Robotic Welding in the Automotive Industry

Challenge

Modern vehicles need to meet increasingly strict regulations (in ex. lower emissions), 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?

Contact Your Fronius Partner for the Automotive Industry

Vlad Tudorache

Ghqbenpur.Iynq@sebavhf.pbz

Body in white

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

Galvanized steel (1)

Challenge

Minimized spatters on welding and brazing for galvanized steel
Low distortion due to optimized heat input
Low porosity
Stable arc
Optimum penetration
High welding speeds

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT (Advanced GMAW)

LaserHybrid (LHAW)

High-strength steels - AHSS, UHSS, Gen 3 Steels (2)

Challenge

Lower heat input (-20% to -35%) than with conventional gas metal arc welding
Reduced/controlled distortion through advanced processes
Reduced rework through advanced arc control processes

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT (Advanced GMAW)

LaserHybrid (LHAW)

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

Platform:

TPS/i

Processes:

LSC technology (Advanced GMAW, GMAB)

PMC technology (Advanced GMAW-P, GMAB)

CMT technology (Advanced GMAW, GMAB)

CMT braze+ technology (Advanced GMAB)

LaserHybrid (LHAW)

Aluminum arc welding (4)

Challenge

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

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

LaserHybrid (LHAW)

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

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Flange (2)

Material: stainless steel

Challenge

Minimum spatter
Stable arc
High Welding Speed

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Muffler (3)

Material: ferritic chrome steel

Challenge

Minimum spatter
Stable arc
High welding speed

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Catalytic Converter ASSEMBLY (4)

Material: ferritic chrome steel

Challenge

Good penetration
Good gap-bridging ability
High welding speed

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Welding challenges

Welding very thin materials and thick to thin combination joints
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

Platform:

TPS/i

Processes:

Pulse technology (GMAW-P)

PMC technology (Advanced GMAW-P)

Shock absorber (2)

Material: steel

Challenge

Good penetration
Less spatter
High welding speed

Solution

Platform:

TPS/i

Processes:

Pulse technology (GMAW-P)

PMC technology (Advanced GMAW-P)

Axle (3)

Material: aluminum, steel

Challenge

High welding speed
Low heat input
Good gap-bridging ability

Solution

Platform:

TPS/i

Processes:

Pulse technology (GMAW-P)

PMC technology (Advanced GMAW-P)

Twin technology (Tandem GMAW)

Laserhybrid (LHAW)

Axle carrier (4)

Material: aluminum, steel

Challenge

High component tolerances
High welding speed
Less spatter

Solution

Platform:

TPS/i

Processes:

Pulse technology (GMAW-P)

PMC technology (Advanced GMAW-P)

Twin technology (Tandem GMAW)

Laserhybrid (LHAW)

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 ultra-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

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Seat frame (2)

Material: Martensitic steel

Challenge

Short weld seams
Stable ignition
Good penetration

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Seat recliner (3)

Material: steel

Challenge

No spatter
Stable arc
Short weld seams
Low heat input

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)

CMT technology (Advanced GMAW)

Welding challenges

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

High performance for e-mobility

Welding battery trays

Battery trays are used in electrically driven vehicles to protect the battery against outside influences. Much is demanded of the components: they must be compact, completely secure to protect the battery packs against corrosion and be extremely durable in the event of a collision. Extruding press and sand-cast profiles are manufactured from aluminum alloys with wall thicknesses of between two and six millimeters.

Welding challenge

The automotive industry is increasingly relying on electric drives. The consequences for production are enormous: the components needed for vehicles with a combustion engine are changing or are no longer necessary, while others are being added – battery trays, for example. New production processes are therefore required, including in welding technology.

Typical applications for battery trays

A) Aluminum alloys

Challenge

Extruding press and sand-cast profiles manufactured from aluminum alloys
High stability of the arc
Lowest heat input
Steel-aluminum joints possible
Minimal spattering
High gap-bridging ability
Cast aluminum joining

Solution

Platform:

TPS/i

Processes:

PMC technology (Advanced GMAW-P)
CMT technology (Advanced GMAW)
LaserHybrid (LHAW)

B) Advanced High Strength Steels and Galvanized Steels

Challenge

Distortion control
High stability of the arc
Lowest heat input
Minimal spattering
High gap-bridging ability
Sealed welds

Solution

Platform:

TPS/i

Processes:

GMAB processes (MIG brazing)
Pulse (GMAW-P)
PMC technology (Advanced GMAW-P)
CMT technology (Advanced GMAW)
LaserHybrid (LHAW)

Video: Bollinger battery tray reference*

*Used with permission of BollingerMotors.

Video: Prototyping Center – Feasibility studies, prototype production and small series welding.

Video: Prototyping Center – LaserHybrid

Save time and money with WELDCUBE:

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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

Benefit from Our Services

Increase productivity and performance

We support you from the startup phase of your production process. Tailor made and quick integration of our products will benefit your production with optimized cycle times, less re-work and ease of use.

Expert know-how for your employees

Our employees are trained to offer top quality level of expertise for your applications.

Make optimum use of resources

We help you to optimize your production processes and parameter settings.

Reduction downtime

We take over the servicing and maintenance of your welding systems, helping you avoid downtimes and saving personnel costs as a result.

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Send your non-binding request directly to Fronius

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Perfect Welding

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?

Contact Your Fronius Partner for the Automotive Industry

Vlad Tudorache

Body in white

Welding challenges

Exhaust gas systems

Welding challenges

Chassis

Welding challenges

Interior (seats, cross car beam)

Welding challenges

High performance for e-mobility

Welding battery trays

Welding challenge

Solutions for process optimization

Read more about the subject

System solutions for the automotive industry

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

Save time and money with WELDCUBE:

Benefit from Our Services

Increase productivity and performance

Expert know-how for your employees

Make optimum use of resources

Reduction 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 in the Automotive Industry Time and cost optimized
production processes

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