To permanently increase the welding speed, it is necessary to do more than just weld faster: it is crucial to coordinate the entire welding process so that quality, safety and productivity are optimally matched. This is precisely where the strength of automation comes into play, because with well thought-out welding technology and the right strategies, cycle times can be reduced while at the same time producing resilient weld seams. Find out what else is important when it comes to increasing welding speed.
Basics: How welding speed affects quality
During welding, the welding speed directly influences the heat input, the penetration, the behavior of the weld pool and therefore the overall quality of the welded joint. One example: If you work too slowly, too much heat enters the workpiece. This can quickly lead to deformation or a wide seam pattern in sheet metal and other components - in the worst case, it can even lead to a decrease in process stability. If, on the other hand, welding is carried out too quickly, the energy is often no longer sufficient for a clean fusion. There is then a risk of pores, lack of penetration or other unwelcome forms of welding defects.
The optimum speed therefore always depends on several interrelated factors. These include the material, the sheet thickness and thermal conductivity, the welding process and the welding positions as well as the arc length and the shielding gas used. Last but not least, the mechanical properties of the material and the surface with any coatings also play a role. All of this shows that the correct welding speed is always the result of a carefully coordinated overall process.
Increase welding speed using process parameters
If you want to increase the welding speed, it is best to start simply: with a sober analysis of the existing process. How high are the current, voltage, wire feed, gas quantity and arc length? How does the arc behave? How strong is the heat input? And where do most reworking or problems with welding defects occur in the current process? Only when you have checked this initial situation can the welding process be specifically improved on this basis.
In practice, the current, travel speed and wire feed are usually increased gradually. This allows the performance of the system to be increased without immediately compromising the quality of the seam. Continuous monitoring is important here: every adjustment must be observed and then evaluated. This is because even small changes in current or pressure in the gas flow can have a negative effect on the weld pool, the seam surface and ultimately on the entire welded joint. Modern systems with intelligent control give you a clear advantage here, as they continuously document the parameters.
Current, voltage and wire feed - what you need to consider
- Increase the wire feed: More wire feed generally leads to a higher current and therefore a higher deposition rate - this can increase the welding speed and productivity.
- Adjust the tension: The tension must match the increased wire feed. If it is too high, the seam will be too flat and wide; if it is too low, the arc becomes unstable and the risk of notches or uneven seams increases. The current-voltage-wire ratio must always be correct.
- Check arc length: An arc that is too long makes process control more difficult; one that is too short can cause spatter, unstable behavior of the weld pool and poor fusion.
- Document and standardize parameters: If the settings are properly documented and employees are trained accordingly, reliable and repeatable welding parameters can be defined for different workpieces, sheet thicknesses and welding positions.
Select shielding gases, cored wires and consumables specifically
In addition to the machine parameters, shielding gas, filler materials and consumables also have a major influence on the welding speed. For example, argon or argon-helium mixtures are often used for MIG and TIG welding of aluminum. Argon ensures a smooth and stable arc, while helium improves heat transfer. Shielding gases containing helium can therefore significantly increase the welding speed in certain applications - in some cases even doubling it - because they create a deeper penetration and therefore also enable concentrated energy input.
The choice of welding wire is also important: while solid wire is used in many standard applications, flux-cored wire is often advantageous for thicker sheets as it achieves a higher deposition rate. This means that more material can be inserted in a shorter time. Keyword material: High-quality wires, gases and wear parts improve process stability and thus reduce typical welding defects such as pores, spatter or incomplete fusion. This is why it is often the case that those who save on material quality often lose time due to rework, rejects or additional quality checks.
Improve welding thanks to powerful welding machines
The greatest effect when increasing the welding speed is often achieved where manual work is supplemented by mechanized or automated processes. Modern welding machines or robot systems work with a particularly high level of repeat accuracy, with a constant feed rate and reliable process control. As a result, automated welding robots can produce components up to 2.5 times faster than human welders. This increases the speed and, at the same time, the consistency of the results.
At Schnelldorfer Maschinenbau, we know how important good welding machines are. That's why our LINEARWELD series includes machines that are specially designed for straight, reproducible seams on sheet metal, pipes and profiles, combining high quality with high productivity. Depending on the version, workpiece lengths of up to 4,100 mm and sheet thicknesses of up to 15 mm can be processed, while the entire welding process is constant and controlled - thanks to intelligent control, stable frame construction, reliable cooling and precise torch guidance.
Short arc and pulse processes for higher speed
Advanced techniques such as pulse welding, short arc or modern pulse processes help to control the heat input in a targeted manner - and thus also play a role in higher welding speeds. This is particularly important for thin sheets or sensitive materials, as it reduces deformation. At the same time, the weld pool is more stable thanks to the pulsed arc and you have better control over the droplet transfer and less spatter. This makes the entire process smoother, cleaner and ultimately faster.
In many applications, MAG pulse welding can also achieve a welding speed that is around 20 percent higher. In pulse welding, the current is modulated in a targeted manner. This stabilizes the droplet transfer considerably. Welders can therefore also look forward to significantly smoother and faster welding with a consistently clean seam appearance. So if you want to develop a good strategy for improved welding speed, you should consider the processes and points mentioned above from the outset.
