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/ Battery Charging Systems / Welding Technology / Solar Electronics
Shipbuilding and offShore platformS.
/ High-quality welding systems for customised solutions.
/ Ever since 1950, we’ve been developing innovative comprehensive solutions for arc welding and resistance spot-welding. Like TransSteel, a digital welding system developed specifically for use in shipyards. Or Cold Metal Transfer. This revolutionary welding process has swept away one old prejudice: that you can’t weld aluminium and steel to one another. Day-in, day-out, we’re working at full power on our vision: to »decode the DNA of the arc«. So it’s no wonder that we’re the welding-sector’s technological leader worldwide, as well as being the European market leader.
Some convincing factS about uS:
/ Fronius is the world market leader for robot welding.
/ Fronius brings you the very latest technologies for arc welding and resistance spot-welding.
/ Fronius guarantees a perfect interplay between all the components in its welding systems.
/ Fronius offers a perfectly co-ordinated programme of service, training and support.
/ Fronius has mastery of the entire spectrum: MMA, TIG, MIG/MAG, plasma, LaserHybrid.
/ Fronius is a byword for superlative product quality, economy and energy efficiency.
What makeS uS the WorldWide technological leader:
/ Our over 650 active patents.
/ Our prowess at discovering and exploring virgin territory.
/ Our track record of turning visions into cost-saving innovations.
/ The spirit we live out in practice: insisting on quality and sustainability.
/ Developing solutions that are always a leap ahead.
4 / Fronius welding systems – the highlights
Whether it’S a Ship or an offSh getS tough, our Welding SySte
/ One thing our 60+ years of welding-technology experience has taught us is this: ‘Shift-ing the Limits’ starts with knowing all about your special wishes and needs. And then infusing these into the development of our revolutionary welding systems for manual, mechanised and automated applications. As a technological leader, we have set ourselves
high-quality Weld-SeamS/ Cracking- and corrosion-resistant welds that withstand heavy dynamic stressing – even out on the stormy deep.
individual SolutionS/ We join with our customers to develop individualised solutions – the tougher the challenge, the better!
rugged build/ Thanks to the machines’ ingenious combination of quality build and choice materials, even their toughest adversaries – like knocks and impacts – don’t stand a chance.
flexible in the field/ The machines' modular design concept and low weight make them easy to move around, greatly facilitating assignments in hard-to-get-at locations.
Fronius welding systems – the highlights / 9
100 % reproducible reSultS/ No matter what you need to weld, and where you have to weld it, all processes are fully digitised – the arc remains stable and the results are 100 % reproducible.
minimal Weld-finiShing Work/ The field-proven predefined parameters ensure that the weld-seams are of “sure-to-pass” test quality, at the same time as cutting wasteful finishing-work to a minimum.
guaranteed availability/ Dust, rain, frost, damp, harsh operating en-vironments – no matter what you throw at our welding systems, you can rely on them to shrug it off and function dependably.
ore platform: When the going mS get going!
the ambitious goal of offering you a range of products and services that is especially tailored to the building of ships and offshore platforms, and of giving you outstanding application support for the special requirements that you have. You’ll find that our unrivalled combination of offerings gives you benefits right across the board.
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5 / Practical examples
SurpriSing inSightS: What SolutionS We can offer for Which materialS and Which requirementS.
/ The following examples will show you what a wide range of applications our welding systems can be used for. And if you have a welding-engineering challenge that you can’t find here in this (simplified) cutaway graphic, then just ask us. We’ll then join with you to develop what will definitely be the right solution.
