Beruflich Dokumente
Kultur Dokumente
The orbital
welding
handbook
PN-0509078
Original edition: 2009 - Polysoude Nantes France SAS
Photos, plans and drawings are used as help to the understanding and are thus not
contractual.
All rights reserved. No total or partial reproduction of this work can be made, under any for-
mat or by any means, electronic or mechanical, including photocopy, recording or computer
techniques, without the written authorization of the publisher.
Printed in France.
Published by Polysoude, Nantes, Fr
www.polysoude.com info@polysoude.com
T h e O r b i ta l W e l d i n g H a n d b oo k
INDEX
1. Preface 7
3
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T h e O r b i ta l W e l d i n g H a n d b oo k
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14.6. Backing gas 39
14.7. Chemical composition and repeatability of the welds 39
15. Tube-to-Tube or Pipe-to-Pipe Orbital Welding with Filler Wire 40
15.1. Applications 40
15.2. Choice of the equipments 40
15.3. Weld preparation 41
15.4. Positioning of the tubes 42
15.5. Multilayer welding 42
15.6. AVC requires precise electrode geometry 43
15.7. Backing gas 43
15.8. Boundary parameters 43
15.9. Geometrical adjustments 44
15.10. Possibilities to increase the performance of Orbital TIG Welding 44
16. Orbital Tube-to-Tubesheet Welding 46
16.1. Range of materials and tube dimensions 46
16.2. Welding equipment 46
16.3. Specific requirements of tubes and weld preparations 47
16.4. Welding of flush tubes 48
16.5. Welding of protruding tubes 49
16.6. Welding of recessed tubes 51
16.7. Internal bore welding behind the tube sheet 52
17. Conclusion 53
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T h e O r b i ta l W e l d i n g H a n d b oo k
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1. Preface
Among industrial welding processes, Orbital equipment: technical approach, advantages,
TIG Welding has become a well-established common and special applications, but also
method, although a considerable lack of restrictions and limits. To give practical
information about the various possibilities examples, the text is illustrated by numerous
of this challenging technique still remains application examples.
in public. Aerospace industry, aviation,
Tables and designs will help engineers and
high speed trains, nuclear industry, pharma
ceutical industry, food industry, tiny micro welding experts, as well as project managers,
electronic devices - to name but a few of the to get quick answers as to whether orbital
most exciting applications - rely on orbital welding could offer solutions corresponding
welding, but the equipment to ensure our to their needs. To obtain specific answers for
daily supply with electric current, oil and gas your questions, visit the Polysoude website
also depends on orbital welding techniques. and consult the customer service team
In this booklet, basic information is provided (info@polysoude.com).
about the orbital weld process and the related
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T h e O r b i ta l W e l d i n g H a n d b oo k
3.1.2. Disadvantages
1 - Compared to other arc welding proc- and the exact values of weld parameters
esses, the deposition rate of the TIG process which are necessary to control the process.
is relatively low. 3 - The welding equipment is sophisticated;
2 - Time-intensive and costly development is it requires much more capital investment
necessary to determine the weld procedures cost than equipment for manual welding.
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3.3. Tungsten electrodes
The application of filler wire may become necessary under the following conditions:
1 - The welding seam must be reinforced. 5 - If the alloys change their composition or
2 - If
carbon steel or mild steel have to be structure during welding.
welded. Alloying elements can evaporate during the
3 - In case of a preparation of the tube ends, weld process or form a new compound. For
for example a J or V preparation. example, chromium carbide is developed if
4 - To prevent metallurgical failure if the chromium combines with carbon. The resul-
tubes to be welded are made of dissimilar ting lack of metallic chromium can cause an
metals or alloys. unwanted loss of corrosion resistance at the
A well-known example is the welded heat affected zone.
connection between carbon steel and
Stainless Steel 316, where a filler wire made
of Stainless Steel 309 or nickel base alloy
Inconel 82® is added.
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T h e O r b i ta l W e l d i n g H a n d b oo k
3.5. Gases
x Prohibited
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3.5.2. Backing gases
Most applications of orbital welding require must not be in contact with oxygen in the
an outstanding quality of the inside of the atmosphere. Depending on the material to
root, as this is the part of the weld which be welded, reducing components like N2 or
will be in direct contact with the transpor- H2 are added to the backing gas. The most
ted medium. To avoid any risk of oxidation, typical backing gases and mixtures appli-
before, during and after the welding opera- cable for the different base metals are:
tion the hot metal on the inside of the tube
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T h e O r b i ta l W e l d i n g H a n d b oo k
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4. Reasons to select Orbital Welding
The decision for the use of mechanised or automatic orbital TIG welding can be taken
for different reasons: economic, technical, organisational, and others may be more or less
important or even become the decisive factor. The orbital welding process offers a large
range of benefits which qualifies it for industrial applications. The major advantages are:
Generally, the weld quality obtained by cycle can be repeated as often as necessary,
mechanised equipment is superior to that without deviations and virtually without
of manual welding. Once an adequate weld weld defects.
program has been developed, the weld
Certified welders are difficult to find and and obtain excellent results. By using this
well remunerated. However, after appro- equipment expenditure on personnel can be
priate training, skilled mechanics are able to reduced.
operate orbital welding equipment perfectly
4.4. Environment
Orbital welding can be executed even under properly, the weld can be carried out wit-
harsh environmental conditions. Restricted hout difficulty from a safe distance; often
space or access, lack of visibility, presence of supported by a video transmission.
radiation; once the weld head is positioned
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T h e O r b i ta l W e l d i n g H a n d b oo k
In the aircraft industry, which was the first required consistent joint quality cannot be
one to recognize the importance of orbi- guaranteed. The only solution is to establish
tal welding for their purposes, more than welding procedures using orbital equip-
1,500 welds are necessary to complete ment. In this way, the parameter values are
the high pressure system of one single reliably controlled by the equipment and the
plane. Manual welding of the small, thin- final welds meet the same quality level as
walled tubes is extremely difficult; finally the the qualified test welds.
