Automating TIG welding means welding with maximum precision and high productivity. For decades, the TIG welding process has been the benchmark for clean weld seams with excellent seam appearance and guaranteed control over the weld pool. Automated TIG systems now enhance these quality features. For companies in industry and production, this opens up completely new possibilities in series production, in multi-shift operation and also with demanding materials such as stainless steel or aluminum. Find out here what the latest welding technology is all about.
Why automated TIG welding?
Manual TIG welding is heavily dependent on the experience and expertise of the welder. Even small fluctuations in the arc, welding speed or welding parameters affect the weld seam quality. An automated TIG welding cell works with consistent performance - the wire feed and robot control always remain constant.
As a result, automated welding significantly increases productivity: approximate welding speeds of 3 to 10 m/h can be achieved, whereas manually only 0.5 to 2 m/h are often possible. At the same time, the reject rate is reduced to less than 1 %, as all important parameters such as current, wire feed and arc distance remain constant. Automated TIG welding therefore not only improves the quality of the weld seam, but also reduces material consumption and therefore costs in operation.
Advantages of automated TIG welding
- Very high reproducible welding results
- Significantly lower reject rates
- Up to 50 % less shielding gas consumption
- 20 to 40 % less welding rod
- Longer arc time up to 90 %
Disadvantages of automated TIG welding
- High initial investment
- Larger footprint
- Programming effort
- Less flexible with frequently changing use
- Technical dependency
Cost-effectiveness and ROI for automated TIG welding
When it comes to automation, there is often the question of cost-effectiveness. For example, a robot welding cell for automated TIG applications costs between €100,000 and €300,000, depending on the design. Cobots start at around €30,000, while specialized welding systems are much more extensively equipped. The decisive factor now is capacity utilization:
Automation can therefore pay for itself from as little as 2,000 to 3,000 m of seam per year. At 10,000 m per year, amortization times of less than 12 months are even realistic. In multi-shift operation, the ROI is further reduced because, unlike employees, robots do not need breaks and therefore deliver consistent results over several hours. However, good planning of maintenance work and set-up times is important in this context, as robots cannot produce during this time.
TIG welding process: Parameters, cold wire and hot wire
The TIG welding process, short for tungsten inert gas welding, works with a non-melting tungsten electrode and a shielding gas, usually argon or helium. Typical welding parameters are between 10 and 500 A, while pulse frequencies can reach up to 20 kHz.
There are two wire welding processes: Cold wire welding and the hot wire process. In cold wire welding, the welding wire is fed into the weld pool cold, whereas the hot wire process heats the wire electrically in advance. This significantly increases the deposition rate, which increases the welding speed and makes the welding process more efficient. Both variants can be integrated into automated TIG welding systems.
Comparison: TIG welding vs. MIG/MAG welding
| Criterion | Automated TIG | MIG/MAG |
| Seam quality | Very high, finest seam appearance | Good, higher splash rate |
| Precision | Extremely precise | Good |
| Speed | Medium | High |
| Typical materials | Stainless steel, aluminum, titanium | Steel, structural steel |
| Heat input | Very controlled | Higher |
TIG is impressive in terms of precision and welding quality, while the strengths of MIG/MAG lie in speed and quantities. Many modern welding systems - far removed from automated TIG welding - therefore flexibly combine both welding processes.
Components of a TIG welding cell
- Industrial robot or cobot
- TIG welding torch with wire feeder
- Welding machine
- Welding booth with welding fume extraction
- Coolant and cooling system
- Clamping technology and welding fixtures
- Interchangeable neck burner
Programming and robot integration for TIG welding
The robot welding torch is programmed on the basis of the TCP (Tool Center Point). This must not change when replacing components on the torch system, as TIG welding has a low fault tolerance - everything should therefore be carried out exactly as planned. Programmers define the accessibility, the torch angle and the welding parameters, while the ignition and lowering sequences are tested automatically.
Typical error patterns and countermeasures
Automated TIG welding is prone to errors. The following problems occur particularly frequently:
- Gas draught in the welding booth
- Incorrect TCP calibration
- Electrode wear
- Inadequate clamping technology
A draught of air has a negative effect on the shielding gas and can cause oxidation. Ideally, you should schedule regular maintenance work and controlled electrode replacement intervals so that the system can carry out its task without faults.
TIG welding cell with Schnelldorfer Maschinenbau
One thing is certain: automated TIG welding increases your productivity, improves welding results and reduces material costs. This is particularly beneficial for industrial companies with high volumes or complex welding tasks. The good news is that with the right planning and experienced programmers, your automated TIG welding cell will quickly become a success factor in your production.
Schnelldorfer Maschinenbau develops individual welding systems and robot welding cells for automated TIG applications. In combination with powerful welding systems such as the V-RoboTIG, complete solutions are created that skillfully combine precision, performance and efficiency.
The services of Schnelldorfer Maschinenbau at a glance
- Individual planning and design of automated TIG welding cells
- Integration of welding robots, cobots and robot welding cells
- Development of complete welding systems and automation solutions
- Integration of modern welding equipment and torch systems
- Design of clamping technology and welding fixtures for tight tolerances
- Programming and optimization of welding processes
- Training of operators, welders and programmers
- Service, maintenance work and long-term technical support
- Expansions, retrofits and process optimization of existing systems
Our goal is always clear: we want to create the highest weld seam quality and productivity for you.
Let us check together how your TIG welding process can be efficiently automated - contact Schnelldorfer Maschinenbau now for a no-obligation initial consultation and take your welding technology to the next level!
Frequently asked questions (FAQ)
When is automated TIG worthwhile?
From around 2,000 to 3,000 m of seam per year or for series >500 components.
Which materials are suitable?
Stainless steel, aluminum, titanium and many other alloys are suitable for automated TIG welding.
Is TIG more precise than MIG/MAG?
Yes, the TIG welding process scores with a significantly higher seam quality with maximum control.
Do you need trained specialists?
Yes, welders and programmers need experience in handling the machine, especially in programming the robot controller.
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