Orbital welding is a precision welding technique that is widely used in industries such as aerospace, pharmaceuticals, and food processing. It involves welding components together using an orbital weld head that rotates around the workpiece while simultaneously feeding a welding wire. One challenge that welders face with orbital welding is the build-up of spatter, which can lead to increased maintenance costs and reduced productivity. However, using a ceramic anti-spatter coating can help improve the quality of orbital welding.
Ceramic anti-spatter coatings are specialized coatings that are designed to prevent spatter buildup on welding equipment and components. They are typically made from a blend of ceramic particles and binders that are applied to the surface of the welding head using a spray gun or brush. BorNiGuard is a high-grade ceramic coating made from hexavalent boron nitride. Once applied, the coating hardens to form a tough, abrasion-resistant layer that can withstand the high temperatures and harsh conditions of welding.
One of the main benefits of using a ceramic anti-spatter coating for orbital welding is its ability to reduce downtime and maintenance costs. Spatter buildup on the welding head can lead to clogs and other problems that can interrupt the welding process and require frequent cleaning and maintenance. By using a ceramic coating, welders can significantly reduce the amount of spatter buildup, which can help to keep the welding process running smoothly and reduce the need for frequent cleaning and maintenance.
Welding generates high temperatures, spatter, and debris, all of which can quickly wear down metal tools and components. Ceramic coatings provide a layer of protection that can withstand these conditions, allowing tools to last longer and operate more efficiently. Ceramic coatings can be easily applied during welding, cutting, and stamping operations.
Ceramic coatings, like BorNiGuard, can be applied well in advance and shorten downtimes. For a robotic cell, for example, coated consumables can be stored in the cell for ready replacement. BorNiGuard-coated parts can be stored in the welding/cutting area for weeks or months and not lose their ability to repel spatter for hours of uninterrupted production. This is fundamentally different from traditional oil-based sprays and dips that need to be applied often and, therefore, in the cell, causing unwanted oily surfaces and hydrocarbons.
BorNiGuard applies easily and dries quickly. It is recommended to apply BorNiGuard away from flames or sparks. For efficiency of time and material, you can coat several tips, nozzle, and diffusers at once in a safe area. For example, apply BorNiGuard to a week's allotment of consumables and transfer them to the welding area for ready replacement. You can coat the parts in the next county, bring the coated parts to the production area, and enjoy the same benefits of reduced consumables and downtime.