In conversation with Amlan Saha, Segment Management National – Automation, Fronius India, we explore cutting-edge innovations in TIG DynamicWire, sustainability in welding, and the future of AI and additive manufacturing. Discover how Fronius is shaping the future of welding automation. What’s next for the industry? Read the full interview to find out!
How has Fronius evolved over the decades to become a leader in welding innovation?
Fronius, founded in 1945 by Günter Fronius in Austria, started as a company producing battery chargers from scraps. By 1950, it expanded into welding technology with products like welding rectifiers. Over the decades, the company continuously innovated, introducing inverter technology in the 1980s and digital microprocessor-controlled equipment in the 1990s. In 1998, Fronius launched its first range of digital inverters, marking a milestone in its global presence, including collaborations in India through Larsen & Toubro.
In 2013, Fronius India was established as a subsidiary, leading to a new phase of innovation with AI-based intelligent welding systems. Revolutionary technologies like Cold Metal Transfer (CMT), widely used in stainless steel applications, further solidified Fronius’ reputation as a leader in the welding industry. These advancements addressed complex challenges and enhanced sustainability.
Fronius’ success is driven by its strong R&D team, comprising 800 engineers and scientists dedicated to developing cutting-edge technologies. Guided by the philosophy of “Decoding the DNA of the Arc,” Fronius continues to redefine welding technology, supporting the fabrication and welding industries with innovative, sustainable solutions.
What role does stainless steel play in your welding technologies and solutions?
Stainless steel is a dominant alloy in the industry due to its durability, corrosion resistance, and versatility. Beyond household applications, it is extensively used in trains, infrastructure projects, chemical industries, and commercial transportation. Its long lifespan makes it ideal for India’s diverse climates, where corrosion is a major challenge. Critical applications, such as pipelines in chemical and petrochemical industries, rely heavily on stainless steel. Since no alloy can be fully utilized without welding, welding plays an integral role in transforming raw materials like sheets, bars, and wires into functional components and equipment.
In high-demand applications like metro coaches, where lightweight yet durable materials are essential, stainless steel outpaces aluminium due to cost and performance benefits. Welding these materials requires precision to avoid distortion and ensure aesthetics, strength, and safety. Fronius has addressed these challenges with technologies like Cold Metal Transfer (CMT), introduced in 2004, which provides low heat input to prevent chromium depletion in stainless steel, preserving its corrosion-resistant properties. Such innovations are critical for manufacturing distortion-free, safe, and visually appealing components, especially for metro coaches and other advanced uses.
Fronius further supports the industry with specialized processes like plasma welding and keyhole techniques for cryogenic applications, where stainless steel excels due to its chemical resistance and performance at extreme temperatures. Additionally, Fronius’ welding equipment includes a database of programs tailored to specific stainless steel grades—such as austenitic, martensitic, or ferritic—ensuring optimal welding parameters for each alloy. These advancements, driven by R&D, position Fronius as a leader in welding technologies for stainless steel.
Can you elaborate on how TIG DynamicWire technology enhances welding precision and efficiency?
TIG DynamicWire, an innovative and patented process by Fronius, is revolutionizing tungsten inert gas (TIG) welding. Traditionally, TIG welding is considered one of the cleanest processes but requires highly skilled operators to manually control the wire feeding. As industries move towards automation and semi-automation to increase productivity, reliance on such specialized skills becomes a challenge. TIG DynamicWire addresses this by incorporating artificial intelligence to automate the wire feeding process, replicating the precision and control typically provided by skilled welders.
This technology introduces self-regulating wire feeding synchronized with welding parameters. It dynamically adjusts the wire movement based on the operator’s hand motion or skill limitations, ensuring consistent quality and reducing defects. By eliminating dependency on high-skilled TIG operators, it not only increases productivity but also makes the process accessible to a wider range of operators, making it an ideal solution for fabrication industries transitioning to automated processes.
TIG DynamicWire also bridges the gap in automation, where the lack of human touch and visual control often posed challenges. By mimicking human-like adjustments through AI, it retains the precision of manual TIG welding while preparing industries for the future of automated welding. This innovation is poised to revolutionize TIG welding in the coming decades, enhancing efficiency, precision, and scalability in manufacturing processes.
