Achieving Consistency in Orbital Welding With Effective Quality Control

Orbital welding is an automated process frequently used to bond pipes and tubes. This option has many advantages compared to manual methods, including better repeatability and enhanced operator safety. However, automation does not cause foolproof results. What should shop managers and other employees do to ensure the best quality control outcomes? 

Keep Software Updated

Software is at the heart of orbital welding systems. Keeping it updated is one of the easiest ways to access all new features and other updates that could improve internal processes while enhancing overall outcomes. Conversely, outdated software prevents operators from accessing the latest upgrades and could pose preventable cybersecurity risks, opening opportunities for quality-related shortcomings due to malicious parties’ external machine tampering.

One recent software version for an orbital welding system uses thousands of stored images to respond to imperfections. Continual monitoring of factors such as the weld gap and out-of-round variations allows the machine to make the necessary corrections, preventing defects that could cause products to fail inspections.

Although the welding system could previously make real-time adjustments to four parameters based on data captured by an integrated camera, the software update adds the image library. This example shows why seemingly minor upgrades can cause significant quality control improvements. 

Select and Track Metrics

Welding shop managers should also select applicable statistics to track in the facility, whether related to quality, efficiency or overall output. Although orbital welding systems reduce issues such as porosity and undercutting, problems can still occur elsewhere.

Some of the most common relate to wire-feed problems, including some caused by operator errors. For example, selecting a wire with a diameter too large for the machine can cause it to bind up rather than progress through the equipment or to feed sporadically and disrupt workflows. 

Managers should speak to the individuals who spend all or most of their time setting up and supervising orbital welding. Details about the problems they encounter most frequently and the reasons for them will shed light on which metrics to monitor. 

Decision-makers should also consider the time frames within which they hope to achieve specific goals. Sharing those milestones with operators will keep them motivated and accountable for contributing to the necessary success. 

Give Operators Adequate Training

Efficiency improvements are among the most compelling reasons to invest in orbital welding systems. One orbital welding head is over 60% faster to use than manual methods. Such gains are especially important in large projects, where the accumulated time-saving effects streamline results while minimizing labor costs. 

However, even as orbital welding becomes more popular, accessible and attractive, it will not replace trained professionals. Instead, the methods to keep their skills sharp and relevant should reflect the work’s evolving nature. Despite the equipment’s automated capabilities, knowledgeable personnel need to set up, supervise and adjust orbital welding systems so the outcomes match client specifications. 

Those overseeing internal training programs should consider how people’s preferred learning styles differ. Although some individuals like reading book chapters, others can retain the information more effectively through interactive methods. 

Understand the Welding System’s Features 

Decision-makers planning to buy orbital welding equipment should give themselves plenty of time to understand how their chosen models work — before and after purchasing them. Then, they will know how to make adjustments for consistently excellent outcomes. 

The specific welding machine a leader chooses also depends on the factors encouraging this investment. In one example, a company purchased two pieces of equipment from France to improve the quality of heat exchanger connections.

One of the equipment features allows controlling the arc voltage to create consistent weld beads. Once operators preprogram the equipment, it will maintain a constant weld pool. Giving them ample time to experiment with those and other settings before working on high-value projects should increase their confidence while enhancing quality control. 

Pursue Continuous Improvement

Besides applying these specific tips to get better orbital welding results, parties in authoritative positions should encourage machine operators to challenge themselves to look for new ways to improve while committing to address known shortcomings. That professional growth will equip welders to thrive while automated equipment becomes more widely used.