DeltaSpotResistance Welding

GENERAL REMARKS

And with DeltaSpot, that’s just what we’ve done

“Shifting the limits” is our credo. And we’ve definitely

lived up to this challenging motto again with DeltaSpot.

The absolutely innovative thing about this resistance-

welding process is its spooling process tape, and it is

this which gives the process its improbable-sounding

advantages: Every weld-spot is 100 % reproducible;

every spot is, so to speak, welded with an unused

electrode; high, indeed unrivaled process reliability;

zero surface spatter; any type of join is possible, even

aluminum to aluminum or steel to aluminum. As so often

with great innovations, the principle is simplicity itself.

So you can look forward to getting results that will

“knock spots off” the competition.

PROCESS

Process reliability that’s “got it taped”

The relatively simple yet so radically new principle

behind this process is the spooling process tape. This

runs between the electrode and the workpiece. After

every spot, the process tape spools on to its next

position. This means that the contact surface always

stays clean. Spot for spot, identically high-quality

conditions for starting the process. Spot for spot, a

“new” electrode. This is what makes the quality so 100 %

predictable. The surface of the electrode itself stays

clean no matter how long it is in use. Depending on the

application, you can expect to get up to 21,000 spot-

welds per tape.

Boundaries are there to bestretched: For us, at any rate

The process tape infl uences the heat balance, with the result that a lower welding current is needed. This means that power sources with a

comparatively low power rating can be used for DeltaSpot. Also, the process tape actively infl uences the position of the weld nugget: despite

differing material resistances, all the sheets are welded.

The process tape protects the

electrode from alloying effects

and provides constant, high-

quality starting conditions. Spot

for spot, a “new electrode”.

WELDING PROPERTIES

“Top Gun” with the C-pincer

The C-pincer gun is a powerful addition to the pincer

gun range, complete with all the familiar advantages of

DeltaSpot. Among the merits of the C-pincer gun are

its high contact pressure and the good accessibility

it allows for special component geometry. It welds

challenging 3-sheet joints with complete process-

reliability, and the high electrode force of 8 kN ensures

good spot-welded joins even in the case of super-high-

strength steel bimetal joins.

Keeping disturbance variables to a minimum

There are certain disturbance variables that are very

common in resistance spot welding. Electrode wear, a

shunt, and batch-related differences in the materials

and coatings are all typical disruptive factors. Here

too, DeltaSpot is different from other resistance spot-

welding systems. The unique process tape is able to

greatly minimize the effects of these disruptive factors.

The vertical electrode manipulation performed by the C-pincer gun is ideal for visually exposed spot-welds using the Expo

electrode. Use of the Q-Master quality assurance system is also possible, of course.

UTILIZATION

All-rounders

DeltaSpot opens up hitherto undreamed-of

perspectives in many different sectors. It can weld

any material: Steel and coated steel, both high and

super-high-strength; aluminum, chrome-nickel,

titanium, magnesium, bimetal joins, steel/aluminum-

joins. As well as joining materials of differing

thicknesses and types, DeltaSpot also welds multi-

sheet joins, with complete process-reliability.

Through thick and thin

DeltaSpot works with all metallic materials. 3-sheet

joins between different materials, thick or thin, can

be welded with just the same high process-reliability

as aluminum to aluminum. And resistance-welding

joins of aluminum have always been a high art

in themselves. In multi-sheet joins, the different

materials and sheet thicknesses encountered here

cause different material resistances to occur. The

choice of process tape can be “fine tuned” to take

account of these dissimilarities.

“Spot-on”, every time

3-sheet join between different steel alloys (1.8 mm / 1.75 mm / 1.0 mm = 0.071” / 0.069” / 0.039”)

Material: H400 1.8 mm (0.071”) / DX 53 D + Z 140 MB;

1.75 mm (0.069”) / DX 56 D + Z 140 MB 1.0 mm (0.039”)

Electrode: R+70

Process tape: plus PT1200, minus PT3000

Parameters: 8kA 500ms 4kN

Aluminum 3-sheet join(3.0 mm / 2.0 mm / 1.0 mm = 0.118” / 0.079” / 0.039”)

Material: AlMg3 3 mm (0.118”) / AlMg3 2 mm (0.079”) /

AlMg3 1mm (0.039”)

Electrode: R+70

Process tape: PT1407

Parameters: 17kA 700ms 4kN

Super-high-strength steel 2-sheet join(1.35 mm / 1.35 mm = 0.053” / 0.053”)

Material: 22MnB5 1.35 mm (0.053”) / 1.35 mm (0.053”)

Electrode: R+70

Process tape: PT1200

Parameters: 7.0 kA 590ms 3.6 kN

Suitable for any utilization

By developing several different pincer guns, Fronius

has opened up a much wider variety of utilizations.

The DeltaSpot pincer gun’s many different welding-

throat depths make for superior weld accessibility in

widely varying areas of utilization. In the automotive

and supplier industries, for instance, where it ensures

welding with complete process-reliability. Or for

highly demanding spot-welded joins in the mechanical

engineering, plant construction or railed-vehicle

construction fields.

