Orbital Technology Blog
Lifespan of equipment: the importance of high-quality welds
The quality of the assembly is a vital factor in ensuring the safety and security of the equipment. The welder is responsible for the quality of the final result. He must be concentrated and make no error. Orbital welding, and automation of the process, will help welders and will meet the need for high quality welds.
Near-invisible threads that are vitally important
Welds and welding enable distinct parts to come together and form a continuous whole. High quality is essential in welds that are formed by fusing the edges of different components to form a single piece, and a poor-quality weld can have dramatic consequences.
The risks of poor-quality welding
- A poorly executed weld can lead to water, chemical or gas leaks, which entail risks of varying seriousness depending on the nature of the product. These risks can range from excess water consumption through to contamination of an entire site, not forgetting the risks of explosion or fire. As such, the importance of high quality welding is obvious. The manufacture of semi-conducting components, particularly for the gas industry, requires tubing that is perfectly sealed against humidity, oxygen and all particulate matter.
- A faulty weld can cause problems for sanitation and healthcare by creating zones where fluids can be retained, cracks, and ingress routes for bacteria coming from the outside.
- Neglecting the quality of welding also leads to a risk of oxidization or corrosion. Pharmaceutical or biotech industries make use of networks of tubes that require specific cleaning. The importance of high-quality welds, and automating the welding process, goes hand in hand with requirements for cleanliness and purity.
- Orbital welding also delivers better visual results.
Automation of orbital welding to ensure perfect quality
Orbital welding is an automation technique that uses a feed block and a welding head with an attached electrode. These are rotated through 360 degrees around a tubular shaft to create the weld. Orbital welding is ideal for welding tubes, pipes, and tubular plate.
- Automation of orbital welding produces identical welds on a repeated basis. Once a suitably adapted orbital welding program has been developed, the automation of the orbital welding cycle can be repeated as often as necessary without creating any differences between individual welds or introducing any new defects.
- The aeronautical industry leads the way in recognizing the benefits of automating orbital welding. Some parts may require 150 identically welded joints. Only automation with the use of appropriate orbital welding hardware can respond to the need for high quality welds while preventing human error from occurring.
- Orbital welding and associated automation can be used in confined spaces and in zones where rotation of parts (which can otherwise get in the way) would make manual welding difficult and introduce risks of defects.
- Delivering all-important weld quality also depends on orbital welded joints, which offer better corrosion resistance. Their smoother surface can then be treated chemically to protect against later corrosion or oxidation.
The quality of weld obtained via automation using an orbital process is better than that obtained via manual welding. Switching to an orbital welding process, using appropriate hardware reflects the importance of high quality welds and guarantees long-lasting installations that will operate safely for a long time to come.