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   Magnetarc Welding: The Innovative Joining Process for High Precision

   The Magnetarc welding process was developed by KUKA and is a pressure welding

   process with magnetically impelled arc and shielding gas. The process can be used to join

   rotationally symmetrical and non-symmetrical hollow sections with wall thicknesses of

   between 0.7 and 10 mm.

   Suitable materials for the process are electrically conductive, fusible materials such as

   unalloyed or low-alloy steels, free-cutting steels, cast steel and malleable cast iron.

   Excellent joining is also obtained with combinations of these materials.

   The process is characterized by extremely fast welding times and high-precision joining.

   Magnetarc Welding: Process Sequence

		Phase 1: Initial situation
		§   Both workpieces securely clamped  § Workpieces are brought together
		Phase 2: Ignition
		§   Shielding gas and welding current switched on    §   Workpieces are moved apart to create a defined gap    §   The arc is struck
		Phase 3: Temperature increase
		§   The arc is rotated by means of a magnetic coil system  §   Uniform temperature increase in the abutting faces
		Phase 4: Welding
		§   The abutting faces are pressed together  §   Shielding gas, magnetic coil and welding current are         switched off

   Process Parameters Under Close Control

   Constant process parameters are the essential requirement for obtaining reproducible

   weld quality. The KUKA PCD system was developed for process control and monitoring and

   is integrated as standard into the machine controller. All quality-relevant parameters are

   monitored within freely definable tolerance limits.

   The parameters are entered and displayed directly at the machine. A particularly user-friendly

   feature is mouse-driven data entry. The required tolerance limits can be set or changed on the

   graphical user interface simply by clicking with the mouse. The current welding parameters are

   displayed automatically after each welding cycle.

   At the same time, the system archives all the program and actual value data. A further plus

   point is the integrated process and machine diagnosis tool. With the aid of this tool, any faults

   that occur can usually be located and corrected directly at the machine.
 

   A built-in modem allows the user to take advantage of all the possibilities of online customer

   support, from remote diagnosis and process analysis through to software updates.

 

   Over 25 years of engineering experience

   Joining parts with thin walls or welding steel/cast iron combinations are some of the specialties

   of Magnetarc welding. Another outstanding characteristic is the precision with which the parts

   are joined, resulting in high-quality weldments that are ready for installation without any further

   processing.

		§   Car axle with steel/ductile cast iron joint
		§   Propshaft (stub) with steel/steel joint
		§   Van axle with steel/ductile cast iron joint
		§   Propshaft (yoke) with steel/steel joint