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MIG CMT spot welding aluminum

Posted: Wed Dec 10, 2014 8:44 am
by mazurzator
Hi all, Im new here Im from Poland, I work in automotive corp and I've got big problem with welding aluminum.
I weld 3003 aluminum details 2,5 and 1,25mm thickness using MIG CMT Advanced by Fronius Austria (TPS 4000), welding wire is 1,2mm ER1100 (made in Italy). Shielding gas pure Argon (local network) Manipulator is an ABB robot IRB 1600ID.
Signal for welding start and welding end comes from robot, welding machine is set for S2-step mode. I make spot welds (tack) with time 0,3 sec per one joint. Proces is very robust when is working, but occasionally process stops. Occasionally – I mean I’ve got 2 tables on each 4 assemblies, each assembly requires 4 spot welds so 16 spots total on 1 table, rotation and so on. Ocasionally means that there is no repeatability in failure. Welding machine gives error code regarding wire feeding: wire stick to end tip, or wire buffer empty. All errors comes from wire and wire feeder. But in fact there is no wire problems, it runs smoth (after error stop) through the end tip. I had Fronius guys in our company but they did not succeed.
Wire stick out is set for 12-13mm, total welding high is 20mm above the detail. I know I should have clean components but ours are not so clean - there is a thin film of oil on it and what’s worse - not always. Welding machine has a lot of options, so far I checked almost all without success. I also simplyfy the robot movement to maximum but without effect. If you have any advises please let me know. Thank you in advance. Best Regards
mazurzator

Re: MIG CMT spot welding aluminum

Posted: Wed Dec 10, 2014 8:50 pm
by Otto Nobedder
mazurzator,

That Fronius machine is top-drawer according to everyone who's discussed it.

We have a member, ESSENTI, (in Italy, I think) who may be able to give you solid advice specific to that machine.

Steve S

Re: MIG CMT spot welding aluminum

Posted: Tue Dec 16, 2014 7:26 pm
by Superiorwelding
I have a Fronius TransSynergic 4000 with CMT set up. I do not have experience with the robot but here are a few questions from my limited exposure to these machines. Which liner set up do you have? If you have the teflon or graphite liner, do you have it tapered on the ends like Fronius recommends? Do you have the center bore or taper bore tips in the robot? And do you have a wire straightener installed? I have had the same of similar codes come up on my machine when something was not right. I am running .045 ER70S-6 through mine and actually had a small kink in the wire I assume from the factory when one code came up. Not sure how much I can actually help but I can ask around to try to help as well.
-Jonathan