TIG orbital welding is one of the most precise and advanced metal joining technologies, mainly used for welding pipes and thin-walled structural elements. This process involves automatically guiding the welding arc around the welded element, which allows for obtaining repeatable, high-quality welds.
Unlike classic manual welding methods, the orbital welding system guarantees parameter stability, elimination of operator errors and excellent mechanical properties of joints, making it an ideal solution in industries with the highest technological requirements.
Application of orbital welding – why is it necessary?
Orbital welding technology is widely used wherever the following is required:
High quality orbital welding – clean, uniform welds without porosity and spatter.
Repeatability and precision – ideal connections in long installations and pipe systems.
Minimization of errors – no influence of human factors such as hand vibration or operator fatigue.
Optimization of costs and work time – mechanized orbital welding shortens the installation assembly time and reduces material losses.
These advantages make orbital welding ideal for industries that require flawless joints, such as:
Food and pharmaceutical industry – where weld cleanliness is crucial for production safety.
Energy and heating – welding of steel pipes in transmission installations.
Chemical and petrochemical industry – resistance to high temperatures and aggressive environments.
How does the orbital welding system work?
Orbital welding is an automated TIG welding method in which the welding arc rotates around a stationary element, usually a pipe. This process allows for high precision, repeatability and elimination of human error, making it an ideal solution in demanding industries such as food, pharmaceutical, chemical and energy.
Orbital welding technology – automation and precision
Unlike traditional manual welding, where the operator controls the entire process manually, orbital welding is based on mechanized guidance of the arc around the element. This allows for precise welding of thin-walled pipes and other components requiring perfect joints without deformation or welding defects.
Automation minimizes the impact of human factors – it reduces the risk of welding errors resulting from hand tremors, uneven electrode guidance or operator fatigue.
High quality of the welding process – repeatability and parameter control ensure excellent weld quality, without porosity and spatter.
Precise adjustment of parameters – it is possible to adjust the orbital head to different materials and pipe thicknesses.
Orbital head and its role – how does it enable welding of steel and thin-walled pipes?
The orbital head is a key element of the orbital welding system. It is a mechanized tool that rotates around the workpiece, guiding the tungsten electrode and controlling all important process parameters, such as:
Welding speed,
Current intensity,
Shielding gas supply,
Filling with additional material.
Thanks to the use of modern orbital welding heads, it is possible to precisely connect steel pipes, including thin-walled ones, and elements of different diameters. This is crucial for ensuring high quality of the welding process in industrial installations.
OWH open heads and TIG closed heads – differences and applications
Different types of heads are used in orbital welding, depending on the material thickness and working conditions.
Open heads OWH
Used for welding pipes with larger wall thicknesses.
They allow additional material to be added, which increases the strength of the connection.
Used in heavy industry, energy and transmission systems.
TIG closed head
Used in precision welding of thin-walled pipes (e.g. pharmaceutical, food, chemical installations).
Provides full gas shielding, which minimizes the risk of weld oxidation.
Guarantees the highest quality of welded joints, especially in materials requiring protection against contamination.
Selection of the appropriate head depends on the type of material, wall thickness and weld quality requirements.
Mechanized TIG welding – optimizing the quality of the welding process
Mechanized TIG orbital welding allows for full control over every stage of the process, which translates into:
Minimization of welding defects such as pores, cracks or lack of fusion.
Consistent welding parameters, regardless of the operator.
Reduction of welding time and higher productivity while maintaining high quality of the joint.
Thanks to advanced welding parameter control systems, orbital welding ensures the highest quality standard, meeting industry standards such as PN-EN SO 14732.
What materials can be orbitally welded?
TIG orbital welding allows for precise joining of dissimilar metals, ensuring high quality joints and minimizing welding defects. Below are the key materials that can be effectively welded with this method.
A. Stainless Steel – The Most Common Material in Orbital Welding
Welding of thin-walled pipes – crucial for the pharmaceutical, food and chemical industries
High corrosion resistance – no contamination, smooth welds.
The use of closed TIG heads guarantees the highest cleanliness of connections.
B. Carbon steel – requirements and applications
Welding of steel pipes – widely used in the power and gas industries.
The need to control welding parameters – stable conditions eliminate the risk of cracks and weakening of the weld.
Requires appropriate adjustment of the orbital head to the material thickness.
C. Nickel and Titanium Alloys – High Technological Requirements
Precision welding in the aviation, space and chemical industries – high cleanliness and strength of joints required.
Adjustment of the orbital head and shielding gases ensures arc stability and resistance to high temperatures.
D. Aluminum – specifics and challenges
Welding aluminum requires a special orbital head – a more difficult process due to high thermal conductivity.
Use in aviation and automotive – low weight and corrosion resistance.
Applications of orbital welding in various industries
TIG orbital welding is widely used in industry, where precision, repeatability and resistance of welds to extreme conditions are important. Below we present the key industries in which this technology is irreplaceable.
Food and pharmaceutical industry
Precise welding of stainless steel pipes – ensures cleanliness and hygiene of production installations.
No contamination in welds – minimizes the risk of bacteria settling.
Use of closed TIG heads – ensures perfectly smooth and tight connections.
Welding of steel pipes – essential in the construction of transmission pipelines.
Resistance to high pressure and temperature – crucial in heating and boiler installations.
Control of welding parameters – ensures the longevity of the structure.
Aerospace and automotive industry
High quality welded joints – resistance to vibrations and high mechanical loads.
Welding of light alloys such as aluminum and titanium – crucial for the aerodynamics and durability of components.
Process automation – ensures repeatability and compliance with rigorous industry standards.
Chemical and petrochemical industry
Welding of pipes resistant to aggressive environments – contact with chemicals and corrosive substances.
High quality welds resistant to corrosion – crucial for installations transporting chemicals and fuels.
Orbital technology minimizes the risk of leaks – which has a direct impact on the safety of industrial processes.
Benefits of Orbital Technology
TIG orbital welding is a modern method that provides precision, repeatability and high quality of welds, making it an ideal solution in demanding industries. Thanks to process automation and parameter control, it minimizes the risk of errors, saves materials and optimizes production costs.
Orbital welding is perfect for difficult applications
High quality orbital welding – uniform and tight welds without defects.
Resistance to high temperatures and pressure – key in the energy, chemical and food industries.
No influence of operator errors – automation eliminates human factors.
Error minimization and repeatability
Mechanized orbital welding ensures weld consistency in large installations.
Consistent process parameters – precise control of the arc and welding speed.
Structural safety – no leaks or weaknesses in welds.
Cost optimization and waste reduction
Less material consumption – no excess overflow or spatter.
Shorter project implementation time – automatic welding increases work efficiency.
Fewer corrections and complaints – elimination of defects means lower production costs.
Orbital welding training and welding operator qualifications
PN-EN SO 14732 certification requirement – qualifications necessary to work with orbital technology.
Professional training increases operator efficiency and process precision.
High quality welding process – well-trained personnel guarantee durable and standard-compliant connections.
Orbital TIG welding with Deffor
TIG orbital welding is a modern, automated technology that guarantees high quality, precision and repeatability of welds. Thanks to full parameter control and elimination of human errors, this method works well in the most demanding industries, such as pharmaceutical, food, chemical, and energy.
Why choose TIG orbital welding?
Ensures maximum reliability of installation in demanding environments.
Reduces time and labor costs, eliminating the need for corrections.
Meets the highest quality and safety standards (PN-EN SO 14732).
Deffor professional services – contact us!
If you are looking for orbital welding specialists, Deffor offers comprehensive TIG welding services, technological installations and training for orbital welding operators.
