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Experimental and numerical investigations of pipe orbital welding process

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DOI: 10.1016/j.matpr.2020.04.902

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 Materials Today: Proceedings 27 (2020) 2964–2969

Contents lists available at ScienceDirect

Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Experimental and numerical investigations of pipe orbital welding

process
Nitish Kumar Singh, Sharad K. Pradhan ⇑
Department of Mechanical Engineering, National Institute of Technical Teachers’ Training and Research, Bhopal 462002, India

a r t i c l e i n f o a b s t r a c t

Article history: In this research work, finite element simulation and experimental investigation of Orbital welding pro-
Received 6 August 2019 cess on stainless steel AISI 316 L with different process parameters are performed. For experimental study
Received in revised form 28 January 2020 three process parameters viz. welding current, welding speed and standoff distance to get 9 dominating
Accepted 30 April 2020
experimental sets according to L-9 orthogonal array for each Orbital and TIG welding. Temperature and
Available online 4 June 2020
Tensile strength during the welding process are taken as an output parameter. Weld zone and defect of
welding are checked by Boroscope. Tensile tests are performed on all welded pipe to determine the ten-
Keywords:
sile strength and elongation. Optimization of the process parameter is done using TAGUCHI and ANOVA
Orbital welding
TIG welding
through MINITAB software. The optimum values of input parameters for temperature distribution during
Process parameters orbital welding are 40A current, 0.72 mm/s welding speed and 1.8 mm standoff distance. It is observed
Optimization that welding current affects the temperature distribution maximum 49.83% followed by a welding speed
Pipe welding of 31.53%. Standoff distance has a minimum effect viz. only 8.83%. The optimum values for input param-
AISI 316 L Stainless steel eters for tensile strength during Orbital welding are 40A current, 1.08 mm/s welding speed and 1.6 mm
standoff distance and welding speed affect the tensile strength maximum 35.19% followed by welding
current 21.23%. Standoff distance has a minimum affect only 7.97%. For numerical study, the 3D model
is prepared with orbital welding boundary conditions. The complete orbital welding process is simulated
using ANSYS APDL software to predict temperature distribution and residual stress in the butt welded
pipe. The average error is of the order of 8.2% hence the simulated environment created for Orbital weld-
ing can be used to predict the temperature and other values for any other material with other welding
parameters. The paper ends with a comparison of experimental temperature with simulated temperature
and tensile strength of orbital and TIG welding process.
Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International conference
on Materials and Manufacturing Methods.

1. Introduction
In this research work, finite element simulation of Orbital and
TIG welding process on stainless steel AISI 316L with different pro-
cess parameters are performed followed by experimentation, opti-
mization and comparison of numerical and experimental results of
both the types of welding.
The 3D model is prepared with orbital welding boundary condi-
tion. The complete orbital welding process is simulated using
ANSYS APDL software to predict temperature distribution and
residual stress in the butt welded pipe. Experimentation is per-
⇑ Corresponding author.
E-mail addresses: hknitish@gmail.com (N.K. Singh), spradhan@nitttrbpl.ac.in (S.
K. Pradhan).
formed with three process parameters viz. welding current, weld-
ing speed and standoff distance with three levels each (low,
medium, high) as per design of an experiment to get 9 dominating
experimental sets according to L-9 orthogonal array. Each Orbital
and TIG welding processes are performed on these 9 sets. The tem-
perature during the welding process is recorded as an output
parameter. Optimization of the process parameter is done using
TAGUCHI and ANOVA through MINITAB software. Weld zone and
defect of welding are checked by Boroscope. Tensile tests are per-
formed on all welded pipe to determine the tensile strength and
elongation in both the type of welding. The paper ends with a com-
parison of experimental temperature with simulated temperature
and tensile strength of orbital and TIG welding process. The path
adopted during the complete investigation is represented through
Fig. 1.

