There are several different welding methods in Mectalent’s service portfolio. Orbital welding is chosen when the final product has high-quality requirements and the weld seam must be clear. It is used in precision mechanics, especially in the manufacturing of piping systems.
Orbital welding is a mechanized TIG welding process in which the arc mechanically rotates around the pipe. In orbital welding, the arc, surrounded by shielding gas, melts either the workpiece or the filler material, bonding the parts together.
TIG welding (Tungsten Inert Gas welding) is a gas arc welding method that uses a non-melting tungsten electrode and inert shielding gas. The inert shielding gas does not react with the workpiece or filler material and protects the solidifying weld pool from oxidation, air impurities, and moisture. This gas ensures that no pores form in the solidifying weld pool, which could weaken the joint's strength or alter its geometric properties.
Orbital welding is a TIG welding method where the arc travels in a semi-circle or full circle around the pipe, joining two pipes together. Both the outer and inner surfaces remain neat and clear.
In orbital welding, the arc is mechanically controlled, removing potential inaccuracies that might occur with manual welding. This method was specifically developed to eliminate the inaccuracies and human errors of manual welding processes. Therefore, orbital welding is particularly well-suited for precision mechanics where tolerances are small and quality requirements are high.
The path of the arc in orbital welding is pre-planned and programmed. The method also allows for the welding of very small pipes. The smallest pipe that can be worked with orbital welding has a diameter of 1.6 millimeters.
Thanks to the shielding gas, orbital welding is also suitable for welding the most sensitive materials. The inert shielding gas ensures that no external factors can affect the weld, and the result meets the requirements even for sensitive materials.
>> Read the blog: Manufacturing precision parts requires special expertise
Due to its precise and high-quality results, orbital welding is well-suited for precision mechanics needs. It is used, for example, in semiconductor industry devices and in the food, chemical, and pharmaceutical industries.
Depending on the material, orbital welding can achieve an extremely durable weld that is suitable for extreme conditions. Therefore, it is used in piping systems that must withstand high pressure or extreme temperatures.
At Mectalent, orbital welding is used, for example, in the manufacturing of piping for ALD coating devices. ALD (Atomic Layer Deposition) is a thin-film coating method used in the semiconductor industry, among others. It enables the manufacturing of computers, various sensors, solar cells, mobile phones, and other microelectronics.
The pipes used in ALD equipment are small: their diameters range from just over six millimeters to thirteen millimeters, and wall thicknesses vary from less than a millimeter to 1.25 millimeters. The work is precise, and the welding seam must be very neat—hence orbital welding is the best method for this type of work.
>> Read the case study: Manufacturing ALD systems for the leading supplier
Quality assurance in orbital welding at Mectalent starts with planning. The material must meet the customer's requirements also in the weld, thus both the work material and any additional material must be carefully selected. In mechanized welding, the design of the welding process is also important. The welding device is programmed to process the material along a specific path accurately.
Before starting the actual work, a test pipe is welded to ensure that the machine produces a seam that meets the customer's quality requirements. When the pipe size changes, a new test pipe is made. The quality of the weld is always first visually inspected, as well as with a sight-pipe stick, which allows for the internal seam quality to be checked. Additionally, each pipe is also leak tested. The final visual inspection is done when the entire piping system is completed.
>> Read the blog: Quality is a continuous process
At Mectalent, we have extensive precision mechanics expertise and a versatile machine base. Thanks to these, we can offer our customers comprehensive precision mechanics design, machining, and assembly services.
We offer CNC machining for precision mechanics needs, and several different welding methods in addition to orbital welding. We also process materials using precision mechanics methods such as wire cutting EDM and die sinking EDM. We also offer extensive options for post-treatment, markings, and surface treatments.
>> Contact our sales team to learn more about orbital welding or our other services!