Design and Development of Automatic Seam Welding of Pipes

F. K. Pathan¹*, A. I. Gond², S. D. Aade³, G. N. Deshpande4

¹, ², ³ Student, 4 Assistant Professor
Department of Mechanical Engineering, Shreeyash College of Engineering and Technology,
Chhatrapati Sambhajinagar, Maharashtra, India

*Corresponding Author Email: farhanpathan07609@gmail.com

ABSTRACT

Productivity, operational safety, and uniform quality act as the vital drivers for modern manufacturing sectors. Industries continuously seek out advanced automation to secure market leadership and minimize dependency on highly variable manual interventions. This paper details the design, fabrication, and optimization of an automatic seam welding setup purposefully engineered for the continuous joining of cylindrical metal pipes. Utilizing a robust mechanical frame integrated with specialized workpiece-holding fixtures and programmable pneumatic clamping actuators, the system ensures rigid, vibration-free alignment throughout the operation. A dedicated gear motor drive mechanism, running within a controlled speed range of 10–15 RPM, governs the precise rotational velocity of the components to sustain continuous weld beads.

The experimental phase involved a metallurgical and structural comparative analysis between Cold Rolled Carbon Steel (CRCS) and Medium Carbon Steel (ER34). Process parameters, including welding current ranges of 11–13 A and wall thicknesses of 2.5 mm, were closely evaluated. Crucially, the implementation of internal water-cooled CuCrZr alloy rotating wheel electrodes effectively minimized extreme heat buildup and localized degradation. The automated setup successfully suppressed joint leakage failure rates from a baseline of 15% down to less than 3%. Ultimately, this research yields a scalable, ergonomically secure, and highly productive manufacturing configuration that satisfies stringent industrial quality assurance standards while offering an accessible pathway toward full industrial automation.

Keywords: Seam welding, Automation in welding, MIG welding, Cold Rolled Carbon Steel, ER34 Medium Carbon Steel, Manufacturing Engineering materials.