https://doi.org/10.1016/j.matpr.2020.04.902
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
 N.K. Singh, S.K. Pradhan / Materials Today: Proceedings 27 (2020) 2964–2969 2965

during TIG double side arc welding (DSAW) process on a low car-
bon steel plate. Guimaraes et al. 2013 [11] Performed numerical
analyses of residual stresses in a TIG weld joint using Finite Ele-
ment Method with ABQUS software on ASTM AH 36 Steel Pipe.
Pengfeiet al. 2011 [12] developed a three-dimensional finite-
element model in the Gaussian manner to simulate the tempera-
ture field of fixed-point TIG welding pool of Q235 steel by the
ANSYS software. Kanaiyaet al. 2017 [13] uses a U type closed orbi-
tal welding head in a specific area of welding where arc from tung-
sten electrode is rotated mechanically through 360° or 180°
theoretically but in practice, it rotates about 410° around the static
workpiece. It is concluded that in the orbital welding process,
parameters like welding current, deposition rate, depth of penetra-
tion, voltage, arc length, current density, flux, tip angle, shielding
gas, electrode, pulse current, standoff distance etc. are of special
importance so far as the quality of the weld is concerned. Hussein
et al. 2016 [14] investigated the process-properties relationship of
welded mild steel tube of dissimilar thickness using Metal Inert
Gas (MIG) orbital welding This study shows that welding current
is the most significant parameter which affected the tensile prop-
erties of welded mild steel tubes compared to jig rotational speed.
Karthikeyan et al. 2016 [15] presented the optimization of process
parameters of Orbital Tungsten Inert Gas welding (OTIG) of stain-
less steel 304 L for a satellite system. Current, rpm and standoff
distance are taken as input parameters. L27 Orthogonal array is
used as the design of the experiment.

Fig. 1. Flow chart of research path adopted. 2. Experimental study

The raw material selected for this experiment is a stainless steel

Orbital pipe welding is a process of welding in which the weld-
316L pipe. Alloy 316L is molybdenum-bearing austenitic stainless
ing head rotates around a fixed horizontal pipe or tube circumfer-
steel. Table 1 depicts the dimension of the selected pipe. For this
entially around the pipe and automated welding process is
performed. It is called orbital pipe welding because the arc travels Table 1
circumferentially around a work piece (usually a tube or pipe). In Dimension of selected pipe.
orbital welding, arc travels at least 360°around the work piece the- Outer diameter (mm) 12.7
oretically but practically the arc travels 410°. Orbital welding is Inner diameter (mm) 11.2
used in pharmaceutical piping welding, dairy product pipeline Inner diameter (mm) 1.6
welding, welding nuclear spent fuel canisters and so on, which Thickness (mm) 203.2
Length of pipe (mm) 36
requires high quality, reliable and high productivity welds.
Number of pipes
Patro et al. 2018 [1] performed experimental and numerical
investigations and optimization of the process parameters during
orbital pipe welding of AISI 304 stainless steel pipes. Rajkumar
et al. 2017 [2] This research paper investigated the heat transfer
behaviour during TIG welding of pipe of Austenitic stainless Steel
304 L using Finite Element Method (sysweld Software). Adak
et al. 2016 [3] simulated thermoelectric plastic rectangular T-
joint plate using Finite Element Method (ANSYS APDL) software.
B.P Abhishek et al. 2015 [4] studied the temperature distribution
and residual stress (output) for a GTAW circumferential butt joint
of an AISI 304 Stainless steel by numerical simulation using finite
element method (ANSYS software) and validation from experi-
ments. Verma et al. 2015 [5] applied the Finite element method
for prediction of residual stress and thermal strain distribution
developed during circumferential TIG welding. Chen et al. 2014
[6] conducted numerical and experimental studies for a St. 37 steel
rectangular plate welding. Islam et al. 2014 [7] performed an effec-
tive numerical approach using MATLAB, SIMUFACT welding soft-
ware. Kumar et al. 2014 [8]. In this research finite element
method is applied for high-density polyethene (HDPE) pipe weld-
ing. Roberto et al. 2014 [9] this paper considered welding as a
thermo-mechanical-metallurgical coupled process. This paper dis-
cussed the different types of heat source model development in
welding simulation process and limitations of each model. Vishnu
et al. 2014 [10] a 3-D thermomechanical simulation model were
developed to predict temperature distribution and residual stress
Fig. 2. Complete orbital welding set up.
2966 N.K. Singh, S.K. Pradhan / Materials Today: Proceedings 27 (2020) 2964–2969

Table 2
Experimental data related to Orbital Welding.