The food, diary and beverage industries everywhere inside the tubes enable success-
need tube and pipe systems which meet ful cleaning and complete sterilisation of the
delicate hygienic requirements. Full pene- system. The requested surface quality can
tration of the welded joints is necessary; only be ensured if orbital TIG equipment is
any pit, pore, crevice, crack or undercut can used to weld these critical joints. Therefore,
become a dead spot where the medium is most standards and specifications oblige
trapped and pathogenic bacteria growth, the manufacturers of hygenic installations
(Listeria etc.), can occur. Smooth surfaces to apply this process today.
Plants in pharmaceutical industries must be are absolutely forbidden, the corrosion resis-
equipped with pipe systems for the trans- tance of these welds must not be undermi-
port and the treatment of the product and ned, especially not by partial overheating
for the safe supply of clean steam and injec- of the base material. Joints made by orbital
tion water. For injection water and its deri- welding qualify for extended corrosion resis-
vatives that are intended for injection into tance. Additionally, to avoid any subsequent
the human body, the purity requirements oxidation or corrosion, their smooth surface
are particularly high. Any traces of corrosion can be passivated.
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5.4. Manufacture of Semi-Conductor devices
A considerable part of plant equipment for lations depend directly on the quality level
chemical industries is manufactured and of the welded joints, strict control and tra-
installed by means of orbital welding. ceability of the weld process are required by
Chemical apparatuses are comprised of customers, inspection bodies and standards
tubes, heat exchangers and converters authorities. For the assembly of one heat
which are made of corrosion-resistant or exchanger, hundreds or even several thou-
refractory metals or alloys of titanium, sand faultless welds have to be carried out,
zirconium, nickel, chrome etc.; not to for- so here orbital welding becomes a must to
get the whole range of different stainless ensure the expected results.
steel types. As the service life of the instal-
For the safety of fossil fuel power stations assembled on site. The welding procedures
and nuclear reactors the whole range of and the weld quality are generally under
orbital joining techniques are applied: tubes constant surveillance of the respective
with small diameters for sensing and control authorities and external organisations, the
purposes must be connected, heat exchan- required complete documentation and tra-
gers and other components are manufactu- ceability is ensured by the provision of orbi-
red using orbital tube to tubesheet welding, tal equipment with online data acquisition
and thick-walled tubes for operation under systems.
high pressure and temperature must be
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T h e O r b i ta l W e l d i n g H a n d b oo k
(1) (2)
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6.3. Programming of sectors
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T h e O r b i ta l W e l d i n g H a n d b oo k
A power source for orbital applications is composed of several subassemblies each with
specific functions:
XX One or two Power Inverters to supply XX Cooling circuit for the torch and the
the welding current, and in case of hot wire welding and clamping tools.
welding, the current to heat up the filler
XX Data acquisition system recording each
wire. Today, state-of-the-art sources are of
welding sequence.
the inverter type.
XX Programmable control unit which is The power sources for orbital welding can
generally based on an integrated or be divided in 3 categories with specific fields
external PC. of application.
The weight and volume of a compact power single phase supply. The programming and
source is limited, the machine must be parameter development is carried out via
carried to the site by the operator himself; an intuitive graphic user interface and a full
its size must be small enough to make it function remote control pendant.
pass through the openings of a manhole. The man-machine-interface allows a comfor-
The smallest power source with a weight of table management of weld cycles, programs
less than 30 kg delivers weld currents up to and weld parameters, sector-programming
160 Amperes; it is operated on a 230 Volt is supported as well.
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THE ART OF WELDING
Power Sources of this type are equipped to material of the tubes to be joined), using a
handle up to four axes of control, i.e. four touch screen or PC. The system consults its
devices can be programmed and control- in-built database to find similar applications
led: the shielding gas flow, the weld current or suggests weld parameters determined by
intensities and pulse rates, the travel speed progressive calculations. The proposed wel-
of the welding head, and wire feeding ding procedure can be finally optimised by
operations. A closed loop Cooling System an expert help menu or Welding Assistant.
is present to operate water-cooled orbi- To relieve the operator from further error-
tal Weld Heads and Welding Tools and is prone tasks, the power source detects and
integrated as part of the machine. recognises connected peripherals auto-
A recently launched power source allows us matically, (plug and play), as well as auto-
to find matching weld programs, (if the user matically adapting itself to available mains
specifies basic information about size and supply voltages.
With their increased weight, medium-sized interface and a full function remote control
power sources for orbital welding are too pendant.
heavy to be carried; they are mounted on Medium-sized power sources are designed
rubber wheels to keep them mobile. to handle up to six axes, which can be pro-
These power sources are for connection to grammed and controlled. Usually these axes
three-phase 415 Volt outlets or feature a are attributed to the shielding gas flow, the
multi-voltage input, they generate welding weld current intensities and pulse rates, the
currents of up to 400 Amperes. For the dia- travel speed of the welding head, the wire
log with the operator, the power sources are feeding operations, and Arc Voltage Control
equipped with a convenient man-machine- & Oscillation.
