A Guide to Automated Welding

Applications for Automated Welding

(Click to Expand) Applications for Automated Welding

Automated welding finds use in the manufacturing applications of a wide range of industries. For example:

  • In shipbuilding applications, it is used to construct and repair ship hulls and their internal elements (e.g., stiffeners).
  • In tank building applications, it is used to fabricate tank floors and external shells.
  • In infrastructure applications, it is used to build bridges and bridge elements, hydroelectric dams, and penstocks.
  • In military applications, it is used to make the exterior of nuclear submarines and spacecraft and other large structures with repeatable, long seams.
  • In general fabrication applications, it is used to create a variety of parts and products, from small-scale pipe systems to tanks for fire extinguishers.
  • In power generation applications, it is used for the construction of various elements in hydroelectric dams, nuclear power plants, and other power generation facilities, such as steam kettles and piping systems.

The above list is not all-inclusive. In addition to those listed above, automated welding systems can be employed in the manufacturing operations of many other industries. Depending on the requirements of the application, they can be utilized as standalone machines or integrated into larger, interconnected automation processes that handle material flow, assembly, and other operational aspects. The appropriate level of automation depends on the complexity of the parts being welded as well as the facility’s available resources and desired production volume and speed.

Automated Welding vs. Mechanized Welding vs. Robotic Welding

Welding automation technology can be split into three general categories, each of which offers a different level of automation and sophistication. They are:

Automated welding

All welding parameters are electronically controlled, and manual adjustments are made prior to starting the process. Human operator tasks include programming and starting the machine, occasionally supervising the process, and troubleshooting when necessary.

Mechanized welding

Weld parameters are mechanically or electronically controlled, and manual manipulations are performed between welding operations to maintain the appropriate welding position. The machine handles the movement of the arc while the operator observes and makes any necessary adjustments.

Robotic welding

A robot is programmed to perform the welds while the operator maintains responsibility for quality control and addresses any deviations or issues during the process. This process is well-suited for complex welding applications, such as the precision micro-welding of small parts used in electronic or automobile applications.

Automated Welding vs. Mechanized Welding vs. Robotic Welding

Welding automation technology can be split into three general categories, each of which offers a different level of automation and sophistication. They are:

  • Automated welding

    All welding parameters are electronically controlled, and manual adjustments are made prior to starting the process. Human operator tasks include programming and starting the machine, occasionally supervising the process, and troubleshooting when necessary.

  • Mechanized welding

    Weld parameters are mechanically or electronically controlled, and manual manipulations are performed between welding operations to maintain the appropriate welding position. The machine handles the movement of the arc while the operator observes and makes any necessary adjustments.

  • Robotic welding

    A robot is programmed to perform the welds while the operator maintains responsibility for quality control and addresses any deviations or issues during the process. This process is well-suited for complex welding applications, such as the precision micro-welding of small parts used in electronic or automobile applications.

Types of Welding Application

Types of Welding Application

While basic automated welding systems are great for performing simple and repetitive welds at high speeds, joining parts with gaps or hard-to-access locations may present some challenges. An automated welding solutions provider can evaluate a blueprint of the part and determine if the welding equipment can be configured accordingly.

Production Volume

Production Volume

Since one of the key benefits of welding automation is the ability to quickly perform high volumes of welds, it is important to make sure your facility’s production volume is large enough to justify the investment cost.

Operator Skill

Operator Skill

It is important to keep in mind that an experienced welder will be required for programming, troubleshooting, and recalibrating the system as needed.

Based on current trends in the welding industry, the growth of automated welding is expected to continue as companies seek to improve the efficiency, safety, and profitability of their operations even further. In response to this rising demand, automated systems are becoming increasingly more precise, affordable, and accommodating of smaller-volume applications and unique welding requirements.