The conventional narrow gap welding can be applied with most welding processes, but it has its disadvantages: Conventional narrow gap welding requires exceptional skills from welders and is practically impossible without special equipment. In addition, setting up these systems is time consuming and therefore reasonable only with very thick materials.
Reducing the groove angle can add significantly to the efficiency and productivity of welding of heavy metal structures. Kemppi has developed a new solution, Reduced Gap Technology (RGT). This technology allows reliable and efficient narrow gap welding with no need for special equipment or accessories for material thicknesses of up to 30 mm. The RGT combines intelligent arc control with Kemppi's high-tech power source, wire feeder and mechanization equipment.
groove angle instead of 45°– 60°
savings in arc time
savings in filler material
weld passes needed instead of 7
Investment costs of RTG are exceptionally low, since no special narrow gap equipment is needed in welding with material thicknesses up to 30 mm.
RGT enables smaller groove volume which yields significant cost savings through reductions in welding time and filler-material consumption.
Thanks to RGT the arc length is always stable. Since the user doesn’t need to adjust it, there is less hassle and the arc time ratio is higher.
RGT minimizes heat input, which improves impact toughness especially with high-strength steels and reduces deformation, so there is less need for straightening.
At the core of Kemppi's RGT solution there is the most advanced arc control system in the field of welding. The intelligent arc control is achieved by utilizing two revolutionary application software developed by Kemppi: WisePenetration, which keeps the arc power consistent and WiseFusion, which provides adaptive regulation that keeps the arc focused and optimally short.
WisePenetration keeps the arc power consistent, regardless of variations in the contact-tip-to-work distance.
WisePenetration keeps the arc power consistent, regardless of variations in the contact-tip-to-work distance. This enables a higher welding speed and deposition rate, resulting in lower labor costs.
WiseFusion provides adaptive regulation that keeps the arc focused and optimally short.
WiseFusion keeps the arc stable, improves the control of the weld pool and reduces the magnetic arc blow. This reduces the risk of welding defects, and lowers the repair costs.
WiseFusion keeps the arc length stable. Since the user doesn’t need to adjust it, there is less hassle and a better arc time ratio.
The high energy density of WiseFusion minimizes heat input, which improves impact toughness with high-strength steels and reduces deformation, thus reducing the need for straightening.
How could you benefit from Kemppi’s Reduced Gap Technology? Learn the principle of the RGT control system and see the savings potential illustrated by preliminary WPS, together with detailed calculations.
Welding work has gained speed, because the groove volume and the number of beads to be welded have decreased. Also less filler material is needed. Mechanization has also improved the arc time ratio and made the welds more consistent in quality.
Niko Rautiainen, Hull Production Manager, Arctech
The Kemppi Reduced Gap Technology is available for Kemppi’s FastMig KMS, FastMig M, FastMig Pulse and FastMig X welding machines equipped with the WisePenetration and WiseFusion application software.
If you have a compatible Kemppi welding machine, but not yet the application software required for RGT, you are always able to update your system. The Wise software is easy to purchase and install.
To optimize usability and welding efficiency, it is recommended to use this technology with the A5 MIG Rail System 2500, since the rail carriage is optimized for use with FastMig power sources.
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