6.5m Max Torch Travel

10T Max Workpiece Weight

Φ1500mm Max Pipe Diameter

2500mm/min Max Torch Travel Speed

Product Overview

The 6m Horizontal Hot Wire TIG Pipe Cladding Machine is designed for automatic internal pipe wall overlay welding. The workpiece is installed horizontally on the welding chuck and driven to rotate by the rotary system. The internal welding torches travel inside the pipe to complete the welding path.

The complete system consists of welding power sources, hot wire welding power sources, wire feeding system, internal water-cooled TIG torches, welding machine body, electrical control system, water cooling system, arc observation system and safety protection devices.

It is suitable for internal cladding of round pipes used in oil & gas, petrochemical, pressure vessel and heavy industrial applications. The system is designed to provide stable automatic hot wire TIG cladding performance with high repeatability.

Key Features

Dual Internal TIG Torch Welding Two specially designed internal water-cooled TIG torches can weld simultaneously, improving overlay welding efficiency for long pipe applications.	Hot Wire TIG Process The hot wire power source works together with the TIG welding system to realize automatic hot wire TIG cladding with stable forming quality.
AVC Arc Voltage Tracking The AVC function monitors arc voltage in real time and adjusts the distance between tungsten electrode and workpiece to keep arc length stable.	BECKHOFF Control System The servo motion control cabinet adopts German BECKHOFF controller and works with Schneider low-voltage electrical components.

Application Range

Item	Description
Workpiece Type	Round pipe
Pipe Diameter Range	Φ156mm – Φ1500mm
Maximum Workpiece Weight	10 tons
Cladding Materials	Stainless steel, nickel alloy, copper alloy and other suitable overlay materials
Typical Industries	Oil & gas, pressure vessel, petrochemical equipment and industrial pipe manufacturing

Equipment Configuration

System	Main Components
Welding Power System	Fronius TT5000 main welding power source × 2 TT2200 hot wire welding power source × 2 KD1500 wire feeder × 2 Cooling water tank × 2 Profinet communication interface and cables
Welding Head System	WTH300 internal overlay welding torch × 2 100% duty cycle maximum current: 350A AVC function module × 2, vertical travel ±50mm Quick connection interface for gas, cooling water and cables
Mechanical Body	Floating hollow rotary chuck Adjustable roller support system Torch driving carriage Wire rope traction and anchoring system Hydraulic wire rope tensioning and positioning system Carriage guide mechanism and base Chuck and roller support travelling rails Hydraulic station and oil pipeline
Control System	Servo motion control cabinet German BECKHOFF controller Schneider low-voltage electrical components Welding control system and water/gas pipeline system

Working Principle

One end of the pipe is clamped by the adjustable floating chuck, and the other end is supported by the roller support. By adjusting the chuck lifting mechanism and roller support, pipes with different diameters can be positioned at a suitable welding height.

The straight rail is driven by a servo motor, allowing the dual torches to travel along the inner wall of the pipe. The wire rope is tensioned by the hydraulic station to provide rigid torch support and reduce vibration during welding.

Pipe Clamping Floating hollow rotary chuck

Pipe Support Adjustable roller support

Torch Movement Servo driven travelling carriage

Mechanical System

• Floating hollow rotary chuck for pipe clamping and rotation.
• Adjustable roller support system for long and heavy pipe support.
• Chuck electric lifting stroke: ≥270mm.
• Wire rope diameter: Φ16mm.
• Wire rope tension force: 10 tons.
• Rotation speed range: 0-2 rpm.
• Torch travelling speed: maximum 2500mm/min.
• Gear reducer ratio: 1:50.

Welding System

Fronius TT5000 Main Welding Power Source

• Fully digital high-performance welding power source.
• Current range: 3A – 500A.
• Water cooling system.
• Water pressure sensing.
• Profinet network communication interface.

TT2200 Hot Wire Welding Power Source

• Fully digital hot wire power source.
• Current range: 3A – 220A.
• Wire heating function.
• Profinet communication interface.