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T h e O r b i ta l W e l d i n g H a n d b oo k
Full-size power sources can be equipped Among the axes to control peripheral or
to meet the specific needs of the intended external units are Control Boards for speci-
welding task: depending on the model, fic equipment (wire feeders, real time data
weld currents from 300 to 600 Amperes can acquisition systems, refrigerators, etc.);
be supplied; they are connected to a three these other boards are equipped with input
phase 415 Volt outlet or can also offer a and output ports which can be program-
multi-voltage input. The programming is car- med entirely by the customer himself.
ried out via a PC and interactive software, a The programming of the full-size power
full function remote control pendant allows sources can be carried out online or offline
the operator to control the equipment. by means of a PC with comprehensible
Full-size power sources are designed to Windows™ based welding software. The
handle six axes or more, which can be pro- only restrictions within PC programming are
grammed and controlled. Basically, shielding given by the characteristics of the equipment
gas flow, weld current intensities and pul- used.
ses, travel speed of the welding head, wire
feeding operations, Arc Voltage Control and
oscillation devices are featured. A second
power source can be installed to deliver a
separate current for hot-wire applications.
The power sources are designed to control
supplementary axes, which can be added
later; the necessary electronic boards are
installed to empty slots at the front of the
machine.
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9.1.2. U-type open welding heads
Open welding heads were designed as a
tool for orbital TIG welding with or without
filler wire. The diameters of the tubes to
be welded cover a range from 8 mm up to
275 mm (ANSI 5/16" to 11").
U-type open welding heads are equipped
with a TIG-torch with gas diffuser. Sufficient
gas protection is achieved only at a zone
around the torch which is covered by the
shielding gas streaming out of the gas lens.
During the welding process, the arc can be
watched and controlled directly by the ope-
rator. The asymmetrical design of the open
heads allows welding to be carried out at a
very short distance to a wall or a bend.
The positioning of the welding torch can
be carried out manually or by means of Polysoude MU Open welding head
motorized slides (Arc Voltage Control and
oscillation).
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T h e O r b i ta l W e l d i n g H a n d b oo k
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10. Wire Feeders
Generally, a wire feeding device can be integra- the filler wire, which must be available on sui-
ted into the orbital welding head or specified table spools; furthermore on the conditions of
as an external wire feeder. The choice of the use, the constraints of the application and the
feeding device depends on the availability of requested mobility of the equipment.
Gas control functions on the synoptic board of a Polysoude PS 406-2 power source
There are three possibilities when controlling 3 - An adjustable pressure reducer is instal-
the gas management of an orbital welding led at the gas supply (cylinder or network),
installation: an electronic device inside the power source
controls the gas flow rate (power sources of
1 - A manually adjustable pressure reducer
the PS 406-2 line or of the PC type).Power
with flow meter, installed at the gas supply,
sources for orbital welding are equipped to
(cylinder or network), an electric valve which
control up to four gases: two welding gases
can be opened and closed by the control
and two additional gases, e.g. backing and
unit of the power source (PS 164-2, P4).
trailing gas. The so-called Bi-Gas function of
2 - An adjustable pressure reducer is instal- a power source allows the unit to change the
led at the gas supply (cylinder or network), type of welding gas when the electric arc is
an electric valve can be opened and closed initiated, which is especially advantageous
by the control unit of the power source; a if helium is used as shielding gas. To avoid
variable area flow meter (where a small ball frequently occurring problems caused by
can freely move up and down inside of an ignition difficulties under helium, the ignition
upright tapered measuring tube) is integra- is initially carried out under argon and, after
ted in the power source (power sources of the arc has become stable, the welding gas
the PC type). supply is switched to helium.
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T h e O r b i ta l W e l d i n g H a n d b oo k
Depending on the standard of the particular welding the gas flow rate drops below a
orbital welding equipment, the welding gas factory-adjusted value, the weld cycle will
flow is continuously monitored. In case of be aborted automatically. By this measure,
an interruption of the welding gas supply, severe damage of the workpiece and equip-
the ignition of the arc is blocked. If during ment is avoided.
11.2. Current
Current control functions on the synoptic board of a Polysoude PS 406-2 power source
The welding current is one of the affecting XXThermal pulsation (2): this current is com-
parameters of the TIG process; therefore its monly used for standard orbital TIG welding
intensities must be controlled accurately by (see chapter 6.2); the maximum frequency of
the power sources. A precision of ± 1 Amp is thermal pulsations is 10 Hz.
guaranteed if the welding current intensity XXFast pulsed current (3): the current is pulsed
rests below 100 Amps, for intensities excee- at increased frequencies between 500 Hz and
ding 100 Amps a precision of 1 % is ensured. 10,000 Hz. The fast pulsed current resembles
To meet the requirements of the different an un-pulsed current but forms an arc which
applications, dissimilar current types are is much more stable. The pulses are not visible
supplied by the power sources: but audible.
XXUn-pulsed current (1): no variation of the
current intensity.
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THE ART OF WELDING
XXThermo-rapid pulsed current (4): this cur-
1
rent form results of a combination of Thermal
pulsation (2) and Fast pulsation (3).
