Orbital tube welding delivers consistency, quality

Orbital tube welding produces repeatable, high-quality and consistent welds on stainless steel tubing. At Axenics, our orbital tube welding process utilizes an orbital welding machine with an enclosure that protects the weld through completion. A belt- or gear-driven circular motion drive welds around the tube automatically.

Our in-house tube welding machines accommodate different angles or thickness of tube. Because orbital weld machines are partially automated, it doesn’t take a journeyman welder to run the machine, but we do rely on journeyman welders to program the welds into the machine. We also inspect the welds once completed.

Our welders are D17 certified by the American Welding Society. Our orbital TIG welding process occurs on stainless steel tubes, an ultra-clean procedure that produces a higher-quality weld than most other types of tube welding.

Industries that demand high-quality weldments rely on the orbital welding process to keep production running smoothly. Some of the the top reasons you may want to introduce orbital tube welding into your next component production include:

Orbital produces some of the cleanest welds

It is essential to keep contaminants away from stainless steel tubing before, during and after the welding process, as impurities trapped inside tubing are a detriment to the entire process, often resulting in significant wastes of time and money. Therefore, orbital welding generally happens in a cleanroom setting, where weldments on tubes and fittings occur in a high-purity, contaminant-free environment. The majority of orbital welds happen in our on-site Class 100 cleanroom.

Orbital tube welding is an efficient process

Orbital is an economical choice for welding components because the welds created are consistent and clean, meaning re-dos and weld repairs are nearly nonexistent. Orbital welding becomes “smarter” every day with more computerized attributes allowing for automating welds and analyzing welds, making the process even more efficient concerning time and overall costs.

Orbital welding is a productive option

Orbital tube welding involves the machinery doing the majority of the work, leaving your technicians’ time open for other tasks. Sure, there are upfront costs required for purchasing the appropriate equipment, but the automated processes within orbital cuts down on labor needs and lead time over time. Plus, utilizing a contract manufacturer such as Axenics means you don’t have to worry about investing in orbital welding machinery, as they already own it.

Orbital weldments are top quality

Our manual welders regularly create high-quality weldments when it makes sense (such as on stainless steel tubing that is too large to fit inside a machine). Generally, we rely on orbital welding because once the machine is programmed, the results are better-quality welds with no human error. Weldments with zero defaults are crucial in applications within the semiconductor and medical industries that have strict requirements.

Orbital tube welding is tops in consistency

While manual welds performed by a skilled technician can be accurate, orbital welding always produces more consistent welds. Orbital welding equipment is specifically programmed to repeat the exact same welds over and over again without error or orbital welding defects. With manual welding, by nature, there’s some variability and inconsistency between welds.

Orbital solves unique challenges

Orbital welding is great for manufacturing situations where it is not feasible or practical to rotate a piece of stainless steel tubing. Orbital is also helpful in situations where welding must be completed in tight spaces that may not be possible with manual welding.

Orbital tube welding is ideal for big projects

When multiple identical welds occur via an orbital welding machine, one sample weld is sufficient for testing because every single weld holds the same integrity, due to the repeatability of the machine.

Orbital tube welding results in lower overhead costs, the highest-quality welds and shorter lead times. If your project requires multiple weldments of the exact same consistency, orbital is likely your best bet.

High-Quality Tube Welding Solutions 

Tube welding can be an essential manufacturing process for industries where consistency, quality, and cleanliness are paramount. Axenics’ technicians specialize in delivering repeatable, high-quality welds on stainless steel and other metals that meet the stringent demands of sectors such as semiconductors, medical devices, chemical manufacturing, and alternative energy.

Tube Welding Precision in Action

We utilize advanced machinery to achieve consistent, defect-free welds on stainless steel tubing. Our process leverages automated equipment enclosed to protect welds during completion, ensuring the highest level of precision and cleanliness.

The equipment accommodates varying angles and thicknesses of tubing, making it versatile for a range of projects. Skilled welders program the machines and inspect the welds to maintain strict quality standards. This combination of automated precision and expert oversight ensures that every weld meets the rigorous demands of high-tech industries.

Industries That Rely on Tube Welding

Semiconductors: Semiconductor manufacturers demand ultra-clean welds to protect sensitive components. Tube welding in Axenics’ Class 100 cleanroom ensures contaminant-free results, maintaining the integrity of these delicate systems.

Medical Devices: High-quality, sterile welds are critical for medical devices to ensure patient safety. Tube welding produces precise results, ideal for manufacturing products that go into machines that produce surgical instruments and implantable components.

Chemical Manufacturing: Chemical processes often involve corrosive or hazardous materials. Durable, leak-proof welds are essential for maintaining safe and efficient operations. Axenics’ tube welding process ensures robust joints that can withstand these challenges.

Alternative Energy: For applications like fuel cells and solar panels, precise and reliable welds are crucial to maintaining system efficiency under demanding conditions. Tube welding provides the consistency required for these innovative energy solutions.

Key Benefits of Tube Welding

Ultra-Clean Welds: Cleanliness is paramount when working with stainless steel tubing. Impurities can compromise the entire system, resulting in costly rework or failures. At Axenics, tube welding occurs in a controlled environment, such as our Class 100 cleanroom, to prevent contaminants from affecting the welds.

Consistent Results: Tube welding ensures uniformity across all welds. Once programmed, the equipment performs identical welds repeatedly with minimal variability, meeting the exacting standards of industries that require defect-free components.

Enhanced Efficiency: Automated processes in tube welding reduce the need for labor-intensive manual welding and minimize errors. The repeatable nature of this process also leads to shorter lead times and lower overall costs, making it an economical choice for high-volume production.

