Welding is an important procedure employed by various companies for the joining of metal components in their products such as in aerospace, automobile, and energy segments. One of the more common types of welding that has gained a lot of attention is orbital welding. This works out to be accurate and consistent and it’s suitable for use in high precision and demands industries.
In this article, we will provide readers with in-depth information about orbital welding; the physics, metallurgy, and other details that placed this technique on the map of welding industry stars. We will also examine some of the tools used and some uses of orbital welding across various industries.
Physics of Orbital Welding
Orbital welding further can be defined as a very accurate computerized version of GTAW or more commonly referred to as TIG welding. This method uses a non-consumable electrode of tungsten that is clamped on a work holder while the filler metal is deposited at the joint.
Understanding of concepts in orbital welding physics can be driven by first considering the electric arc between the tungsten electrode and the workpiece. The arc is a plasma that’s maintained by having a small space between the electrode and workpiece. The example of such plasmas is the plasmas containing ions and free electrons capable to transfer electric current.
In orbital welding, the welding torch is positioned on a robotic structure or rail and the weld joint has the arc dragged along. [The robot] intricately position, open and close the torch, set the correct speed and direction to maintain a good weld bead.
Another major consideration in orbital welding is the shielding gas used in the process and this is argon or helium among others. The shielding gas acts to protect the molten weld pool from oxidation or contamination in order to produce good quality welds.
The Metallurgical logic behind the Orbital Welding
The metallurgy of orbital welding is based on the various manifestations during the welding process which are occasionally of major concern. When the heat input from the arc melts the base metal and the filler wire, a sequence of transformations take place to produce the formation of solid weld bead.
The first process is the formation of a molten pool at the base metal and the filler wire. The heat input from the arc define the size and the depth of the pool. High heat input rates cause high penetration rates and large weld bead size and low heat input rates might create poor fusion or lack of penetration.
When they are solidifying, the molten pool is beginning to cool and turn into a solid weld bead. The cooling rate of the base metal and the pattern in which it solidifies varies with composition and heat inputs. It was observed that the kind of microstructure that forms during the solidification process in the weld metal does influence the mechanical properties of the welds such as strength and ductility.
Another important factor in the metallurgy of orbital welding is heat affected zone (HAZ) which plays an important role in controlling the properties of resultant weld metal. This is that zone of the base metal that is altered in terms of its microstructure specifically due to the heat influence of the welding procedure. Thus the extent of the HAZ and the extent of microstructural changes vary in dependence to the base metal type and the parameters of welding process.
Some of the practical use of Orbital Welding
Orbital welding is quite flexible because it may be used in any industry. Some of the most common applications include:
- Aerospace: In this sector, orbital welding is applied to connect very important parts, other than fuel tanks, tubing, and pipe systems. Aerospace demands high quality welds because rust has a direct impact on life of the airplane and safety of passengers on board or travelers.
- Automotive: Auto makers employ orbital welding in joining together various parts, for instance fuel conduits, coolant conduits and exhausts. os and strong welds provide the necessary reliability and performance of the vehicle.
- Nuclear and Power Generation: In the energy sector, orbital welding is applied to join pipes and tubing in nuclear plants, coal fired power stations and renewable energy facilities. Precision and reliability of welding through orbit control is of significant importance in the energy industry because of safety requirements for the structural integrity of pipes and energy facilities.
- Biopharma: In the biopharma industry, orbital welding is employed in joining the pipes and tube used in the transport of the sterile fluids. This industry places so much emphasis in the quality and cleanliness of welds for the simple reason that any contamination may have a detrimental effect on the quality of the end products, namely the pharmaceutical products.
Conclusion
Orbital welding is an accurate and efficient welding technique, which utilizes physics in metallurgy to manufacture accurate welds. Having this kind of understanding of science of this technique let the engineer and the technicians in employing any welding parameters and selecting the right welding equipment in order to meet the requirement of the application needed.
Orbital welding brings unparalleled flexibility and accuracy to industries such as aerospace, automotive, nuclear, and biopharma, where precision and high standards in welded joints are paramount. Understanding the principles of orbital welding, its suitable applications, and the benefits it offers is crucial for industries striving to achieve superior results in their operations. This technology provides a reliable solution for creating consistent, high-quality welds that meet the stringent demands of these sectors.
For industries seeking advanced orbital welding solutions, UPM Technology delivers state-of-the-art equipment and expertise, empowering businesses to achieve precision and efficiency in their welding projects.
