Fronius iWave powers welding solutions for modern manufacturing

By Staff Report December 11, 2024 11:54 am IST

The iWave Multiprocess PRO is flexible and adaptable, allowing users to expand their iWave’s range of applications to meet future welding requirements.

The Fronius iWave is a standout in robot applications and automation systems due to its excellent weld appearance, targeted heat input, and reproducible ignition. The all-rounder is now available in power categories 300i, 400i, and 500i, each as a DC or AC/DC variant and with water or gas cooling as required. With dynamic wire control, this system is setting new standards in cold wire TIG welding, and as a Multiprocess PRO version, this future-proof 2-in-1 solution has already become the go-to for high-end TIG and MIG/MAG welding.

Be it in rolling stock construction, in the production of automotive parts, or in container and pipeline construction, the iWave increases productivity in TIG welding in industrial manufacturing and delivers maximum weld quality for every material. Innovative technologies ensure targeted heat input, improved ignition, and maximum control over the arc. 

The CycleTIG process variant, for example, is the perfect solution whenever an excellent weld appearance with fewer temper colours is crucial. Outstanding control over the weld pool and precise heat input are particularly beneficial when working with very thin sheets or when delicate corner and butt welds are on the agenda, as well as for repairs involving edge applications. The extremely stable ignition behaviour due to the high-frequency (HF) ignition during TIG welding is another outstanding feature. The RPI auto setting ensures fast and reproducible ignition regardless of the material properties, and the tacking function causes the weld pool to oscillate, which can reduce the time needed for tacking by up to 50%. 

Paul Hofer, technical product manager at Fronius International GmbH, said, “Equipped with the patented Fronius TIG DynamicWire Welding Package, the iWave is taking cold wire TIG welding to a whole new level. The innovative advantage over conventional continuous wire feeding is the dynamic wire control, which always supplies the exact amount of wire needed at the time. This means that the iWave actively adjusts the wire speed to the conditions and can easily compensate for air gaps of up to 30% in relation to the material thickness.”

What’s more, TIG DynamicWire provides support when setting the optimum welding parameters. Defining one parameter—such as the welding current—is the only thing you need to do, and all other values are added based on material-specific characteristics. Another advantage is that all existing iWave cold wire systems can be quickly expanded to include TIG DynamicWire at any time, simply by means of a software upgrade. 

Multiprocess PRO—Equipped for the challenges of tomorrow

“You never know what your welding work will involve in one, two, or five years,” Hofer points out. “The iWave Multiprocess PRO is flexible and adaptable. No matter what welding requirements you come across in the future, it will always be easy to individually expand your iWave’s range of applications.” In addition to all the high-tech TIG functions, it provides you with access to the full scope of process variants from the MIG/MAG range and even enables AC/DC welding for the first time. The range of modular welding packages is huge and includes Standard, Pulse, PMC (Pulse Multi Control), LSC (Low Spatter Control), CMT (Cold Metal Transfer), PMC AC, and CMT AC—the iWave even has the perfect characteristic for additive manufacturing. 

Switch between TIG and MIG/MAG in a single step

Equipped with suitable peripheral components, such as a welding torch and wire feeder, a single high-tech welding machine becomes a universal all-rounder while taking up only minimal space. You can switch between processes simply by pressing a button, or this can also be automated with the right equipment. The user interface also changes automatically and clearly displays the main parameters required in each case. 

Another highlight is the new hosepack with its own torch coupling, which allows the corresponding torch body to be replaced quickly without having to change the entire hosepack. This means that the appropriate welding torch is ready for use in the desired application in no time. 

The iWave is equipped with the most important communication standards, e.g., WLAN, Bluetooth, and Ethernet, and meets the highest requirements when it comes to cybersecurity. Peripheral devices or remote controls can be connected wirelessly, and thanks to WeldCube Premium’s central data documentation, transparency and control are gaining traction in welding production. Potential savings can be determined based on the welding data obtained, for example, in relation to material, energy, and gas consumption, to make production more resource-efficient.