XX Pulsed current with mono-pulses (5): the
pulsed current is superposed by an intensity 2
peak at the beginning of each pulse, which
provokes an increased arc pressure on the
weld puddle. This function is particularly
helpful to get convex root geometry when 3
welding in overhead position (the torch is
situated below the workpiece), where the
force of gravity provokes a concave weld at
the I.D. of the tube. 4
Torch rotation control functions on the synoptic board of a Polysoude PS 406-2 power source
During welding the torch must rotate with applications require a linear travel speed range
the desired linear travel speed around between 50 mm/min and 200 mm/min.
the tube or pipe. Standard orbital welding
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T h e O r b i ta l W e l d i n g H a n d b oo k
In most cases the travel speed remains un- impulse emitters or tachometer encoders on
pulsed, but it can also become pulsed and request.
synchronized to the weld current pulsations. These pulses are also processed by the
It is possible to program different speeds control system of the power source to iden-
during base and pulse current. Usually, as tify the actual position of the torch relative
in the case of step pulsed welding, rotation to the start point, which means that the pro-
stops (V = 0 mm/min) during the high current gramming of a weld cycle can be carried out
level, whereas during the base current period using angular degrees instead of time spans.
the torch moves forward. Intuitive programming is possible because
The achieved speed precision is 1 % of the one tour of the torch always covers 360°
programmed value. Polysoude standard per pass, independently of the linear wel-
welding equipment can be operated using ding speed and the tube or pipe diameter.
Wire feeding control functions on the synoptic board of a Polysoude PS 406-2 power source
Power sources for orbital welding are equip- the inside of the workpiece.
ped to control different types of wire fee- At the end of welding, a wire retract func-
ders; the attainable wire speeds range from tion allows the reversal of the feeding direc-
0 to 8,000 mm/min, a precision of about tion. The wire end is drawn back a few
1 % is attained. millimetres, avoiding the formation of a
Standard functions of wire feeding which terminal wire ball or, even worse, the wire
are managed by all power sources are the becomes lodged in the weldment.
control of the wire start and stop as well Expert information:
as a pulsed feeding rates. The wire feeding
1 - Common diameters of wire for welding
pulses can be synchronised to the pulses of
the weld current; the wire speed is kept at purposes range between 0.6 mm and 1.2 m;
a high level when the weld current is at its the best choice for standard orbital welding
high level, and is decreased during low level is a proper wire with 0.8 mm diameter.
current. The independence between wire 2 - The melting rate of the wire depends not
speed and weld current offered by the TIG only on the precision of the wire feed speed,
process allows the reversal of synchronisa- but also on the precision of the wire itself:
tion; the wire is fed at a high speed when a variation of 0.02 mm at a wire with a dia-
the current intensity is low; the wire arrives meter of 0.8 mm represents a difference of
at a small weld puddle and melts with resis- already 5 % of added metal.
tance. The mechanical stability of the wire
can be used to push the bath of molten
metal to get a convex root pass surface at
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THE ART OF WELDING
11.5. AVC (Arc Voltage Control)
Arc voltage control functions on the synoptic board of a Polysoude PS 406-2 power source
During welding, it is important to keep the arc length constant; but there are no simple
methods to measure it. In any case, if the welding conditions do not change, each particular
arc length corresponds to a related arc voltage. This phenomenon is used to control the
distance between the electrode and the workpiece during welding.
The characteristic of arc voltage at different XX Rule n° 3: if a different type of shielding
arc lengths and welding current intensities gas is used (with other weld parameters
are shown in the graph below: remaining unchanged), the arc length will
change: if the shielding gas changes e.g.
U (V)
from argon to an argon-hydrogen mixture,
2 mm
the arc becomes significantly shorter.
U2-h 1 mm
U1-h XX Rule n° 4: if the geometry of the
U2-b electrode differs (taper angle, tip diame-
U1-b ter), the arc length at a given weld current
changes or, at a constant arc length, the arc
Imini I-b I-h I (A) voltage changes.
XX Rule n° 5: if a pulsed weld current is
At an arc length of 1 mm, the arc voltage applied, the arc voltage pulsations are not
measured between the electrode and the proportional.
workpiece at different welding current
intensities is characterised by the black line. I
The red line shows the result of the same I1-h
measurement at an arc length of 2 mm.
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T h e O r b i ta l W e l d i n g H a n d b oo k
As well as the AVC control, the torch posi- The mentioned function is often used to
tion can be determined by the programmed get the electrode in position e.g. with tube-
distance between electrode and workpiece to-tubesheet applications or, if special wel-
function. Here, starting from a reference ding tools are used, to follow the complex
value, the torch is moved by a motorized surface geometry of a workpiece in piggy-
slide over the selected distance in mm to the back position.
desired height.
11.6. Oscillation
Oscillation control functions on the synoptic board of a Polysoude PS 406-2 power source
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THE ART OF WELDING
Parameters needing to be set to get the It is possible to synchronise the torch oscilla-
correct oscillation are width and speed of tion with the pulsed current. For example, to
the stroke, as well as the dwell time, during increase the penetration at the sidewall, the
which the torch remains at the end points high current intensity value is maintained
of its movement next to the sidewalls of the continuously during the dwell time.
groove.
