Benefits of Automated Pipe Welding

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Automated pipe welding offers a host of advantages, from increased production speed and exceptional flexibility, to material savings and dramatically improved end product quality. 

Unparalleled Flexibility:
Pipe welding requires finesse and flexibility. Different pipe dimensions, materials, fittings call for different welding applications, torch angles, etc. Automated pipewelding provides a reliable, flexible solution. It accommodates straight cut pipe welds as well as fittings such as a Sockolet, Threadolet, or Elbolet.

A 6-axis robotic arm is capable of quick, efficient torch positioning. It saves time and provides unbeatable flexibility while maintaining optimal weldment quality. 

Quality: Automated pipe welding produces exceptional weld quality. 

  • Control and Integration – Every element of the process can be monitored and controlled – from voltage, current and wire feed speed to torch angle and weld penetration. Adjustments to workpiece positioners, torch orientation, welding power source, robotic arm movements allow for fine-tuned, precise results.
  • Advanced Technology – On their own, robots are extremely consistent and accurate. When combined with sensors, through-the-arc tracking, and even vision software, robotic pipe welding is a force to be reckoned with. Automated pipe welding offers higher deposition welds and greater fusion. 

Savings: Automated pipe welding saves time and materials.

  • Materials – This approach to welding is consistent and repeatable. With robots welding, the results are the same every time, so there isn’t the variation in quality that can sometimes occur with manual welding. Fewer do-overs equals less wasted product material and better throughput.
  • Time – Automated pipe welding allows you to calculate cycle times with much more precision. Increased flexibility and speed when positioning the welding torch leads to shorter cycle times. In addition, off-line programming options allow for performance adjustments to be made without incurring unnecessary downtime. 

 

How to Lower Your Welding Costs

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Gravity makes welding more expensive, it’s a fact… That is why downhand welding costs less than vertical or overhead welding.  It’s all about deposition rates.  When welding in the vertical or overhead position, the higher your metal deposition rate, the more likely the weld metal is to sag and run out of the joint.  To combat these problems try using a pulsed power source that produces less heat, or use current and voltage settings that reduce the burn-off rate or use smaller diameter electrodes with good out of position characteristics. All of these solutions require a skilled welder. 

Another disadvantage is that deposition rates are lower, therefore production costs are higher, not to mention the cost of a skilled welder and the ability to find one! Every solution to out of position welding problems has the same disadvantage – deposition rates are lower, and your production costs are higher.  They often are much higher. 

Predicting Deposition Rates

The following is a rule of thumb guideline to predict deposition rates.  In the vertical position a welder should be able to weld approximately 3 pounds per hour with a stick electrode when welding.  Unfortunately even a good welder welds only about 25% of the time.  The rest of his time is spent changing electrodes, chipping slag and positioning. The actual deposition rate will then be about ? lb per hour.  Downhand, the same welder should be able to weld 10 to 15 lbs. per hour, when he is welding. 

By replacing the stick electrode with flux core wire or submerged arc, weld downhand and your welder should double his output to 30 lbs per hour.  That’s also when he is welding.    Using semi automatic welding equipment, your welder can weld a heavy work piece from 50% to 75% of the time, actual arc-on time.    He’s then only giving you 15 to 20 lbs. per hour of weld per man hour worked in the down hand position.  Using semi automatic power sources designed for overhead welding, a welder can weld about 1/8th of what he can deliver in the down hand position. 

In Position Welding Can Provide a Payback

While change in welding process has a positive impact on welding costs in position versus out of position welding, the major cost savings is generated by moving the weld into position far outweigh the benefits of process changes.  The savings offered by in position welding are often large enough to provide a payback of the positioning investment in less than one year. 

Positioning Equipment Reduces Materials-Handling Risks

By mechanizing the weld system using the proper positioning equipment and multi wire welding, expect 60 lb. weld deposition per hour. There are several reasons for using positioning equipment.  Operator fatigue is a factor in lost productivity and reduced weld quality.  Safety is another important factor.  Any time that a work piece is manually handled, accidents can occur.  Positioning equipment reduces materials-handling risks because the work is handled one time to load and only once more to unload it.  

Positioning creates better weld quality.  If the weld metal is all down hand, gravity helps the weld.  The result is equal legs on fillet welds, a smoother bead surface, minimum cleanup and less weld-repair time, and often a reduction in weld defects.

Effective Use of Available Floor Space

Positioning equipment also makes more effective use of available floor space.  A positioner under the weldment will shrink the total space required to handle the work.  For example, a weldment cannot be turned over 180 degrees without setting it on the floor and re-hooking it to a crane.  A positioner can do that in about half of the space. 

Positioning equipment should be considered a cost savings due to improved safety, weld quality, better floor space utilization, possibly a lower welder skill level requirement.  But most importantly a positioner can reduce your cost per pound of weld metal deposited by moving your welding into a down hand position. 

SOHO WELDING can custom design systems to increase your deposition rates by using new and used welding equipment.  The company’s experienced staff can help you size your positioning equipment.  “Call us, we know welding”

How to Weld Steel Pipes

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Welding pipes is one of the simplest and most durable ways to join piping together and steel pipes can simply be welded together with MIG (metal inert gas), TIG (tungsten inert gas or SMAW (stick metal arc) welding. Before welding two pipes together, avoid any gaps between the two pipes. While welding, take measures to ensure the continual alignment of the two pipes.
Instructions

1.Align the two pipes and use clamps to hold them together, if necessary.

2.Fire your welding torch or strike your welding electrode on the steel to open an arc between the welding tool and pipes. Allow the torch to form a small welding puddle on the surface of the steel, called a tack weld.

3.Move the arc slightly and create another welding puddle elsewhere on the circumference of the pipes. Continue to move the arc and create more welding puddles until you have formed a series of tack welds at regular intervals along the circumference.

4.Move the welding tool thoroughly along the circumference of the pipes creating a welding puddle that extends fully around the circumference and connects the two pipes together.

5.Extinguish the arc and allow the welding puddle several minutes to dry.