Industrial automated tube and pipe welding systems LE.DI.CA. Srl

Selection and integration of New Combo systems, Tricathode STX TIG setups, Key-Hole plasma torches and fiber laser machinery from LE.DI.CA. Srl.

New Combo System TIG-Plasma pipe welding systems

The New Combo System combines tricathode TIG modules and Key-Hole plasma welding for longitudinal tube production with wall thicknesses from 0.5 to 10 mm. The engineering layout allows a complete tool change in 15 minutes during tube schedule adjustments on continuous roll-forming mills.

Tricathode TIG-TIG-TIG torch unit for thin-walled tubing from 0.5 to 3.5 mm
TIG-Plasma-TIG module for single-pass full-penetration welding up to 10 mm
Magnetic arc oscillator to smooth weld crowns and eliminate puddle inclusions
Quick-disconnect torch mount with a 15-minute complete changeover sequence

Tricathode STX TIG automated welding units

Tricathode STX TIG multi-electrode welding units feature three independent 600 A torches with dedicated liquid cooling circuits. The rigid support allows individual adjustment of torch tilt angles and electrode spacing to accommodate challenging stainless and nickel alloys.

Three independent STX TIG 600 A torches for stepped heat input distribution
Individual torch inclination and spacing adjustments for molten pool stability
Tube welding production throughput speed increase of up to 50 percent
Protective trailing gas shielding shoe for hot stainless weld zone shielding

Multi-cathode plasma torches with Key-Hole technology

Plasma Plasma TIG multi-cathode torches operate with deep-penetration Key-Hole plasma physics for single-pass butt welding without edge preparation up to 10 mm. Equipment includes electromagnetic arc oscillation, integrated cold wire feeding and an optical laser tracking sensor.

Single-pass square butt welding up to 10 mm with Key-Hole plasma technology
Electromagnetic arc deflection system providing uniform weld bead geometry
Integrated cold wire feeder ensuring controlled joint filler deposition
Optical laser seam-tracking sensor compensating for strip lateral alignment

Internal TIG welding torches with magnetic arc oscillator

Internal TIG torches rated at 600 A are engineered for cantilever boom installation inside continuous pipe mills. The assembly performs automated root re-melting and bead flattening on pipes with inner diameters starting from 160 mm without requiring a mechanical rolling mandrel.

Welding current capacity up to 600 A with internal liquid cooling circulation
Internal seam welding for pipes and vessels with inside diameters from 160 mm
Magnetic arc oscillation spreads weld metal without mechanical rolling mills
Motorized Arc Voltage Control unit ensuring precise arc gap regulation

Fiber laser automatic welding units with rotary turntables

Fiber laser automated welding cells with precision rotary turntables are designed for joining complex shapes, exhaust ducts and flue pipes in stainless and carbon steel up to 1.8 mm. This laser method doubles throughput compared to standard TIG while eliminating electrode dressing delays.

Doubled welding production speed relative to standard orbital TIG setups
Zero production downtime for tungsten electrode grinding or redressing
Precision welding of curved elbow ducts and flue pipes on a rotary fixture
Minimal heat-affected zone preventing distortion across thin wall sections

Service components, tool fixtures and tooling accessories

Auxiliary manufacturing hardware for LE.DI.CA. tube welding lines includes Pulseweld series power units, multicathode control consoles, shielding gas nozzles, collets and wire feeders. All components are engineered for continuous 24/7 duty in demanding tube production plants.

Pulseweld 15K22 high-frequency generators for super-austenitic 904L steel
Combo PPT-TTT control consoles with individual cathode power adjustment
Custom trailing gas shoes engineered for pipe diameters up to 600 mm
Replacement nozzles, tungsten electrodes and magnetic oscillator spare coils

Operating procedures for New Combo System TIG and plasma welding lines

The New Combo System welding station serves tube rolling mills handling diverse wall thicknesses from 0.5 to 10 mm. Its modular carriage allows swapping the tricathode TIG torch for the TIG-Plasma unit in 15 minutes without dismantling the main machine bed.

Before changeover, operators isolate high-voltage power lines and shut off argon and cooling water circuits. The carriage slides to its maintenance position, where quick-disconnect hydraulic couplers and electrical harnesses are uncoupled.

After locking the replacement welding head, torch alignment with the tube seam is confirmed via laser pointer, cooling loop integrity is verified and shielding gas flow is regulated through flow meters.

Adjustment and alignment of Tricathode STX TIG welding equipment

The Tricathode STX TIG system integrates three sequential 600 A torches to optimize heat input distribution and boost continuous tube production speeds up to 50 percent.

The lead torch preheats and fuses strip seams, the secondary torch establishes full depth penetration, and the trailing torch smooths the molten puddle into a uniform weld bead.

Operators adjust torch inclination angles and electrode spacing to accommodate thermal conductivity and wall dimension variations. Following alignment, an extended trailing gas shield is secured over the hot seam to provide laminar argon coverage until the joint cools below oxidation limits.

Key-Hole plasma welding operational parameters for thick pipe seams

Plasma Plasma TIG multi-cathode welding heads utilize Key-Hole plasma arc physics combined with a trailing TIG torch for single-pass butt welding on pipes up to 10 mm thick without bevel preparation. High-pressure orifice gas creates a stable plasma Key-Hole through the entire wall thickness.

The secondary TIG arc with an electromagnetic oscillator flattens the weld profile and removes surface undercuts. Before starting, technicians set torch stand-off distance using optical sensors and calibrate the laser seam tracker to compensate for strip wander.

The cold wire feeder introduces filler alloy directly into the trailing molten pool.

Operational protocol for internal TIG root welding torches at 600 A

Internal TIG torches rated at 600 A mount directly onto longitudinal cantilever booms to smooth weld roots inside pipe diameters starting from 160 mm.

The integrated electromagnetic arc oscillator produces controlled transverse arc oscillation, spreading weld metal smoothly without mechanical planishing mandrels. Arc gap stability is maintained via an automated Arc Voltage Control unit with high-resolution servo positioning.

Prior to production runs, operators check tungsten electrode geometry, purge shielding gas nozzles, and verify continuous coolant circulation through the internal torch manifold.

Fiber laser welding procedures for thin-walled elbow ducting

Automated fiber laser welding cells with precision rotary turntables join shaped elbows, flue pipes and thin-walled tubular components up to 1.8 mm thick.

Concentrated laser beam energy doubles production speed compared to conventional orbital TIG welding while minimizing heat input into adjacent parent metal. Workpieces are centered and locked in rapid pneumatic chucks on the rotary positioner.

Operators select the numerical motion program and configure laser power ramps. Routine inspection and wiping of the protective optical cover slide prevent beam distortion and maintain focal spot precision.

Preventive maintenance of Combo PPT-TTT consoles and Pulseweld units

Combo PPT-TTT multicathode control consoles and Pulseweld 15K22 high-frequency generators require systematic servicing to maintain arc ignition stability under continuous manufacturing schedules.

Maintenance teams blow out electrical cabinets with dry dehumidified air monthly to eliminate conductive metal particulates and examine high-current terminals for thermal discoloration.

Closed-loop water cooling systems undergo fluid conductivity checks, pump pressure monitoring, and filter cleanings. Periodic calibration of internal shunts and arc voltage feedback channels ensures process repeatability across superalloys.

LE.DI.CA. Srl and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of LE.DI.CA. Srl and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.