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Automation for arc welding with KUKA

KUKA offers a wide range of automation components, function packages and cells as standard products that are quickly available. They can be combined in a modular fashion and flexibly adapted to specific requirements. 

Always one step ahead: Arc welding with KUKA

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 welding 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 throughout the entire value chain in industrial welding.

All-round package for a perfect weld seam

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

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

White Paper: Welding aluminum? No problem! Score high now in production for electromobility.

Due to its ideal combination of strength and light weight, aluminum plays an important role in electromobility. In welding and joining processes, aluminum places high demands on the technologies used. With comprehensive process know-how and the right products, KUKA prepares you for the technological transformation towards electromobility. The battery box example shows how robots enable the production of aluminum components to the highest quality standards.

Read about what is important for aluminum welding in the electromobility sector

Download White Paper

  • Engineering

    We provide you with comprehensive support in the planning and implementation of your application, such as helping to select the appropriate 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 maintenance and servicing to spare parts supply as well as process and system training. 

    Learn more

Learn about the different arc welding processes 

Gas metal-arc welding is an arc welding process in which an arc is ignited between an electrode and the component, fusing the workpiece 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 seam quality and a high welding speed.

MIG/MAG welding

MIG/MAG welding is an arc welding process in which an arc is ignited between a welding wire and the component, fusing the workpiece 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 welding speed

  • High deposition efficiency

  • Inexpensive

 

Application

  • MIG: alloyed and unalloyed steel

  • MAG: precious metals such as stainless steel, aluminum, titanium or copper

TIG welding

In tungsten inert gas welding (TIG), 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 welding positions

 

Application

  • All weldable metals

  • Thin-walled workpieces

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, is introduced to create a plasma that has a greater power density than the arc alone.


Advantages

  • Greater power density

  • Higher welding speed

  • 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)

Technical expertise, years of experience and a broad product portfolio for welding automation – with KUKA it is all from a single source

KUKA enables the customer to get involved in the trial welds in order to develop the best possible application.

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

KUKA offers ideal solutions for all welding automation requirements – from individual arc welding robots with high path accuracy to preconfigured welding cells and fully-automated welding systems. A wide range of positioners and welding technology software as well as linear units round out the portfolio for perfectly coordinated overall packages.

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.

Robotic Arc Welding
The arc welding of challenging workpieces is enormously simplified with KUKA positioners.

Want customized solutions?

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