Orbital welding is accurate and reliable method employed to weld pipes and tubes in many applications and environments such as chemical, petrochemical and nuclear. Orbital welding ensures that you can produce quality welds without the need for extra handiwork by a specialized technician. Such a process has become common since it is able to minimize mistakes from the human side, standardize, and increase output. In this article, you are going to learn about the detailed guidance of the orbital welding process including the setup and programming phase, execution stage, and inspection phase.
Step 1: Selection Criteria of Orbital Welding Equipment
The first thing in the orbital welding process is the selection of tools. Orbital welding machines can be of a large variety of types, from small, simple devices to large, complex machines. Some factors that should be considered when choosing equipment includes; the type of weld to be produced, the material and thickness of the pipes, the position of the welder, and the quality desired in the weld. The next step is to select a machine that will provide the specific requirements of your project or operation.
Step 2: The preparation of the Welding Components
Ensure that the welding components are well prepared if you are to embark on weld or welding before they start welding. This involves the process of preparing the areas to be welded through several processes such as removing oil, grease, and rust from the surfaces. You must use a wire brush, sandpaper, or any other suitable tool to get rid of the debris. Also, guarantee that the pipes and fittings are properly aligned to one another and then fixed appropriately.
Step 3: Program the Orbital Welder
After that you will need to set the orbital welder to the type of weld you would like to make. To do this, measure type of weld, wire feed speed, voltage, current pulse settings, travel speed and feed into the machine’s control system. The right parameters are important if one wants to produce quality welds. If you feel confused about the correct settings, refer to the producer’s specifications in the manual of your particular machine or contact an experienced welding specialist.
Step 4: The layout of the orbital welding head should be established
The second step following setting of welding parameters is setting of orbital welding head. This include orientating the welding head in relation to the welding joint, to achieve the right torch angle and height of the torch above the joint. The next thing that is of utmost importance as far welding is concerned is the torch position because it has a role to play throughout the welding process with regard to producing a uniform weld. The welding head is also motorised and may be operated manually or on an automated basis if required.
Step 5: The next step is to do the Orbital Welding Process
At this point, the welding equipment has been installed and also initialized, and the welding can commence. Point the welding tool provided at the desired surface and press the start button; the orbital welder will then weld the orbital weld all by itself. During welding, the welding head will travel along the seam to lay down filler metal to form what is known as a weld bead. The welder will also continue to work until the welding joint has been done.
Step 6: Inspect the Weld Quality
When using welding, one should keep an eye on the weld to ensure that it has been uniformly done and the quality is good when the welding process is done. Visual inspection is normally used; it is the process where one assesses the weld to check if it has had cracks, pores and poor joint formation. In case of weld, the other method that can be used is Non destructive testing method which includes the use of ultrasonic testing, radiography or dye penetrant inspection in order to identify any internal or surface crack.
Step 7: Cleaning and Finishing
If further welding is to be done then the welding joint may have to be cleaned in order to remove the slags, the fluxes and other materials. In specific applications, post welding operations may be required, for example, grinding, polishing or coating of the weld as required.
Conclusion
Orbital welding is a highly productive and precise welding technique that significantly enhances the quality and standards of welds. This step-by-step guide ensures that the welding process is executed flawlessly, from selecting the right orbital welding equipment and inspecting weld components to setting up the orbital welder and checking weld quality before and after the process. By adhering to these steps, high-quality orbital welds can be achieved, tailored to the specific requirements of your project.
For those seeking reliable orbital welding equipment and expert guidance, UPM Technology offers advanced solutions designed to help you achieve exceptional results while maintaining precision and efficiency in your welding operations.
