Orbital Welding

What is orbital welding and how does it work?

Orbital welding is an automated GTAW process for pipe and tubing,
principally steel, stainless steel, and exotic alloys. The typical system welds
1/8- through 6-inch (3 through 150 mm) diameter material. The main
applications are high-pressure tubing in aerospace and power station
applications, high-purity tubing in semiconductor manufacturing, and
sanitary tubing in food, beverage, diary, and pharmaceutical industries. While
many older analog orbital welding systems are still in use, the latest designs
are digital and use a microprocessor-controlled constant-current power
supply and a welding head in which the welding occurs. The operator
communicates with the system through a keyboard and LCD display. System
software suggests a welding cycle based on the size, joint type, and work
metal, but the weldor can alter and fine tune the welding variables such as
weld speed, number of revolutions, start delay, current level, tacks, and
WELDINGFA BRICATIO&N R EPAIR 93
pre/postweld inert gas flow. A cable connects the power supply with the
welding head to provide welding current, motor control lines, and inert gas. A
clam shell design permits the head to open, fit over the tubing (or pipe) ends,
then close to clamp them rigidly in coaxial alignment.
Once the weldor clamps the ends in the welding head and turns on the
welder, the process is fully automatic. Inert gas fills the head interior to
protect the molten weld metal from the atmosphere. A DC motor drives a
tungsten electrode circumferentially around the outside of the tubing (or pipe)
joint to make the weld. The microprocessor monitors the progress of the weld
to assure the set parameters were accomplished. Some systems have a small
printer in the welding power supply to provide a permanent record of the
weld parameters. Parameters can also be stored, or transferred to other
machines. Figure 3-54 pictures an orbital welding power supply and its
welding head, Figure 3-55 diagrams how welding is done inside the welding
head itself.
What are the advantages of orbital welding?
All the advantages of GTAW: high-quality welds without spatter, smoke,
slag, or filler metal.
Produces high-quality welds with smooth interiors that prevent debris
from hanging up and accumulating inside the pipeline.
Fully automated with welding parameters monitored and verified during
welding, permanently documented, all under microprocessor control.
Weld quality not dependent on weldor’s hand skills.
Faster than hand GTAW process.
Process makes welds in tighter confines than human weldor.
Orbital welding equipment readily moved by one weldor.
What are the drawbacks to orbital welding?
Requires a larger volume of welds to justify the equipment cost.
Tube ends must be machined square, no saw cuts permitted.
High quality, low production rate process.