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The New CMT Cycle Step Process Variant Provides the User with Greater Control over the Welding Process

Press Release Summary:

Fronius’s new CMT Cycle Step process variant allows the operator to control the pause time between welding cycles as well as the number of individual droplets produced. The reduced heat into the workpiece is beneficial during position welding with gap tolerances. The CMT Cycle Step helps ensure clear ripples in the bead and welding of the smallest fixation points. It is ideal for overlay welding and additive manufacturing applications.

Original Press Release:

CMT Cycle Step from Fronius: A New Level of Welding Process Control

The new Cycle Step process variant for the CMT (Cold Metal Transfer) welding process allows users to set both the number of individual droplets and the pause time between cycles. The result is a heat-reduced bead with clear ripples and a high degree of reproducibility. It has a wide range of applications – from visible weld seams and additive applications to fixation points. 

During MIG/MAG welding, a droplet melts at the end of the wire electrode and is transferred to the weld pool during the short circuit phase of the CMT process. Following this characteristic short circuit, the arc ignites again and a new welding cycle begins. With CMT Cycle Step, Fronius can control these individual cycles so precisely that the user can define the exact number of droplets per welding spot, thus representing a whole new level of control and reproducibility. The extent of the resulting material removal in a sequence can also be set.


With Cycle Step, the heat input into the workpiece is minimal and can be effectively controlled, which is particularly useful during position welding with gap tolerances. Another advantage is the clear rippling of the weld seam, making Cycle Step ideal for high-quality visible seams. CMT Cycle Step also enables the smallest fixation points to be welded and is therefore an alternative to spot welding guns. Furthermore, CMT Cycle Step can be used to weld galvanized sheets or to produce hold points for supporting bonded joints. Overlay welding and applications in additive manufacturing are also possible with Cycle Step.

The Cycle Step option is available as an upgrade from TPS/i firmware version 1.9.0. Following the upgrade, the function is available on TPS/i systems for all CMT characteristics.

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