Fronius iWave Syncropulse: A Step-by-Step Guide

January 27, 2025 Account Jake Genever

Fronius iWave Syncropulse Guide

Key Takeaways

  • Reduced Heat Input: Less heat is applied to the workpiece, preventing distortion.
  • Improved Weld Appearance: More uniform beads with fewer imperfections.
  • Enhanced Arc Stability: Easier to control the welding arc, especially on thin materials.
  • Low Spatter: Less cleanup required after welding.
  • Setting Up the iWave for Syncropulse

Table of Contents

Fronius iWave Syncropulse Guide

Syncropulse is a pulsed MIG welding function that adjusts the current during the welding process in a synchronized pattern.The software was originally introduced in Fronius’ iconic TransPulsSynergic 2700 (TPS2700) Alu-Edition and is now a standard feature of the TransSteel PULSE, TPSi & iWave series MIG equipment. This technology is particularly ideal for the MIG welding of aluminum but also provides excellent features when used on stainless steel, and additional non-ferrous materials.

  1. Power Up:
    • Switch on the Fronius iWave and navigate to the main menu.
    • Ensure that the correct process (e.g., One of the MIG processes) is selected.
  2. Activate Syncropulse:
    • Go to the welding parameters screen.
    • Select the Syncropulse mode from the list of available features.
  3. Adjust Pulse Frequency:
    • The pulse frequency determines how often the current fluctuates during welding. Adjust the frequency to fit your specific material and welding position.
    • The frequency setting ranges between 0.5 Hz and 100 Hz, but typically somewhere between 1.5 and 3.0 Hz covers most material thicknesses. However it is very dependant on the welding task.
  4. Set Pulse Amplitude:
    • Pulse amplitude controls the power variation during each pulse cycle. Adjusting this allows you to fine-tune the heat input during welding and also amplify the ‘ripple’ appearance of the finished weld bead.
    • You can increase or decrease the pulse height based on the material thickness.
  5. Set Arc-Length:
    • The arc-length control regulates the distance from the welding wire end to the weld pool during welding. When in Sycropulse mode, the arc-length for both base and peak currents can be set individually.
    • As a typical rule of thumb, a higher arc-length setting for the peak as opposed to the base current will give the weld bead a wider and more defined ripple effect while the reverse tends to give the weld bead a tighter appearance.

Welding with Syncropulse

Once the settings are configured, you’re ready to start welding.

  1. Get Yourself into a Comfortable Position:
    • Ensure the torch angle is correct for the joint type.
    • Do a ‘dry-run’ welding pass to ensure nothing is obstructing the either torch, your line of sight or your ability to move the torch along the complete length of the weld joint.
  2. Begin Welding:
    • Start welding by triggering the torch and maintaining a steady hand.
    • As you weld, the Syncropulse feature will automatically pulse the arc, providing smooth transitions between the peak and base current.
    • The arc-length control will provide consistant a distance from the wire end and weld pool with both the peak and base current parts of the pulse cycle.
  3. Monitor the Weld:
    • Watch for consistent bead formation and smooth transitions. The machine will automatically hold the pulse frequency and amplitude, ensuring a stable arc.
    • If necessary, adjust the settings slightly based on the material and weld pool behavior.

Troubleshooting Syncropulse Issues

iWave Settings

If you experience issues while using Syncropulse, here are some common problems and solutions:

  • Uneven Weld Beads: Ensure the Syncropulse settings (pulse frequency and amplitude) are optimized for the material. A low pulse frequency may cause inconsistent beads.
  • Excessive Spatter: If there is spatter, increase the arc-length a little on both peak and base current settings and possibly experiment by adjusting the pulse frequency. Ensure the torch angle and travel speed are consistent.
  • Arc Instability: This could be due to a worn contact tip or liner in the torch creating inconsistent wire feeding. Check condition of the liner and tip and replace as necessary. This may also be caused by improper torch angle and travel speed.

Maintenance Tips for the Fronius iWave

iWave MIG welding

To keep your Fronius iWave in top condition:

  • Clean Regularly: Remove any dust, dirt, or spatter from the machine’s components, including the torch and cables.
  • Inspect the Torch Consumables: Ensure the contact tip is clean and free from wire burn-back onto the end. Clean out any weld spatter from inside the gas nozzle and check the condition of the liner.
  • Check for Firmware Updates: Periodically check for software updates that may improve machine performance or introduce new features.

The Fronius iWave Syncropulse feature is a powerful tool for achieving high-quality MIG welds with minimal spatter and distortion. By understanding and adjusting pulse frequency, amplitude, and current settings, you can tailor the welding process to suit a wide range of materials and applications. Regular maintenance ensures the longevity of the equipment and consistent performance.