Legend: R = requirement, S = solution
crane (Steel)/ R: Extremely thick materials, multi-pass (up to 200 passes)/ S: MIG/MAG system TPS 5000
outSide of hull (Steel, With Solid Wire)/ R: Excellent gap bridgeability/ S: MIG/MAG system TransSteel 5000 (Steel Root)
repair Welding (caSting/nial bronze)/ R: Robust repairs/ S: MIG/MAG system TPS 5000
Slide bearingS of propeller Shaft (Steel, With inconel 625 filler metal)/ R: Overlay welding, extremely low dilution of base metal/ S: MIG/MAG system TPS 5000 CMT
offShore pipe joint, root (Steel)/ R: Guaranteed root fusion around entire circumference of pipe (360°)/ S: TransSteel 5000 (Steel Root)
6 mm/0.24 in
5 mm/0.20 in
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moSS-roSenberg aluminium lng tank (al alloy, 6 paSSeS)/ R: Extremely low porosity, very high deposition rate in PF position, narrow-gap/ S: TimeTwin tandem system
block conStruction (Solid Wire on Steel)/ R: Extremely low spattering, mini-mised fume formation, all positions/ S: TransSteel 5000 (Steel Prime)
valve and valve houSing (Steel, With inconel 625 filler metal)/ R: Overlay welding, extremely low dilution of base metal/ S: MIG/MAG system TPS 5000 with Fronius Automation components
panel line butt-Weld (Steel)/ R: High welding speed, minimal distortion, and no manual handling of weldments/ S: Simultaneous welding with TimeTwin tandem process (PA) and TPS 5000 CMT MIG/MAG system (PE)
panel line fillet Weld (Steel)/ R: Long seams, highly cost-efficient, high welding speed (150 cm/min, 'a' 3.5)/ S: TimeTwin tandem process
60 m
m/2
.36
in
10 m
m/0
.39
in
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block conStruction uSing fdv 15/22 (rutile flux-cored Wire on Steel)/ R: Flux-cored wire welding, multi-pass, positions: PF, PB/ S: TransSteel 3500 combined with FDV 15/22 self-travelling carriages
bridge & funnel conStruction (aluminium)/ R: Extremely low spattering, minimum distortion/ S: MIG/MAG system TPS 4000 CMT
panel line fillet Weld (Steel)/ R: Long seams, highly cost-efficient, high welding speed (150 cm/min, 'a' 3.5)/ S: TimeTwin tandem process
pipe jointS (crni/cu/Steel)/ R: Reproducible weld-seams of consistently high quality/ S: Fronius Orbital welding systems
panel line fillet Weld (Steel)/ R: Fillet weld through-welded on one side – sheet thickness 4 - 8 mm (PB)/ S: LaserHybrid with fillet-welding head 10 kW
1.6 mm/0.06 in
6 mm/0.24 in
Special applicationS, fine-grained Structural Steel (high-Strength and loW-alloy SteelS)/ R: Exceptionally low thermal input, superior mechanical-technological attributes/ S: TimeTwin tandem process
70 m
m/2
.76
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Practical examples / 8
panel line butt-Weld (Steel)/ R: Butt-weld through-welded on one side, no manual handling of weldments (PA)/ S: LaserHybrid with butt-welding head 10 kW
hull and SuperStructure (al)/ R: Time-savings: no oscillating motion needed in PF, flawless seam appearance/ S: MIG/MAG system TPS 2700 – 5000 (Syncropuls)
12 m
m/0
.47
in
additional componentS, e.g. ladderS (aluminium)/ R: Extremely low spattering, excellent gap bridgeability/ S: MIG/MAG system TPS 5000 CMT
2.5 mm/0.10 in
2 mm/0.08 in
10 / References
‘reference’ comeS from ‘preference’: exampleS of the 1St-claSS connectionS We have all over the World.
/ In deciding to develop welding systems specifically for shipbuilding and for offshore platforms, we definitely embarked on the right course. The proof can be seen in the grow-ing popularity of our well-engineered solutions, and the constantly rising worldwide demand for them – from both existing and new clients.
Stx france/ Key data: Workforce: 2200 (in 2009)/ Products: Cruise ships, ferries and special vessels/ Challenge: 1.2 – 4.5 mm thick wall plates made of Invar 8221 on LNG tankers (without burning the polyurethane foam behind the plates)/ Solution: TIG welding process with TransTig 2200 power source/ Customer benefit/conclusion: Higher productivity from fast, safe tack-welding, precision setting of welding parameters as power sources are digitally controlled
p.u.S.-Werften (formerly peene Werft) – germany:/ Key data: Turnover: approx. € 210 m. (in 2010), workforce: 1820/ Products: Oceangoing, short-sea and inland-waterway vessels up to PanMax size/ Challenge: Automated fillet welds of 3 - 5 mm thickness in the panel line, 12 m long stiffening profiles made of normal and high-strength shipbuilding steels; simultaneous joining on both sides, with four arcs/ Solution: Joining the bulb profiles using the TimeTwin Digital tandem process/ Customer benefit/conclusion: 25 % productivity increase in the panel line, 40 % reduction in thermal input leading to lower workpiece distortion, good advisory work, very good after-sales service