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T h e O r b i ta l W e l d i n g H a n d b oo k
1 2 34 5 6 7 8 9
1 Start of the weld cycle (triggered by the Start button of the control pendant)
1 to 2 Shielding gas flow during the programmed pre-flow time before the ignition of the arc
2 Ignition of the arc and beginning of the pulsed weld current. The clock is reset to zero
4 Start of the torch rotation* (initial position of the torch is set to zero position of the weld cycle)
End of wire feeding* (and wire retract if programmed). Generally, the end of wire feeding is
6 positioned at approx. 360°
Begin of the weld current downslope before the arc is finally switched off. Generally, the downs-
7 lope is positioned at 360° + 5° to 10° of overlapping to re-melt the beginning of the weld seam
and to ensure a perfect joint at the end of the weld
7 to 8 Time of the weld current downslope to finish the weld without crack and crater formation
Time period of post-gas flow to protect the weld zone of the workpiece until a sufficiently low
8 to 9 temperature has been reached and to protect the hot tungsten electrode against oxygen of the
atmosphere.
* Depending on the expected result the functions may be programmed in a different chronological order.
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THE ART OF WELDING
12.2. Interfaces for the programming of weld cycles
Generally, three different types of interfa- files from the PC can also be transferred to
ces are actually used for the interactions the power sources via compact flash cards.
between the user and the orbital welding 2 - An interface with extended possibilities
equipment. to guide the operator is supported by a PC
1 - On a synoptic board, the weld cycle which is integrated in the power source
occurs in the form a graphic presentation. itself. The principle of the synoptic presen-
The operator has to move a cursor to choose tation is still maintained, but the 6" VGA
a parameter; the related values occur on a display allows a more complete context to
display (2 lines) and can be modified if be shown.
necessary. At the beginning, some general This type of interface is installed, for exam-
conditions must be fixed: ple, in the PS 406-2 Power Source. The input
XX Whether pulsed or un-pulsed welding is not limited to machine parameters; infor-
current is required mation about the workpiece (diameter, wall
XX If wire feeding shall be switched off or thickness, & material) can be filed as well.
executed un-pulsed or pulsed. Additionally, utility functions (copy, rename,
etc.), the management of the weld cycle
Depending on this selection, only the para-
program files and the storage of online data
meters to be specified are accessible one by
acquisition are supported.
one. The microprocessor-controlled power
sources, PS 164-2 and PS 254-2, are based
on this type of interface. The programmed
values can be stored on memo cards.
This kind of technique allows handling of
the main machine parameters, but the input
of additional documentation via the power
source is not possible. However, the data can
be stored on a compact flash card and trans-
ferred to a PC. Particular software allows to
addition of missing information, to create
Synoptic board of the
complete weld cycles offline and to manage Polysoude PS 406-2 power source
the weld cycle library. As the software is
executed under a Windows™ environment,
it is easy to handle and understand. The data
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T h e O r b i ta l W e l d i n g H a n d b oo k
The programming of weld cycles for tasks is carried out offline by means of a
very complex applications and research personal computer without connection to
the power source. The sequences are created
line after line. Similar to the programming
of a numerical controlled machine tool, but
here the commands are made available to
the operator in his native language. After a
short training period, each welder is able to
understand these commands and to build
up his own weld programs autonomously.
The welding software is designed for a
Windows® environment; the user surface is
similar to an Excel® worksheet.
Due to Windows® commonality, files of any
format can be integrated, leading to com-
Programming of a weld cycle for plete documentation of the weld cycle and
a Polysoude power source of the PC series the attached parameters.
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THE ART OF WELDING
13. Real Time Data Acquisition
13.1. In summary
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T h e O r b i ta l W e l d i n g H a n d b oo k
When using PC type equipment the real- parameters. In this case, the concerned
time data acquisition is not integrated in the parameter values are continually compared
power source. The Polysoude RECORDING to a previously recorded defect-free sam-
SYSTEM which is used in the place of of ple weld. If the system is operated in the
the typical system represents a development passive mode, the graph changes its
using DASYLab® software made available colour as soon as a parameter limit is
by National Instruments. DASYLab® is a reached; switched to the active mode, the
software environment which is specialised data acquisition system aborts each weld
in data acquisition, analysis and real-time cycle if the specified limits are exceeded.
control.
Parameters such as values for welding and
hot wire current intensities, arc voltage, tra-
vel speed and wire feed speed are recorded
at a frequency of 200 Hz. When the weld
cycle starts, (arc ignition), the recording
starts automatically, at the same moment,
the storing of data on the hard disk of the
PC begins. The created files are named
automatically with an unambiguous code
including date and time.
The progress of the weld cycle can be moni-
tored and appears as a graph on the display. Example of a weld cycle report generated
The data acquisition system allows the by the Polysoude data acquisition system
operator to set limits for the different weld
Fusion welds of thin-walled tubes cover a are made of austenitic stainless steel, but
wide range of applications. Clients include nickel alloys as well as titanium and its
for example: semiconductor industry, bio- alloys can also be found. The range covers
chemistry, instrumentation, food and diameters from 1.6 to 170 mm; with wall
beverage, pharmaceutical industry, thicknesses of varying between 0.2 and
chemical/sanitary industry, and aero- 3.2 mm.
nautics/aerospace. In most cases, the tubes
34
THE ART OF WELDING
14.2. Equipment
reduced.
