Key Points of Pipeline Welding Robot Welding Technology

Don't underestimate the welding technology of pipeline welding robots; they are very capable. Currently, with the maturity of industrial robot technology, robots are widely used in pipeline construction. The emergence of pipeline welding robots aims to improve welding quality and reduce the labor intensity of welders. How good is the welding technology of welding robots? Let's take a look.

Welding Robots

1. Selection of Welding Process

Submerged arc welding, gas shielded welding, friction welding, and electroslag welding are all widely used in pipeline welding. Currently, besides manual welding, submerged arc welding and gas shielded welding are the most common pipeline welding processes.

Submerged Arc Welding Process

Submerged arc welding is performed under a layer of granular flux. The welding wire is continuously fed, and the arc burns under the flux layer. The flux melts to form slag and a gas-protected molten pool. Excess flux can be recycled.

Advantages

1. Extremely High Production Efficiency

l Welding current can reach 1000-2000A, with high deposition efficiency.

l Single-pass welding can penetrate steel plates up to 20-30mm thick.

l Welding speed is typically 30-100 cm/min, 5-10 times faster than manual welding.

l Can be combined with multi-wire welding technology (double-wire, triple-wire) for further efficiency improvement.

2. Excellent Weld Quality

l The flux layer completely isolates the weld from air, providing excellent protection.

l Beautiful weld formation, deep penetration, and low porosity.

l High weld metal purity and stable mechanical properties.

l No spatter, no need for spatter cleaning.

3. Good Working Conditions

l No arc radiation, no need for operator face masks.

l No smoke or dust emissions, clean working environment.

l High degree of automation, low labor intensity.

4. Good economic efficiency

l High wire utilization rate (up to 98% or more)

l Fluid is recyclable (recovery rate 80-90%)

l Low overall cost per unit weld length

Gas shielded welding process

Gas shielded welding delivers shielding gas (CO₂, Ar, or a mixture of gases) to the welding zone through the welding torch nozzle, forming a gas protective layer that isolates the molten pool from air.

Advantages

1. High applicability and flexible operation

l Capable of all-position welding (flat, vertical, horizontal, overhead)

l Suitable for various joint types of thin, medium, and thick plates

l Can operate in complex environments such as on-site and field operations

2. High welding efficiency

l No slag cleaning process, continuous welding

l Welding speed can reach 30-80 cm/min

l Deposition efficiency is higher than manual welding, but lower than submerged arc welding

3. Good visibility

l Welders can directly observe the molten pool and arc status

l Facilitates real-time adjustment of welding parameters

4. Wide material adaptability

l Suitable for various materials such as carbon steel, stainless steel, aluminum alloy, and copper alloy

l Welding results can be optimized by changing the shielding gas

5. Easy to automate

l Easy to integrate with robots and automated welding machines

l Capable of pulse welding and controlled heat input

Uses a solid wire welding process with gas shielding. For multi-pass welding, the process can be simply divided into three stages: root pass, fill pass, and cap pass. No surface cleaning is required before proceeding to the next step, but the welding speed is slower compared to forced pass welding. In suitable areas, using carbon dioxide and argon as shielding gases is ideal.

2. Wire Feeding Method

The smoothness of wire feeding directly affects welding quality. Wire feeding methods can be simply divided into two types: pulling and pushing. When pulling, the welding torch is closer to the wire feeder, resulting in less resistance after the wire leaves the feeder, thus ensuring a smooth feeding process. When using the pushing method, the wire feeding mechanism is installed outside the welding carriage, reducing its size and weight. This allows for the use of a high-power wire feeder and a large 1.2mm diameter spool of welding wire (weighing approximately 20kg), thereby improving welding efficiency.

How good is the welding technology of pipeline welding robots? I believe everyone understands now. There are many places that need welding robots. In the face of fierce market competition, only by improving our technology and equipment can we avoid being eliminated. The welding technology of pipeline welding robots will be further improved in the future.