Robotic Welding in the Automotive Industry

Challenge

Modern vehicles needs to meet increasingly strict exhaust emission regulations, but at the same time customers expect more and more safety and comfort features. The automotive and supplier industry therefore relies on lightweight concepts, and light metals such as aluminum and magnesium, as well as high-strength and super-high-strength steels, are becoming increasingly important as materials.

This also means that welding technology is facing new challenges, and requires innovative solutions. Cost effectiveness is also crucial in the automotive industry, and in order to keep up with international competition, manufacturers and suppliers need to make their production processes as efficient as possible in terms of time and costs.

Partner in the automotive industry

Fronius has been a reliable partner of the automotive industry for many years. Together, we develop tailor-made solutions for your welding challenges using high-quality products and outstanding service. No matter whether you are dealing with robotic welding of exhaust systems, bodywork (body in white) or chassis components, you can rely on our experience and our know-how.

Quality

First class products according to the highest industry standards
Outstanding service from highly trained specialists
Worldwide support directly on the customer’s premises

Cost effectiveness

Technology and innovation leader in welding technology
Professional training for your employees
Comprehensive knowledge of the automotive and supplier industry

Know-how

Time and cost optimized production processes
Seamless integration into the production process
Constant new development and further development of efficient welding processes

Good relationships

25 years of experience in the automotive industry
Long-term partnerships and reliable cooperation with customers around the world

Questions on welding solutions for the automotive industry?

Submit your non-binding inquiry directly to Fronius.

Our team will gladly provide you further information.

Send inquiry now

Production monitoring with WeldCube.
One piece of software - all power sources at a glance.

Process and cost optimization are of central importance for the automotive and supplier industry, and the documentation of production data is an important key to achieving this. With WeldCube from Fronius, you can continuously record and analyze the welding data of all power sources on all production lines.

The result: greater transparency, safety and verifiable weld quality for your series production.

Save time and money with WeldCube:

Access welding data of up to 50 power sources centrally irrespective of the device, and analyze data at the touch of a button
Create and manage jobs centrally and distribute to the power sources
Optimize costs with simple analysis of consumption of gas and filler metals
Call up data quickly when servicing is needed, and therefore reduce downtimes
Continuous data documentation for quality assurance and to comply with standards

Body in white

Whether steel, aluminium or mixed applications.
Fronius offers the optimum welding process.

Galvanized steel (1)

Challenge

Practically spatter-free welding and brazing on galvanised steel
Low distortion due to optimised heat input
Low porosity
Stable arc
Optimum penetration
High welding speeds

Solution

TPS/i PMC/CMT

LaserHybrid

High-strength and ultra strong steels (2)

Challenge

Practically spatter-free welding of hot pressed components
Lower heat input (up to -50%) than with conventional gas metal arc welding

Solution

TPS/i PMC/CMT

LaserHybrid

Visible weld seams (3)

Challenge

Fast brazing (up to 3 m/min)
Lower heat input
Flat and clean weld seam
Best weld seam appearance
Up to 60% less shielding gas
Spatter-free

Solution

TPS/i PMC/CMT

LaserHybrid

Aluminium arc welding (4)

Challenge

High stability of the arc
Lowest heat input
Steel-aluminium joints possible
Minimal spattering
High gap-bridging ability

Solution

TPS/i PMC/CMT

LaserHybrid

Welding challenges

High welding speeds
Joining different materials (Steel-aluminium joints possible)
Flat and clean weld seam
Lowest heat input and low distortion
Spatter-free welding

Exhaust gas systems

Exhaust gas systems have developed into very complex systems. To reduce weight, increasingly thin materials are used.

