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 Author: Christian Aitzetmüller, Welding Torch Product Manager in the Business Unit Perfect Welding at Fronius International GmbH

 The welding torch is the ultimate tool of the trade for a welder. Professional welders can expect to have it in hand all day long, frequently with a need for extended arc times and a high degree of robustness. Whereas, delicate TIG welding work demands featherlight, flexible action from the torch – like an artist guiding a fine brush. Very different demands are placed on the welding torch, depending on the application and part. At the same time, it must be easy and comfortable to use, to suit the personal preferences of the welder.

Insert and rotate – swapping the torch body is quick and straightforward with the Multilock System.

Costs in time and money for different torch systems

A welder might typically need to move from welding a fillet weld that is easily accessible to – immediately afterwards – welding an angled part. In the past, the question for the welder would often be whether to accept sometimes awkward handling of the welding torch due to the changed component accessibility, or instead to change the entire hosepack to get better weld properties. The first approach means loss of valuable time, while the second means a big investment on the part of the business in acquiring a range of torch systems, all of which come with extra storage and maintenance costs.

The wide choice of torch bodies (shown here for TIG) ensures ideal accessibility for all part geometries.

The solution: modular system with Multilock

The modular TIG and MIG/MAG welding torches from Fronius provide a solution for varied manual welding challenges and considerably reduce time and effort spent on changing bodies. Torch bodies of varying lengths and angles can now be swapped with ease, so that one welding torch and hosepack form the base for different components such that all welding tasks are covered.

More than 40 different torch bodies are available to choose from for TIG welding and over 80 for MIG/MAG. These also include flexible torch bodies that can be individually bent to shape. The welder simply presses and turns the torch body to release it from the hosepack: absolutely no tools are needed. The new torch body is then locked in place by inserting and rotating it. The system works with both gas-cooled and water-cooled devices.

Durable torch system: reparable and with a long service life

The Fronius Multilock System also proves its worth in the event of a fault: if the hosepack is unaffected, but the torch body is damaged, each component can be independently replaced in next to no time using the Multilock connection. Moreover, spare parts are always available from Fronius. Consequently, a modular torch system not only provides greater flexibility, it also enables resource-conserving and sustainable use of the system.

The extremely long service life of the welding torch components also plays a part here. Fronius designs its wearing parts to enable optimal heat dissipation, significantly extending their life. For instance, Fronius uses a high-quality copper alloy for contact tips, and the outer tubes for the MIG/MAG torch body are made from stainless steel, while the hosepack components also feature high-quality materials.

The torch body and operating elements can be swapped on the modular MIG/MAG welding torch system – all that is needed for the installation of a Multilock welding torch is a Multilock shielding gas hosepack.

Welding fume extraction for enhanced workplace safety

When designing the welding torch, the developers at Fronius not only had their sights set on flexibility and ease of repair. Promoting safety for welders was, if anything, an even greater consideration. As a result of their efforts, the modular MIG/MAG welding torch system can now easily be upgraded to function as a fume extraction torch. The FumeEx kit is compatible with all TPS/i-MIG/MAG welding torches from Fronius. It ensures that welding fumes are extracted at the point at which they are generated.

Fronius supplies flexible torch bodies for both MIG/MAG and TIG that can be individually bent to shape, enabling their use for situations where part accessibility is particularly challenging.

Maximum ease of use and handling for the welder

The developers were also focused on enabling easy, comfortable, and ergonomic handling as far as possible: non-slip, soft components on the handle ensure a secure hold for the new welding torch generation. The ergonomically shaped handle protects the hand musculature from early fatigue. In addition, the ball joint between the torch and the hosepack plus the soft materials used for the hosepack enable effortless, flexible handling.

Welders can also choose between different operating elements depending on personal preference. The Up-Down rocker switch or the rotatable potentiometer make it easy to control the amperage, while the JobMaster function makes it possible to select and activate saved parameters (jobs) on the power source using the welding torch. This function is especially useful if the power source is not within hand reach – such as in the case of repair and installation work. Finally, even the control module can be replaced, should the welding requirements change.

The FumeEx extraction kit can be fitted to any TPS/i MIG/MAG welding torch. It acts by extracting the welding fumes immediately behind the gas nozzle – without affecting the gas shroud around the weld pool.

Business Unit Perfect Welding

Fronius Perfect Welding is an innovation leader for arc welding and a global market leader for robot-assisted welding. As a systems provider, the Fronius Welding Automation division also implements customized automated complete welding solutions, for the construction of containers or offshore cladding for example. The range is rounded off by power sources for manual applications, welding accessories, and a broad spectrum of services. With more than 1000 sales partners worldwide, Fronius Perfect Welding has great customer proximity.

Fronius International GmbH

Fronius International GmbH is an Austrian company with headquarters in Pettenbach and other sites in Wels, Thalheim, Steinhaus and Sattledt. With 5,440 employees worldwide, the company is active in the fields of welding technology, photovoltaics and battery charging technology. 93% of its products are exported through 34 international Fronius subsidiaries and sales partners/representatives in over 60 countries. With its innovative products and services and 1.264 granted patents, Fronius is the global innovation leader.

Fronius UK

Fronius UK, a subsidiary of Fronius International, provides the UK welding market with solutions for MIG/MAG, TIG, electrode, laser, plasma and resistance spot welding and automation. Its new state-of-the-art facility in Milton Keynes extends over 30,000m2 and houses the Tech Support team, the Repair Center, a warehouse and a training area and epitomises the importance of being able to deliver a first-class service to customers.

Fronius UK, a subsidiary of Fronius International, provides the UK welding market with solutions for MIG/MAG, TIG, electrode, laser, plasma and resistance spot welding and automation. Its new state-of-the-art facility in Milton Keynes extends over 30,000m2 and houses the Tech Support team, the Repair Center, a warehouse and a training area and epitomises the importance of being able to deliver a first-class service to customers.

Sales and service teams, both at head office and regionally, ensure that customers are supported as quickly as possible on their own premises. In addition, customers benefit from services such as calibration, a warranty extension and a maintenance contract.

For decades, Fronius has made significant contributions to advances in welding technology. The company is still in family ownership and its welding technology division is now one of the world’s technology leaders in the arc welding market segment. It is also the market leader in Europe.

Welding Technology is one of three Fronius divisions. Since the 1940s, Fronius has been creating technologies and solutions for monitoring and controlling energy in battery-charging systems, and since 1992 the same in solar electronics. The mains-connected inverter, the unique Fronius Service Partner programme and products for monitoring photovoltaic systems make Fronius one of the leading suppliers in the field of solar electronics.

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