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Aluminium tanks


Material: AlMg 3 t=2mm
Filler metal: Al Si 5 Ø1.2mm
Welding speed: 150cm/min
Position: PA
Type of seam: Butt joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Aluminium ladders


Material: AlMg Si 0.5
Filler metal: Al Si 5 Ø1.2mm
Welding speed: 150cm/min
Position: PG
Type of seam: Fillet weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Aluminium frame


Material: AlMgSi 0.7 t=1.5mm
Filler metal: AlSi 5 Ø1.2mm
Welding speed: 85cm/min
Position: PG
Type of seam: Lap joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Aluminium insulating walls


Material: AlMgSi 1.0 t=2mm
Filler metal: AlMg 5 Ø1.2mm
Welding speed: 80cm/min
Position: PB
Type of seam: Lap joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Aluminium heat exchanger


Material: AlMg Si 2.4mm t=3mm
Filler metal: AlSi 5 Ø1.2mm
Welding speed: 150cm/min
Position: PB
Type of seam: Fillet weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Concrete anchor


Material: 1.4401
Filler metal: 1.3343 Ø 0.9mm
Welding speed: 150cm/min
Position: PB

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Pipe adapter


Material: 1.4571 pipe t=3mm
Adapter t=0.4mm
Filler metal: ER 316 Si Ø1.0mm
Welding speed: 100cm/min
Position: PA
Type of seam: Butt joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Furnace pipe


Material: 1.4301 t=1.0mm
Filler metal: ER 308L Si Ø1.0mm
Welding speed: 100cm/min
Position: PA
Type of seam: Butt weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Beer tank


Material: 1.4301
Filler metal: G 19 9 L Si / ER 308 L Si
Ø1.0mm
Welding speed: 165cm/min
Position: PA
Type of seam: Butt weld, lap joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Drip tray


Material: 1.4301
Filler metal: G 19 9 L Si / ER 308 L Si
Ø1.0mm
Welding speed: 150cm/min
Position: PA, PB
Type of seam: Fillet weld, corner weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Steel furniture


Material: S 235 JR
Filler metal: G3 Si1 Ø1.0mm
Welding speed: 80cm/min
Position: PF
Type of seam: Fillet weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Hydraulic hose


Material: 1.4404
Filler metal: 1.4430 / ER 316 Ø1.0mm
Welding speed: 40cm/min
Position: PA
Type of seam: Fillet weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Container doors


Material: DX 51 D + Z 275 N
Filler metal: CuSi 3 Ø1.0mm
Welding speed: 150cm/min
Position: PA
Type of seam: Butt weld, fillet weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Switch cabinet


Material: DX 53 + Z 100
Filler metal: CuSi 3 Ø1.0mm
Welding speed: 80cm/min
Position: PG, PB
Type of seam: Fillet weld, corner weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Roof gutter outlet tube


Material: Hot-galvanized t=0,5mm
Filler metal: CuSi 3 Ø1.0mm
Welding speed: 190cm/min
Position: PB
Type of seam: Butt joint

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT Process - Applications

Component: Fire doors


Material: DX 53 + Z 140
Filler metal: CuSi 3 Ø1.0mm
Welding speed: 100cm/min
Position: PG
Type of seam: Flanged weld

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The CMT process
 History
 Process
 System
 Manual configuration
 Steel with aluminium
 Welding with CO2
 Applications
 CMT Advanced

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The new CMT Advanced Technology
A revolution in heat input and gap bridgeability

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
The new CMT Advanced Technology
For the first time, integration of polarity into the process control with
reversing wire movement allows:

 the CMT Advanced Process


- Combination arc process
- Consisting of CMT cycles with negative and positive polarity
of the wire electrode

 the CMT Pulse Advanced Process


- Combination arc process
- Consisting of CMT cycles with negative and pulse cycles with
positive polarity of the wire electrode

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
CMT Advanced Processes:
CMT Pulse Advanced

- - - - - - - + + + +

EN-CMT phase Init phase 2

+ + + + + +

Pulse phase Init phase 1 ...

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
CMT Advanced Processes:
CMT Advanced

- - - - - - - + + + +

EN-CMT phase EP-CMT phase

+ + +

EP-CMT phase ...

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Arc behaviour

+ -
arc
length

EP-CMT phase EN-CMT phase

0 % EN-CMT 100 % EN-CMT


100 % EP-CMT 0 % EP-CMT

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Deposition rate and heat input

+ -

EP-CMT phase EN-CMT phase

0 % EN-CMT 100 % EN-CMT


100 % EP-CMT 0 % EP-CMT

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Deposition rate and heat input

Filler metal: AlSi5 1.2 mm


Base material: AlMg3
Protective gas shield: 100% Argon
Welding speed: 80 cm/min

CMT Pulse (conventional) CMT Pulse Advanced

IS = 87.3 A IS = 88.5 A
US = 11.43 V US = 11.80 V
vd = 2.9 m/min vd = 4.75 m/min

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Deposition rate and heat input

Filler metal: AlSi5 1.2 mm


Base material: AlMg3
Protective gas shield: 100% Argon
Welding speed: 130 cm/min

CMT (conventional) CMT Advanced

IS = 72.1 A IS = 84.0 A
US = 9.95 V US = 10.67 V
vd = 2.92 m/min vd = 4.95 m/min

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
Gap bridgeability

Process: CMT Pulse Advanced


Filler metal: AlSi5 1.2 mm
Base material: AlMg3
Protective gas shield: 100% Argon
Welding speed: 60 cm/min
EN / EP cycles: 14 : 10

zero gap gap: 2.6 mm

t=2 mm

IS = 100 A
US = 11.6 V
vd = 6.7 m/min

 Either is possible – A max. gap X and zero gap


with the same parameter setting

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
CMT Advanced - Summary

 Up to 60% higher deposition rate

 Better gap bridgeability

 Flexible adjustment (control) of heat input

 Fewer welding emissions

 Guarantees the customary process stability of CMT

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
CMT Advanced - Outlook
 The system will become available at the beginning of Q2/2010

 Synergic lines

 for both process variants

 with steel or CrNi and

 aluminium with wire diameter 1.2 mm

CMT Advanced - Schweißen & Schneiden 2009


09/2009 © Fronius
PERFECT WELDING