WELDING PROCESS automation

 

Automated welding with our most stable welding process

EWM React, which stands for Reversing Actively Controlled Transfer, is our most stable automation welding process. In detail, this means: Active forward/backward movement of the wire ensures maximum process stability and achieves high-quality welding results thanks to controlled droplet transfer. Using EWM React, even thin and sensitive materials can be welded with maximum reliability and precision. Achievable welding speeds are more than doubled in some cases in comparison to other arc types.

 

EWM React

Automated welding process with active wire movement and full control over droplet transfer

EWM React

Compared to the short arc, the EWM React welding process involves up to 35 percent less heat input with a deposition rate that’s twice as high. With this welding process, you have full control over droplet transfer. Instead of uncontrolled transfer from the wire end into the weld pool, the droplet is reliably deposited even at high welding speeds. This in turn results in virtually no weld spatter and significantly reduces the need for finishing work, ensuring maximum efficiency and productivity in your operation.

Advantages:

  • Greatly increased welding speed
  • Higher deposition rate
  • Reduced heat input
  • Minimal distortion
  • Maximum ignition reliability
Steel and stainless steel welding throat thickness micrograph

Up to
30 percent

reduction in welding fumes*

This significantly reduces the welder’s exposure and provides a demonstrably healthier working environment.

Up to
100 percent

higher welding speed*

This enables significantly more efficient utilisation of working time and a considerable increase in productivity.

Up to
35 percent

lower heat input*

This means less distortion, less weld spatter and less finishing work.

*Compared to a standard short arc

Video

EWM React

Greatly increased welding speed

The process

1

The wire is actively moved towards the weld pool, where the arc burns on the molten metal and produces a molten droplet.

The arc burns on the molten metal and simultaneously produces a molten droplet

2

When the wire touches the molten metal, a short circuit occurs and the droplet passes into the weld pool. The short circuit resolution is controlled by the RCC module.

A short circuit occurs and the droplet passes into the weld pool

3

The wire is now actively and very precisely withdrawn from the weld pool, and the arc ignites again.

Active backward movement

Fields of application

Demanding welding tasks are no problem for EWM React. Our welding process is an advanced solution wherever precision, process stability and controlled heat input are required.

Joint welding

The two process variants EWM React Speed and EWM React Positionweld are ideal for welding high tensile steels and CrNi components. This is made possible by the fact that with EWM React, the welding speed can often be doubled and the heat input reduced by up to 35 percent.

Advantages:

  • Perfect ignition for every component
  • Less finishing work
  • Suitable for all welding positions
  • Quick and easy setting with just a few parameters
  • Welding speeds from 250–350 cm/min
Joint welding

Cladding

Conventional cladding can often lead to melting of the lower-alloy parent metal while the high-alloy protective layer is being applied. EWM React prevents this thanks to its low heat input paired with a high deposition rate. This results in perfect, highly corrosion-resistant weld seams.

Advantages:

  • Best corrosion resistance
  • High productivity
  • Efficient use of materials
  • Also possible with pure argon or Ar/He shielding gas
Cladding

Wire Arc Additive Manufacturing (WAAM)

In the automated production of large components and complex geometries, the EWM React automation welding process stands out with a host of advantages and makes the workflow significantly more efficient. Significant cost reduction, as well as considerable time savings and increase in weld seam quality are just a few of the benefits.

Advantages:

  • Controlled minimum heat input
  • Stable and constant welding process
  • High deposition rate
Wire Arc Additive Manufacturing (WAAM)

You can find detailed information in the brochure.

EWM React brochure
Download brochure