Fronius UK Ltd (Perfect Welding)

Plasma instead of chemicals

The Acerios system developed by Fronius allows for particularly environmentally friendly and cost-effective surface cleaning using hot active plasma. The technology removes organic residues from metal surfaces with pinpoint precision, meaning that in industrial production, components are optimally prepared for processes such as adhesion, painting, or welding.

Chemicals are often used for surface treatment, which are subject to strict safety regulations as well as being harmful to the environment and expensive. Acerios offers an alternative: the system generates a plasma flame with a temperature of up to 1,000 degrees Celsius, which is guided over the surface by a robot at speeds of up to 6 meters per minute.

Depending on requirements, the entire surface or specific areas can be treated. Acerios cleans in an efficient and environmentally-friendly manner, is space-saving, and can be easily integrated into automated systems and production lines thanks to its different interface variants.

Fronius TIG DynamicWire

TIG cold-wire components are available now for Fronius iWave. The pioneering innovation lies in its intelligent control. With the patented new TIG DynamicWire welding package, even amateurs can achieve perfect TIG welds with ease. This is because the dynamic wire control always selects the right travel speed. The process adapts to the welder, not the other way around!

TIG welding represents the top tier of welding processes and demands skill as well as years of practice – or does it? “All the new features that we’ve packed into the iWave cold-wire components as well as the corresponding software solution make TIG welding significantly easier,” explains Manuel Rumpl, Head of Strategic Product Management Industrial Welding Solutions, Fronius International GmbH. “Thanks to TIG DynamicWire, welders can focus all their attention on the arc and the welding system regulates the optimal wire speed at all times.”

The iWave power categories from 300i to 500i can be upgraded to the TIG cold-wire system. The TIG DynamicWire welding package is ready for use immediately by means of software activation and can also be retrofitted to existing iWave systems at any time.

Market innovation: active wire control

The innovative advantage of Fronius DynamicWire compared to a conventional continuous wire feed lies in its automatic self-regulation. The welding system actively adjusts the wire speed to the welding behavior, torch position, and current conditions, even automatically compensating for component tolerances of up to 30%. The result? Perfect welds every time.

Precise and user-friendly

During development of the cold-wire system, no detail was too small for Fronius when it came to ensuring that welders could work optimally with minimal steps and adjustments. The wirefeeder is set once and then remains in a stable position. The ergonomic and flexible tungsten holder is particularly lightweight as it is produced using material-saving aluminum 3D printing. There are also no disturbing vibrations at the torch handle, as – unlike with comparable solutions – the mechanical forward and backward motion of the wire has been dispensed with entirely with the new TIG DynamicWire cold-wire welding process.

Change the tungsten electrode at the touch of a button

With the Tungsten Fast Clamp system (TFC), welding expert Fronius is bringing out another new patent. A single touch of the button releases and clamps the tungsten electrode in the spring-loaded clamping sleeve. Like the lead of a mechanical pencil, the electrode is changed in a matter of seconds. This system can now also be mounted on existing torch bodies.


Self-regulating, time-saving, and resource-conserving
In times of skills shortages, iWave complete with cold-wirefeeding and TIG DynamicWire can help all TIG novices and those with less experience achieve a great welding result and fast. Self-regulating parameter settings and characteristics as well as a compensatory active wirefeeder provide the necessary safety and ensure a high level of quality.

Since the wire does not continuously move back and forth during intelligent TIG cold-wire welding, even wear parts such as the torch body, torch cap, and clamping sleeve experience reduced abrasion and last longer than comparable solutions.

Ready for every challenge

The iWave from Fronius – launching in January 2022 – is an intelligent, high-end series that sets new standards in quality, flexibility and connectivity. The TIG power source enables perfect weld seams to be produced on all weldable materials. It also possesses multiprocess capability and comes with a host of innovative features. The modular system design assures a customized solution whatever your welding requirements – both now and in the future.

Fronius developed the iWave to enable the very best TIG weld quality and flawless results to be produced on different metals. The innovative Option CycleTIG provides for maximum control over the arc and targeted heat input. Further highlights include improved ignition control and greater ease of use with intuitive operation. Whether welding pressure vessels, pipes or the most demanding requirements in medical technology and food & drink production – in fact, all applications where avoiding pores and temper coloration is critical – the iWave is the perfect choice. The series is available as of now in power categories 190 A to 500 A.

Universal solution with Multiprocess PRO

Multiprocess capability is important if you are switching between different welding tasks on a day-to-day basis. The new iWave really proves its worth here with sophisticated TIG technology and is ideally suited for manual metal arc welding – even with cellulose electrodes. The Multiprocess PRO option is a real winner, giving the user unlimited access to all MIG/MAG processes in power categories from 300 A. This makes the iWave a multi-talented all-rounder producing outstanding welding results with all welding processes.

Flexible, customizable and future-proof

"The iWave provides flexibility in that customers can individually choose the specific functions they actually need from a range of modular Welding Packages. The customer also has the assurance that they can add to the range of functions as and when needed", reveals Manuel Rumpl, Head of Strategic Product Management at Fronius International GmbH. Starting with standard TIG or standard MIG/MAG applications, the iWave enables upgrades to the full Fronius range, including the Cold Metal Transfer (CMT), Pulse Multi Control (PMC) and Low Spatter Control (LSC) Welding Packages.

Bluetooth, WLAN and NFC as standard

The iWave supports the main communication standards and is ready for Industry 4.0. Modern wireless connections give welders greater freedom and security, allowing them to exploit the full potential of the device. Peripheral devices, such as remote control or the high-tech Vizor Connect welding helmet, can be wirelessly connected via Bluetooth. WLAN enables communication with other devices in the same network so the user can enjoy a whole host of digital advantages, such as central user management, real-time data transfer and rapid updates.

Energy efficiency and long service life

Fronius has really gone the extra mile in the iWave series, combining resource-conserving know-how with rugged, durable design. It is the first TIG power source on the market with a Real Energy (kJ) display and analysis feature. In addition, Power Factor Correction (PFC) provides for efficient energy consumption and no-load power consumption is always below 50 W.

Before a Fronius welding system can get the go ahead to enter production, it is subjected to a battery of load and endurance tests that it must pass. These tests go way beyond the standard requirements, and are the key to why our systems enjoy such a long service life. Moreover, in the event of servicing, the service-friendly design means the main components can be replaced with ease.