CMT Aluminum Tubing 2023 June 30

Welding Test
CMT_Aluminum
Tubing_2023_June_30
Fronius International, Cinnamon Digan, 06/30/2023
Information Class: Confidential
Description
The objective for the test was to decrease heat input on the part so
when it goes through the next fabrication process (induction and
flame brazing) the secondary heating of the part will be less prone
to cracking.
Customer information
Coclisa
Hanon Systems
Chris Vsetula
Cycle Step
Right Side Left Side

CMT-Mix
Right Side Left Side

Cycle Step
Brackets
TPS/I PUSH PULL
CMT PAP SB60I
• TPS 500i
Seam 1 (Right Side)
Right Side Cycle Step
Using CMT Cycle Step would be our

recommending solution for this particular
joint. The Cycle Step process allows complete
shut of off the arc for maximum heat
reduction. A spot size of 10 with an interval
break at .1 of a second was used.
Note: Wire placement is very particular for

weld location.
Welding parameters
Layer 1 End Arclength correction 0.0
Shielding gas I1 100% Ar End current time 0.2 s
Name Hanon SFI on
Welding mode MIG CMT SFI Hot start off
Characteristic 4138 Wire retract 2.0
Property universal Penetration stabilizer 0.0 m/min
Gas I1 100% Ar Arc length stabilizer 0.0
Wire EN: AlSi 5, AWS: ER 4043 CMT Cycle Step on
Wire diameter 1.2 mm Cycles (Spot size) 10
Trigger mode S2-step Interval break time 0.10 s
Welding process line 1 Interval cycles Permanent
Wire Feed Speed 6.9 m/min Gas preflow 0.5 s
Current 133 A Gas postflow 0.9 s
Voltage 14.9 V Command value gas 16.5 l/min
Material Thickness 2.9 mm Gas factor 1.65
Arclength correction 0.0 Upper power correction limit 0%
Pulse/dynamic correction 0.0 Lower power correction limit 0%
Starting current 175 % Upper arc length correction limit 0.0
Start Arclength correction 0.0 Lower arc length correction limit 0.0
Start current time 0.2 s Job slope 0.0 s
Slope 1 0.3 s Sampling rate off
Slope 2 0.2 s Limit reaction ignore
Welding Properties
• Travel angle: 0.00°
• Work angle: 45.00°
• Contact tip to work distance: 15.00mm
• Offset X: 0.00mm
• Offset Z: 1.00mm (on coupling as shown)
• Welding speed: 38.00cm/min
• Note: Travel speed slightly slower (~30 cm/min) at the start to allow proper
fill
• Component inclination: 0.00°
• Seam length: 66.00mm
General Information
• Process: Cmt (Cycle Step)
• Segment of Application: tbd.
• Type of Application: tbd.
• Base material(s): AlMg3
• Surface(s): Blank
• Additional material(s): AlSi 5
• Filler metal diameter (mm): 1.2
• Shielding gas: I1 100% Ar
• Welding position: PA (P1F)
• Shape of seam: Single fillet weld
Seam 2 (Left Side)
Left Side Cycle Step
Again, Cycle step would be recommend for

the other side of the joint as well. This joint
required a spot size of 8 with an interval
break of .1 second.
Welding parameters
Name hanon 2 SFI on
Welding Properties
• Offset Y: 1.00mm (away from coupling as shown)
fill
General Information
• Process: Cmt
Seam 3 (Right Side
No Cycle Step)
Right Side CMT-Mix
Because the Cycle Step function is not