Welding heads of the UHP type provide
distinct reduced radial and axial dimen-
sions; they are especially adapted to the
welding of small diameter tubes. These
welding heads are designed in a modular
structure. The drive motor is integrated into
a unique handle and can be combined with
3 gear modules UHP 250-2 for tube sizes
up to 6.35 mm (1/4"), UHP 500-2 for up to
12.7 mm (1/2"), and UHP 1500 for diame-
ters up to 33.7 mm (1 1/3"). Interchangeable
clamping cassettes for example allow prepa-
ration of the work pieces independently in
advance. The handle with the motor is only
attached during the time which is necessary
Enclosed chamber welding
to accomplish a weld.
head Polysoude UHP 500-2 Clamping cassettes and flexible Tube
Clamp Inserts (TCI) made from titanium are
The UHP weld heads are specially designed perfectly adapted to fit the typical standard
to meet the requirements of high purity outside diameters of tubing used in semi-
applications. Inside the weld head, the conductor applications or pure gas supplies.
shielding gas is flowing separately through The asymmetric shape of the weld head
a high purity gas circuit and arrives directly allows the joining of fittings with a short
at the weld zone without any contact with stick-out, and fixture blocks ensure reliable
gears or rotating parts. Thus, the danger centring, on alignment and clamping of all
of particle contamination is significantly kinds of common micro-fittings.
35
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
36
THE ART OF WELDING
14.3. Calculation of weld parameter values
Depending on the diameter and wall thic- wire can be calculated. The calculations are
kness of the tubes to be joined the para- based on formulas developed for stainless
meter values for fusion welding without steel of the 300 series (e.g. 316 L), but the
results can be transposed for other mate-
rials. Recent power sources like the P 4 and
P 6 are equipped with software to calculate
weld parameter values automatically if the
particular application cannot be found in
their integrated library.
In any case, the validity of the calculated
results must be confirmed by test welds.
Materials with the same designation, and
of an equal nominal composition, may still
have very different welding properties (see
also chapter 14.7 - Chemical composition
Menu to access existing weld procedures and repeatability of welds).
or calculated parameters
37
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
38
THE ART OF WELDING
14.6. Backing gas
During orbital welding, the inner surface minated by moisture, oxygen, particles or
of the tubes must be protected against other contaminants.
oxidation. Therefore, the interior of the During welding, the specified values of flow
tube system is purged by backing gas. The rate and internal pressure of the backing
purity of the backing gas depends on the gas must be respected and kept constant.
required weld quality. Before the weld can be The internal pressure must be controlled
started, a sufficient purge time must elapse, because excessive pressure will produce
allowing the backing gas to remove the a root weld with a concave surface at the
oxygen out of the system. The remaining outside or, even worse, cause a weld bead
oxygen content of the backing gas can be short circuit.
analysed at the outlet; if it has decreased to
If tubes with small diameters below
an acceptable value, the welding operation
9.52mm (3/8") are welded, the internal
can begin. Usually in the case of UHP appli-
pressure can be used to prevent any excess
cations (Ultra High Purity) the oxygen level
of convexity or inside diameter reduction.
must fall below 10 PPM (Parts per Million),
i.e. less than 0.001 %. Expert information: A light heat tint, due
Expert information: The supply of ultra- to remaining oxygen in the backing gas, can
pure process gas requires that it passes be removed by passivation.
through the tubes without being conta-
Influence of oxygen content in the backing gas on the colouration of the root weld
39
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
For several reasons, it can become neces- A wide range of base materials are used:
sary to apply filler metal in orbital welding zzPlain carbon steel
procedures: zzLow-alloyed chromium or chromium
zzWall thickness of the tubes requires a manganese containing carbon steel
preparation of their ends zzHigh-alloyed chromium nickel steel
zzTubes or pipes to be welded are made (austenitic or with an austenite-ferrite
of different base metals crystal structure)
zzThe weld must be reinforced zzNickel base alloys (like e.g. Inconel®-
alloys or Hastelloy®-alloys)
zzStrength and/or corrosion resistance
zzTitanium and its alloys.
are compromised by fusion welding.
Tube-to-tube welding applications with the Although the tube dimensions differ very
addition of filler wire are often demanded in much, the great majority is to be found in
the field of energy production (power plants) the range of:
and chemical or petrochemical industries. zz26.9 mm and 219 mm (¾" and 8")
diameter
zz2.77 mm to 12.7 mm wall thickness
For orbital welding with additional filler Independently from economic or other pro-
wire, standard equipment with 4 controlled ject-related considerations, the table below
axes (shielding gas flow, weld current inten- shows the technical requirements for 4 or 6
sity, torch rotation speed and wire feeding axes equipment to be used:
speed) or with 6 axes (4 axes + AVC and
oscillation) can be used.
Type of equipment
Criterion 4 axes 6 axes
Wall thickness small (< 4 mm) + +
to be welded medium and thick (> 4 mm) - +
reduced + -
Accessibility
free + +
simple + +
Weld sequence
difficult - +
low + +
Level of automation
high - +
40
THE ART OF WELDING
In the case of reduced accessibility of the tation of the welding tool is required, the
work area, equipment with 4 controlled use of equipment with 6 controlled axes is
axes is reccommended. If easy implemen- advised.
