Welding technology meets reach: Influencers visit the ITC

Welding professionals are under constant pressure to meet ever-increasing quality requirements while also seeking workplaces that ensure safety and provide air that is as free of welding fumes as possible. Cobots, laser processes and fume extraction systems offer valuable support here: greater efficiency, more stable processes and cleaner air.

But do they really deliver what brochures and websites promise?

That is exactly what we tested at the ABICOR BINZEL Innovation and Technology Center (ITC) together with two absolute welding pros: Erik Löffel, known in the industry as "Alu Löffel" with a strong focus on aluminum welding, and Christian Barfuß, owner of a company specializing in custom-built special vehicles. Both work daily with demanding components and materials and share their experiences with thousands of followers across their social media channels.

At the ITC, three key topics were in focus: aluminum welding, fume extraction and flexibility through interchangeable neck torches. Cutting systems from Thermacut were evaluated as well. You can get a first impression in this video by Erik Löffel:

Aluminum welding: when every detail counts

A clear focus of the visit was aluminum welding – manual, automated and also laser-based. Aluminum reacts sensitively to parameter deviations, meaning that heat input, wire feeding, seam guidance and shielding gas coverage must interact perfectly. Even minor fluctuations can result in porosity, undercut or distortion.

guidance and shielding gas coverage must interact perfectly. Even minor fluctuations can result in porosity, undercut or distortion.

In the automated segment, both influencers tested the iROB^® power source series live for MIG/MAG robotic applications. The key question was not maximum speed, but rather: How stable does the process remain when welding aluminum? The conclusion: The power source's precise arc ignition ensures smooth welding behavior and reproducible weld seams.

The tests with the collaborative welding robot iBOTone^® demonstrated how automation can be implemented easily even for smaller production runs. Especially in custom vehicle manufacturing, where components are often repeated, a welding cobot can significantly increase productivity and process reliability.

The tactile laser optics MPH Ti also complements this portfolio in a meaningful way. It integrates optics and wire feed through just one interface (Ti = "Tactile integrated"). This reduces space requirements, lowers data traffic and enables faster signal processing within one controller.

Fume extraction in practice: clean air without compromise

In addition to stable processes, the working environment plays a crucial role – particularly clean air during welding. Christian Barfuß described a situation familiar to many workshops: intensive welding creates a visible "haze dome" inside the facility.

The influencer then tested the xFUME^® PRO 36 fume extraction torch for extraction at source, connected to the xFUME^® POWER 350M⁺ – a combination unit consisting of a welding power source and integrated welding fume extraction system. This space-saving solution enables efficient work while reducing emissions at the source. His impression: noticeably less fume in the air without compromising weld quality.

In terms of handling, he emphasized that the fume extraction torch did not present any noticeable disadvantages. Weight and balance were comparable to conventional torches in the same performance class. After testing, he was convinced by its comfortable handling and reliable efficiency.

Neck change torches: flexibility that saves time

Since time pressure is also part of everyday workshop life, the two welding experts were introduced to ABICOR BINZEL's TIG interchangeable neck torches. They were particularly impressed by the liquid cooled ABITIG^® GRIP W T. Erik Löffel summed it up perfectly: "What I like most about it is that you can quickly adjust the torch depending on the required performance."

Especially when working on tight components or hard-to-reach areas, Erik clearly saw the advantage of improved accessibility to the weld seam and thus a noticeable time saving within the process. For him, optimization is a continuous part of workshop routine. Processes should become more efficient and more comfortable for the entire team. Flexibility within the torch system is key to achieving this goal.

Technology must prove itself in everyday practice

After two intensive days at the ITC, both agreed: this was not a classic product presentation, but a technical exchange at eye level. Both guests share the same standard – welding technology must prove itself under real workshop conditions.

That is precisely why maintaining close dialogue with users from a wide range of industries is so important for ABICOR BINZEL. In the end, technology only convinces when it delivers on its promises in everyday practice.

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