1、Process Introduction | What problems can gas shielded welding solve?
High speed deposition: solid wire with a diameter of 1.2 mm, with a deposition rate of 5 kg/h at a current of 300 A, which is three times faster than manual arc welding
Thin to thick plate: 0.8mm automotive plate -60mm thick plate with multiple layers, fully covered by one device
Low spatter: pulse/dual pulse mode, spatter amount ≤ 1 g/min, almost no cleaning after welding
All position: robot six axes+external axis, programming for flat, horizontal, vertical, vertical, and circumferential seams in one go
Wide range of materials: carbon steel, stainless steel, aluminum, copper silicon alloy, heterogeneous steel (Q355+304L) can be formed in one go
2、Capabilities
| Item | Parameter |
|---|---|
| Maximum Workpiece Size | 3500 × 1500 × 800 mm (Robot Arm Reach) |
| Plate Thickness Range | 0.8 mm – 60 mm (Multi-pass) |
| Weld Type | Butt, Fillet, Lap, Circumferential, 3D Curved Seam |
| Welding Position | All-position (Flat, Horizontal, Vertical, Overhead, 360° Circumferential) |
| Surface Quality | Free of pores & undercuts, Ra ≤ 2.5 µm, Paint-ready |
| Batch Capacity | 1 – 100,000 pieces/batch, 24-hour continuous operation |
3、Our Equipment
Fronius TPS 500i Pulse + FANUC M-20iA
500 A pulse/double pulse, carbon steel/stainless steel 0.8-8 mm, splash ≤ 1 g/min
Lincoln Power Wave S500 + KUKA KR30 HA
High speed pulse, aluminum magnesium alloy 1-12mm, robot repeat ± 0.02 mm
MAG Robot Island 3 × 500 A Double Wire
60mm thick plate with multiple layers and passes, with a 40% increase in cycle time, suitable for construction machinery boom
CO ₂ Handheld car 350 A × 6 sets
Prototype welding repair, first piece verification for large orders, real-time current/voltage acquisition
4、Gas Shield Welding Case Studies | Typical Application Cases
Material: Q355B hot-rolled plate with a diameter of 4mm and a diameter of 400mm
Weld seam: outer circumferential seam docking, single-sided welding, double-sided forming
Process: MAG pulse 280 A, 80% Ar+20% CO ₂, robot speed 0.6 m/min
Result: Melting depth of 4.5 mm, no undercutting, X-ray grade I film rate of 99%, monthly production of 50000 pieces
Material: 6061-T6 extruded profile 3 mm
Weld seam: continuous corner joints on all sides, with a total length of 1.8 meters
Process: Double pulse 220 A, Ar+He mixed gas, interlayer temperature ≤ 80 ℃
Result: Deformation ≤ 0.3 mm, helium leak detection ≤ 1 × 10 ⁻⁶ Pa · m ³/s, batch of 800000 pieces with no leakage
Material: Q690D high-strength steel 40mm, double-sided groove
Process: MAG dual wire 500 A+400 A, multi-layer and multi pass, robot swing 3 mm
Result: -40 ℃ impact ≥ 47 J, tensile strength ≥ 690 MPa, saving 25% of welding materials
5、 Gas and energy consumption
80% Ar+20% CO ₂: Carbon steel/stainless steel, with minimal spatter and bright welds
Ar+He 30%: Aluminum magnesium alloy, deep melting+no porosity
Pure CO ₂: Low cost thick plate, slightly higher splash, suitable for 60mm multi-layer base coating
Energy consumption: Robot+power supply of 8 kW, saving 30% compared to manual welding of the same specifications
6、 Quality and traceability
ISO 15614-1 MAG Welding Process Certification
Online laser weld seam tracking: real-time compensation for width and offset, automatic marking of defects
QR code engraving: furnace number+welder number+current/voltage/speed, scan the code for full traceability
Each batch: first piece profile+stretching+bending, mass production 10% appearance+ultrasonic sampling
AddressNo. 66 Xingpu Road, Lujia Town,Kunshan City, Factory Buildings 3 and 4 
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