Case Study: Salzburger Aluminium Group achieves precise seam tracking and reduced rework with Fronius WireSense

SAG reduces welding rework with Fronius WireSense and CMT

The Salzburger Aluminium Group (SAG), a manufacturer of lightweight vehicle components, faced a challenge with welding inaccuracies caused by component deviations. These variations in clamping tolerances risked losing the ideal welding position, potentially leading to a lack of fusion in their welds. To solve this, SAG opted for Fronius technology, specifically the WireSense assistance system used with their TPS/i Robotics PushPull welding machine.

Fronius implemented its WireSense solution, which uses the wire electrode itself as a high-frequency sensor to scan the component and track the weld seam path. This system allows the robot to detect misalignments and react to deviations by correcting the robot's program in real time. For SAG, this resulted in a practically spatter-free process with low heat input and a significant reduction in rework, ensuring their high quality standards for products like helium-tight air pressure tanks were met.

Salzburger Aluminium Group (sag)