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The history of orbital welding dates back to the 1960s when it was first implemented to mitigate fluid leaks in the famous X-planes series of experimental aircraft. Since then, the process has been used in rockets, commercial passenger aircraft, petrochemical industries, semiconductors, and biopharmaceuticals. The unique properties and benefits of orbital welding — along with processes such as Metal Inert Gas (MIG), Submerged Arc Welding (SAW), Flux Core Arc Welding (FCAW), and laser beam arc welding — soon extended to industries beyond aviation. However, Gas Tungsten Arc Welding (GTAW) continues to yield welds of superior strength and quality. Below, we detail the types of orbital welding, the benefits and components of GTAW orbital welding, and its continued popularity across industries.
Orbital welding was designed specifically to address the inconsistencies of manual welding caused by human error and fatigue that can compromise weld quality. By automating the welding process, manufacturers can ensure the consistency necessary to meet quality standards and improve productivity. In high specification industries, orbital welding has replaced manual arc welding processes for applications where the tolerances do not allow for any errors and flaws are costly to repair. The quality and precision of the final weld are determined by the properties of arc, metal deposition, and weld cleanliness. The following are the most common orbital welding processes.
This wire feed welding process utilizes an inert shielding gas such as carbon dioxide, argon, or helium to prevent weld contamination; the consumable electrode is fed wire continuously as it travels. Also known as Metal Inert Gas (MIG) welding, it is the most common form of wire feed pipe welding and is the fastest common welding practice. However, with unreliable and unpredictable sidewall fusion and penetration, GMAW is a gamble for high-specification projects and often requires reworking.
Utilizing wire with a core of flux as an electrode, the FCAW welding process is forgiving and offers welders more options to approach the weld. The flux core shields the weld from contaminants and is less easily disrupted by environmental factors. FCAW can be used in remote locations with little or no shelter from the outside environment. However, the flux core requires more amperage to start the arc than a gas shielded process like GMAW or GTAW, making it difficult to utilize FCAW for welding thin-walled materials. Excess heat can increase the chances of heat distortion, even in thick-walled stainless steels. And increased heat distortion during welding can make meeting specifications more challenging.
GTAW welding utilizes a tungsten electrode that creates a narrow arc directed at the workpiece with an inert shielding gas preventing oxidation and other contamination during welding. The high degree of control in the welding process yields precise and consistent welds. Carefully controlled gas promotes weld purity that makes stronger welds. The process is also deployable in a variety of environments. With enough wind screening and forethought, operators can set up GTAW in an outdoor environment; this, however, is rare. However, compared to other welding processes, GTAW is complex and is difficult to learn. Mastering GTAW requires a great deal of practice.
Considered a more advanced type of GTAW welding, PAW uses two kinds of gas, one for shielding the weld and the other for generating plasma. Like the TIG welding process, plasma arc welding utilizes a tungsten electrode to create a plasma arc, generating heat. The benefit of plasma arc welding is the arc control that produces superior quality welds regardless of material thickness. However, the larger heat-affected area created by PAW (compared to TIG welding) can cause heat distortion or metal stresses that can weaken or ruin the workpiece. Also, the welding process utilizes large weldheads, limiting PAW’s range of environments.
As one of the older welding processes, SAW utilizes a continuously fed wire as an electrode, with the flux falling out of the hopper and burying the weld as it progresses. Although the process yields high-quality welds and is very fast, it is limited to welding in a fixed and, generally, flat position. Process immobility and increased material consumption mark the main disadvantages of SAW.
This fusion welding process utilizes laser beams to join metal pieces. It is widely performed in high-volume applications using automation, such as the automotive industry. Because of its energy density, the laser beam arc welding process enables operators to melt the area located at the edges of the joint without affecting a large area. The high aspect ratio welds produced with a relatively low heat input compared to other arc-welding processes is one of the major advantages of deploying this welding process. However, laser beam arc welding is expensive, and the equipment size limits its usage to purpose-built environments.
Of the welding processes described, the GTAW process stands out. It offers a high degree of control over amperage and weld to produce pure-finished welds in high-specification projects. This can be credited to the flexibility of use that facilitates deploying the weld head and power supply where needed without requiring a special rig. The complexity of the welding process and the difficulty of finding skilled welders who have mastered this process can be effectively addressed through automated orbital GTAW welding.
In high-specification and critical projects, there is no room for error that might result in system failure. The reliability and safety provided by GTAW orbital welding in such projects minimize human error while producing consistent, high-quality welds to meet specifications. The key benefits of GTAW orbital welding are:
GTAW orbital welding produces high-quality, pure welds free from contamination by atmospheric oxygen, hydrogen, or nitrogen, making GTAW orbital welding ideal for applications that require hygiene and purity.
In automated GTAW orbital welding, the weld head travels steadily and consistently, ensuring high-quality and repeatable welds.
With higher quality welds, automated GTAW welding improves productivity by reducing rework and damaged material costs in high-specification, low tolerance environments.The benefits of GTAW orbital welding are attributable to the elements deployed in the welding process that improve the manual GTAW welding process and allow welders to create continuous welds.
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