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Application:
Re-melting of the penetration bead inside a small bore tube.
Process:
TIG welding.
Capacity:
Boom reach is 240" (6,100 mm).
Description:
Plasma keyhole welding of formed stainless steel tubes leaves an unacceptable penetration bead which must be smoothed and flattened to provide the necessary tube quality.
Jetline created a unique solution for this application, which uses a 9500 microprocessor controller to provide precise, repeatable welds with full operator control. The 9500 controller is used to control the welding current, arc length, travel speed and wire feed speed. Pre-programmed weld schedules were created for different types and thicknesses of material, these were capable of being recalled at any time.
The requirement of the system was to provide the ability to weld tubes with bores as small as 8" (200 mm) on tubes with lengths up to 20 ft (6,100 mm). This creates a challenge in the manufacture of a TIG welding head small enough to fit into the bore of the tube and with enough capabilities for the operator to be able to monitor and control the weld and its position in the tube.
Jetline created a special weld head which included arc length control, motorized, remotely-controlled cross seam positioning, wire feed, magnetic arc oscillation and video monitoring. The camera provides a magnified view of the weld area so that the operator is able to see the position and effect of the welding.
An operator control station is provided, this incorporates the color video monitor as well as the joystick which allows the operator to control cross seam position. The 9500 system controller is mounted in the operator control station and is equipped with Jetline’s unique "SYNERGIC TIG" firmware. This firmware allows the operator to make corrections to the weld process in such a way that all the parameters are changed in harmony with each other.
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