Description

Lincoln HyperFill – Increase Deposition Rates Up to 100%

The Lincoln HyperFill Twin-Wire Solution is a licensed, proprietary welding process developed to dramatically increase productivity in heavy fabrication environments. Designed for high-deposition welding, HyperFill® allows fabricators to achieve up to 100% higher deposition rates compared to conventional single-wire applications.

Engineered for both semi-automatic and robotic applications, HyperFill® makes larger welds faster and easier — without increasing system complexity.

How HyperFill® Works

HyperFill® uses a patented twin-wire feeding system that operates through:

• A single power source
• A single feeder
• A single contact tip
• A single gun liner
• A single electrical arc

Despite feeding twin wires, the system maintains minimal complexity while delivering significantly higher deposition rates and faster travel speeds.

The result is a large, stable weld puddle that remains easy to control, even at high output levels.

Proven Deposition Performance

Compared to traditional 1.2mm single-wire FCAW:

• Standard single wire: approx. 4.5 kg/hr
• HyperFill® twin-wire: 6.8–9.0 kg/hr
• Robotic applications: 8+ kg/hr achievable

This translates into substantial welding time savings when depositing high volumes of weld metal.

For structural steel, heavy fabrication and production welding, this means:

✔ Faster weld completion

✔ Increased throughput

✔ Reduced labour hours

✔ Higher overall profitability

Minimal System Complexity

HyperFill® improves productivity without adding setup headaches:

✔ Single power source

✔ Single feeder

✔ Single arc

✔ No additional control cables

The system integrates with compatible Lincoln Electric Power Wave® and PIPEFAB™ systems using a licensed HyperFill® waveform.

Note: HyperFill® waveform activation may require compatible premium Lincoln Electric wire or separate licensing.

Available Package Options

🔴 K3168-HD – Solid Wire Package

Configured for use with compatible Lincoln solid wire consumables. Ideal for structural and fabrication applications requiring smooth arc performance and high productivity.

🔴 K3168-1HDMC – Metal Core Package

Configured for metal core applications, delivering high deposition with excellent weld profile and reduced spatter. Ideal for heavy fabrication and production environments.

Both packages are sold as licensed welding and consumable systems.

Applications

• Heavy fabrication
• Structural steel
• Production welding
• Robotic welding cells
• High deposition FCAW operations
• Industrial manufacturing

Why Choose Lincoln HyperFill®?

✔ Increase deposition rates up to 100%

✔ Make larger welds faster

✔ Stable, controllable arc performance

✔ Minimal added system complexity

✔ Designed for semi-automatic and robotic welding

HyperFill® isn’t just equipment — it’s a productivity solution built for serious fabrication.