Welding goes an important way in industries since it connects various substances in a way that the connection they form is inseparable. This process is used in the construction industry, ship building, automobile manufacturing, aerospace engineering industries and many more. Among the numerous welding methods used in industrial applications, orbital welding deserves a special attention since it is a highly accurate, repeatable and accurate method of welding. In the following guide, the reader will learn all about what orbital welding actually is and how it can be used.
What is Orbital Welding?
Orbital welding is an automatic welding process that utilizes a very unique equipment known as an orbital weld head. This tool grips the welding torch and moves it along the length of the joint without requiring any movement or rotation of the workpiece. Orbital welding provides the ability to accurately control the speed of the procedure, the rate at which the wire is fed, the current being used to weld, and the flow rate of the gas used. They are characterized by high productivity, repeatability and quality of the welds made in a very controlled manner.
The Orbital Weld Head
The most important tool of the orbital welding process is the orbital weld head. Its function is meant for joining pipes, tubes and other cylindrical parts with each other in a very precise manner. By means of a readily convertible orbital weld head it is possible to wield different types of welding like for instance gas tungsten arc welding also referred to as GTAW or gas metal arc welding commonly referred to as MIG welding. The Current model has the functionality to rotate the welding torch around the workpiece, making it possible to carry out a full penetration weld. Moreover, the weld head can be instructed to change the welding factors so that there is full control of the entire welding procedure.
Orbital Welding Process
Orbital welding is divided into two main subcategories: Seamless as well as fully automated and semi automated with orbital welding. Only in case of the fully automated orbital weld head the entire process of welding is performed automatically and does not require the participation of a welder. In the case of the semi-automated welding process, while the capable operator tends to install the welding orbital weld head and starts welding, the track of the process is majorly determined by the system.
In orbital welding, an orbital weld head is used to make the weld while welding the joint, the head rotates around the workpiece in such a way that the cross-sectional area of the weld bead formed is circular. The welding voltage, current, wire feed speed, and gas shielding all have been fine tuned into the control of the weld head. When the weld head is moving along the joint, it makes sure that the weld bead lays flat; thus, creating an excellent welded joint.
Advantages of Orbital Welding
Due to the nature of the application of Orbital welding, the following advantages are seen over conventional welding processes. These include:
- High Precision: Since the orbital welding is a well-controlled process it requires accuracy to produce better quality of welds compared to other welding techniques.
- Repeatability: Because the values of the welding parameters are adjusted beforehand, these precise values of welding parameters can be performed repeatedly so as to produce welded joints with matching characteristics in terms of dimensions and material makeup.
- Reduced operator fatigue: Orbital welding is indeed a semi or even fully automatic method and this eliminates the extreme use of manpower and reduces chances of fatigue or inadequate welding.
- Improved safety: On the same note, due to its non-contact procedure, orbital welding lowers the occurrence of welding-related accidents for example; burns, impacts of smoke or toxic gases.
- Versatility: High quality materials which can be used in orbital welding process include stainless steel, carbon steel and aluminum as well as titanium.
Some areas of using Orbital Welding
Orbital welding is common in various industries because it is precise and accurate. Some of these applications include:
- Aerospace: In industrial applications such as aerospace, orbital welding is widely used to join pipes and tubing in high pressure fuel systems, aircraft hydraulic systems and other assemblies.
- Biopharma: Orbital welding is used in the biopharma industry for welding the sterile components like reactors, fermenters and purification systems used in the industry to achieve a high degree of cleanliness in the weld area to avoid contamination.
- Semiconductor: In the formation of semiconductors like wafers and chips, the semiconductor industry employs orbital welding due to the intimate contact from roots and faces as well as micro-joining of major and minor components.
- Nuclear power: Orbital welding is applied in nuclear power plants for joining pipes and tubing for equipment that operates at high temperature and high pressure for long periods.
- Food and beverage: In food and beverage industry, orbital welding is widely used when welding pipes for equipment for food processing to avoid contamination of foodstuffs.
Conclusion
Orbital welding is a sophisticated fabrication method that offers numerous advantages over traditional welding techniques. By utilizing an orbital weld head, this process ensures precise, repeatable welds with exceptional accuracy. The result is consistently high-quality welds, enhanced worker safety, and broad applicability across various industries. With its array of benefits, orbital welding is poised to remain an essential welding process for many years to come.
For those seeking advanced orbital welding solutions, UPM Technology provides cutting-edge equipment and expert support to help businesses achieve unparalleled accuracy, efficiency, and reliability in their welding operations.