The Weld Wizard app from Fronius for Android-, iOS devices and BlackBerry helps welders, design engineers and work schedulers to identify and optimise welding parameters.

April 10, 2014 - The Weld Wizard app from Fronius for Android-, iOS devices and BlackBerry helps welders, design engineers and work schedulers to identify and optimise welding parameters. The results are directly applicable to the real-life situation. Embedded high-speed videos provide deep insights into the inner process-flows; together with descriptions of the weld processes, they make it easier to select the most suitable process for the application in question. Various costing functions, and a job manager for storing welding-jobs, together round off the functional range of this handy tool. Interest in the new app is correspondingly large. This free software, available in German and English language, has already been downloaded over 10.500 times.

Developed by practitioners, for practitioners, the Weld Wizard gives valuable assistance in determining the ideal welding process and parameters for a particular welding task. The software lets users calculate the deposition rate and the energy per unit length quickly and accurately, with only a few inputs, on the basis of interpolated welding parameters. It takes account of the stated welding power source and the available welding processes, and warns users if they go beyond this power source’s specifications. For Weld Wizard users, there is no longer any need to start up the welding power source or gradually find out the right parameters by the time-consuming ‘trial and error’ method.

The wirefeed speed, weld-seam area and deposition rate are calculated on the basis of the parameters stated by the user for his particular welding task (type of seam, wire diameter, welding speed, ‘a’ dimension, type of filler metal being used, etc.). In a second step, the tool can be used to calculate the guideline values for amperage and voltage, and the energy per unit length, once the user has entered the type of arc and the desired weld process and welding position. Users are assisted here by a graphic showing the available welding positions, and by video clips that capture the arc and the droplet detachment in extreme slow motion.

Parameter records can be saved, administered and shared with other users by means of an integral job manager.

The Weld Wizard not only makes light work of finding the ideal welding parameters, it also lets users carry out profitability calculations in their own currencies. For this purpose, details of all Fronius welding systems can be called up, complete with pictures and key data. Based on inputs such as the projected costs of jigs, the planned depreciation period, investment-, material- and labour costs, and the amount of welding work involved (length of seam in metres per day), the software calculates the total resulting costs per year.

The Weld Wizard can be downloaded free of charge from the Apple iTunes Store the Google’s Play Store and the BlackBerry Appworld.

The tool has been so successful that the Fronius experts are already working on extending its functional range with a view to including special processes such as TimeTwin. In future, it is also intended to make the software available as an HTML version.