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Tubesheet Weld Heads
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Tubesheet Weld Heads - Orbital Welding Equipment / Automated Welding Equipment Tubesheets

Tubesheet Application 1

Tubesheet Application 2

These Magnatech weld heads are specifically designed for making tube-to-tubesheet welds.  Configured for fast and simple operation, the Head is inserted into the tube to be welded, and the operator pushes the START WELD switch.

Multiple torch positioning adjustments allow virtually all tubesheet joint designs to be welded.  All three models weld a wide range of tube sizes and operate in any position.

For welds requiring filler wire addition, an optional wire feeder can be mounted on the weld head.  A standard wire spool, mounted directly on the Head, provides precise and positive wire feeding, not possible with floor-mounted feeders.

These weld Heads bring the productivity and repetitive precision of machine welding to the fabrication and repair of steam generators and heat exchangers.

All three weld Heads models are used with Magnatech power sources, ranging form simple to operate analog models to microprocessor-based systems with program storage capability.

TUBE GEOMETRIES

Model 424 is ideal for all tubesheet geometries.

Model 425 with AVC is for multipass welding

Model 426 is ideal for fusion welding where preheat is not required.

                 
Process: GTAW
                 
Weld Head Type: Open arc.
                 
Tube Size Range:

Model 424: 10mm - 78mm (0.4" - 3.07") OD 

Model 425: 10mm - 140.2mm (0.4" - 5.52") OD

Model 426: 10mm - 70.1mm (0.4" - 2.76") OD

Tubesheet Sample Weld

                   
Functions: Torch rotation, Arc length control (Model 425 only), Filler wire feed (Optional)  
                   
Features:
  • Water-cooled torch and weld Head body (models 425 & 426 only) allow use on pre-heated tubesheets
  • Lifting eye allows use on a counterbalance for weightless operation
  • Multiple torch angle and wire feed positioning mechanism allow optimum torch position and wire entry angle
  • Simple centering cartridge design allows quick installation without requiring prior installation of expensive custom-fabricated locating fixtures
  • Inexpensive centering cartridges fit the exact tube ID
  • Filler wire spool rotates with the torch - eliminating wire entry problems common with floor-mounted feeders (Models 424 & 425)
  • No cable wrap-up
Tubesheet Application 3

Tubesheet Application 4

Options:
  • Filler Wire feeder using standard 1kg (2lbs.) spools
  • Three point standoff for welding "extended tube" geometries
  • Transparent purge gas chamber for titanium floods the enclosed weld area independent of torch shielding gas, reducing purge time and weld oxidation
  • Arc Voltage Control parallel to tungsten electrode - even when the torch is angled for a fillet weld
  • Torches for internal bore welding
  • Extension Cables
  • Dual Head Switcher allows two Heads to be used alternately maximizing "arc on" duty cycle
 
Applications:
  • Heat exchanger seal and strength welds
  • Power generation
  • Petrochemical
  • Sanitary
  • Food and beverage
 
     
  Model 424 Model 425 Model 426

Applications

  Joint Design

 

 

 

 

  Pitch Pattern

 

  Tube O.D. Size Range*

 

Extended, Flush, Recessed and Internal Bore

 

 

Triangular or Square

 

10-78mm (.4-3.07")

*10-38mm (.4-1.5") with Electrode Angle at 30°

*10-78mm (.4-3.07") with Electrode Parallel to Tube

 

Extended, Flush, Recessed and Internal Bore

 

 

Triangular or Square

10-140mm (.4-5.52")

 

Extended, Flush, Recessed and Internal Bore

 

 

Triangular or Square

 

10-70mm (.4-2.76")

*10-26mm (.4-1.02") with Electrode Angle at 30°

*10-70mm (.4-2.76") with Electrode Parallel to Tube

Basic head

  Rotation Speed

 

0.33-6rpm

 

0.33-6rpm

 

0.33-6rpm

Filler Wire Module (Optional)

  Wire Size

  Speed Capability

  Spool Size

Rotates Coaxially with Torch

0.8/0.9/1.0/1.2mm (.030"/.035"/.040"/.045")

0-1500 cmpm (0-60ipm)

1kg (2lbs.)

Rotates Coaxially with Torch

0.8/0.9/1.0/1.2mm (.030"/.035"/.040"/.045")

0-1500 cmpm (0-60ipm)

1kg (2lbs.)

 

 

0.8/0.9/1.0mm (.030"/.035"/.040")

0-1500 cmpm (0-60ipm)

1kg (2lbs.)

Water-Cooled Torch

  Amperage Capability

 

200 A Continuous

 

200 A Continuous

 

200 A Continuous

Cable Length

8m (25') Standard

Extension Cables Available

8m (25') Standard

Extension Cables Available

8m (25') Standard

Extension Cables Available

Head Weights

  Weight

  Weight with Filler Wire

  Dimensions

 

8kg (18lbs.)

10kg (22lbs.)

See Specification 424

 

9kg (20lbs.)

11kg (24lbs.)

See Specification 425

 

5kg (11lbs.)

6kg (13lbs.)

See Specification 426

Torch/Wire Nozzle Adjustment

3 Axis Adjustment

3 Axis Adjustment

3 Axis Adjustment

Machine Body Cooling

Yes, Water

Yes, Water

No

Torch-Workpiece Adjustment

  Manual

  Arc Voltage Control

  AVC Stroke

 

Threaded Ring

±5 mm (0.2")

No

N/A

 

Threaded Ring

±5 mm (0.2")

Yes

16mm (0.625")

 

Threaded Ring

±5 mm (0.2")

No

N/A

Weld Orientation

All (Vertical & Horizontal Gravity Positions)

All (Vertical & Horizontal Gravity Positions)

All (Vertical & Horizontal Gravity Positions)

Use With

All Tubemaster & Pipemaster models, except Tubemaster Model 514

All Pipemaster models

All Tubemaster & Pipemaster models, except Tubemaster Model 514

       

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