How does Fronius integrate sustainability into its product development, particularly in welding and energy solutions?
Sustainability is a core value at Fronius, embedded in every aspect of our operations. Our manufacturing plants and offices, including the Fronius India headquarters in Pune, are powered entirely by solar energy. For instance, the Pune facility operates a 150-kilowatt rooftop solar plant, making us self-sufficient and eliminating reliance on fossil fuels. We actively monitor and display our green energy consumption and CO2 savings, converting these metrics into relatable terms like the equivalent number of trees saved or planted. This demonstrates our commitment to reducing our carbon footprint and promoting environmental conservation.
Fronius also plays a pivotal role in the solar energy sector by manufacturing solar inverters, the critical components that convert DC power generated by photovoltaic (PV) cells into usable AC power. This innovation complements our welding business by offsetting its environmental impact with sustainable energy solutions. By integrating solar energy technology into our product portfolio, we balance industrial processes like welding—which generate heat and emissions—with solutions that actively reduce carbon footprints and foster renewable energy adoption.
In addition, Fronius ensures sustainability in our manufacturing processes by using recycled materials wherever possible. For example, heat sinks in our welding equipment are made from recycled aluminum, significantly reducing the energy consumption associated with aluminum production. We’ve also eliminated non-biodegradable packing materials, opting instead for recycled paper and materials in our packaging processes. These practices reflect our commitment to preserving the environment and minimizing harm to our planet in every aspect of our business.
What are the key challenges in advancing automated welding systems, and how is Fronius addressing them?
One major challenge in the welding industry is the rapid evolution of technology. For example, in the automotive sector, manufacturers aim to reduce vehicle weight while increasing safety and fuel efficiency. This has led to the use of ultra-high-strength steels, which are often alloyed with high-strength materials that are difficult to weld. To address this, Fronius continually develops new welding processes, databases, and programs to meet the demands of emerging materials and technologies, ensuring our solutions keep pace with industry needs.
Another challenge is the increasing demand for automation across industries, driven by the need for higher productivity and skill shortages. While automation offers advantages, issues like material quality—such as warped or improperly cut stainless steel—can lead to defects and rework. Additionally, automation requires significant investment, making the return on investment a critical factor for many businesses. Fronius is addressing this by supporting the adoption of robotics and automation while also developing solutions to improve material quality and reduce defects.
Finally, the welding industry faces a significant shortage of skilled workers, particularly as younger generations increasingly move away from manual trades. To combat this, Fronius runs the FACT program (Fronius and Academia Centre for Technical Training), which offers advanced training for young people interested in welding. This initiative provides free training, connects trainees with potential employers, and even includes programs specifically for women, promoting empowerment and increasing workforce diversity. By investing in the future workforce, Fronius is working to ensure the sustainability of the welding industry.
What trends do you foresee shaping the future of welding and energy technology, and how is Fronius preparing for them?
One of the most significant trends shaping the future of welding and energy technology is the integration of Artificial Intelligence (AI) and the Internet of Things (IoT). Fronius is already working on this front, with a strong software team developing smart managers that connect welding power sources across an entire manufacturing plant. These smart managers allow operators to monitor and analyze data from multiple machines, identifying potential faults or mistakes. By consolidating and analyzing this data, companies can proactively address issues, improving efficiency and reducing downtime. As industries gradually replace outdated equipment with newer, AI-driven technologies, we expect this shift to become more widespread.
Another trend gaining momentum is additive manufacturing, particularly metal 3D printing. Traditional fabrication methods, such as subtractive manufacturing, can be time-consuming and wasteful. Additive manufacturing, on the other hand, deposits metal in layers according to the desired shape, significantly reducing material loss and production time. While this technology is still in the research and development phase in India, it has already been commercialized in more advanced countries. The cost efficiency of additive manufacturing—potentially 75% cheaper than traditional methods—will likely revolutionize the industry in the coming years.
Finally, the continued evolution of IoT will further transform the welding and energy sectors. With the ability to connect equipment, sensors, and machines, IoT enables more efficient operations and real-time monitoring. As these technologies converge, they will shape the future of manufacturing, enhancing productivity, reducing costs, and improving quality across various industries. Fronius is well-positioned to lead this transformation by staying ahead of these trends and continuously innovating in both welding and energy technologies.
