Abstract: An orbital welding system and methods of operation controllably and safely weld a first metal tubing to a second metal tubing. A weld head includes interlocking clamping jaws for clamping the tubing. An alignment mechanism aligns the second tubing with the first tubing. The interlocking clamping jaws clamp the second tubing following the aligning of the second tubing with the first tubing. An alignment measurement mechanism measures relative alignment between the first tubing and the second tubing. A weld environment mechanism establishes a gaseous environment for orbitally welding the first tubing to the second tubing. The weld environment mechanism includes a weld environment sealing mechanism for sealing the gaseous environment and an electrode for gas arc welding. The weld environment mechanism orbits the first tubing and second tubing during the orbitally welding. Interface circuitry interfaces a power supply with the weld head and controls parameters associated with said weld head.

Abstract: The invention is of an improvement to orbital welding heads and welding systems for welding pipe and tubing butt joints, consisting of a novel combination of materials, including a ceramic weld insulator and a metal weld gear. Such a combination, which has a greater dielectric strength than a plastic housing design, results in a more concentric tungsten travel path, increases the duty cycles of the weld head, minimizes erratic and wandering arcing, creates an electrical insulation yielding minimal expansion, allows for increased clamping surface for improved tube alignment, and provides a compact and very robust weld head.

Abstract: The invention is of an improvement to orbital welding heads and welding systems for welding pipe and tubing butt joints, consisting of a novel combination of materials, including a ceramic weld insulator and a metal weld gear. Such a combination, which has a greater dielectric strength than a plastic housing design, results in a more concentric tungsten travel path, increases the duty cycles of the weld head, minimizes erratic and wandering arcing, creates an electrical insulation yielding minimal expansion, allows for increased clamping surface for improved tube alignment, and provides a compact and very robust weld head.

Abstract: Applicant's invention includes an apparatus and associated method for precisely aligning two pieces of weldable material and welding the two pieces, the apparatus contains means for independently securing the two pieces of weldable material and for centering the junction of the two pieces in line with the welding electrodes.

Abstract: Applicant's invention includes an apparatus and associated method for precisely aligning two pieces of weldable material and welding the two pieces, the apparatus contains means for independently securing the two pieces of weldable material and for centering the junction of the two pieces in line with the welding electrodes.

Abstract: Applicant's invention includes an apparatus and associated method for precisely aligning two pieces of weldable material and tack welding the two pieces together. The apparatus contains means for independently securing the two pieces of weldable material and for centering the junction of the two pieces in line with the tack welding electrodes.