Orbital welding uses an automatic rotating arc to join objects with little room for user error. Special equipment is needed, including a non-consumable electrode and a power and control system. This technique is popular in cleanroom applications and requires a variety of welding heads to fit different objects.
Orbital welding is a method of joining two objects under a high level of heat. In traditional welding, users manually swirl the arc, or heat source, around objects. With an orbital welder, the arc automatically rotates 360 degrees around objects to create a smooth, even joint. This process results in very clean welds with little room for user error.
To use orbital welding techniques, workers need special equipment, including a power and control system. A special orbital weld head connects to the power supply via hoses or tubing. These heads feature a built-in clamp that locks around the object being welded, as well as a built-in motor to rotate the electrode around the object. This electrode remains hidden inside the head during the entire orbital welding procedure.
This process often requires a non-consumable electrode, meaning the electrode itself does not melt to create the weld. Instead, the electrode produces enough heat to melt the edges of the metal object to each other, forming a permanent bond. In this type of application, the welder relies on tungsten inert gas (TIG) rather than standard welding wire. Orbital welding projects that require a consumable electrode often use a wire feeder to supply wire to the welding arc.
One of the major benefits of this type of welding is that it eliminates much of the risk of human error to produce a high quality, consistent weld. Once the welding head is locked around the object, the electrode is automatically guided through the process. While it can be difficult for humans to maintain an even distance when welding around an object, these welding heads move the electrode around the object in a constant circular pattern. Since no consumable electrode is needed in most projects, orbital welding also results in a very clean, spatter-free bond.
The clean bond created by orbital welding equipment makes this technique very popular in cleanroom applications. This includes food processing, lab work, and even nuclear welding projects. Orbital techniques can also be used in standard pipe welding inside homes or businesses.
Welders wishing to use this technique should carry around a large selection of welding heads to accommodate various sized objects. Orbital techniques can only be applied when the right size welding head is available to fit each object. This may require a significant initial investment by companies in order to ensure a large section of the welding head size.
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