Frequently Asked Questions

Orbital welding is an automated GTAW/TIG welding process in which a non-consumable tungsten electrode mechanically rotates around a securely clamped pipe. The arc is stably maintained under shielding gas—usually argon. The result is reproducible, documentable, high-quality weld seams.

Orbital welding is used wherever the highest requirements for purity, tightness, and process reliability exist—for example, in the pharmaceutical, food, semiconductor, chemical, and energy industries. The process is particularly suitable for thin-walled stainless steel pipes.

Compared with manual TIG welding, orbital welding offers greater repeatability, digitally storable welding parameters, lower error rates, and consistently high weld quality—ideal for quality-critical applications.

Depending on the welding head used, pipe diameters from approximately 3 mm to over 170 mm outside diameter can be processed. Closed welding heads are suitable for smaller diameters, open systems for larger pipe dimensions.

A square, burr-free, and clean cut edge is a prerequisite for a uniform joint gap, complete penetration, and tight connections. Incorrect cut geometries lead to gaps, incomplete fusion, and increased rework.

Orbital welding is an automated TIG welding process (Tungsten Inert Gas, also internationally referred to as GTAW) in which a non-consumable tungsten electrode rotates mechanically around a fixed pipe or component. In contrast to manual TIG welding, the arc is not guided by hand, but is moved precisely around the workpiece by a closed or open welding head. The workpiece remains fixed while the torch rotates orbitally. The arc is stably guided under shielding gas—usually argon. This results in reproducible, documentable, and high-quality weld seams with controlled heat input. Orbital welding is particularly suitable for thin-walled stainless steel pipes where the highest requirements for purity, tightness, and traceability exist.

Orbital welding is used wherever consistent weld quality, a minimal defect rate, and documented process parameters are required. Typical industries include pharmaceuticals, food processing, semiconductors, chemical and petrochemical plants, energy and power plant construction, and high-purity applications. The process offers significant advantages, particularly for stainless steel pipes in material groups 304L and 316L with wall thicknesses under 3 mm. In sensitive areas such as high-purity gas lines or purified water systems, orbital welding is now state of the art.

Orbital welding offers significantly higher process reliability and reproducibility compared to manual TIG welding. Welding parameters such as current intensity, pulse frequency, gas flow, and rotation speed are digitally programmable and can be stored. This significantly reduces the error rate and enables consistent weld quality across large production runs. Further advantages include improved traceability, lower rejection rates, controlled heat input, and the possibility of integration into automated manufacturing lines.

Modern orbital welding systems cover pipe diameters from approximately 3 mm to over 170 mm outside diameter, depending on the weld head. Closed weld heads are primarily used for smaller diameters and hygiene-critical applications, while open weld heads can process larger pipe dimensions and thicker-walled materials. The specific operating limit depends on the power source, cooling capacity, and mechanical design of the system.

A square, burr-free, and clean cut edge is the basis for high-quality orbital welds. Inaccurately cut or deformed pipes lead to gap formation, an uneven root, lack-of-fusion defects, or leaks. Especially in automated processes, the geometry of the butt joint must be exact. Precise pipe preparation using orbital pipe saws or beveling machines significantly reduces rework and greatly increases process stability.

Orbitalum offers a comprehensive portfolio of orbital welding systems, consisting of digital power sources, closed and open welding heads, and tube-to-tubesheet welding heads. The systems are modular in design and cover applications from on-site installation to industrial series production. Digital interfaces enable integration into quality management and documentation systems.

The orbital welding power source is the central control element of the process. It precisely controls current intensity, pulse parameters, rotation speed, and gas flow. Modern power sources enable the storage of welding programs, the traceability of individual welds, and a constant energy supply to compensate for gravity and heat effects.

Yes. Thin-walled stainless steel pipes with wall thicknesses under 3 mm can be butt-welded without filler wire. For greater wall thicknesses, a V- or J-bevel is required, where filler wire is used for complete seam filling. The choice depends on the material, wall thickness, and quality requirements.

Pulsed current reduces the average heat input and improves control of the weld pool. Particularly with thin-walled pipes, pulsed operation minimizes distortion and material alterations. The weld geometry is stabilized, which further increases reproducibility.

Orbital pipe saws enable perpendicular, burr-free, and cold-working cuts of metal pipes. The saw blade rotates around the firmly clamped pipe, creating a precise cutting geometry. This is particularly important for subsequent orbital welding processes.