Exceptional Quality: The tube welding process delivers precise welds that surpass many traditional methods. At Axenics, our welders ensure every project meets or exceeds quality expectations, whether it’s for medical devices, semiconductors, or chemical systems.

Adaptability for Complex Scenarios: Tube welding is highly effective for projects where rotating tubing is impractical or where welds must occur in tight spaces. This adaptability makes it an excellent choice for complex assemblies requiring precision and reliability.

Scalable for Large Projects: When multiple identical welds are needed, tube welding shines. The repeatability of the process ensures that every weld maintains the same level of integrity, reducing the need for extensive testing and streamlining production.

High-Purity Welding at Axenics

High-purity welding is essential for industries requiring contaminant-free environments. Even the slightest impurity in a weld can lead to oxidation and compromise the entire system. At Axenics, tube welding is performed in a Class 100 cleanroom to eliminate risks associated with dirty welds.

Our team specializes in high-purity welding techniques, including TIG welding and automated tube welding, to deliver clean, durable joints. Whether your project involves joining flanges, tubes, or other components, our process ensures precision and reliability.

Questions to Consider for Your Tube Welding Project

To deliver the best results, Axenics evaluates several factors before beginning a project:

• What type of tubing material is required?
• What are the size and thickness specifications of the tubing?
• How many fittings and weldments are necessary?
• What is the required spacing between welds and fittings?
• Does the project need specialized welding heads or tools?

These considerations help us tailor our approach to meet the unique needs of your project while optimizing for cost and efficiency.

Challenges and Considerations in Welding Different Types of Metal Tubes

While stainless steel remains a primary focus at Axenics due to its widespread use in high-purity applications, welding other metals like aluminum, brass, and copper presents unique challenges and requires specialized expertise. Including insights into these materials helps provide a comprehensive understanding of the tube welding process.

Welding Aluminum Tubes

Aluminum is a lightweight and highly corrosion-resistant material, often used in aerospace, automotive, and alternative energy applications. However, its properties can create challenges during the welding process:

Oxidation: Aluminum forms an oxide layer almost immediately when exposed to air. This layer must be removed before welding to prevent weak or contaminated welds.

Heat Sensitivity: Aluminum has a high thermal conductivity and low melting point, making it prone to distortion or burn-through during welding.

Porosity: Gases like hydrogen can become trapped in aluminum welds, leading to porosity that weakens the weld integrity.

To overcome these issues, precise control of heat input and an inert shielding gas, typically argon or a mix of argon and helium, are essential.

Welding Brass Tubes

Brass, a copper-zinc alloy, is often used for decorative or electrical applications due to its attractive appearance and excellent conductivity. However, welding brass poses distinct challenges:

Zinc Vaporization: Brass contains zinc, which has a lower boiling point than copper. During welding, zinc can vaporize, leading to porosity and contamination.

Cracking: Improper welding techniques or overheating can result in stress cracks in the material.

Health Hazards: The vaporized zinc produces fumes that can be hazardous to the welder, requiring proper ventilation and protective equipment.

Specialized techniques, including careful temperature control and filler materials designed for brass, help address these challenges.

Welding Other Metals

Copper, titanium, and nickel alloys are also common in tube welding but require different considerations due to their unique properties, such as thermal expansion, conductivity, and chemical reactivity. Each material demands tailored techniques and tools to achieve defect-free welds.

The Historical Evolution of Tube Welding Techniques

The modern precision of tube welding is the result of centuries of innovation and technological advancement. Understanding the history of welding helps contextualize its importance and demonstrates how the process has evolved to meet the demands of modern industries.

Early Techniques and Innovations

Welding has its roots in ancient blacksmithing, where metals were joined by heating and hammering. By the 19th century, advancements like the oxy-acetylene torch allowed for more precise joining of metal components. However, early methods were labor-intensive and lacked consistency, limiting their application for large-scale industrial use.

The Rise of Arc Welding

The invention of electric arc welding in the late 19th century marked a major turning point. This method, which uses an electrical current to melt and join metals, laid the foundation for many modern welding techniques. By the mid-20th century, the development of tungsten inert gas (TIG) welding enabled high-precision work, particularly with stainless steel and aluminum, setting the stage for today’s advanced processes.

The Birth of Tube Welding

As industries like chemical manufacturing and aerospace grew in the 20th century, the need for specialized tube welding techniques emerged. The introduction of orbital welding in the 1960s revolutionized tube welding by automating the process, ensuring consistent and repeatable welds for critical applications.

Modern Advancements in Tube Welding

In recent decades, tube welding has become more sophisticated, incorporating automation and real-time monitoring. Computerized welding systems now allow for unparalleled precision and control, accommodating materials with diverse properties and ensuring defect-free results. Cleanroom environments, like those at Axenics, have further enhanced the process by eliminating contaminants, enabling the production of high-purity components for industries such as semiconductors and medical devices.

The evolution of tube welding reflects the growing complexity of industrial applications and the relentless pursuit of precision, efficiency, and quality. By understanding its historical context, it becomes clear why tube welding remains a cornerstone of modern manufacturing.

Why Choose Axenics for Tube Welding?

At Axenics, we pride ourselves on delivering precision, consistency, and quality in every weld. Our team’s expertise, combined with advanced equipment and cleanroom facilities, ensures defect-free results for the most demanding applications. Whether your project involves semiconductors, medical devices, or alternative energy systems, Axenics has the experience and capability to exceed your expectations.

Contact us today to discuss how our tube welding solutions can elevate your next project.

Related Posts