30 ° 30 °
Tube range Angle Collar
(mm) (°) (mm)
Wall thickness A T L
(mm)
3<E≤6 1 2
Tube end preparation commonly 30°
used for manual tube welding E≤6
1,5 2
10≤E≤15 20°
41
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
To remove all traces of Rust as well as Oil, of magnetism or at least a very low flux
Carbon or Calamine Oxide Scale, the inside density (less than 3 gauss) is acceptable.
and the outside of tubes made from carbon Otherwise, welding problems or defects
steel must be machined. (lack of penetration, lateral sticking or poro-
Expert information: Metals which can be sity) can occur.
magnetised must be inspected: no remnant
42
THE ART OF WELDING
Multilayer welding with the stringer bead function the distance between electrode
technique is quite complicated and time-con- and workpiece is controlled, the oscillation
suming, as the process has to be interrupted allows coverage of the entire joint width or
after each pass and mechanical adjustments to position the torch laterally. Once the torch
need to be made: the lateral position of the is positioned above the joint, the electrode
torch and the distance between the previous will be centred in the gap automatically.
pass and the electrode must be corrected. The different passes of a weld can be chai-
These adjustments can only be executed if ned, the winding up of the hose and supply
the particular parts of the welding head are cables can also be executed automatically,
accessible in its working position. and so the operator is not distracted by
Welding equipment with six controlled repetitive actions and can fully concentrate
axes significantly reduces the time required on supervising the welding process
for manual interventions. With the AVC
zzBacking gas: type, purity, flow rate zzGround cable position and
connection.
zzGas lens: type and size
43
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
Orbital GTAW welding with cold wire is relatively low (0.15 to 0.5 kg/h). In order
an adequate choice for standard applica- to boost the efficiency of the process it is
tions which require high quality levels but possible to use the narrow gap or/and the
compared to other arc welding processes, hot wire technique.
the deposition rate of the TIG process is
44
THE ART OF WELDING
Expert information: The narrow gap technique is not recommended for base materials
which are sensitive to hot cracking.
45
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
Nearly all weld able metals and alloys are and 38.1 mm (1.5") with wall thicknesses
used in the field of tube-to-tubesheet between 1.65 mm and 3.4 mm.
applications, but the range of the tube
dimensions is relatively restricted. Their Boilers and heat exchangers are used in all
diameter range covers 12.7 mm to 101.6 kinds of industries, whereas the heaviest
mm, the wall thicknesses are between 0.5 equipment is found in the plants of the
mm and 5 mm. Most of the tube diame- chemical or petrochemical industries and in
ters measure between 19.05 mm (3/4") electric power stations.
In most cases, the welding equipment used * Portable power sources are rarely used for
for tube-to-tubesheet welding is strictly these applications: there is no need for the
adapted to the kind of application and the machines to be carried.
desired level of automation:
2 - The welding equipment, including four
1 - Welding equipment featuring three controlled axes (gas, current, rotation,
controlled axes (gas, current, rotation) is wire), is composed of a stationary installed
composed of a stationary installed power power source* and an open welding head.
source* and a closed welding head. This The equipment is suitable for single pass
equipment allows for the execution of fusion welding; two passes must be welded in two
welding without addition of filler wire. separate steps.
3 - The welding equipment fitted with
five controlled axes (gas, current, rotation,
wire, AVC) is composed of a power source
designed to control 6 axes and a welding
head of the type TS 2000 with AVC configu-
ration. The equipment allows the chaining
of multiple passes with filler wire, the raising
of the torch between the passes can also
be programmed and is carried out without
interruption of the weld cycle.
Example of a three axes application with
a Polysoude TS 25 welding head
46
THE ART OF WELDING
4 - Welding equipment furnished with six
controlled axes, (gas, current, rotation, wire,
AVC, oscillation), comprises a PC Power
Source and a welding head of the type
20/160. The equipment allows multi-pass
welding (two or more passes); the torch can
be positioned in a radial direction.
47
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
3 - In some cases, if a good thermal conduc- sion and the tube diameter at the expanded
tion is requested, the play between the tube zone as well as the original diameter.
and the bore must be eliminated by a sli- 4 - The contact zone between the tube and
ght expansion of the tube. Play is necessary the tubesheet must be clean. Grease, oil or
for the assembly of the apparatus before other residues from the tube manufacturing
the welds are carried out, but if clearances or machining can cause the formation of
become too great, problems of repeatability unacceptable blowholes, with outlets on the
may occur. However, it is difficult to specify surface or enclosed in the welds.
a maximum amount of play; it depends on
5 - A strong expansion of the tubes inside
the demanded weld quality and the thic-
the tubesheet must never be carried out
kness of the tube.
before automatic welding. A strong expan-
Expert information: To get optimised cen- sion (with or without longitudinal grooves
tring tools for the tube-to-tubesheet welding in the bore) causes almost always explosive
heads, each order must be accompanied by degassing effects which make automatic
information about the depth of the expan- welding impossible.
1 2 3 4
48
THE ART OF WELDING
16.4.2. Welding of flush tubes with addition of filler wire
Welding equipment fitted with four or five Expert information: The AVC function is
controlled axes can be used for this appli- recommended especially for the welding of
cation; the open tube-to-tubesheet welding flush tubes.
head should be configured with devices Generally, the tube end preparations are of
adapted to the requirements: the type 1, 2 or 3. If a preparation of the
zz Integrated or external wire feeder tubesheet is carried out, the V-joint can be
zzWith or without AVC avoided. With this type of preparation, there
is always the risk of incomplete penetration
zzWith or without shielding gas cham-
of the root. A J-preparation (with or without
ber (for the welding of titanium or
radius) should be preferred, if the depth of
zirconium)
the bevelled edge exceeds 1.5 mm, the tube
zz Torch angle of 0° or 15°. end should be positioned at the half of it.
