Nikit Engineering | Welding Automation and Robotic Solutions India

Automated TIG welding of Flexible Stainless Steel Hoses

INTRODUCTION

Welding flexible stainless steel hoses is a process that requires precision, skill, and attention to detail. The hoses are typically used in a variety of industries, including automotive, aerospace, and medical, and they must be able to withstand high pressures and temperatures while remaining flexible and durable.

The traditional method of welding flexible stainless steel hoses is manual TIG welding. This method involves the use of a TIG (tungsten inert gas) welding torch, which is held by the welder, who manually guides the torch along the length of the hose while simultaneously feeding a filler wire into the weld joint. This process is time-consuming and requires a high degree of skill and experience from the welder.

NEW METHODS OF WELDING

However, with the advent of automation, the process of welding flexible stainless steel hoses has become much more efficient and reliable. Automated TIG welding systems, also known as robotic TIG welding, use a robotic arm to guide the TIG welding torch along the length of the hose. This eliminates the need for a skilled welder to manually guide the torch, and it also allows for a more consistent and precise weld.

One of the main benefits of automation in welding is the ability to program and repeat the welding process. This means that the same welding parameters can be used for every hose, ensuring that the final product is consistent and of high quality. Additionally, automated welding systems can be programmed to weld at specific intervals, making the process much more efficient and reducing the need for manual labor.

Another advantage of automation in welding is the ability to weld at faster speeds, which can reduce the overall time required to complete a project. This can help to increase productivity and lower costs for manufacturers. Additionally, automated welding systems can also be programmed to detect and correct any errors or inconsistencies in the weld, further improving the quality of the final product.

DIFFERENT TYPES OF AUTOMATED PROCESS

There are a variety of different automated TIG welding systems available on the market today. Some systems are designed for specific industries, while others are more general-purpose. Some of the most popular automated TIG welding systems include:

Robotic TIG welding systems: These systems use a robotic arm to guide the TIG welding torch along the length of the hose. They are typically used in high-volume manufacturing environments and are ideal for welding large numbers of hoses.

Orbital TIG welding systems: These systems use a circular motion to guide the TIG welding torch along the hose. They are typically used for welding hoses with tight radius bends and are ideal for aerospace and automotive applications.

Automated TIG welding systems with integrated cameras: These systems include cameras that are used to monitor and inspect the weld in real-time. They are ideal for applications where quality control is of the utmost importance, such as in the medical industry.

In conclusion, welding flexible stainless steel hoses is a process that requires precision and skill. However, with the advent of automation, the process has become much more efficient and reliable. Automated TIG welding systems can be programmed to weld at specific intervals, increasing productivity and reducing labor costs. Additionally, these systems can also be programmed to detect and correct any errors or inconsistencies in the weld, further improving the quality of the final product.

DIFFERENT APPLICATIONS OF FLEXIBLE HOSES

Stainless steel flexible hoses are used in a variety of applications where a durable and flexible hose is required. Some common applications include:

  1. Plumbing and gas systems: Stainless steel hoses are used for connecting appliances such as ovens, stoves, and water heaters to the main gas supply.
  2. Automotive and industrial machinery: Stainless steel hoses are used in automotive and industrial machinery as flexible connections for oil, coolant, and other fluids.
  3. HVAC systems: Stainless steel hoses are used in HVAC systems as flexible connections for air and ventilation ducts.
  4. Medical equipment: Stainless steel hoses are used in medical equipment as flexible connections for gases and liquids.
  5. Food and beverage processing: Stainless steel hoses are used in food and beverage processing as flexible connections for liquids and gases.
  6. Pharmaceutical industry: Stainless steel hoses are used in pharmaceutical industry for transfer of different fluids.
  7. Chemical industry: Stainless steel hoses are used in chemical industry as it can resist various chemicals.
  8. High-temperature applications: Stainless steel hoses can handle high-temperature applications such as exhaust systems.

FLEXBILE HOSE WELDER –  TIG AUTOMATED WELDING SOLUTION

One of the most difficult process in the hydraulic industry is to weld the flexible metallic hoses that not only requires high precision but also controlled skill to orchestrate the pattern of weld to fuse the initial layers. Once the fusion of all the three elements are done, i.e; the bellow, the mesh & the sleeve, then the connectors & the flange joints has to be welded along with wire feeding. And all these process has to go through high pressure leak test before forming the right joint post welding.

Flexi hose welder, has a vast range of welding area varying from 10mm to 300mm with absolutely no limitation on the length of the hose. The pattern weave by the tig torch is the most unique configuration of this system as this creates an interwoven beads as done by highly qualified weld professionals, thus creating a layer of exemplary weld bead. The system has been tested and certified by more than 5000 hours of actual production cycles.

Keeping the component stationary and rotating the torch along with the wire feeder gives a better control for the system to weld different patterns of weld bead at various angles around the periphery of the component both in fusion and wire feed modes.

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