Exp No Input parameter Output parameter

Starting Welding current (A) Welding speed (mm/s) Standoff distance (mm) Tensile Strength (Mpa) Displacement (mm) Temperature (K)
1 35 0.72 1.4 1467.93 21.4 683
2 35 0.90 1.6 1477.88 19.2 663
3 35 1.08 1.8 1514.50 21.9 623
4 40 0.72 1.6 1497.89 21.5 718
5 40 0.90 1.8 1478.59 17.7 755
6 40 1.08 1.4 1487.63 18.8 708
7 45 0.72 1.8 1462.59 17.8 783
8 45 0.90 1.4 1470.68 18.6 710
9 45 1.08 1.6 1483.20 19.1 670

Table 3
ANOVA table of temperature (S/N data).

Source DOF Sum of square Mean square F Value % contribution

Current 2 1.44 0.720 5.03 49.83
Welding speed 2 0.911 0.456 3.18 31.53
Standoff distance 2 0.25350 0.127 0.89 8.83
Error 2 0.258 0.143
Total 8 2.8898

Table 4
ANOVA table for Tensile strength (S/N data).

Source DOF Sum of square Mean square F Value % contribution

Current 2 0.01460 0.0073 0.59 21.23
Welding speed 2 0.02420 0.01210 0.99 35.19
Standoff distance 2 0.005481 0.00274 0.22 7.97
Error 2 0.0244 0.01220
Total 8 0.06876

Table 5
Experimental data related to TIG Welding.

Exp No Input Parameters Output parameter

Starting Welding current (A) Welding speed (mm/s) Standoff distance (mm) Temperature distribution (K) Tensile Strength (Mpa)
1 35 0.72 1.4
2 35 0.90 1.6 814 1165.5011
3 35 1.08 1.8 806 1217.0889
4 40 0.72 1.6 790 1194.5431
5 40 0.90 1.8 801 1240.39
6 40 1.08 1.4 782 1413.8866
7 45 0.72 1.8 828 1323.7036
8 45 0.90 1.4 818 1280.140
9 45 1.08 1.6 829 1242.6917

Table 6
ANOVA table of temperature (S/N data).

Source DOF Sum of square Mean square F Value % contribution

Current 2 0.1986 0.0993 13.56 85.88
Welding speed 2 0.00618 0.00309 0.42 2.67
Standoff distance 2 0.01180 0.00590 0.81 5.10
Error 2 0.01464 0.007322
Total 8 0.231245

Table 7
ANOVA table for tensile strength (S/N data).

Source DOF Sum of square Mean square F Value % contribution

Current 2 0.9874 0.4937 1.79 40.77
Welding speed 2 0.3693 0.1847 0.67 15.25
Standoff distance 2 0.5144 0.2572 0.93 21.24
Error 2 0.5503 0.2751
Total 8 2.4215
 N.K. Singh, S.K. Pradhan / Materials Today: Proceedings 27 (2020) 2964–2969 2967

research work, orbital welding machine (Fig. 2) set up with orbital

welding closed head CA-75Mas available at UNIVERSAL ORBITAL
SYSTEM PVT. LTD. Dharavi, Pune is used to perform all the exper-
iments. After cutting the pipe stock into 18 numbers of pieces of
8 Inch length each the ends of all the pipe pieces are faced on lathe
machine. The input parameters viz. Current, Welding speed, Stand-
off-distance is set on the selected machines (Orbital and TIG)
according to the design of the experiment table. In case of Orbital
welding, each pipe pair is mounted in the welding head in butt
weld position and argon gas pipe is inserted from one end of the
pipe set while the other end is closed with an industrial tap. The
‘Orbitron power source’ is set to manual from automatic and weld-
ing is performed by pressing the ‘Run’ button. After welding is over
the welded pipe is removed from the head and the joint is
inspected through BOROSCOPE while the temperature is measured
with a thermometer. The same procedure is repeated for all 8 pipe
pieces. For TIG welding the same procedure is applied with TOR-
NADO TIG 315 welding machine. The measured tensile strength
and temperature of 2 sets of 9 welded pipes through Orbital and Fig. 5. Residual stress of Experiment after Orbital welding.
normal TIG welding is shown in Tables 2 And 5.

