The Fronius TPS/i is one of the most advanced synergic MIG/MAG welding systems available today. Its modular software allows you to choose from Standard Synergic MIG, Pulse, PMC (Pulse Multi Control), LSC (Low Spatter Control) and CMT processes depending on your application. The TPS/i combines intelligent synergic control with penetration and arc-length stabilisation, allowing users to achieve highly repeatable weld quality across steel, stainless steel and aluminium.
Step 1 – Select the Correct Welding Process
The first step is selecting the material you intend to weld.
Create a new welding job and select:
Material
- Mild Steel
- Stainless Steel (CrNi)
- Aluminium
Next select:
- Wire diameter
- Shielding gas
- Welding process
Once selected, the machine loads the correct synergic line specifically developed for that material, wire diameter and shielding gas combination.
One of the biggest advantages of the TPS/i platform is that every synergic characteristic has already been optimised by Fronius, leaving only small adjustments for the welder to make.
Step 2 – Mild Steel Setup
Typical setup:
Wire
- ER70S-6
- 0.8 mm
- 1.0 mm
- 1.2 mm
Shielding Gas
- Argon/CO₂ 82/18
or - Argon/CO₂ 92/8
Select:
- Steel
- Correct wire diameter
- Correct shielding gas
The machine will automatically calculate:
- Wire feed speed
- Voltage
- Burn back
- Arc characteristics
- Dynamic settings
Normally, only small Arc Length adjustments are required to fine-tune the arc.
Recommended Mild Steel Wire Sizes
Material Thickness – Recommended Wire
1 mm – 0.8 mm
2 mm – 0.8 mm
3 mm – 1.0 mm
5 mm – 1.0 mm
6 mm+ – 1.2 mm
Step 3 – Stainless Steel Setup
Select:
- Stainless Steel (CrNi)
- Correct wire diameter
- Correct shielding gas
Typical shielding gases include:
- 98% Argon / 2% CO₂
- Trimix gases where required
Recommended filler wires:
- 308LSi
- 316LSi
- 309L
Stainless steel generally benefits from:
- Slightly shorter arc lengths
- Lower heat input
- Consistent travel speeds
For the highest quality finish, Pulse or PMC welding is normally recommended.
Step 4 – Aluminium Setup
Select:
- Aluminium alloy
- Wire diameter
- Shielding gas
Recommended gas:
- 100% Argon
Typical filler wires:
- 4043
- 5356
For the best feeding performance use:
- U-Groove drive rollers
- PTFE liner
- Correct aluminium contact tip
- Push-Pull torch whenever possible
Aluminium almost always produces the best results using Pulse or PMC welding due to the lower heat input and smooth droplet transfer.
Pulse Welding Explained
Pulse welding uses a controlled pulsing current to transfer a single droplet of molten metal with each pulse.
This dramatically reduces spatter while maintaining excellent penetration.
Pulse welding is ideal for:
- Aluminium
- Stainless Steel
- Thin Mild Steel
Advantages
✔ Extremely low spatter
✔ Lower heat input
✔ Excellent weld appearance
✔ Better positional welding
Typical Applications
- Food industry
- Pharmaceutical fabrication
- Pipework
- Automotive
- Architectural metalwork
PMC (Pulse Multi Control)
PMC is Fronius’ premium pulse welding process.
It continuously monitors and controls the welding arc, automatically adjusting parameters to maintain consistent penetration and weld quality even if stick-out or travel speed changes.
PMC is designed for maximum productivity while maintaining exceptional weld quality.
Best Applications
- Heavy fabrication
- Structural steel
- Production welding
- Robotic welding
- High-quality aluminium fabrication
Advantages
✔ Faster travel speeds
✔ Extremely stable arc
✔ Consistent penetration
✔ Very low spatter
✔ Excellent weld appearance
If you’re unsure which advanced process to choose, PMC is generally the best all-round option.
LSC (Low Spatter Control)
LSC is designed to improve conventional short-circuit transfer.
It provides a smooth, stable arc while significantly reducing spatter during welding at lower current levels.
LSC is particularly effective on thinner materials where weld appearance and minimal cleanup are important.
Best Applications
- Thin sheet steel
- General fabrication
- Root runs
- Gap bridging
- Positional welding
Advantages
✔ Reduced spatter
✔ Stable short arc
✔ Excellent root penetration
✔ Easier positional welding
✔ Less post-weld cleaning
Arc Length Correction
Arc Length Correction is one of the most commonly adjusted settings on the TPS/i.
Negative Values
- Shorter arc
- Narrower weld bead
- Increased penetration
Positive Values
- Longer arc
- Wider weld bead
- Flatter weld profile
A setting of 0 is usually the best starting point.
Make small adjustments while welding until the arc sounds smooth and the weld profile suits your application.
Dynamic Correction
Dynamic Correction changes how aggressive the arc feels.
Increase Dynamic
- More forceful arc
- Greater penetration
- Better fusion on thicker materials
Reduce Dynamic
- Softer arc
- Less spatter
- Better control on thin material
- Improved cosmetic appearance
Only make small adjustments, as even minor changes can noticeably alter the welding characteristics.
EasyJobs
One of the TPS/i’s most valuable productivity features is EasyJobs.
Once you’ve perfected your welding settings, simply save them as an EasyJob.
This allows you to instantly recall the exact setup in the future without having to re-enter any parameters.
EasyJobs are particularly useful if you regularly switch between:
- Mild Steel
- Stainless Steel
- Aluminium
- Different wire diameters
- Different shielding gases
- Various welding positions
WeldAssist Pro Tips
✔ Always select the correct material, shielding gas and wire diameter before making any adjustments.
✔ Leave Arc Length at 0 as a starting point before making fine adjustments.
✔ Use LSC when welding thin steel where reduced spatter is important.
✔ Use Pulse when welding aluminium or stainless steel.
✔ Use PMC for production welding where maximum speed and consistent penetration are required.
✔ Save frequently used setups as EasyJobs to reduce setup time and maintain consistency.
✔ Keep the correct contact tip, liner and drive rollers fitted for the material being welded.
✔ Regularly inspect torch consumables to maintain optimum arc stability.
Final Thoughts
The Fronius TPS/i is far more than a conventional synergic MIG welder. Its intelligent software packages allow the machine to be tailored to almost any welding application, from thin-gauge sheet steel to heavy structural fabrication and precision aluminium welding.
Understanding when to use Standard Synergic MIG, Pulse, PMC and LSC will help you achieve cleaner welds, higher travel speeds, reduced spatter and consistently outstanding results.
By taking the time to select the correct welding process and fine-tune the machine, you’ll unlock the full capability of the TPS/i platform and produce professional-quality welds across a wide range of materials.
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