the orbital 

Welding in orbit involves the use of automatic Tunguston inert gas. It makes welding far more precise and less prone to human mistake. The accuracy in welding is ensured since it generates identical welds hundreds of times.

When aircraft companies needed a better way to attach hydraulic lines, they turned to orbital welding in the 1960s. A method was devised that involved revolving the arc produced by a tungsten electrode around the tubing weld junction. The entire process was automated by regulating the arc welding current with a control system. The outcome was an improvement over the previous manual welding procedure in terms of accuracy and dependability.

With the development of compact combined power supply/control systems that could be moved from one location to another on a construction site to perform numerous in-place welds, orbital welding became a viable option for numerous industries in the early 1980s. These systems ran on 110 V AC. Computer control is a feature of modern orbital welding systems. This allows users to save welding parameters for different applications in memory and retrieve them when needed. The method incorporates the expertise of a trained welder, resulting in a high volume of consistent welds with less space for mistake.

Devices for Orbital Welding

After clamping the pipes or tubes into position, an orbital weld head spins an electrode and electric arc around the joint to create the necessary weld. The two main components of an orbital welding setup are the power source and the orbital weld head.

The welding parameters are supplied and controlled by the power supply / control system in accordance with the individual weld program that is either developed or recalled from memory. The power source controls the unit, generates arc welding current, powers the weld head motor, and activates or deactivates the shield gas(es) as needed.

Head for Welding: Most orbital weld heads are enclosed, creating a chamber of inert gas to encase the joint. For welding tubes with wall thicknesses up to 0.154 inches (3.9mm), standard enclosed orbital weld heads are suitable for sizes ranging from 1/16 inch (1.6mm) to 6 inches (152mm). Open design weld heads may accept larger diameters and wall thicknesses.

How GTAW Works Physically

Orbital welding creates a weld by melting the base material with an electric arc that originates from the Gas Tungsten Arc Welding process (GTAW). An electric arc is formed between a tungsten electrode and the material to be joined in the GTAW process, which is also called the TIG process. Arc starting requires the application of a high voltage signal, typically between 3.5 and 7 KV, to ionize the shield gas, which removes its insulating qualities and makes it electrically conductive, allowing a small amount of current to pass through. The arc voltage is reduced to a level where the power supply can supply current for the arc by dumping current into this electrical route from a capacitor. In response to the requirement, the power source supplies weld current to maintain the arc's establishment. The ferromagnetic arc melts the metal that is to be welded, causing it to fuse.

The Purpose of Orbital Welding Machines

The utilization of orbital welding equipment is advantageous for numerous reasons. Having the capability to consistently produce high-quality welds at a speed near the maximum weld speed has numerous advantages for the user:Productivity. When compared to manual welders, an orbital welding system is far superior, and the savings from just one work can cover the expense of the equipment.High standard. When compared to manual welding, the results produced by an orbital welding machine using the appropriate weld program are far superior. Orbital welding is the sole method that can provide the weld quality standards needed for some applications, including welding semiconductor or pharmaceutical tubes.The quality of being consistent. After a weld program is set up, an orbital welding system can do the same weld hundreds of times, removing the typical human error, inconsistency, variable, and flaw from the process.When it's not possible or practicable to spin the tube or pipe to be welded, orbital welding may be the way to go.When the physical size of the welding apparatus is limited due to access space limits, orbital welding may be the best option. If a manual welder would have trouble seeing the weld joint or using a welding torch in a row of boiler tubing, a weld head could be the way to go.Using orbital equipment instead of manual welding is beneficial for many other reasons as well. In some cases, it may not be feasible to check the interior weld of every single weld that is produced. If a certified sample weld can be made, then it stands to reason that subsequent welds produced by an automated machine using the same parameters should likewise be of high quality.



Sectors and Uses of Orbital Welding

The aircraft sector was the pioneer in recognizing the need for orbital welding, as mentioned above. More than 1,500 welded joints can be automatically generated using orbital equipment in a single plane's high-pressure systems.

Orbital welding is a great tool for installing and repairing boiler tubes. Clamping a small orbital weld head between heat exchanger tubing rows makes repeatable welds much easier than with a hand welder.

All weld joints in the food, dairy, and beverage industries must have full penetration welds consistently. There are usually plans on when to clean and sanitize these tubing and plumbing systems. The efficient operation of the plumbing system depends on the tubing being as smooth as feasible. Bacteria can thrive in any imperfect weld joint, fracture, pit, or crevice that might trap the fluid inside the tubing.

Orbital welding has long been favored by the nuclear industry because to the stringent requirements for a high-quality weld and the harsh working conditions seen in this field.

Use in Offshore Environments: Subsea hydraulic lines are constructed from materials whose characteristics can be changed by the typical heat changes that occur during a welding cycle. Orbital welding provides hydraulic joints with exceptional mechanical qualities and resistance to corrosion.

The pharmaceutical industry relies on pipe networks and process lines to supply its operations with potable water. To do this, high-quality welds are necessary to guarantee that the water flowing out of the tubes is free of any contaminants, such as germs or rust. By avoiding overheating, which might reduce the final weld zone's corrosion resistance, orbital welding guarantees full penetration welds.

To avoid contamination buildup on tubing walls or weld joints, the semiconductor sector necessitates pipe systems with an exceptionally smooth interior surface finish. A buildup of contaminants, moisture, or particles could release once big enough to disrupt the batch process.

Pipes, valves, and regulators: Tubing with fittings is necessary for hydraulic lines and gas and liquid delivery systems. Welding productivity and quality can both be enhanced with the use of orbital systems. Welding the tubing into place on a valve or regulator body is a common practice. In this case, the orbital weld head allows for the production of high-quality welds even when access to the weld joint is limited.

A hand-weld retrieved from a manufacturing facility.

Problems with this weld include misalignment, lack of penetration, and

an enormous fissure, and discolouration as a result of inadequate ID purging. Under no circumstances is this weld acceptable.

316L electropolished stainless steel undergoes an orbital weld. An evenly spaced inner weld bead, free of crevices, has traversed the whole weld. The ID was evacuated with argon, which caused the HAZ to become somewhat discolored.

Ugale Mahesh’s


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