5 Expert Tips To Avoid a Lack of Fusion in Orbital Welding

Orbital welding is a highly precise and efficient welding process commonly used in industries such as aerospace, semiconductor, and pharmaceuticals. However, lack of fusion is a common issue that can occur during orbital welding, leading to weak welds and potential safety hazards. In this blog, we'll explore the causes of lack of fusion and provide expert tips to prevent it.

What Is Orbital Welding?

Orbital welding is a highly specialized welding technique that utilizes automated equipment to produce accurate, high-quality welds. Unlike traditional welding methods, which require a welder to manually manipulate the welding torch, orbital welding machines use a precision-controlled welding head to produce a continuous, uniform weld around a cylindrical object, such as a pipe or tube.

One of the primary advantages of orbital welding is that it produces high-quality, repeatable welds with minimal operator intervention. The welding head is programmed to follow a specific welding path, which ensures that the weld is consistent and uniform throughout the length of the pipe or tube. This results in a strong, reliable weld that is free from defects such as porosity, undercutting, and weld spatter.

1. Double check your weld schedule

The welding parameters such as current, voltage, and travel speed play a crucial role in the quality of the weld. Incorrect parameter settings can result in insufficient heat input, which can cause a lack of fusion. Therefore, it's essential to follow the manufacturer's recommendations and optimize the parameters according to the specific material and welding conditions.

2. Cleanliness is Key

Contamination of the weld area can also lead to a lack of fusion. Before welding, it's important to remove any dirt, oil, or other impurities from the surface using a solvent, wire brush, or other suitable cleaning method. It's also important to clean the welding equipment, including the filler wire and welding torch, to prevent any contaminants from entering the weld pool.

3. Control the Welding Environment

The welding environment can also affect the quality of the weld. Exposure to drafts, humidity, or temperature variations can cause fluctuations in heat input and lead to a lack of fusion. Therefore, it's essential to maintain a stable environment with controlled temperature, humidity, and air flow.

4. Ensure Proper Fit-Up

Welding fit-up is the process of preparing and positioning the workpieces before welding. It involves ensuring that the two parts are aligned correctly, and any gaps or misalignments are eliminated.

A good fit-up is crucial for producing high-quality welds that are strong and durable. A poor fit-up, on the other hand, can lead to various welding defects, such as lack of fusion, porosity, and cracks. Before starting your weld check to make sure the collets you use are clean and the work piece sits flush. Also check for that to clamps are tightened properly.

5. Monitor the Welding Process

Monitoring the welding process is critical in detecting any issues and preventing lack of fusion. Various methods can be used to monitor the weld quality, such as visual inspection, X-ray, or ultrasonic testing. It's also important to track the welding parameters, including current, voltage, and travel speed, to ensure they remain within the recommended range.

A lack of fusion is a common issue in orbital welding, but it can be prevented by following the manufacturer's recommendations, maintaining a clean and stable environment, ensuring proper fit-up, and monitoring the welding process. By implementing these expert tips, you can ensure high-quality, strong, and reliable welds.