Orbital Welding

What is Orbital Welding?

Orbital welding is a mechanized welding process in which the welding torch (or electrode) travels around a stationary workpiece, often a tube or pipe, creating a high-quality, repeatable weld. This method was originally developed to reduce variability in manual Gas Tungsten Arc Welding (GTAW) processes, addressing the challenge of achieving uniform, defect-free welds consistently.
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Because the welding head is precisely controlled by a digital power supply, orbital welding greatly diminishes the need for operator intervention. Instead, the operator programs and oversees the process rather than performing the weld directly. As a result, orbital welding ensures superior weld quality, consistent results, and strict adherence to industry standards and acceptance criteria.

What is Orbital Welding used for?

Orbital welding is widely applied in four key areas:

Tube-to-Tube: Used for joining sections of tubing with uniform, repeatable welds
Pipe-to-Pipe: Used for joining sections of piping with uniform, repeatable welds
Tube-to-Tubesheet: Common in the fabrication of heat exchangers and other components where multiple tubes must be joined to a tubesheet with precise consistency
Cladding/Overlay: Depositing corrosion-resistant alloys or hard facing materials onto surfaces of pipes, tubes, and other components, enhancing their durability, extending service life, and improving performance under harsh operating conditions

This high degree of reproducibility and accuracy makes orbital welding equipment indispensable in industries where the purity, strength, and reliability of welds are critical, such as pharmaceutical, semiconductor, food and beverage, aerospace, energy, and petrochemical sectors.

What Makes Up an Orbital Welding System?

A typical orbital welding system comprises several key components:

Power Supply

The power supply converts and controls the electrical current for the welding process while also controlling the motors onboard the weld head. It allows for precise programming of parameters such as welding current, pulse rate, wire feed speed, and shielding gas flow. Modern power supplies incorporate data capture, advanced analytics capabilities for improved process control and intuitive control interfaces.

Weld Head

The weld head is the specialized mechanism that orbits around the workpiece. Depending on the application and material thickness, different sizes and styles of weld heads can be used. All weld heads are designed to:

Maintain proper arc distance and alignment within the groove
Hold the torch (or electrode) as the body of the head travels around the workpiece
In cases where filler material is required, a wire feeder supplies a continuous flow of filler wire into the weld joint. The feeder may be integrated into the weld head or used as a separate module. Adjusting wire feed speed and angle is crucial for proper weld profile and penetration

Specialized weld heads are available for both small-diameter (often enclosed) and large-diameter (open) applications, as well as unique configurations like Inner Diameter (ID) welding.

Human-Machine Interface (HMI)

HMI devices, such as a vision system console (such as our FireView solution) or handheld remote pendant, give operators a direct and intuitive way to interact with the orbital welding process. These interfaces can:

Adjustment Parameters: Allow real-time control of weld parameters such as torch position, current, travel speed, and wire feed rate, enabling quick fine-tuning without stopping the weld cycle
Monitoring & Diagnostics: Provide a live video feed and data readouts, helping operators observe the weld pool, verify alignment, and ensure proper penetration - even in challenging or remote locations
Data Logging & Review: Record critical weld data and footage for quality control, troubleshooting, and future reference
User-Friendly Operation: Offer ergonomic controls, clear visual displays, and simplified menus, reducing training time and making it easier for operators to achieve consistent, high-quality welds

Cooling System

Depending on the heat load, an air or water cooling system ensures that the welding head and related components remain at safe operating temperatures. Proper cooling helps maintain weld head integrity, and extend the life of the consumables.

Benefits of Orbital Welding

A typical orbital welding system comprises several key components:

Superior Weld Quality - Because parameters are precisely programmed and controlled, orbital welding produces uniform weld beads with full penetration and minimal defects. This reliability meets stringent criteria in high-specification industries where contamination and imperfections are unacceptable
Increased Productivity and Efficiency - Once the welding parameters are set, the automated cycle can be repeated indefinitely. High productivity is achieved through minimized rework, reduced downtime, and faster overall throughput
Repeatability and Documentation - Weld schedules can be saved, recalled, and repeated, ensuring consistent results across multiple shifts and operators. The systems can record and store weld data, providing traceability, validation, and quality documentation for compliance and auditing purposes
Reduced Operator Skill Requirements and Costs - While operators still need training, orbital welding reduces the reliance on master-level welders. By shifting the task from manual skill to process monitoring and programming, companies can lower labor costs and expand their available talent pool
Versatility in Challenging Environments - Orbital welding can be performed under restricted access, poor visibility, or harsh conditions. Once the weld head is mounted, the operator can stand at a safe distance, often using remote viewing systems to guide the process
Enhanced Safety and Cleanliness - Enclosed weld heads create an inert gas environment that shields the weld pool from contamination, delivering welds with exceptional purity - especially important in food, beverage, pharmaceutical, and semiconductor applications. Additionally, removing the welder from direct exposure to the arc improves safety conditions on the worksite

