Welding at KTM sports motorcycles

Leading sports motorcycle manufacturer KTM uses innovative digital welding systems from Fronius, and have now installed 100 Fronius systems on their production lines

Leading sports motorcycle manufacturer KTM has enjoyed lasting success in the sports motorcycle sector.

Their "Ready to Race" success strategy focuses on two elements: the high quality assembly of parts that make up the frame and exhaust system, and innovative staff management.

Management insists on the highest quality in the welding technology used for these tasks.

Welding specialists at their Austrian plant are more than satisfied with the Fronius systems.

The frame and exhaust of the top-selling KTM machines are manufactured at their Mattighofen site.

Sheeting and piping made from special, high-alloy or standard steels are welded by 160 qualified welders of both sexes, producing seams of the highest quality.

Welding is one of the KTM key skills, and women excel at KTM as qualified welders.

This applies across a whole range of processes, from robot welding through automated/orbital to manual welding.

The manufacturing experts in Mattighofen list technological leadership, reliability and customer service as the decisive criteria for choosing their partners, and they prefer welding systems from Fronius.

Josef Baier, head of sheet manufacturing and exhaust production/framework, explains: "We use the TransPuls Synergic 5000 for MIG/MAG welding in the automation section and the TransPuls Synergic 2700 for manual welding in exhaust production and frame assembly.

For the TIG welding of chrome-nickel, we use the TransTig 1600 and 1700 or even the MagicWave 2200".

Daily quality control checks support the decision to choose Fronius welding systems, not to mention the decision to increase the number of females in the welding team.

The frame is the most important safety component, so it is on this that test experts perform a 100% visual inspection of the seams.

After every five hundred frames, a sworn, legally accredited expert inspects the polished sections and hardening characteristics.

Fronius was the first to develop digital welding systems.

The Austrian company still enjoys a reputation as the trendsetter that is leading the digital revolution in welding technology.

Those who use Fronius systems benefit from 100% repeatability, flexibility and precision.

At KTM, these characteristics of Fronius welding systems are highly prized: "It is currently the best on the market: highest quality, minimal rework, barely any spatter, maximum availability, no machine breakdowns.

We can choose the correct configurations according to our requirements", reasons Baier.

In 2005, the welding technicians at KTM will install their hundredth Fronius welding system in their production lines.

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