KD1500 Wire Feeding System

• Fully digital wire feeder.
• Wire feeding speed range: 0-10m/min.
• Four-wheel wire feeding structure.
• External high-frequency ignition module.

Cooling System

The machine is equipped with a temperature-controlled cooling water system for high-load continuous welding. The cooling system includes temperature control, water flow protection and water level indication.

Item	Specification
Rated Voltage	1×220V / 50Hz
Compressor Load	1.5P
Water Tank Capacity	52L
Temperature Adjustment Range	-5℃ to +40℃

Operating Modes

Mode	Description
Automatic Mode	Select the workpiece program number on the HMI, input workpiece parameters, create or recall welding procedures, and start automatic welding.
Manual Debugging	Supports position jogging, gas testing, wire feeding jogging and other commissioning operations.
Simulation Welding	The welding machine does not ignite arc, and the system automatically completes the programmed welding trajectory for inspection.

Automatic Functions

Function	Description
AVC Arc Voltage Control	Real-time arc voltage tracking keeps constant arc length and improves welding stability.
Parameter Storage	Stores welding parameters for repeated production of the same workpiece type.
Breakpoint Memory	After welding interruption, the system can return to the stop point after troubleshooting.
Tungsten Contact Detection	Stops welding when tungsten electrode contacts the workpiece to protect torch components.
Safety Monitoring	Includes wire detection, gas flow monitoring and cooling water monitoring.

Welding Process Capability

Item	Specification
Welding Position	1G position
Recommended Single Layer Thickness	1.0mm – 2.5mm
Wire Diameter	1.0mm / 1.2mm
Tungsten Electrode Diameter	3.2mm / 4.0mm
Shielding Gas	99.99% pure argon

Main Technical Parameters

Parameter	Value
Equipment Type	Horizontal internal pipe hot wire TIG cladding machine
Workpiece Type	Round pipe
Torch Travel	Maximum 6.5m
Pipe Diameter Range	Φ156mm – Φ1500mm
Minimum Diameter After Welding	Φ156mm dual torch / Φ130mm single torch
Maximum Workpiece Weight	10 tons
Rotation Speed	0-2 rpm
Torch Travel Speed	Maximum 2500mm/min
Chuck Lifting Stroke	≥270mm
Wire Rope	Φ16mm, 10 tons tension force
Control System	BECKHOFF industrial control system

Working Environment Requirements

Item	Requirement
Power Supply	Three-phase five-wire system, AC 380V ±10%, 50Hz ±1Hz, dedicated grounding wire
Compressed Air	0.4-0.7MPa
Ambient Temperature	-10℃ to 40℃
Relative Humidity	≤90% at 30℃
Argon Gas	99.99% or above pure argon

Welding Quality Inspection

The welding result can be inspected according to project requirements. Recommended inspection methods include:

• UT ultrasonic inspection: no lack of fusion and no welding cracks.
• PT surface inspection: no surface defects.
• Radiographic inspection: no pores and no slag inclusion defects.
• Mechanical performance testing according to ASME Section IX requirements for overlay welding.

Service & Support

Service Item	Description
Factory Pre-Acceptance	Equipment function inspection and welding test before delivery.
Welding Test & Process Development	Support welding process development according to workpiece and material requirements.
Welding Process Training	Including welding process training and welding programming training.
On-Site Installation & Commissioning	Equipment installation, integration, debugging and welding test support.
Operation & Maintenance Training	Training for equipment operation, maintenance and daily care.
Technical Documents	General assembly layout, installation requirements, operation manual and maintenance manual.

Standard Spare Parts & Tools

Item	Specification	Quantity
Tungsten Electrode	Φ4.0	10
Tungsten Collet	Φ4.0	10
Gas Lens / Diffuser	Φ4.0	10
Ceramic Nozzle	Φ4.0	10
Contact Tip	Φ4.0	10