A Complete Guide To Buying Orbital Welding Equipment

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18.07.2014
orbital welding, orbital welding equipment, orbital welding system

A Complete Guide To Buying Orbital Welding Equipment

Orbital welding is an economical and viable method for connecting stainless steel tubing, particularly in applications in which high performance, maximum leak integrity, ultra cleanliness, and vibration resistance is of utmost importance. It is not a surprise, then, that more and more companies are opting for this system to get their jobs done. If you are considering orbital welding, it is important to remember that not all systems are alike. You can take steps to make sure that the selection of equipment that will meet your specific needs while maximizing efficiency and productivity.

Choose The Right Orbital Welding System

Remember that price is not the primary determinant of whether an orbital welding system is right for your application. There is not much difference in price among orbital welding systems, but the capabilities of every system can be very different. An orbital welding system is a capital investment. Determine if the system is designed in a manner that allows for modifications, like the acceptance of new software. It is important that you study what every system can offer; you would not want to invest on something that renders itself obsolete after just a few years. For one, you need to make sure that that you get systems with the best features, or those that suit your needs best. Below are some capabilities to consider when getting orbital welding equipment sale:

Factors To Consider When Buying Orbital Welding Equipment

• Mobility: There are some systems that are compact and lightweight, while others are bulkier. If you need to move into tight spaces or travel, go for the lighter weight model, so you can quickly and easily move from one job to another.

• Power: Consider input and output capacities: Some systems output 100 amps from a 110 V/20 amp line. Others require a 110 V/30 amp line to create the same 100 amp output. If you use traditional power sources and want to avoid upgrades, get systems that can be powered by 110 V/20 amp lines.

• Weld head and fixturing flexibility: In orbital welding tubes to fittings or tube to valves or similar combinations, you want a system in which the weld heads and fixtures can easily be adapted for a quick setup change. There are some fixtures that can be taken apart and reconfigured to accommodate a range of weld setups. Detachable fixtures and remote controls allow joints to be pre-positioned and allow orbital welding to be done in tight places.

• Programming: There is a program or procedure that should be developed for every weld type. These programs need to be adjusted and stored to accommodate variations in material heats. If your application at any time requires extensive weld programs, get a system with technology that makes the programming process simpler. A system that is user-friendly can allow programs to be built in an accurate and consistent manner via auto-generation capabilities. These reduce human error and shave up to 90 minutes off the time devoted to building programs.

• Documentation: The process of documentation can be time consuming and expensive. Detailed weld logs should be kept, and the information usually is entered in databases. Get a system that automatically logs and stores data for easy transfer and retrieval to databases. This reduces the cost and time of documentation.

• Data management: Data management features enhance greatly the ability to track trends, calculate costs per weld and review production rates. This can go a long way to improving bid accuracy, lowering costs and improving efficiency.

Maintenance and serving programs are just as important as the equipment itself. If something should go wrong, you would be want to be forced into huge downtime because of the responsiveness issues of the manufacturer. See if a supplier has a local network of service providers, giving easy access to replacement equipment and maintenance. See if the manufacturer gives backup equipment for free. Training, which improve orbital welding protocol and play a role in getting weld consistency, is another important consideration. Training programs from equipment supplies can vary. Some focus on how to give genuine orbital welding courses, while others on learning the usage of the controls of a particular type of equipment.

Go For Orbital Welding

In conclusion, make sure that you do your homework before and during the selection process. If you focus your sights on these areas, you can maximize performance and achieve high quality, repeatable welds on a consistent basis. Choosing pro fusion welding equipment can have a direct effect on whether compliance is achieved in the most efficient, productive and cost-efficient manner. Most importantly, ensure that you choose a reputable company or manufacturer from where you will buy your equipment.

Reuben Salazar

Most Common Applications Of Orbital Welding

The process of orbital welding got its name from the fact that an electrode rotates around the stationary product that is being welded. As with tungsten inert gas welding (or TIG welding), an electric arc is produced between a non-consumable tungsten electrode and the metal that is welded. The weld pool is made up of the base metals themselves. Orbital welding is especially valuable in applying quality welds to tubes and pipes, as well as other difficult or complicated welds.

Since its birth in the 1960s, orbital weld systems have since then evolved to cater to the growing needs and technologies through time. Today, they have computer programs that can store welding parameters in memory. This basically allows the skills of a certified welder to be programmed into the system, allowing the on-going production of identical welds, and virtually eliminating welder error and defects.

The commonly used 300-series stainless steels offer a high degree of weld ability using orbital equipment, except for types 303/303SE, which allow for machining ease. The 400-series stainless steels, while weldable, may require post-weld heat treatment. Welders adjust the orbital-welding setup to accommodate for potential differences among material heats.

Other Applications Of Orbital Welding

• Aerospace – The aerospace industry was the first to use automated orbital welding. The high pressure hydraulic systems of a single aircraft can contain more than 1,500 welded joints.

• Boiler-tubes – Boiler-tube installation and maintenance offer perfect scenario for orbital welding. Compact orbital weld heads can be placed in between rows of boiler tubes.

• Food, dairy and beverage industries – This sector of the industry requires consistent full-penetration welds on all weld joints. For maximum piping system efficiency, the tubing and pipe welds must be as smooth as possible. Any defect or incomplete weld joint can trap fluid inside the pipe or tubing, harboring bacteria.

• Nuclear piping – The nuclear power industries severe operating environment, and specifications for high quality welds, has long been a user of orbital welding.

• Offshore applications – Submerged hydraulic systems welded with orbital equipment offer superior corrosion resistance and mechanical properties.

• Pharmaceutical industry – Pharmaceutical process lines and piping systems require high quality welds to ensure a source of water from the tubes is uncontaminated by rust, bacteria and other contaminants. Orbital welding ensures full-penetration welds with no overheating that can affect the corrosion resistance in the welded joint.

