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POLYSOUDE

POLYSOUDE specialises in the design and manufacturing of high-quality orbital welding equipment and automated solutions for TIG welding and TIGer weld overlay/cladding. This is all achieved by the implementation of state-of-the-art arc welding processes and techniques.

POLYSOUDE PROVIDES A WIDE STANDARD RANGE OF ORBITAL WELDING EQUIPMENT, FOR ORBITAL TIG/GTAW TUBE AND PIPE WELDING, AS WELL AS AUTOMATED SOLUTIONS INTEGRATING THE LATEST TECHNOLOGIES.

Two out of every three users worldwide rely on POLYSOUDE solutions and their guarantee of the highest weld quality and maximum productivity. POLYSOUDE has a complete range of open and closed welding heads and orbital welding power sources, dedicated to diverse applications such as:

  • tube to tube welding

  • tube to tubesheet welding

  • every size of wall thickness from thin to thick

  • welding tools for every type of workpiece

Modular welding heads and tools easily adapt to various applications covering a wide range of diameters, wall thicknesses and workpiece geometries.

TUBE TO TUBE SHEET

Nowadays tubesheet welding is becoming an essential process as much industrial equipment like heat exchangers, steam turbines, condensers, air coolers or boilers are composed by thousands of metal tubes. These tubular constructions are usually assembled on thick metal plates and TIG welded (GTAW) for best performance and long lasting. Automated tube to tubesheet welding has replaced manual welding for advanced productivity and reproducibility of the tube-to-tube sheet joints and of course to shorten production times of industrial tube heat exchangers.

OPEN WELDING HEAD

Open welding heads were conceived as a tool for orbital TIG welding with or without filler wire. The diameters of the tubes to be welded range from 8 mm up to 275 mm (ANSI 5/16" to 11"). Open welding heads of the U-type are equipped with a TIG-torch with gas diffuser. Excellent gas protection is achieved in the zone around the torch, which is covered by the shielding gas streaming out of the gas lens. During the welding process, the arc and wire impact can be observed and controlled directly by the operator. The asymmetrical design of the open heads allows welding to be carried out at a very short distance to a wall or bend. The positioning of the welding torch can be carried out manually or by means of motorised slides: Arc Voltage Control (AVC) and torch oscillation (OSC).

CLOSED CHAMBER WELDING HEADS

Closed chamber welding heads are specially designed for autogenous welding of tubes without filler wire. Different sizes are available, covering a range of diameters from 1.6 mm to 170 mm (ANSI 1/16" to 4"). Excellent results can be achieved when welding austenitic stainless steel, metals susceptible to oxidation, such as titanium, or alloys such as Inconel. Depending on the application, clamping cassettes or TCIs (Tube Clamping Inserts) are used to fix the closed chamber head onto the tubes and fittings, to be welded.

UHP Head -  Modular - Ultra High Purity, closed chamber welding head.  Specially designed for autogenous welding of stainless steel precision tubing and micro-fittings, with unique titanium clamping cassettes.

 

MW Head  - Long Life - High duty cycle, closed chamber welding head. For the autogenous welding of stainless steel medium sized tubing and fittings, with unique titanium Tube Clamp Inserts (TCI)

CARRIAGE TYPE WELDING HEADS

Open orbital welding heads of the carriage type travel around the tubes or pipes on suitable rails or tracks, which can be mounted on any tube OD from 32 mm (1,3") upwards. The wall thickness of such tubes and pipes always requires multi-pass welding. The robust design of the carriage welding heads enables them to carry the necessary equipment, such as a torch with an AVC and oscillation device and on-board wire feeder with a spool weight of up to 5 kg. In addition, video cameras can be mounted, allowing the operator to watch and record the weld process. Depending on the application, these welding heads can be equipped with a conventional TIG torch with gas lens or with a Narrow Groove torch.

Polycar 30 -  Low Profile –Compact carriage-type welding head

Polycar 60 - Standard duty – Full function V- and J-groove carriage-type welding head

Polycar MP - Heavy duty - Narrow Groove (NG) carriage-type welding head

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WELD OVERLAY/CLADDING

SOLUTIONS FOR WELD OVERLAY AND AUTOMATED CLADDING OPERATIONS USED IN MANUFACTURING AND MAINTENANCE.

Horizontal weld overlay / cladding

Internal CRA cladding can successfully be carried out by overlay welding. The horizontally positioned pipes are rotated around their longitudinal axis while the torches with the attached wire feeding devices are mounted at the end of a welding lance and guided along the inner wall. A bi-cathode TIG/GTAW cladding process named TIGer, exclusively developed by Polysoude, executes a smooth surface of the corrosion-resistant layer, which together with low dilution rates between deposit and substrate, produces reliable results and significantly improves productivity.

Vertical weld overlay / cladding

Installations designed for cladding in a vertical position (2G) are usually dedicated to perform cladding operations on cylindrical parts. In most cases the workpieces are positioned on a turntable or positioner. However, there are other, much more complex scenarios, where it is impossible to set the workpieces in motion, either due to their size and weight, or quite simply because of their geometry (e.g. eccentric bore holes or nozzles). A group of endlessly rotating collector welding and cladding heads, with torches which can be rotated without twisting the cable/hose bundles, has been specifically designed for such situations. These machines handle cladding operations on fixed workpieces with a high level of automation.
For even more complex workpiece geometries, such as manifolds with intersections or cross sections, ‘bore-to-bore’ functions, supported by Polysoude’s CN-Controller can complete the installation.

Services

You can contact us for the below services of POLYSOUDE Equipment

Part Sales

Spare parts &  Accessories

Machine Sales

Power sources and Welding lance

Maintenance/Training

We provide training and maintenance of all Polysoude equipment

Contactus on : polysoude@salwo.net 
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