auStal ShipS – uSa:/ Key data: Turnover: approx. € 384.8 m., workforce: 2000 (in 2010)/ Products: Passenger and vehicle ferries, cargo vessels/ Challenge: MIG welding on a 103 m long high-speed catamaran made of aluminium/ Solution: MIG welding with TransPuls Synergic 2700/3200/4000 power sources and push-pull welding torches/ Customer benefit/conclusion: Welding systems have excellent suitability for aluminium, lower costs due to lower gas consumption, higher-quality weld-seams, very good after-sales service
References / 11
royal huiSman – netherlandS:/ Key data: 1 – 2 yachts per year; workforce: 360 (in 2011)/ Products: Building / rebuilding individually customised, top-quality sailing yachts and motor yachts of between 30 and 90 m in length/ Challenge: Weld-seam quality and appearance on aluminium hulls, superstructures, additional components and masts/ Solution: Aluminium welding using TransPuls Synergic 4000 with PT Drive/ Customer benefit/conclusion: The MIG welding system has proven ideal for meeting the requirements made in respect of these exclusive yachts, as has the good advisory work and excellent after-sales service
j & k anlagenbau – germany/ Key data: Turnover: € 14.0 m., workforce: approx. 170 (in 2010)/ Products: Shipbuilding components, aluminium funnels, cylinder heads for diesel engines/ Challenge: Shipbuilding steels, Hardox® steels, high-strength steels, and as a highlight, joining together 50 tonne aluminium funnels for e.g. the luxury cruise liner AIDA – without spattering and with no distortion/ Solution: MIG/MAG weld process with TransSynergic 4000/5000 power source andTransTig/MagicWave 3000/ Customer benefit/conclusion: Gap bridgeability from 3 – 11 mm in vertical-down position, extremely high welding-system reliability in 2- and 3-shift working, service within easy reach of customer
keppel verolme b.v. – netherlandS:/ Key data: Workforce: 350 (in 2011)/ Products: Inspection, dry dock, repair and maintenance, refitting and modifying oceangoing vessels and offshore platforms/ Challenge: Welding sponsons for offshore platforms, constructing transformer substations/ Solutions: TransSynergic 4000, TransPuls Synergic 4000 with VR 4000 Yard, TransPocket 330, TransTig/MagicWave 3000 and TransSteel 5000 welding systems with VR 5000/ Customer benefit/conclusion: Fronius is a reliable partner for high-grade welding systems that offers good after-sales service and delivers on time
brigantine ServiceS ltd – hong kong and Southern china:/ Key data: Workforce: 30 - 40 (in 2010)/ Products: Repairing marine diesel-engine components (especially valves)/ Challenge: Cladding valve tappets and valve faces, with component weights of 300 kg/ Solution: Complete automation package consisting of tilt-and-turn table, system controller, tripod, oscillation unit, TransPuls Synergic 5000 MIG/MAG welding system and Robacta Drive welding torch/ Customer benefit/conclusion: 30 - 50 % time savings on each marine valve with Fronius Automation, ultra-high quality thanks to reproducibility, maximum reliability even in multi-shift operation, very good after-sales field service
Source: Hans Westerink
SOLAR ELECTRONICS/ The greatest challenge of our timeis to make the leap to a regenerativeenergy supply. Our vision is to userenewable energy to achieve energyindependence. With our mains-connected inverters and products for monitoring photovoltaics systems,weare now one of the leading suppliers in solar electronics.
WELDING TECHNOLOGY/ We develop welding technologies,such as entire systems for arc andresistance spot welding, and have set ourselves the task ofmaking impos-sible weld joints possible. Our aim is to decode the »arc welding‘s DNA«. We are the technology leader world-wide and themarket leader in Europe.
BATTERY CHARGING SYSTEMS/ We started a technological revolutionwith Active Inverter Technology andare now one of the leading suppliers inEurope. We are driven by the aim ofproviding intelligent energy manage-ment systems that ensure mobilitystays as economically viable as possible in the twenty-first century.
Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com
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WE HAVE THREE DIVISIONS AND ONE PASSION:SHIFTING THE LIMITS.
/ What Günter Fronius started in 1945 in Pettenbach, Austria, has now become amodern day success story. Today, the company has more than 3,000 employees worldwide and owns 737 active patents. Since the very beginning, our goal has not changed: to be the technology and quality leader. We shift the limits ofwhat‘s possible. While others progress step by step,we innovate in leaps and bounds.
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Fronius International GmbHFroniusplatz 14600 WelsAustriaTelephone +43 7242 241-0Fax +43 7242 [email protected]
Fronius USA LLC10421 Citation Drive, Suite 1100Brighton, Michigan 48116USATelephone +1 810 220 4414Fax +1 810 220 [email protected]
Fronius Canada Ltd.2875 Argentia Road, Units 4,5 & 6 Mississauga, ON L5N 8G6Canada Telephone +1 905 288-2100 Fax +1 905 288-2101 [email protected]