Concentric clamping means that the pipe is uniformly secured at multiple points. Multi-point clamping systems prevent ovalization and deformation of thin-walled stainless steel pipes. This ensures precise 360° cutting and high repeatability.

A precise 90° cut is a prerequisite for a uniform butt joint. Even minor deviations can lead to gaps, an uneven root, or rework. Orbital pipe saws achieve very tight squareness tolerances, thereby improving the quality of the subsequent weld seam.

Why is cold cutting so important when separating stainless steel pipes?
Cold cutting refers to a mechanical separation process without thermal influence on the material. In contrast to thermal cutting processes such as plasma or flame cutting, no heat-affected zone (HAZ) is created during orbital pipe sawing.

This is particularly critical for stainless steel pipes in pharmaceutical, food, and semiconductor applications.

Advantages of cold cutting:

• No microstructural changes in the edge area
• No oxidation or discoloration at the cutting edge
• No material hardening due to thermal stress
• Optimal weld preparation for subsequent orbital welding
• No particle or slag formation

Thermal cutting processes can compromise the corrosion resistance of stainless steel and require additional post-processing. Cold cutting, on the other hand, ensures a metallurgically unchanged cut surface and thus increases process reliability for subsequent orbital TIG welding.

For wall thicknesses exceeding 3 mm, weld preparation is required. A V-, J-, or U-bevel according to ISO 9692-3 enables complete penetration and optimal weld filling. Without beveling, the energy input during TIG welding would be insufficient.

The machining is performed by chip removal using milling tools. Unlike thermal processes, no microstructural changes or heat-affected zones occur. This ensures reproducible and metallurgically stable results.

Argon is the standard shielding gas for orbital welding. Depending on the material, argon-hydrogen or argon-helium mixtures are used. The choice of gas affects arc stability, penetration depth, and weld appearance.

Impure shielding gas leads to oxidation, discoloration, and reduced corrosion resistance. In high-purity applications, continuous residual oxygen monitoring is therefore required.

With controlled parameters, proper pipe preparation, and appropriate gas management, the defect rate is typically below 1%. This makes the process particularly attractive for quality-critical industries.

Yes. The process can be fully integrated into automated production lines. Welding programs can be saved and reproduced as often as required. This enables series production with consistent quality and complete documentation.

Orbitalum supports customers with product selection, process optimization, and application engineering. Technical experts accompany projects from planning through commissioning.

Product training and application-focused training provide knowledge on parameter settings, gas management, tube preparation, and quality control.

Yes. Modern systems enable digital data storage, network transmission, and batch traceability.

Orbitalum offers structured training courses, certified programs, and practical advanced training in orbital welding, pipe cutting, and weld preparation.

The training courses are aimed at operators, welding specialists, maintenance personnel, quality managers, and technical planners.

Training content may include, among other things:

• Fundamentals of orbital TIG welding (TIG/GTAW)
• Parameterization and programming of orbital welding systems
• Selection and use of suitable shielding gases
• Residual oxygen measurement and purge gas management
• Weld preparation according to ISO 9692-3
• Influence of materials (e.g., 316L, Duplex, Titanium)
• Error analysis and quality control
• Documentation and traceability of welding parameters
• Maintenance and safe handling of systems

The training courses can be conducted as:

• User training
• Advanced and in-depth courses
• Project-specific workshops
• In-house company training
• Or certified courses with a certificate of attendance.

Depending on the course format, participants receive a certificate or a certificate of attendance documenting successful completion.

The goal of the certified advanced training is to increase process reliability, reduce error rates, and ensure consistently high welding quality – especially in regulated industries such as pharmaceuticals, food, or semiconductor manufacturing.

Regular maintenance ensures arc stability, mechanical precision, and consistent weld quality. Wear parts should be inspected and replaced in accordance with the manufacturer’s specifications.

Extended warranty terms apply to certain product groups. Details can be found in the respective product documentation.

Orbitalum products are used worldwide in industrial applications—from Europe and North America to Asia and the Middle East.

Warranty terms are adapted regionally and handled in accordance with the applicable legal requirements and sales structures. The scope, duration, and processing of the warranty may therefore vary depending on the country or region.

Regardless, the following principles apply:

• High quality standards in development and manufacturing
• Use of tested components
• Technical support from authorized service partners
• Transparent provisions in the respective product documentation

For specific warranty terms, we recommend contacting the responsible country representative or the regional sales partner.