Cladding

Chemical load, wear and corrosion cause problems for metal components. Using overlay welding of additional special alloys, also known as cladding, however, components can be protected and therefore their service life can be increased. This is a technologically challenging process. Fronius offers modern systems and tailored welding processes for this purpose, which help the user to ensure the necessary high level of quality.

Compact Cladding Cell – Advantages

Ergonomic design

Welding torch – quick change system
Wirespool holder at operator height
Power sources on rail expansion device

Compact and mobile

All components pre-assembled on a platform
Short commissioning times

Welding processes

TIG HD
SpeedClad 2.0

Area of application

Max. component diameter (external): 1 m
Max. component height: 1.4 m (1.9 m optional)
Max. bore depth: 1 m

HMI system controls

21" touchscreen panel
Central control of all system components
Multi user management

System overview – Compact Cladding Cell (CCC)

Inner overlay welding torch

TIG HD welding torch (from 25 mm bore diameter)
TWIN wire option

SpeedClad 2.0

SpeedClad welding torch system for top overlay welding performance

Ring groove welding torch

SpeedClad welding torch system for top overlay welding performance

Wirefeeder

4-roller drive
Wire speed monitoring
TWIN wire option

PowerLiner

Roller-guided wirefeeding hose for perfect wirefeeding

Ergonomics

Wirespool holder at operator height for easy changing of the wire spools

Stand

Highly precise welding torch positioning due to the use of servo motors and precision guides
Optimized cable guide management

Power source set

TransTig 5000 Job and TransTig 2200 Job – fully digital for optimum welding results
High performance cooler for SpeedClad

Rotary table

Servo drive with precision gearing for maximum positioning accuracy
Slip ring option for pre-heating unit

Inner overlay welding torch

TIG HD welding torch (from 25 mm bore diameter)
TWIN wire option

SpeedClad 2.0

SpeedClad welding torch system for top overlay welding performance

Ring groove welding torch

SpeedClad welding torch system for top overlay welding performance

Wirefeeder

4-roller drive
Wire speed monitoring
TWIN wire option

PowerLiner

Roller-guided wirefeeding hose for perfect wirefeeding

Ergonomics

Wirespool holder at operator height for easy changing of the wire spools

Stand

Highly precise welding torch positioning due to the use of servo motors and precision guides
Optimized cable guide management

Power source set

TransTig 5000 Job and TransTig 2200 Job – fully digital for optimum welding results
High performance cooler for SpeedClad

Rotary table

Servo drive with precision gearing for maximum positioning accuracy
Slip ring option for pre-heating unit

Applications

Bore to bore

Bore to bore advanced

Flange with bore

Straight/conical bore

Multi diameter

Ring groove

Cylindrical bore

ETR-S advantages

Synchronized movement axes allow for the welding of complex component shapes
Considerably reduced setup times due to automatic determination of the component position in the 3D space
SpeedClad 2.0 compatible – up to three times better cladding performance in comparison with conventional TIG HD welding processes
HMI-T21 system controls – the new generation of control with an expanded scope of functions

System overview ETR-S HMI-T21

Machine carrier

- Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides

- Vertical axis with travel distance of 3 to 5 m available

- Rotating assembly unit, can be rotated 340°

ETR head

- TWIN wirefeeder

- Motorized rotating and tilting

- Integrated oscillating unit

- Collision setup (electro-pneumatic)

- Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

HMI-T21 system controls

- 21” touch screen user interface

- CNC platform, STEP data import

- Autom. component position detection

- Real-time process visualization

Welding equipment

- TransTig 5000 Job power source

- TransTig 2200 Job hot wire power source

- Power sources on telescopic extension devices for easy maintenance

- High performance cooler for SpeedClad 2.0

Machine carrier

- Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides

- Vertical axis with travel distance of 3 to 5 m available

- Rotating assembly unit, can be rotated 340°

ETR head

- TWIN wirefeeder

- Motorized rotating and tilting

- Integrated oscillating unit

- Collision setup (electro-pneumatic)

- Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

HMI-T21 system controls

- 21” touch screen user interface

- CNC platform, STEP data import

- Autom. component position detection

- Real-time process visualization

Welding equipment

- TransTig 5000 Job power source

- TransTig 2200 Job hot wire power source

- Power sources on telescopic extension devices for easy maintenance

- High performance cooler for SpeedClad 2.0

Applications

NEW: Sphere*

NEW: Circle segment*

NEW: Hemisphere*

NEW: Flange with bores*

Bore to bore

Bore to bore advanced

Straight/conical bore

Cylindrical bore

Multi diameter

Ring groove

Rectangular

Race track

* Only in combination with CAD import option

ETR Ultimate advantages

High-end cladding system

Expanded working area due to motorized track
Complex component shapes
Multi station operation (fully automated)
Synchronized movement axes
SpeedClad 2.0 compatible
HMI-T21 system controller

System Overview ETR Ultimate

Machine carrier

/ Servo motors, encoder, precision guides

/ Assembled on motorized track (“track motion”)

