Greater productivity is the ultimate goal in almost any fabrication setting. Even if the required quality standards are being met, going slow is not an option. This reasoning applies to the manual welding that takes place on construction sites, pipelines, shipyards, and in automotive and heavy fab industries. One area where companies can look to find productivity improvements is in their MIG welding processes and equipment.
pressing the torch trigger. The wire feeder can be located on a crane for welding in
challenging environments.
To achieve strong, reliable welds in these tough, challenging environments, it helps if the power sources, welding torches and wire feeders feature advanced technologies and capabilities. The wire feeder, in particular, must deliver a steady, stable supply of welding wire to ensure high-quality welds. Furthermore, a good wire feeder enables welders to work without interruptions, minimizing downtime and enhancing productivity.
Dual feeding
One way to increase wire feeding productivity is to use a dual-wire feeder over a single-wire feeder, which gives the welder access to two welding setups. When meeting and exceeding deadlines is the goal, the dual-wire feeder can be a big timesaver.
“With a dual-wire feeder, the welder has the flexibility to have different filler metals and different wire diameters for the task at hand,” says Shaun Relyea, head of tech support, Fronius USA. “The biggest benefit to the dual-wire feeder is reducing the setup time between jobs, which allows for more productivity. It minimizes the need for frequent spool changes and helps maintain a continuous workflow, which can lead to better overall efficiency.”
Several heavy industrial operations can benefit from the dual-wire feeder because it directly affects the overall quality and efficiency of their welding operations. But it’s not just heavy fabrication that will benefit. In automotive applications, general fabrication work and beyond, being able to quickly change between wires offers a big boost in productivity.
“In pipeline work, it’s common to need to switch between a solid wire like ER70S-6 and a flux-cored wire,” Relyea says. “For example, for open root applications, the welder can use a 0.035-in. ER70S-6 for the root pass and then with the other torch, change to a 0.045-in. flux-cored wire for the remaining weld passes. In automotive applications, particularly exhaust work, the dual-wire feeder allows the welder to easily change between, for example, a 409 and a 309 stainless wire. In fab shops, this can help the welder easily switch between a stainless and a steel wire.”
Feeder operation
Fronius’ WF 25i Dual system features a wire feeder with two wire spools, two welding torches and one power source, the Fronius TPS/i or iWave multi-process system. The dual-wire feeder utilizes two wire feed motors and two gas valves, allowing for each process line to use a different setup and shielding gas.
The technology behind the WF 25i Dual system gives the welder multiple ways to switch between the process lines. First, they can start the process line directly with the torch trigger. When the torch trigger is pressed, the active process line moves automatically to the corresponding torch. Second, selection can still be made at the wire feeder, which features two buttons where the active process line can be changed when jogging new wire through the torch.
“The third way to switch between process lines is at the power source, which is very helpful when creating jobs and welding programs,” Relyea says.
He also points out that “welding parameters can be saved as a job and the active process line of the dual-wire feeder can be saved in the job, as well. When the process line is changed between the torches, the last-used parameters or job from that torch is automatically recalled and ready to use.”
The welder also has the flexibility to use a water-cooled torch on one process line and an air-cooled torch on the other.
“As an example, they can have a lightweight, low-power air-cooled torch for making tacks and a heavy-duty water-cooled torch for production, which can help reduce fatigue and increase comfort for the welder.” Relyea says.
Wire drums of any size or wire spools up to 60 lbs. can be used. And, depending on where it needs to be used, the WF 25i Dual wire feeder can be placed on top of a power source or mounted on a cart, crane or boom. This helps with reaching large or difficult-to-access areas in challenging welding environments.
Dual asset
Wire feeders are integral to heavy industrial and automotive operations and need to provide accuracy and consistency in the welding. Dual-wire feeders, therefore, can be a major asset from a cost perspective and an environmental one. There is no need to purchase a second welding setup or waste time making frequent changeovers.
“Dual-wire feeders can be more cost-effective and environmentally friendly by reducing material waste and the need for multiple welding systems,” Relyea says. “Each torch can be set up for the filler metal being used, allowing for seamless changeovers for both welding parameters and consumables.”