• Semiconductor industry – The semiconductor industry requires piping systems with very smooth internal surface finish to prevent contaminant build-up on the tubing wall or weld joints. A build-up of particulate, moisture or contaminant could increase and ruin the batch process.

• Tube fittings, valves and regulators – Hydraulic lines, oil and natural gas storage, delivery systems, and medical gas systems all require consistent quality and defect-free welds. Orbitally welded systems give the means to ensure high productivity of welding and optimal weld quality.

Find Certified Orbital Welding

If you are looking to weld parts for any of the industries listed above – or for any other not found above – look for a certified orbital welding company to do it for you. Ensure that they have certified orbital welders to ensure quality work.

Reuben Salazar

Orbital Welding Is Widely Used In Different Industries

Orbital welding is a specialized kind of welding. Many essential industries used this kind of welding process. Orbital welding virtually replaced the manual type of welding. The process is more favored in highly specialized industries because the results are very neat, much more precise, and it is highly efficient.

The term ‘orbital welding’ pertains to the method of joining tubular objects together. There are several unique challenges when it involves the orbital welding method. It is different as compared to the traditional flat welding because the materials involved are totally different, different tools are required, and the amount of complication in the welding process. It needs a very trained welder to do the job.

Why Orbital Welding Is Different?

Orbital welding tools are distinct in their function and type. In orbital welding, tubes and pipes are put together in order that movement is eliminated. A device referred to as an orbital weld head rotates an electrode within the welded area to make the desired results. Weld heads are readily available in various sizes, styles, and shapes. A different kind of weld head is usually used if there are area restrictions and if there is a particular part to be welded.

If the area has more surface, the more heat is needed to finish a successful weld. Therefore, larger tube and pipe diameters need a great deal of heat and energy to weld. That is why weld heads with a cooling mechanism are very popular by welders. Companies like this cooling feature since it permits for a better work without having discomfort, wear, and much safety.

Orbital welding could sound new to you but there are a variety of functions and comforts that you merely enjoy every day without learning that orbital welding has made it possible. Gas and fluid distribution on your property is a good example that is something not possible without orbital welding. In the construction industry, numerous metals have special challenges when it involves orbital welding. But, a well-trained welder even though it is a difficult material to weld like alloy and alternative precious metals will be handled and effectively welded.

Orbital Welding In Different Industries

Welding a pipe that will be distributed throughout a home or business is offered with utmost importance because it is handling gas products. When safety is jeopardized, it might threaten people and property if the work is not correctly done. Oxygen analyzers are sometimes used to ensure that the oxygen content is low enough to give a weld and in just specific limits so that no likelihood of a gas leak or other malfunction might occur.

The food, dairy and beverage industries need to have orbital welding on all weld joints. Most of their piping equipment has regular schedules for cleaning as well as sterilization. Their piping system should be extremely clean and smooth as possible because any imperfect weld joint can be a placed where bacteria can get in and develop. In pharmaceutical industries they need their piping system to deliver high quality water to be used in their various procedures. This will need orbital welding to ensure a supply of water from the tubes is not infected by bacteria, rust or different impurities.

Reuben Salazar

Advantages Of Orbital Welding

Orbital welding is a special kind of welding technique that is used primarily to bond larger sizes of pipe. This welding technique was initially developed over fifty years ago. Welding is a method that uses heat and melting to bond 2 metal parts. Welding can be done either in your home, welding shop, or on the site itself. Welding is used to repair your vehicle, a pipe, or any two metal parts that must be joined permanently. Orbital welding is specialized method where the arc is mechanically rotated around a static work piece, like for instance a pipe, in a very continuous process.

Whole Orbital Welding Process

The whole welding process normally includes the power supply, controller, the welding head and when necessary a wire feed device which will be connected. The welding result varies depending on the factors involved. The thermal conductivity of the two materials, the length of the arc, the frequency of the current, and weld preparation are some of the factors involved.

Some welding positions will result to poor quality welding finish if you do not know the technique in orbital welding. Like for example, welding for overhead materials usually will lead to defective and unstable weld. The limited approach to the work piece can also be a hindrance to an effective weld. To have a good and effective weld the welder must have complete control of the material at each position the machine is used.

Modern technique of the welding method is using a machine to do the welding and run by a computerized program. In this kind of method, the welder only monitors at the same time controlling the whole welding process. Before any welding work, the welder has to put the whole welding parameters in a program for the machine to follow. However, in the real world, that is not always possible because of restrictions posed by location and different circumstances. The welder must observe the welding process and make the necessary corrections if there are problems in the operation.

Orbital Welding Is Very Important In Many Industries

In some industries this kind of welding technique is very important. Like for instance the pharmaceutical and semiconductor industries where high levels of quality weld is needed. With automation this kind of technique eliminates the possibility of human error. Consistency of the weld is also necessary in these industries. Once the welding program is set up, the machine will produce the same pattern repeatedly for a number of times. It is more productive compared to using a manual welder.

Orbital Welding Is Very Reliable

Orbital welding is most typically accomplished by using Tungsten Inert Gas (TIG). This technique of welding uses non-consumable electrodes along with cold-wire feed when necessary. This welding technique permits for numerous kinds of metals to be welded including, corrosion resistant , high temperature and strength steels. Unalloyed and low-alloyed carbon steels, like titanium, nickel alloys, aluminum, copper, and other kinds of alloys will all be welded using this unique welding method. In order to make sturdy welds, welding process should be done in a non-moving surroundings. Orbital welding technique produces welds that are very clean, consistent, have minimal particle counts and free from dirt.

Reuben Salazar

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A Complete Guide To Buying Orbital Welding Equipment

Choose The Right Orbital Welding System