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The development of tube-to-tubesheet welding from automation to digitization

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Abstract

Tube-to-tubesheet welding is widely used in manufacturing of heat exchangers, steam turbines, condensers, boilers, etc. It has evolved from manual arc welding, automatic welding to digital welding. In the future, it will be toward intelligent welding. However, the key technologies related to tube-to-tubesheet welding are seldom summarized. This paper presents the sensing, positioning, and control methods of tube-to-tubesheet welding in recent decades. The fundamental difference between automatic and digital tube-to-tubesheet welding is whether the operator or the sensors interacts or transmits data with the welding system. The characteristics of tube are obvious and consistent so that vision-aided robotic positioning is the most promising. Moreover, arc length control which is important to tube-to-tubesheet welding has also been reviewed. Three typical sensing methods and five typical control methods are proposed to realize arc length control. The development direction of tubesheet welding is also predicted. This paper has an active influence on the development of pressure vessels and related industries.

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Funding

This research is supported by the State Key Lab of Digital Manufacturing Equipment and Technology (DMETKF2020026), Major Project of Science Research of Hubei Province (2020BAB033), National Natural Science Foundation of China (51805190), Major Project of Science Research of Hubei Province (2018AAA027), and Launch Fund of Huazhong University of Science and Technology (05), The Fundamental Research Funds for the Central Universities(213304001).

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Authors and Affiliations

  1. School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, China

    Ting Lei & Chaoqun Wu

  2. State Key Lab of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, China

    Ting Lei, Chaoqun Wu, Youmin Rong & Yu Huang

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  1. Ting Lei
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  2. Chaoqun Wu
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  4. Yu Huang
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Contributions

Ting Lei: writing original draft, visualization, and conceptualization. Chaoqun Wu: review and editing. Youmin Rong: investigation and formal analysis. Yu Huang: funding acquisition and project administration.

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Correspondence to Ting Lei or Chaoqun Wu.

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Lei, T., Wu, C., Rong, Y. et al. The development of tube-to-tubesheet welding from automation to digitization. Int J Adv Manuf Technol 116, 779–802 (2021). https://doi.org/10.1007/s00170-021-07379-7

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  • DOI: https://doi.org/10.1007/s00170-021-07379-7

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