Digital Wolfram Nex

We aim to develop two hardware-software products also available as services: the CaliWeld portable calibration and OptiWeld modular optimization stations, combining arc-plasma emissions with physics-based models for industrial TIG welding quality assurance and process optimization.

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Description

Wolfram Industrie GmbH (WIS) specializes in products and services for validating, optimizing, and monitoring industrial TIG welding. In collaboration with BFH and ZHAW, WIS recently developed the Digital Wolfram Expert System (DW) — a hardware-software platform that identifies process irregularities in real time and delivers actionable feedback to weld line operators.

Leveraging the proprietary DW system and the project’s scientific findings, the consortium is addressing critical challenges beyond weld production monitoring: using the physical properties of the arc plasma for advanced calibration and process optimization. This is achieved by capturing local arc-plasma emissions, applying basic physics to extract quantitative plasma properties and integrating these metrics into a FE-based digital twin that accurately predicts weld quality features such as weld seam geometry and welding efficiency. This will results in two new integrated hardware-software solutions, also offered as service-based models for SMEs: CaliWeld and OptiWeld.

CaliWeld is engineered as a portable diagnostic unit for the systematic auditing of industrial TIG welding equipment. It will be tailored to ISO 17662 which recommends a comprehensive approach to welding equipment verification encompassing shielding gas impurities, heat input, arc instability, and electrode degradation. Its portable architecture will allow for seamless deployment across multiple production lines offering a scalable solution for high-volume manufacturing environments. Conversely, OptiWeld will provide a modular, high-end R&D platform dedicated to the formulation and optimization of rigorous TIG welding procedure specifications (WPS) following ISO 15614.

CaliWeld and OptiWeld address the specialized needs of high-criticality metal industries and precision manufacturing. Based on its established market position, for 2028-2032, WIS expects an additional turnover of about 5 Mio. CHF and 10 additional FTE created in Winterthur.