pipeTruck from EWM: Automated MAG orbital welding in TIG quality

Factor "5" for root, fill and final passes

Mündersbach, Germany, 6th June, 2011. A number of competing orbital welding processes have become established on the market for providing the most economical pipe connection in the construction of pipelines and for DN300 or larger lines laid in the ground for a pipeline. For example, a seam root can be joined using the tungsten inert gas (TIG) process and then the fill and final passes processed with metal active gas (MAG) welding. These two processes require two sources of power. Another example is the purely MAG welding process used in America, which requires lots of additional processing. Both solutions thus make field and work done in the workshop more difficult and expensive.

EWM HIGHTEC WELDING, located in Mündersbach, Germany, will be presenting their complete automated orbital welding system for the first time at Schweisstec. This extremely economical system handles every joining task at the pipe in an exemplary way: the "pipeTruck" orbital pipe welding system with its track system; the highly dynamic multi-process inverter power source "alpha Q" with the patented welding processes "pipeSolution", "coldArc", "forceArc", "superPuls" process switching and the pulse arc; automatic welding torches (AMT) and welding consumables.

An overview of the economic and technological advantages of the new MAG orbital welding system:
"pipeSolution", the automated MAG process for root welding, offers welding speeds up to five times faster in comparison to manual TIG welding, and the seam is up to 100% X-ray proof. This is MAG welding in TIG quality. No second power source is required for subsequent welding of the fill and final passes. The "alpha Q" is equipped with a double wire feeder for optional supply with additional welding wire (solid or flux cored wire). To change the seam type, all that's needed is to exchange the torch. The system is then ready to continue working at the push of a button. A deposition rate of up to five times higher in comparison to MMA welding can be achieved with flux cored wire.

With the commonly used purely MAG process, root welding with the short arc is followed by grinding out in preparation for filling, i.e. removal of excess weld metal and uneven sidewalls. With pipeSolution from EWM, all that's required is brushing to remove silicates from the seam surface. Further passes are created step by step without expensive intermediate work. Fill and final passes are welded as per the customer's wishes or according to the WPS either with the pulse arc or flux cored wire.

The orbital welding system from EWM welds at high speed and with high precision in the vertical-down and vertical-up positions. The control of the "alpha Q" also offers the option of dividing up the process into programmable sections. Convenience is increased by JOBs already integrated in the system. After entering the basic parameters, i.e. the welding consumable type and diameter and the shielding gas type and after a subsequent fine adjustment, a perfect program for continually reproducible welding results is available. Evenness and precision come up to weldings with robots.

High stability is also a result of ingenious development details. Actual values are taken directly from the arc, so an additional measuring lead and many of the otherwise unavoidable sources of error, such as contact problems or corrupted values, can be eliminated.

Additional advantages of the "pipeTruck" system: The pipe welding carriage (tractor) can be placed effortlessly on the track system. Weighing only 19 kilograms, it's easy to handle. The stainless-steel track system is available for nearly every pipe dimension from 300 mm and up. The standard remote control allows the operator to fully monitor the orbital joining process and to make corrections if necessary.

Fig.1: Handles joining tasks at the pipe in a cost-effective and exemplary way: the "pipeTruck" orbital welding system with its highly dynamic multi-process inverter power source "alpha Q" and the patented welding processes. The program for continually reproducible seams is created in the blink of an eye.
Photo: EWM HIGHTEC WELDING

Fig.2: The orbital welding system from EWM welds at high speed and with high precision in the vertical-up position
Photo: EWM HIGHTEC WELDING

Fig.3: "alpha Q" multi-process inverter power source with the patented welding processes pipeSolution®, coldArc®, forceArc®, „superPuls“ process switching as well as pulse arc
Photo: EWM HIGHTEC WELDING

Fig.4: Automated MAG welding in TIG quality: The standard remote control allows the operator to fully monitor the orbital joining process and to make corrections if necessary
Photo: EWM HIGHTEC WELDING

Fig.5: pipeSolution®, the automated MAG process for root welding, offers welding speeds up to five times faster in comparison to manual TIG welding , 100 % X-ray proof seam
Photo: EWM HIGHTEC WELDING

Fig.6: Absolutely safe root welding with pipeSolution® –
For every wall thickness, in all positions and for a host of different seam preparations.
Photo: EWM HIGHTEC WELDING

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