Types of Orbital Welding Heads

Closed (Fusion) Weld Heads

Closed weld heads surround the tube or pipe joint within an enclosed chamber filled with an inert gas. This sealed environment ensures contamination-free welds with minimal discoloration. Closed weld heads are commonly used for high-purity tubing applications in industries like pharmaceuticals and semiconductors. With closed heads, the entire process is fully automated once started, eliminating the need for protective welding helmets and reducing operator fatigue. Closed weld heads are limited by the amount of heat that they can sustain from the welding arc before causing damage to internal components. This means that closed weld heads can only be used on thinner materials and can not be used with wire feed.

Open Weld Heads

Open weld heads can be clamped onto the workpiece or attached using a track (guide ring). They are typically used for larger-diameter pipe welding where multiple passes and filler material are required. Although open heads provide flexibility in adjusting parameters during the process, this method demands more operator skill, as the operator may need to track the weld seam and make minor adjustments during the weld cycle. Open weld heads can withstand far greater temperatures than closed weld heads and can be used for wire fed applications.

Types of Orbital Welding Processes

Orbital welding can encompass several common welding processes, each selected based on material type, thickness, and desired weld characteristics:

Gas Tungsten Arc Welding (GTAW/TIG Welding)

GTAW uses a non-consumable tungsten electrode and inert shielding gas, such as argon, for exceptionally clean, precise welds. Ideal for applications requiring high purity, such as pharmaceutical and semiconductor installations.

Gas Metal Arc Welding (GMAW/MIG)

GMAW employs a continuous consumable wire electrode and shielding gas. It offers high deposition rates and faster speeds, making it suitable for general fabrication and industrial piping systems where productivity is a key concern.

Flux-Cored Arc Welding (FCAW)

FCAW uses a tubular electrode containing flux, making it more tolerant to external conditions and more forgiving. It’s often deployed in less controlled environments, including outdoor or remote locations.

Plasma Arc Welding (PAW)

An advanced variant of GTAW, PAW provides a constricted, stable arc for deeper penetration and higher deposition rates. It is well-suited to demanding applications that require precise control over heat input and weld quality.

When to Use Orbital Welding

Orbital welding is invaluable in scenarios where manual welding is challenging, costly, or risky. It excels when:

High-Purity Requirements - Industries that demand contamination-free welds, like semiconductor and pharmaceutical, rely on orbital welding to produce defect-free welds
Consistent, Large-Volume Production - In situations where hundreds or thousands of identical welds are needed, orbital welding ensures uniformity, reduces rework, and increases output
Restricted Access - Complex configurations, overhead joints, or difficult-to-reach areas become manageable with orbital welding’s automated torch movement and remote monitoring capabilities
Safety-Critical or High-Specification Projects - Nuclear, petrochemical, and power generation applications often require welds that meet stringent integrity standards. Orbital welding provides the repeatability and accuracy necessary to meet these demands

Applications of Orbital Welding

Orbital welding’s flexibility and high quality make it central to a wide range of industries and applications, including:

Nuclear, Power Generation, and Petrochemical - High-integrity pipe welds that can withstand extreme temperatures, pressures, and corrosive environments
Construction, Shipbuilding, and Infrastructure - Reliable, repeatable welds that maintain structural integrity over long service lifetimes, even under harsh or dynamic conditions
Semiconductor Manufacturing - Ultra-clean, contaminant-free welds for gas and fluid delivery lines in cleanroom environments
Pharmaceutical, Biotechnology, Food & Beverage - Sanitary tube and pipe welds that ensure smooth, crevice-free surfaces, preventing bacterial growth and maintaining product purity
Aerospace and Aviation - Critical fluid lines and structural components benefit from precise, reliable welds that meet stringent safety and performance requirements

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What gas is used for Orbital Welding?

Orbital welding primarily uses argon as the shielding gas. Argon is an inert gas that protects the weld pool from atmospheric contamination, ensuring high-quality, defect-free welds. In some applications, helium or a mix of argon and helium may be used to improve heat transfer and penetration, especially for thicker materials.

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