Manifold (1)

Material: ferritic chrome steel

Challenge

High component tolerance
High welding speed

Solution

TPS/i PMC / LSC

Flange (2)

Material: steel

Challenge

No spatter
Stable arc
High Welding Speed

Solution

TPS/i CMT

Muffler (3)

Material: ferritic chrome steel

Challenge

No spatter
Stable arc
High welding speed

Solution

TPS/i CMT

Cataslytic Converter cap (4)

Material: ferritic chrome steel

Challenge

Good penetration
Good gap-bridging ability
High welding speed

Solution

TPS/i CMT

Welding challenges

Welding very thin materials
Joining materials of different thicknesses (flange)
Multiple sheet joints
High component tolerances
Damage to sensitive parts such as catalytic converters or particle filters by welding spatter
Cost effectiveness in production, large quantities

Chassis

Chassis components are usually safety-related components that require weld seams of the highest quality.

Control arm (1)

Material: steel

Challenge

High welding speed
Continuous root formation

Solution

TPS/i PMC

Shock absorber (2)

Material: steel

Challenge

Good penetration
Less spatter
High welding speed

Solution

TPS/i PMC

Axle (3)

Material: aluminium

Challenge

High welding speed
Low heat input
Good gap-bridging ability

Solution

LaserHybrid

Axle carrier (4)

Material: steel

Challenge

High component tolerances
High welding speed
Less spatter

Solution

TPS/I PMC

Welding challenges

Reduced porosity and quality welds
High travel speeds for improved cycle time
Gap bridging ability at high travel speeds
Reduced distortion

Interior (seats, cross car beam)

Other materials, such as high-strength and super-high-strength steels, are often built into the interior of a vehicle. Fine mechanisms require welding with very low spatter.

Cross car beam (1)

Material: steel

Challenge

Low heat input
Less spatter
Thick/thin joints

Solution

TPS/i CMT

Seat frame (2)

Material: steel

Challenge

Short weld seams
Stable ignition
Good penetration

Solution

TPS/i PMC

Seat recliner (3)

Material: steel

Challenge

No spatter
Stable arc
Short weld seams
Low heat input

Solution

TPS/i CMT

Welding challenges

Very thin materials
Mechanisms sensitive to spatter
High-strength and super-high-strength steels
Very short weld seams
Consistent quality
Different material thicknesses
Cost effectiveness in production

Benefit from our services

Increase productivity and performance

We support you in the startup phase of your production process by providing production monitoring. Due to tailor-made and quick integration of our products, you benefit from optimized cycle times, avoid reworking and the system will be easy to use.

Expert know-how for your employees

To ensure that production is top quality in all countries, it is essential that all employees have the same level of knowledge, which is achieved through instruction, seminars and training.

Make optimum use of resources

With our years of experience in the automotive industry, we help you to optimize your production processes and parameter settings.

Reduction in downtime

We take over the servicing and maintenance of your welding systems for you and help you to avoid downtimes and save personnel costs as a result.

This may also interest you

Magna Steyr: aluminum welding of vehicle bodywork on the border

Simple, robust, cost-optimized: steel welding with a push system

Send your non-binding request directly to Fronius

Let’s get connected.

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Welding Wiki

The encyclopedia about welding

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Perfect Welding

Robotic Welding in the Automotive Industry Time and cost optimized production processes

Challenge

Partner in the automotive industry

Quality

Cost effectiveness

Know-how

Good relationships

Questions on welding solutions for the automotive industry?

Production monitoring with WeldCube. One piece of software - all power sources at a glance.

Save time and money with WeldCube:

Read more about the subject

System solutions for the automotive industry

Newsletter Registration

Body in white

Welding challenges

Exhaust gas systems

Welding challenges

Chassis

Welding challenges

Interior (seats, cross car beam)

Welding challenges

Benefit from our services

Increase productivity and performance

Expert know-how for your employees

Make optimum use of resources

Reduction in downtime

This may also interest you

Magna Steyr: aluminum welding of vehicle bodywork on the border

Simple, robust, cost-optimized: steel welding with a push system

Send your non-binding request directly to Fronius

Let’s get connected.

Thank you for your message. We will process your request as soon as possible.

Welding Wiki

The encyclopedia about welding

Robotic Welding in the Automotive Industry Time and cost optimized
production processes

Production monitoring with WeldCube.
One piece of software - all power sources at a glance.