Engineering company Fronius leverages its expertise in welding to enhance the metal 3D printing process. The company has developed CMT Additive Pro, a 3D-optimized welding process with an even layer structure.
CMT which stands for Cold Metal Transfer is a stable, easily controllable, and comparatively cool welding process, Fronius has been providing industries for decades. It therefore makes perfect sense for the company to enhance this process for metal 3D printing.
Fronius CMT Additive Pro consists of an integrated arc-on rate stabilizer which ensures a consistent wire speed, resulting in an even and predictable build-up of layers. This significantly improves the overall stability of the manufacturing process.
Philipp Roithinger from Fronius International GmbH explains, “The right welding path with the right welding parameters and processes is crucial for a good result in metal 3D printing. However, this requires a high-performance welding system that precisely ensures the accuracy of the welding torch. The new iWave Multiprocess Pro combined with the Fronius CMT Additive Pro feature is optimized for metal 3D printing.”
“Another innovation is the adjustable heat input, which ensures consistency in the height and width ratio of the bead, regardless of the current temperature of the base material or the previously welded layer. Weld layers usually become wider and flatter as the component heats up. The power correction feature counteracts this so that identical welds can be stacked on top of each other, layer after layer,” adds Roithinger, an expert in Additive Manufacturing at Fronius.
According to the team, the start of the weld within the construction process is another important criterion for metal 3D printing. Welding errors or cambers in the area where the weld was started can affect the quality of the result.
Fronius has the perfect solution to this with the Pulsed Hot Start function, which simultaneously achieves sufficient penetration and a constant layer height by starting welding within the pulsed arc. The whole process is controlled automatically, so no extra settings are necessary.
At the prototyping center, Fronius offers tailor-made solutions developed specifically to meet individual user needs in Additive Manufacturing processes. From the first stage of consultation & feasibility trials to the last phase of development & parts manufacturing, every step is accomplished in close quarters with high discretion in the client’s knowledge.
The ultimate goal is to reduce the process of time-to-market & completely incorporate modern technology during the project execution. The expert assistance during initial prototype creation will allow a seamless entrance into the Additive Manufacturing arena.
Also, you can check for valid suggestions on the welding process, prototype charge, built quality & implementation procedures during the initial stages of production. The 900 m² prototyping center in Wels, Austria has multiple isolated robot cells & systems that provide end-to-end services such as offline programming & simulations, metallurgical investigations, 3D component alignment, data documentation & more.
The company will showcase its solutions this year at Formnext in Frankfurt am Main, Stand C99, Hall 12.0 from November 19 to 22, 2024.
Author: Nagarjun M
Remember, you can post free-of-charge job opportunities in the AM Industry on 3D ADEPT Media or look for a job via our job board. Make sure to follow us on our social networks and subscribe to our weekly newsletter: Facebook, Twitter, LinkedIn & Instagram! If you want to be featured in the next issue of our digital magazine or if you hear a story that needs to be heard, make sure to send it to contact@3dadept.com.