So speaking of welding, it is a very labuor intensive process, requiring an adroit welder. Regardless of the experience of a welder, it is challenging and really time consuming for a welder to produce consistently accurate and high quality welds manually. The history of Orbital Welding goes back to 1960s when the aerospace industries required an extremely accurate welding process that would be able to produce aircraft hydraulic lines for commercial purposes using GTAW. For this special requirement, a new technique of welding was introduced and it was orbital welding. Not to confuse with rotary welding in which one part is rotated and is pressed against another part that is held stationary. Orbital Welding is officially recognized as being created by a Senior Design Engineer for North American Aviation. They needed to find a new way to weld tube bundles for the space Nuclear Auxiliary Power Project. Afterwards in 1970, pharmaceutical companies adapted Orbital Welding process to eradicate contamination. Orbital Welding can also effectively help to decrease the possibility of any egregious errors or defects related to surface cracking and porosity
NEED FOR ORBITAL WELDING
There is always a need for new technologies and so was the need of Orbital Welding. Orbital Welding had to supersede the regular welding in Aerospace Industries. For very precise joining of the tubes in aerospace technology and in space industries orbital GTAW process came into demand.
Also the use of orbital process was done in nuclear industries. It was because there was a need for high quality welds that would resist inter granular stress corrosion and cracking that frequently occurred in piping systems.
Later Orbital Welding became prevalent in Food, Dairy industries due to its hygienic and clean condition welding which was a boon for these industries.
Hence as we can see, the need of orbital welding basically raised for perfect welds, clean welds and leak proof welds.
WHAT IS ORBITAL WELDING?
It is basically a welding process in which the tungsten electrode carrier is rotated through gear mechanism around the work piece which can be a pipe or a tube.
The basic components of orbital welding are CNC power source, weld head. The CNC power source supplies and controls the welding parameters according to the specific weld program created or recalled from memory. The weld head is basically that part of the machine which carries all the assembly for the welding purpose and the tungsten electrode. These weld heads are generally closed, which provide the inert atmospheric chamber that surrounds the weld joint.
ADVANTAGES OF ORBITAL WELDING OVER MANUAL WELDING.
-The irregularities in the weld due to manual welding can be totally avoided in case of orbital welding.
-Due to orbital welding the production time decreases thus increasing production.
-Due to manual welding hygiene of the welds and the components is compromised. Hence by orbital welding this problem is surmounted.
-The welds produced by orbital welding are smooth and free of crevices and cracks.
-Manual welding can cause a leakage problem which is totally surmounted in orbital welding.
So concluding thus discussion we can clearly observe that orbital welding can be considered as the backbone of all the high purity and high precision industries. Use of orbital GTAW helped a lot in quality production and reducing production time and thus providing with welds of high quality. The leakage problems, various complicated problems, due to contamination of welds due to manually welding are solved by orbital GTAW making it really efficient.