1. Introduction

In the heat exchanger manufacturing industry, welding quality plays a decisive role in ensuring sealing performance, structural integrity, and service life. Our company specializes in the design and production of shell-and-tube heat exchangers and has long recognized the limitations of manual welding in terms of consistency and efficiency. To address this, we have heavily invested in automated welding technology, establishing a comprehensive and mature system that significantly enhances product quality, production efficiency, and competitiveness.

2. Role of Automated Welding in Our Manufacturing System

Automated welding equipment is widely applied throughout our production processes, including tube-to-tubesheet welding, cylinder seam welding, nozzle and branch welding, and dished head assembly. By integrating CNC control systems, tracking mechanisms, and multi-channel data monitoring, we have achieved high-precision and digitalized production workflows.

3. Key Applications of Automated Welding in Our Workshops

1. Tube-to-Tubesheet Welding

• Equipment Used: Orbital TIG Tube Sheet Welding Machines

• Applicable Products: Fixed tube sheet, floating head, U-tube heat exchangers

• Advantages:

  • High precision control of internal and external tube welds, ensuring excellent air-tightness and pressure resistance

  • Compatible with various hole patterns and pitches, weld pass rate ≥ 99%

2. Shell and Head Seam Welding

• Equipment Used: Longitudinal/Circumferential Seam Automatic Welding Machines + Roller Support

• Technical Features:

  • Automatic centering and uniform wire feeding for neat and consistent weld beads

  • Reduces human error, improving weld strength and corrosion resistance

3. Nozzle and Branch Pipe Welding

• Welding Type: Small-diameter butt welding / dissimilar metal TIG welding

• System Features:

  • Supports multi-angle, multi-axis automatic welding for complex structures

  • Real-time data logging and traceability of each weld

    
    

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4. Overall Benefits of Automated Welding

5. Customer Cases & Market Feedback

Our automated welding process has been applied in the mass production of shell-and-tube heat exchangers for clients in the petrochemical, metallurgy, and power sectors, both domestically and internationally. All products have passed third-party inspection and received highly positive feedback:

Large Refinery Project: Delivery time shortened by 15 days; pressure testing passed in one attempt

Russian Client: Weld quality exceeded local industry standards; repeat orders secured

6. Ongoing Optimization & Future Plans

• Introducing robotic welding arms for multi-station synchronized welding

• Implementing vision-based tracking systems for adaptive weld path control

• Establishing a welding database and quality traceability platform to support digital manufacturing

7. Conclusion

The adoption of automated welding marks a critical step forward in our company’s journey toward high-end manufacturing. Through standardized and intelligent welding systems, we not only improve product quality and delivery capabilities but also offer customers more reliable and value-added heat exchange solutions. Moving forward, we remain committed to innovation and excellence in building a smarter and more efficient manufacturing platform for thermal equipment.