3. Optimization of orbital welding process parameters Table 8

ANSYS result of temperature and residual stress for orbital welding.
Orbital welding experimental values are optimised using Tagu- Experiment no. ANSYS Temperature (K) ANSYS Residual stress (Mpa)
chi orthogonal array and ANOVA and the effects of individual orbi-
1 712.60 384.0
2 613.596 214.56
3 550.773 176.55
4 755.308 239.96
5 666.391 207.7
6 556.39 191.5
7 801.819 216.28
8 691.925 199.43
9 616.39 183.81

tal welding process parameters on the selected quality

characteristics are calculated separately and presented through
Tables 3 And 4.
It can be observed from Table 3 that welding current affects the
temperature distribution maximum 49.83% followed by welding
speed 31.53%. Standoff distance has minimum affect only 8.83%.
Similarly, from table 4it can be concluded that the welding speed
affects the tensile strength maximum 35.19% followed by welding
current 21.23%. Standoff distance has minimum affect only 7.97%.
Fig. 3. Temperature distribution after just welding Experiment 1.
4. Optimization of TIG welding process parameters

A similar approach is applied for TIG welding with same weld-

ing parameters and pipes so as to compare the degree of superior-
ity of Orbital welding. The experimental results of Temperature
and Tensile strength so obtained with TIG welding are tabulated

Table 9
Comparative table of experimental and simulated result (Temperature field) of orbital
welding.

EX No. Experimental Temperature Simulated Temperature Error

(K) (K)
1 683 712.60 4.24
2 663 613.596 7.45
3 623 550.773 1.5
4 718 755.308 5.19
5 693 666.391 3.84
6 708 556.39 21.4
7 783 801.819 2.40
8 710 691.925 2.54
9 670 616.39 8.00
Fig. 4. Temperature vs time curve of Experiment 1.
2968 N.K. Singh, S.K. Pradhan / Materials Today: Proceedings 27 (2020) 2964–2969

Table 10
Comparative table of experimental temperature distribution of TIG and Orbital welding.

Ex no Orbital experimental temperature (K) TIG experimental temperature (K) Orbital Tensile strength (Mpa) TIG Tensile strength (Mpa)
1 683 812 1467.93 1161.6591
2 663 814 1477.88 1165.5011
3 623 806 1514.50 1217.0889
4 718 790 1497.89 1194.5431
5 693 801 1478.59 1240.39
6 708 782 1487.63 1413.8866
7 783 828 1462.59 1323.7036
8 710 818 1470.68 1280.140
9 670 829 1483.20 1242.6917

Fig. 6. Load-displacement graphs of experiment no 5 (Orbital Welding).

in Table 5 and after optimization, the optimised values are given in

Tables 6 And 7
It can be observed from Table 6 that welding current affects the
Temperature distribution maximum 85.88% followed by Standoff
distance 5.1%. Welding speed has a minimum affect only 2.67%.
Similarly, from Table 7, it can be concluded that welding current
affects the Tensile strength maximum 40.77% followed by Standoff
distance 21.24%. Welding speed has a minimum affect only 15.25%.

5. Simulated results of orbital welding process

The simulation is performed with two selected pipes with butt

welding joint setup using ANSYS APDL. Three input parameters
with three levels and two output parameters are selected to per-
form the simulation. The FE analysis was carried out in two steps.
A non-linear transient thermal analysis was conducted first to
obtain the global temperature distribution generated during the
welding process and sequentially, in the second stage, stress anal-
ysis is done with temperatures obtained from the thermal analysis
as loading on the model.
Fig. 7. Load- Displacement graph of experiment no 5 (TIG Welding).
iment No 7 with welding parameters (current = 45A, welding
speed = 0.72 mm/s, standoff distance = 1.8 mm) has highest tem-
perature rise in 8.76 sec time while Experiment No 3 with welding
parameters (current = 35A, welding speed = 1.08 mm/s, standoff
distance = 1.8 mm) has lowest temperature rise in 8.5sec time.