MaximumDesignation Throat depth electrode force Weight

BASIC DESIGN OFPINCER GUN

X350 350 mm 7 kN 102 kg

(13.8”) (225 lb)

X500 500 mm 5 kN 106 kg

(19.7”) (234 lb)

X750 750 mm 3 kN 116 kg

(29.5”) (256 lb)

C300 300 mm 8 kN 120 kg

(11.8”) (265 lb)

Every spot is documented

immediately after welding, and

inspected for quality, diameter,

size, spot-position and spatter,

providing a seamless, traceable

data record.

QUALITY ASSURANCE

Controlling with Fronius Xplorer

This software was specially developed as an easy-

visualization tool for administering networked and

automated production areas, and for operating,

monitoring, documenting and diagnosing them on

a centralized basis. Any number of systems can be

controlled from a master control station. When it comes

to user-friendliness, Fronius Xplorer is hard to beat.

For ease and speed of handling, Fronius Xplorer is also

touchscreen-capable, of course.

Inspecting with DeltaSpot Q-Master

DeltaSpot Q-Master is a brand-new quality assurance

system developed specifically for DeltaSpot. Automated

and cost-effective. Q-Master can completely replace

the usual destructive testing methods. 100 % inspection

is possible at only minimal extra expense.

DeltaSpot Q-Master photographs and measures

each individual spot, by which we mean every single

“fingerprint” on the tape. The camera that does this sits

directly on the pincer-gun arm.

Fronius Xplorer is very easy indeed to operate: For example, the program

lets you create ideal curves for certain characteristics not only by keying in

exact figures, but also completely intuitively, by drawing the curve yourself.

SYSTEM

Versatile configurability

One of the big advantages of DeltaSpot is that it is

a perfectly matched, interoperable welding system

comprising various different components. These

include the pincer welding gun and the gun control. Any

standard medium-frequency inverter can be used as the

welding power source. The mechanical and electrical

interfaces enable the DeltaSpot system to be flexibly

connected to all common types of robot and field-bus

systems.

Example of a DeltaSpot system

1. DeltaSpot pincer gun

C- or X-pincer gun using medium-frequency

technology (1000 Hz).

2. Pincer-gun control

With its graphic user interface, the pincer-gun control

makes it easy to create the welding parameters.

3. Medium-frequency inverter

All common MF inverters with analog addressing

can be used here.

4. Water heat exchanger

Cooling unit for cooling the pincer-gun arm and

the MF transformer.

FACTS

Process characteristics

- process tapes protect the electrodes and

the materials to be joined

- 100 % reproducible weld-spots

- spatter-free spot-welding, with complete

process-reliability, even of 3-sheet joins

between different types of materials and

thicknesses of sheets

Recommended base metals

- steel, coated steel, high and

super-high-strength steels

- aluminum materials

- CrNi steel, titanium, magnesium

- bimetal joins, e.g. steel-to-aluminum

Customer segments

- automotive and supplier industries

- mechanical engineering and plant

construction

- construction of rail vehicles & rolling stock

ECONOMY

Surface spatter:None, zero, null, ninguna, nessuno

DeltaSpot leaves no surface spatter on the material. Both

the weldment itself and the working environment stay

clean, and there is no need for laborious cleaning of the

workplace. Nor, in most cases, is any post-weld machining

of the workpieces needed.

Welding on narrow flanges

An electrode specifically developed for use on flanges

provides superior weld accessibility, making it possible to

reduce the flange width by as much as 40 %. This means

that less base metal is needed and that the entire weldment

can be lighter. The process tape lessens wear-and-tear on

the electrode, ensuring long electrode service life.

Invisible with the Expo electrode

For visually demanding applications, the Expo electrode

has been developed. This is arched towards the inside

rather than the outside. Thanks to this special shape, the

base metal has sufficient space in which to expand before

regaining its original shape after the end of the joining-

process. The result is that the electrode indentation on the

workpiece disappears to almost nothing – and in turn, so

does the post-weld machining: there is no longer any need

to regrind the join. The Expo electrode is suitable for all

metallic materials such as aluminum, CrNi, steel or special

metals.

The special shape of the Expo electrode makes for minimal

electrode indentation.

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FRONIUS USA LLC10421 Citation Drive, Suite 1100Brighton, Michigan 48116, USA

Tel: +1 810 220 4414Fax: +1 810 220 4424

E-Mail: sales.usa@fronius.com

FRONIUS INTERNATIONAL GMBHBuxbaumstrasse 2, P.O.Box 264

A 4602 Wels, AustriaTel: +43 7242 241-0, Fax: +43 7242 241-3940

E-Mail: sales@fronius.com

www.fronius.com

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FRONIUS CANADA LTD2875 Argentia Road, Units 4,5 & 6 Mississauga, ON L5N 8G6, CanadaTel: +1/905-288-2100Fax: +1/905-288-2101E-Mail: sales.canada@fronius.com

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