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IBW Weld Heads

The ability to complete a weld from the inside can very often provide the solution to a seemingly insurmountable problem. This can be achieved in a variety of ways using modified standard OD weld heads or dedicated internal bore welding (IBW) heads. Applications typically require torch assemblies that are tailored to suit the reach and diameter necessary to access the weld joint.

Some applications such as heat exchangers with back face IBW welds have been around around for a number of years. However, the equipment and expertise required to successfully apply the process in this way can be difficult to source. In recent years we have provided specialised equipment and application engineering for a number of IBW projects for the aerospace, power generation and nuclear industries.

Outline drawing showing an Orbitec IBW weld head for a back face tube to tubesheet application (photo shows the torch end at the joint prior to fitting the tube for welding).

Application Engineering

Whether you require tooling to adapt a standard weld head to fit your application, or a if your application requires a completely new weld head we can help.

All design is completed 'in-house' here in Derby with full 3D CAD capability and our network of subcontract manufacturing facilities provide all the necessary CNC machining, EDM wiring, electro-plating and hardening services required to complete a project.

A selection of recent projects are detailed for reference:

Modified OSK21-C to accept a tight access aerospace component, tube size is 0.250” (6.35mm), the assembly comprises ‘S’ shape tube with a fitting welded at each end. Photo right shows a batch of welded assemblies

IBW weld head for a 'back face' tube to tubesheet joint on an HP Heater for power generation. Inset photos show a completed test sample weld (as welded) and IBW weld head positioned at the front face for welding.

Auto loading mechanism for an OSK65-W weld head, mechanism has PLC controlled pneumatic actuation for loading and clamping of components. An Orbitec Tigtronic controller was fully integrated with the loading mechanism to provide a single operator interface. All mechanical, pneumatic, electronic and PLC software design was completed 'in-house'. Photo shows some completed welds.