curretnly on the welders in Mexico, we
wanted to test the CMT-Mix Process on the
joints as well. A Low Power Time Correction
of 20 with a High Power Time Correction of
0.4 yeilded the best results.
Welding parameters
Name Hanon CMT-Mix SFI on
Property mix Penetration stabilizer 0.0 m/min
Wire EN: AlSi 5, AWS: ER 4043 High power time corr. 0.4
Wire diameter 1.2 mm Low power time corr. 20
Trigger mode S2-step Low power corr. 0.0
Welding process line 1 CMT Cycle Step off
Wire Feed Speed 6.0 m/min Cycles (Spot size) 8
Current 137 A Interval break time 0.10 s
Voltage 18.1 V Interval cycles Permanent
Material Thickness 3.0 mm Gas preflow 0.5 s
Arclength correction 0.0 Gas postflow 0.9 s
Pulse/dynamic correction 0.0 Command value gas 16.5 l/min
Starting current 180 % Gas factor 1.65
Start Arclength correction 0.0 Upper power correction limit 0%
Start current time 0.2 s Lower power correction limit 0%
Slope 1 0.3 s Upper arc length correction limit 0.0
Slope 2 0.0 s Lower arc length correction limit 0.0
Welding parameters
Sampling rate off Inching value 5.1 m/min
Limit reaction ignore

Welding Properties
• Offset Z: 1.00mm
fill
General Information
• Process: Cmt
Seam 4 (Left Side No
Cycle Step)
Left Side CMT-Mix
On the left side of the joint a Low Power

Time Correction of 20 and a High Power
Time Correction of -2 gave us the results we
were looking for. This process will put
slightly more heat into the part compared to
Cycle Step, however testing with the
secondary processes will need to be
conducted to determine if CMT-Mix is a
feasible solution.
Welding parameters
Name Hanon CMT-Mix side 2 SFI on
Property mix Penetration stabilizer 0.0 m/min
Wire EN: AlSi 5, AWS: ER 4043 High power time corr. -2.0
Wire diameter 1.2 mm Low power time corr. 20
Trigger mode S2-step Low power corr. 0.0
Welding process line 1 CMT Cycle Step off
Wire Feed Speed 5.1 m/min Cycles (Spot size) 8
Current 116 A Interval break time 0.10 s
Voltage 17.2 V Interval cycles Permanent
Material Thickness 2.3 mm Gas preflow 0.5 s
Arclength correction 0.0 Gas postflow 0.9 s
Pulse/dynamic correction 0.0 Command value gas 16.5 l/min
Starting current 150 % Gas factor 1.65
Start Arclength correction 0.0 Upper power correction limit 0%
Start current time 0.2 s Lower power correction limit 0%
Slope 1 0.2 s Upper arc length correction limit 0.0
Slope 2 0.0 s Lower arc length correction limit 0.0
Welding parameters
Sampling rate off Inching value 5.1 m/min
Limit reaction ignore

Welding Properties
• Offset Y: 1.00mm
fill
General Information
Seam 5 (Bracket
Weld)
Brackets
CMT Cycle Step was tested on the brackets

as well. This process would be ideal for this
joint set-up and configuaration.
Welding parameters
Name Hanon brackets SFI on
Welding Properties
• Offset Y: 1.00mm
General Information
Note
We are grateful for your confidence and look forward to a continuing good cooperation.
Should you require additional information concerning the present evaluations, please do not hesitate to contact us.
Please note that the welding test was performed under laboratory conditions.
We cannot guarantee 100% transferability of the welding parameters to production conditions, the determined
parameters serve as a guideline.
Cinnamon Digan
Application Engineer Global TechSupport Management
Fronius International GmbH

Froniusplatz 1 / 4600 Wels / Austria
Tel.: +43 (7242) 241-3000
Questions about report: Digan.Cinnamon@fronius.com

General technical questions: welding.techsupport@fronius.com
All information is without guarantee in spite of careful editing –
liability excluded.
Intellectual property and copyright: all rights reserved.

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apply to the content of this presentation and the documentation
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unless expressly indicated otherwise. It is not permitted to use,
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commercial purposes without explicit consent of Fronius.

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Welding Test

Right Side Left Side

Right Side Left Side

Using CMT Cycle Step would be our

Note: Wire placement is very particular for

Again, Cycle step would be recommend for

Because the Cycle Step function is not

Limit reaction ignore

On the left side of the joint a Low Power

Limit reaction ignore

CMT Cycle Step was tested on the brackets

Fronius International GmbH

Questions about report: Digan.Cinnamon@fronius.com

Intellectual property and copyright: all rights reserved.

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