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Automated arc welding

Arc welding is the most widely used joining process. KUKA provides many automation components, function packages, robots, and cells. These standard products are easy to use and available quickly. 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 a highly effective method used in various industrial environments. It is fast and can work with many types of metal. At KUKA, we provide more than just regular welding functions. We excel in robotic welding systems and automated welding processes, enhancing efficiency in manufacturing.

Our smart integration capabilities connect you to the digital and networked world of production. Our solutions transform manufacturing with industrial robots that integrate advanced technology. The result is more effectiveness and flexibility with KUKA machines. This applies to the whole value chain in robotic welding. Our units ensure consistent quality in welding applications by performing complex, repetitive tasks.

Welding automation from a single source - efficient, innovative, reliable!

High-quality automation: KUKA enables the customer to get involved in the trial arc welds in order to develop the best possible application for their manufacturing.

All-round package for a perfect weld seam

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

Customers worldwide benefit from our expertise in programming welding robots and robotic welding systems. This support includes everything from consulting to customer service. We manage every aspect of the robotic welding process, including programming and tasks optimization. Our team handles process validation, with projects developed for efficient production.

 

  • Engineering

    We offer compete support for planning and implementing your application. This includes helping you choose the right robot welding technology or process.
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  • Technology packages

    As a leading robot manufacturer, KUKA provides ready-to-use packages that include a robot, controller, and software. By using industrial robots, programming becomes seamless with precise control over operations. These packages are easy to set up and use 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

    Our robotic welding systems deliver high efficiency and precision, tailored to your requirements. KUKA services extend from machine maintenance to programming training, ensuring optimal manufacturing operations.

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

KUKA provides great solutions for all robotic welding needs. This includes robotic welders with high path accuracy, preconfigured arc welding robot cells, and fully automated welding systems.

We offer many workpiece positioners, special software, and linear units. These complete our six-axis robotic portfolio. Together, they create well-coordinated packages and improve production at your company. 

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

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.

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?

We have the skills and experience in robotic welding. We would be glad to help you find the best solution for your welding needs.
Contact us.

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;

Read what is important for aluminium welding in electromobility.

Download e-book

Learn about the different arc welding processes 

Gas metal-arc welding is a type of welding. In this process, an electric arc forms between an electrode and the metal using a welding machine. This arc uses heat input to melt the metal parts together. If needed, we also use a filler metal. Here, we distinguish between several methods.

Among these, MIG/MAG welding and TIG welding are the most used methods for the process. These differ based on the type of gas 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)

Find an integrator near you

Further robotic welding processes for industrial automation: