Welding is one of the most ancient processes encompassing several industries, which have served to join metals and alloys. For many years welding has been changing and has gone through many improvements to come up with better welding methods and technologies. One of these technologies is the orbital welding technology that has gains popularity in many fields of industrial usage.
What is Orbital Welding?
Orbital welding is one of the broadly used fully automatic welding procedures that employ a welding machine with an orbital motion round the workpiece. Welding is automatic and is accomplished by a CNC program to achieve uniform and quality welds on complex and/or hard to reach locations. The term ‘orbital’ comes from the circular motion through which the welding torch moves like an orbit around an object.
In orbital welding the welding power source is fixed on a support or a holder and the welding torch and wire feed unit follow a circular arc pattern around the component to be welded. This leads to developing high-quality weld geometry that is accurate and does not require a human operator to control the torch or the welding factors independently.
How does Orbital Welding Operate?
Orbital welding uses such types of welding techniques as GTAW, also known as TIG welding, and the GMAW, also known as MIG welding. The particular process employed varies according to the material being joined, the quality of the weld needed, etc.
In GTAW orbital welding, using a non-consumable electrode of tungsten, an arc is struck between the electrode and the work piece with a covering shield of an inert gas which is normally argon. The welding wire known as the filler metal is melted and added to the weld junction to make up the weld. It is operated by a programmable computer device which controls the feed rate, heat energy and other parameters resulting to quality production of the weld.
The use of GMAW orbital welding involves a continuously forwarded consumable wire electrode and the protection of the arc by an inert or a semi-inert gas. In this process, droplets of the filler metal from the wire electrode are deposited on the workpiece and become the weld. Comparable to GTAW, the procedure of welding is computer aided, the Computer control of wire feed, voltage, current and the other vital parameters are controlled.
What is the Increasing Interest in Orbital Welding?
The technique of orbital welding provides a number of benefits over the manual welding and this is the reason that why the orbital welding technique is emerging as an industrial standard method of welding technology. Some of the main reasons include:
- Improved Weld Quality: Compared to manual welding, the Orbital welding provides a high degree of accuracy and repeatability, reduced defects and imperfections. This is because the various welding parameters are well set and regulated by the computer making sure that its environment is the best all through the welding.
- Enhanced Safety: Orbital GMAW also does not require the operator to hold the torch or work close to the welding arc therefore avoiding cases of burns, heat stress, or other welding injuries. Secondly, the process of separation is automated which minimizes the risk of operation error, thus increasing safety.
- Increased Efficiency: Orbital welding can often be faster than manual welding because large scale welds and complex welds can be more easily achieved through orbital welding. These enhanced efficiency can translate into shorter time taken to per produce a product, reduced cost of labor and in general increased productivity.
- Greater Precision: Orbital welding is characterized by a high degree of control and a relatively large amount of automation, thus rendering somewhat greater accuracy and repeatability even in difficult to gain access or highly complex geometries. This is particularly important in industrial applications where weld quality and positional accuracy is paramount; they include the nuclear, aerospace and pharmaceutical industries.
- Versatility: The orbital welding process does not have any limitations with the type of material or the process used in the welding of the material. This ability means that orbital welding is capable of being fine tuned for any project’s particularities and limitations.
Conclusion
Thus, orbital welding offers inherent advantages over other welding processes, including unmatched accuracy, reproducibility, and superior weld quality. These attributes make orbital welding ideal for industries where high-quality welds are critical to ensuring safety and operational efficiency. While the initial investment in orbital welding equipment may be significant, the long-term cost savings and efficiency gains make it an indispensable technology for welders. Looking ahead, orbital welding technology is poised for continuous growth, with its potential applications expanding across various industries.
For businesses aiming to leverage the benefits of orbital welding, UPM Technology provides advanced welding solutions that deliver precision, efficiency, and long-term value, ensuring your operations stay ahead of the curve.
