Automated arc welding

Arc welding is the most widely used joining process. KUKA offers a wide range of automation components, function packages, robots and cells as standard products that are easy-to-use and quickly available. From MIG welding to MAG welding and on to TIG welding.

Robotic arc welding with KUKA robots: always one step ahead

Robotic arc welding is one of the most popular welding processes in industrial settings because of its speed and ability to process many metallic materials. In addition to conventional weld functions, we at KUKA – as a thought leader and trailblazer in the field of automation – also offer long-term security of investment through the smart capability of integration into the digital and networked world of production. The result is greater effectiveness and flexibility with a KUKA machines and throughout the entire value chain in robotic welding.

All-round package for a perfect weld seam

From engineering to service as well as customized turnkey solutions for automated arc welding

All around the world, our customers enjoy expert advice and comprehensive support for the implementation of KUKA robots and robotic welding system – from consulting to customer service. We can take care of the entire robotic welding process for you, from process validation to prototype construction and small-batch production.

Engineering

We provide you with comprehensive support in the planning and implementation of your application, such as helping to select the appropriate robot welding technology or welding process.
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Technology packages

As a leading robot manufacturer, KUKA offers preconfigured and intuitive complete packages, consisting of robot, controller and software, that can be put into operation quickly.
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TechCenters around the world with global standards

KUKA TechCenters are available to customers as test laboratories at various locations in Europe, the Americas and Asia.
Global service

KUKA service ranges from machine maintenance and servicing to spare parts supply as well as process and system training for welders.
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Learn about the different arc welding processes

Gas metal-arc welding is an arc welding process in which an electric arc is ignited between an electrode and the component, fusing the components and, if applicable, a filler metal. Here, a distinction is made between several methods. Among these, MIG/MAG welding and TIG welding are the most used methods for the process. These differ in the type of gas that is used and the choice of materials. They impress with maximum weld quality and a high weld speed.

MIG/MAG robot welding

MIG/MAG welding is an arc welding process in which an electric arc is ignited between a welding wire and the component, fusing the components and the filler metal. To protect the weld pool from the reactive oxygen in the environment, a shielding gas is supplied with the welding wire. This displaces the oxygen at the welding point and thus prevents oxidation of the weld pool.

In metal active gas welding (MAG), an active gas, such as CO2 or a CO2 mixture, is used. The active gas reacts with the weld pool and stabilizes the arc.

Metal inert gas welding (MIG) uses an inert – i.e. non-reactive – gas such as argon or nitrogen.

Advantages

High weld speed
High deposition efficiency
Inexpensive

Application

MIG: alloyed and unalloyed steel
MAG: precious metals such as stainless steel, aluminum, titanium or copper

Pre-assembled and ready to use MIG/MAG robot cell includs welders, positioner, application software

TIG robotic welding

In tungsten inert gas welding (TIG), also known as gas tungsten arc welding (GTAW), the welding current is supplied through a tungsten electrode, which is temperature-resistant and does not melt. As in MIG welding, inert shielding gases (such as argon or helium) are used to prevent a reaction with the oxygen in the air. If a filler metal is required for a specific application, it is fed separately via an external wire feeder.

Advantages

Excellent seam quality and appearance
Suitable for all weld positions

Application

All weldable metals
Thin-walled components

Welding solution with the TIG method: A line with an argon chamber and two small robots

Plasma welding

Plasma welding is a variant of TIG welding in which the arc is constricted by a water-cooled nozzle. In addition, a plasma gas, usually argon, also flows between the electrode and the nozzle, is introduced to create a plasma that has a greater power density than the arc robot alone. Plasma welding process employs a copper nozzle and the electrode is tungsten 2 % thoria. The diameter of the eletcrode tip is not as critical as for GTAW. It should be maintained around 30 to 60 degrees.

Advantages

Greater power density
High-speed metal arc welding
Low distortion
Can be combined with external wire feed

Application

Micro-plasma welding (0.1 - 1 mm workpiece thickness)
Plasma welding with keyhole (3 - 9 mm)
Plasma MIG welding (3 - >10 mm)

Webinar Special: Explore Advanced Arc Welding Solutions

Get in-depth insights into the acceleration of Arc Welding with KUKA.ArcTech and the welding capabilities in specific webinars.

Welding robots, positioners and welding cells:
Standardized modular components that can be ideally combined

KUKA offers ideal solutions for all robotic welding requirements – from the use of robotic welders with high path accuracy to preconfigured arc welding robot cells and fully-automated welding systems. A wide range of workpiece positioners, special software and linear units round out the six-axis robotic portfolio for perfectly coordinated overall packages and optimized production at your company.

Welding robots

KUKA robots for arc welding are available with payload capacities from 6 to 22 kg and reaches of up to 3,100 mm, with a wide range of special variants available.

Workpiece positioners

Broad portfolio of standardized and customer-specific positioners and turntables for payloads from 250 to 12,000 kilograms.

Software and sensor technology – no matter how complex the welding task

Strong KUKA partners for arc welding

Our robots achieve the best possible welding quality with the appropriate welding equipment from our strong partners such as Fronius, Kemppi, Miller, Lorch, Lincoln, EWM, SKS, ESAB and Migatronic.

The welding equipment is connected to the robot controller quickly and easily via a field bus interface, such as EtherCAT (present in every KR C4 controller). In this way, the full range of functions is available to the operator at all times.

KUKA robots weld bicycle frames in a Russian factory.

Want customized solutions?

With our expertise and experience in robotic welding, we would be happy to advise you and work with you to find the perfect solution for your specific weld requirements.

E-book: Welding aluminium? No problem!

Aluminium and aluminium alloys play an important role in e-mobility because of the ideal combination of lightness and strength. In welding and joining processes, aluminium has high demands on the processes used. With comprehensive process know-how and the right products, we make you fit for the technological transformation towards e-mobility. The example of the battery box shows how robots enable the production of aluminium components at the highest quality level;