Workpiece preparation, welding position and technology
A fast welding process does not just start with the ignition of the arc. The foundation for this is laid during the preparation of the workpiece. To ensure that the welding process is stable and efficient, these three points need to be right:
- Clean edges and cleaned surfaces without oil, rust or dirt
Contamination or coatings interfere with the gas coverage and can significantly impair the fusion. This increases the risk of pores or other welding defects.
- Precise gap dimensions so that the arc can work evenly
Gaps that are too large or uneven often result in an unstable weld pool, insufficient penetration or uneven seams. The components will only fuse together cleanly with a uniform gap size.
- Stable and reproducible joining positions of the components
Unfavorable positions make it difficult to control the weld pool and often lead to slower travel speeds. Rotary and tilting tables provide a remedy here: they bring the workpiece into an optimum position, which significantly improves the deposition rate and welding speed.
Avoid welding defects: Root cause analysis and prevention
If you want to increase the welding speed, you must not lose sight of possible welding faults. Typical problems include
- porosity
- cracks
- Insufficient merging
- Splash formation
- Uneven seam geometry
- Burn-in notches
In many cases, the causes lie in parameters that have not been optimally adjusted, but sometimes also in inadequate workpiece preparation or unfavorable gas routing. An incorrect arc length or a lack of operator training can also quickly destabilize the process.
Systematic fault analysis has proven its worth here: First, the seam appearance is evaluated, then the parameters, filler materials, gas flow and welding position are checked. If there are any anomalies, the process should not simply continue, but the source of the fault should be eliminated. This creates a solid basis for stable, fast and economical welding processes.
Quality control and process monitoring
The higher the speed, the higher the load - and the more important regular quality control is. The good news is that modern welding systems now automatically store current, voltage, wire feed and other process data. This makes monitoring and traceability much easier. This transparency is a real advantage, especially in series production processes, as deviations can be detected more quickly and improvements can be implemented in a more targeted manner.
Companies that further develop their welding technology on the basis of data noticeably increase their efficiency and ensure the quality of their components in the long term.
Spot checks, visual inspections and the evaluation of the seam shape also help to ensure lasting quality.
Economic efficiency: When higher welding speed increases productivity
| Factor | Effect on the process | Advantage |
| Higher welding speed | Shorter sewing times | more productivity |
| Controlled heat input | Less distortion and rework | better quality |
| Optimized shielding gas | More stable arc and deeper penetration | Higher efficiency |
| Automation | uniform processes | more reliability |
| Training and monitoring | fewer welding defects | Higher security |
Increase welding speed with Schnelldorfer Maschinenbau
Schnelldorfer Maschinenbau knows what is important when it comes to efficient welding and helps companies to increase their welding speed - without compromising on quality and safety. Our proven and popular LINEARWELD series combines precise welding technology with flexible configuration and intelligent control, embedded in a robust machine architecture. This results in reproducible weld seams with high quality, even with long components and changing production requirements. For less scatter, more productivity, greater reliability and welding technology that pays off all round.
Improve your welding speed together with us and contact us - we look forward to finding the solution that best suits your production.
Frequently asked questions about welding speed
What is the optimum welding speed?
This cannot be said in general terms. The optimum welding speed depends on the material, sheet thickness, welding process, welding position and desired penetration. The aim is always to achieve a good balance between sufficient fusion, controlled heat input and high quality.
How long does 1 meter of weld seam take?
This depends heavily on the process. With manual welding, one metre can take several minutes; with an automated welding process with optimized parameters, it is often significantly shorter. However, the speed increases considerably with mechanized or automated systems.
How many liters per minute for MAG welding?
In MAG welding, the gas flow is usually around 8 to 20 liters per minute. However, the exact value depends on the shielding gas, torch size, position and component geometry.
What happens if the welding speed is too high?
If the welding speed is too high, the penetration may be too low. The welded joint will then not be fully fused and there is a risk of pores, insufficient strength and other welding defects.
How important are maintenance and training for welding speed?
Very important. Regular maintenance of torches, nozzles and power sources prevents downtime and keeps the welding process stable. Wearing parts that are not replaced in good time can have a negative impact on the arc, the weld pool and therefore also the quality of the weld seams.
Training for employees is also important, as it improves their skills and helps them to recognize welding errors at an early stage. Well-trained personnel therefore increase productivity and simultaneously reduce costs throughout the welding process.
What role do modern high-performance processes play in welding speed?
Modern high-performance processes such as pulse welding achieve significantly higher speeds than conventional processes: Wire feed speeds of over 25 m/min can be achieved with some of them. This significantly increases the deposition rate and the material input per time.
Why is seam preparation so important in robot welding?
Clean edges, precise gap dimensions and a precisely prepared seam are important to ensure that the robot can weld stably throughout. This ensures that the welding area is heated evenly, particularly in the case of sheets and components with different sheet thicknesses, resulting in reliable fusion. The following therefore applies: good preparation reduces welding errors, improves the quality of the weld seams and increases the productivity of the automated processes at the same time.
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