The maximum value of the tube end to be
recessed is 50 % of the tube thickness, the
tube becomes flush by the weld.
Depending on the dimensions and the
required weld thickness one or two passes
are necessary. One tour of the torch is
always applied in case of a pass for tight-
ness; the layers for mechanical resistance
often require a second tour.
Protruding tubes are always welded with addition of filler wire, but in some cases the weld
is beginning with a fusion pass. As shown below, different joint designs are possible.
A B C
49
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
Welding equipment fitted with four or five In any case, to avoid melting down the tube
controlled axes can be used for this applica- edge, the tube length measured from the
tion. Depending on the pitch and the pro- ground of the groove must exceed at least
truding distance, the torch inclination may 5 mm.
be varied. Standard torch angles are 15° or Note: If equipment fitted with five control-
30°: led axes is used, the AVC has to be opera-
XX torches with an angle of 15° are prefe- ted in the relative height mode. Thus it is
rentially used in case of thin-walled tubes possible to adjust the distance between
(1.6 mm to 2.11 mm), thus melting the electrode and tube plate to get the best
inside can be avoided result; independently of the torch position.
XX torches with an angle of 30° are applied
for thick-walled tubes (from 2.5 mm
onwards) if there is sufficient space with
regard to the tubes around (reduced pitch).
+X
50
Special attention must be paid to the training of the operators; differently to orbital tube-to-
tube welding, where the mechanical adjustments of torch and wire guide are carried out in
the same plane, tube-to-tubesheet welding requires three-dimensional operation.
α
Se
50
THE ART OF WELDING
16.6. Welding of recessed tubes
D E F G
Welding equipment fitted with four or five Expert information: Different to those
controlled axes and an open tube-to-tube- applications with protruding tubes, in the
sheet welding head can be used for the case of recessed tubes a V preparation of
application D, E and F. the tube plate is possible. If joint prepara-
The preparation of the type G is frequently tions of the type E or F are applied, the tubes
used in the petrochemical industry; welding may protrude slightly from the base of the
equipment with six controlled axes and a groove.
TIG 20/160 welding head with separate Depending on the dimensions, and the
clamping device have to be used. This type required weld thickness, one or two passes
of application generally requires a specific are necessary. One rotation of the torch is
project to study the best adaptation of clam- always applied on the first pass for tight-
ping tools and welding procedures. ness; layers needed for mechanical strength
and wear resistance will often require a
second rotation.
Particular application: Welding behind
the tube plate of a double-walled collector
for air-cooling or fluid condensation. The
AVC operation is indispensable to do the
weld in this application.
51
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
To avoid gap corrosion between the tube and the tubesheet, gapless joints are welded from the
inside of the tubes at the backside of the plate. This type of application requires extended accu-
racy of the workpiece preparation and welding. Some possible joint designs are shown below:
X Y Z
A joint preparation of the type X is not of the type X, where the tube end is positio-
recommended: the greater mass difference ned sufficiently deep in the bore (e.g. half of
between the tube and the plate excludes the tube wall thickness), a root protection is
the possibility to achieve a sufficient not necessary. The protection can be provi-
penetration. ded by flooding the entire apparatus with
The joint preparation of the type Y overco- inert gas or, if the backside of the plate is
mes the penetration problem by creating a accessible, by a local protection applied tube
welding zone with a better balanced mass after tube.
of the tube and the plate. With a tube I.D. of more than about 35 mm,
For three reasons, by the joint preparation the use of welding tools with filler metal is
of the type Z the weld conditions become possible.
quite similar to those of a standard orbital
tube-to-tube weld operation:
zzBy the recess the tube is aligned on the
bore.
zzMelting down the collar offers some
additional metal which increases the
mechanical strength of the weld.
zzThe concave form of the weld is
reduced.
Expert information: Unlike classic tube-
to-tubesheet applications, the internal bore
welding operations behind the tubesheet
require a gas protection of the root, (at the Example of welding recessed tubes
outside of the tube). Only with a preparation to a tube sheet
52
THE ART OF WELDING
If relatively thick walled tubes of 3 mm to Welding equipment fitted with three or four
3.6 mm, (depending on the base material), controlled axes can be used for this applica-
are to be welded, a horizontal weld posi- tion, in the case of a joint preparation of the
tion with the plate at the bottom with the type X, five controlled axes are necessary.
Weld Head also horizontally positioned, is The welding heads must be equipped with a
recommended. particular lance for internal bore welding
The distance from the face of the plate Similar application: If nipples have to be
to the welding joint must be very precise, welded on a collector, (this is typical appli-
(close tolerance). The operator cannot see cation in the field of power plant equipment
the torch position inside the tube, he has construction), identical base materials are
no possibility of adjustment and he cannot used, and the joint preparation and the pre-
watch the welding process. cautions to be taken are similar to those of
The weldability problems resemble those internal bore welding behind the tubesheet.
discussed in Chapter 1.4 for tube-to-tube
fusion welding.
17. Conclusion
53
THE ART OF WELDING
T h e O r b i ta l W e l d i n g H a n d b oo k
Notes
54
THE ART OF WELDING
Notes
55
THE ART OF WELDING
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