5.1. Temperature distribution 5.2. Residual stress

A non-linear transient thermal analysis was conducted first to After performing the non-linear transient thermal analysis, in
obtain the global temperature distribution generated during the the second stage, stress analysis is done with temperatures
welding process and the temperature distribution results obtained obtained from the thermal analysis as loading on the model. The
for experiment 1 as sample are presented through Figs. 3–4. Exper- temperature results of Experiment 1 as the sample is presented
 N.K. Singh, S.K. Pradhan / Materials Today: Proceedings 27 (2020) 2964–2969
through Fig. 5. Experiment No 1 with welding parameters (cur-
rent = 35A, welding speed = 0.72 mm/s, standoff dis-
tance = 1.4 mm) has highest residual stress 384.0Mpa, while
Experiment No 3 with welding parameters (current = 35A, welding
speed = 1.08 mm/s, standoff distance = 1.8 mm) has lowest resid-
ual stress 176.55Mpa.
The temperature and residual stress values obtained above are
tabulated and presented in Table 8.
6. Comparison of simulated and experimental temperature
distribution of Orbital welding
Experimental and simulated results of the temperature distri-
bution of orbital welding are shown in Table 9.
The maximum error is 21.4 % which is present in only one case
but otherwise the average error is of the order of 8.2% hence the
simulated environment created for Orbital welding can be used
to predict the temperature and other values for any other material
with other welding parameters for welding pipes using orbital
welding process.
7. Comparison of experimental temperature distribution and
tensile strength of TIG and orbital welding
Experimental values of Maximum Temperatures and Tensile
strength of TIG and Orbital welding are shown in Table 10. The
temperature generated in Orbital is less as compared to TIG for
the same welding input parameters but the quality of the weld is
very superior in Orbital welding as compared to TIG welding. It
is obvious that the strength of Orbitally welded pipes is higher
than the TIG welded components which show that Orbital welding
not only creates aesthetically improved joints but also high
strength welds. Figs. 6 and 7 show the comparison of Load Vs
Deformation curves for both Orbital and TIG welding processes.
8. Conclusion
In present study following are the results and concluding
remarks which have been obtained during the above research
attempt:
 The optimum values of input parameters for temperature distri-
bution during orbital welding are 40A current, 0.72 mm/s weld-
ing speed and 1.8 mm standoff distance (Table 2)
 During orbital welding, It is observed that welding current
affects the temperature distribution maximum 49.83% followed
by welding speed 31.53%. Standoff distance has minimum effect
viz. only 8.83% (Table 3).
 The optimum values for input parameters for tensile strength
during Orbital welding from Table 6.9 are 40A current,
1.08 mm/s welding speed and 1.6 mm standoff distance.
 During orbital welding, It is also observed that welding speed
affect the tensile strength maximum 35.19% followed by weld-
ing current 21.23%. Standoff distance has minimum affect only
7.97% (Table 4).
 In case of TIG welding of same pipes, it is observed that the
Temperature is optimum when Current is 45 A, welding speed
is at 0.90 mm/s (40% of maximum speed) and standoff distance
is 1.8 mm (Table 5).
 In case of TIG welding of same pipes, it is also observed that that
welding current affect the temperature distribution maximum
85.88% followed by Standoff distance 2.67%. Welding speed
has minimum effect viz. only 5.10% (Table 6).
View publication stats
2969
 During TIG welding, the optimum values of input parameters
for Tensile strength are 45amp current, 1.08 mm/s welding
speed and 1.4 mm standoff distance (Table 5).
 During TIG welding, it is also observed that welding Current
affects the tensile strength maximum 40.77% followed by
standoff distance 21.24%. Welding speed has minimum effect
viz. 15.25% (Table 7)
CRediT authorship contribution statement
Nitish Kumar Singh: Software, Formal analysis, Investigation,
Resources, Data curation, Writing - original draft. Sharad K. Prad-
han: Conceptualization, Supervision, Writing - review & editing,
Project administration.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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