ETR head

/ Twin wirefeeder

/ Motorized rotating and tilting

/ Integrated oscillating unit

/ Collision detection (electro-pneumatic)

/ Welding torch holder with clamp fasteners for new generation TTHW welding torches & SpeedClad 2.0

Welding equipment

/ TransTig 5000 Job

/ TransTig 2200 Job

/ Telescopic extension devices for power sources to allow for easier maintenance

/ High performance cooler for SpeedClad 2.0

Track motion

/ Motorized track

/ Platform for machine carrier and welding equipment

HMI-T21 system controls

/ 21" touch screen

/ CNC platform, STEP data import

/ Automatic component position detection

/ Real-time process visualization

Machine carrier

/ Servo motors, encoder, precision guides

/ Assembled on motorized track (“track motion”)

ETR head

/ Twin wirefeeder

/ Motorized rotating and tilting

/ Integrated oscillating unit

/ Collision detection (electro-pneumatic)

/ Welding torch holder with clamp fasteners for new generation TTHW welding torches & SpeedClad 2.0

Welding equipment

/ TransTig 5000 Job

/ TransTig 2200 Job

/ Telescopic extension devices for power sources to allow for easier maintenance

/ High performance cooler for SpeedClad 2.0

Track motion

/ Motorized track

/ Platform for machine carrier and welding equipment

HMI-T21 system controls

/ 21" touch screen

/ CNC platform, STEP data import

/ Automatic component position detection

/ Real-time process visualization

Applications

Bore to bore

Bore to bore advanced

Flange with bores

Straight/conical bore

Hemisphere*

Circle segments*

Sphere*

Multi diameter

Race track

Rectangular

Ring groove

* Only in combination with CAD import option

Conventional Cladding System Advantages

/New control and drive technology for an even more precise cladding process

/Motorized tiltable welding torch axis (up to 90°) to comply with the optimum weld layer

/SpeedClad 2.0 compatible - up to three times better cladding performance in comparison with conventional TIG HD welding processes

/HMI-T21 system controls - the new generation of control with an expanded scope of functions

System overview Conventional Cladding System

Machine carrier

Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides
Rotating assembly unit, can be rotated 270°

Welding equipment

TransTig 5000 Job power source
TransTig 2200 Job hot wire power source
Power sources on telescopic extension devices for easy maintenance
High performance cooler for SpeedClad 2.0

Welding head

Motorized tilting of the welding torch axis 0 - 90°
AVC/oscillating axes
Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

HMI-T21 system controls

21" touch screen user interface
STEP data import
Real-time process visualization

Machine carrier

Highly precise welding torch positioning due to the use of servo motors, absolute encoders and precision guides
Rotating assembly unit, can be rotated 270°

Welding equipment

TransTig 5000 Job power source
TransTig 2200 Job hot wire power source
Power sources on telescopic extension devices for easy maintenance
High performance cooler for SpeedClad 2.0

Welding head

Motorized tilting of the welding torch axis 0 - 90°
AVC/oscillating axes
Welding torch holder with clamp fasteners for new generation TTHW welding torches incl. SpeedClad 2.0

HMI-T21 system controls

21" touch screen user interface
STEP data import
Real-time process visualization

Applications

Bore to bore

Bore to bore advanced

Straight/conical bore

Flange with bore

Cylindrical bore

Multi diameter

Ring groove

Ultra fast overlay welding SpeedClad 2.0

A new dimension in cladding

In comparison with SpeedClad Twin, the new cladding process only requires one electrode and one additional wire for the same or quicker welding speeds. Considerably fewer wear parts and less maintenance work are clear benefits of this process.

In addition, the much slimmer welding torch allows for the surfacing of small interior diameters.

What makes SpeedClad 2.0 a good choice?

Waste 2 Energy

Membrane walls

Overlay welding to increase the corrosion resistance of membrane walls in power plants and waste incinerators. A special device is used to tension the component and bring it into a vertical position. The trolley, which is guided on a gear rack, moves the two CMT welding heads safely and precisely over the entire weld length. Each welding torch is located on a linear oscillating unit and can be positioned manually using motorized carriages and adjustment units. More about membrane walls

Heat exchanger pipes

Overlay welding system with HMI-T10 system controls for mechanized CMT exterior overlay welding of heat exchanger pipes, which are used in power plant construction and waste incinerators. A safety light grid guarantees optimum protection of personnel during the welding process. More about heat exchanger pipes

Customer solutions that are impressively cost effective

Our customers need systems that produce perfect welds throughout the entire product life cycle. They need to be efficient and as profitable as possible. During the engineering phase we therefore place great importance on feasibility studies, simulations, and welding tests.

Take a look at our customer solutions

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Perfect Welding

Cladding

Compact Cladding Cell – Advantages

Applications

ETR-S advantages

Applications

ETR Ultimate advantages

High-end cladding system

Applications

Conventional Cladding System Advantages

Applications

Ultra fast overlay welding SpeedClad 2.0

A new dimension in cladding

Waste 2 Energy

Membrane walls

Heat exchanger pipes

Customer solutions that are impressively cost effective