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Welding Positioners – The Ultimate FAQ Guide
How do you think welders perform welds that are so complicated? Did you ever think they did it manually? – No, they used welding positioners!
Welding positioners have been one of the best machines that assist welders with their projects. And in this guide, we’ll help you understand welding positioners more.
You will learn what they are, how they can help you, and so on.
What is a Welding Positioner?
A welding positioner is a mechanism that holds, moves, and rotates workpieces being welded.
It’s a device that helps a welder be in one position, instead of moving around.
Why Use a Welding Positioner?
Many companies choose to use this mechanism for various reasons – but all for welding.
The most common reasons why you should consider using a weld positioner include:
The main advantage you can get is reduced effort. Your welders don’t need to move around.
This device would allow a welder to just stand in a single position and a single level.
Because the welder will just stand in one position, you can expect that it’ll produce less mess.
In addition to that, you can expect less splatter because the surface could protect your floors.
Better and Improved Quality of Work
Using welding positioners have been strongly linked and connected to better quality welds.
In fact, many welders choose to use them because they bring a lot of benefits to them and their work. So, if you want to ensure the quality of your projects, use a welding positioner.
There are a million more reasons why you should consider using weld positioners; and it’s all for the benefit of your company and your projects!
What are the Four (4) Different Welding Positions?
The different welding positions that are currently known include:
An image of a welder performing horizontal position welding
It’s self-explanatory; it’s actually the simplest and the most basic type of weld out of all positions.
This position employs the weld to be laid flat on a horizontal plane, above the joint.
The vertical weld is a type of weld where the axis followed is along a vertical plane.
Considered as one of the most complex positions, vertical welds allow better locomotion for the welder.
From its term alone, you’d already know what it is.
Overhead welding is a type of welding position where the weld is performed from under the joint.
It’s “overhead” because usually, it’s done to workpieces that are large and taller than the average height.
Last but most definitely not the least is the horizontal weld – and it’s not the flat weld.
This type of weld runs along the horizontal plane, and is usually angled – used for groove and/or fillet welds.
These 4 are known as the different types of welding positions that are currently known.
What is a DIY Welding Positioner?
DIY or Do-It-Yourself welding positioners are positioners that aren’t ordered or bought as a whole.
A welding positioner made out of various materials and scrap metals
They’re weld positioners that aren’t assembled by the manufacturer. More often than not, there are kits that contain electronic parts of weld positioners.
These kits are what people use to fabricate and produce their own welding positioner.
Can You Purchase Welding Positioners on Craigslist?
Craigslist is one of the most versatile e-commerce websites available. But would you be able to find reliable welding positioners there?
More often than not, all heavy-duty industrial equipment you’ll find there would be pre-owned. While this is cheaper, it might not meet the expectations you have for what you’re looking for.
To answer the question, yes, you can use Craigslist to find weld positioners – but most, if not all you’ll see would be owned or used welding positioners.
What Materials Can You Weld Using a Welding Positioner?
Welding positioners don’t necessarily have torches with them.
Welding positioner rotating a large workpiece to position it for the welder
They’re called “welding positioners” because their main goal is to help position the workpiece for the weld.
The materials you can weld using weld positioners would depend on your positioner’s ability to clutch or grab onto it.
The most common materials you use welding positioners for include:
Tubes and Fittings
Tanks and Vessels
And Many More!
You use welding positioners to assist you with welding – it’s not that picky when it comes to the workpieces you’ll be working with.
What is a 2-Axis Weld Positioner?
It’s a type of welding positioner that involves two (2) movements: tilting the table & rotating the table.
A 2-axis weld positioner (able to tilt the table and to rotate the material mounted on top of it)
You can easily identify a 2-axis weld positioner if it’s only able to perform two (2) locomotive movements.
More often than not, 2-axis welding positioners are turntables (either with a welding chuck or without). The clue is with its movement!
Why is Weld Positioning Important?
Positioning in welding isn’t only for the benefit of the weld – it incorporates a ton of perks for the welder, too.
Overhead welding is done to achieve the needed and the required weld
We can easily summarize the importance of weld positioning by understanding what it does and how it helps and assists welders.
From appropriately meeting the required position without moving, to stabilizing the weld; those are among the many benefits of weld positioning.
How Do Welding Positioners Work?
The principle of how a weld positioner works is simple – it functions by actively clutching or gripping onto the particular workpiece.
Then, it will move and rotate to achieve the position that a welder needs.
You can imagine it taking the place of the welder’s hand; but in a more precise, accurate, and an automated manner.
Are There Cheap Welding Positioners?
Many manufacturers are offering cheap and affordable welding positioners.
An example of a homemade weld positioner, which is cheaper if already assembled
In fact, you’ll surely encounter a ton of welding positioners that have similar prices. However, you need to expect that the overall quality and durability of them wouldn’t be what you expect.
But, there are cheap weld positioners – they’re usually DIY weld positioners where you can use kits for some of the parts and components.
How Does a Welding Manipulator Work?
We already know that a weld manipulator is far different from a welding positioner.
Welding manipulator offered by Waldun
Welding manipulators work by “manipulating” or “altering” the welding head or torch.
Positioners move the workpiece, while manipulators move the welding head or torch closer to the workpiece.
The goal of manipulators is to allow welders to reach locations that are far and complex.
Are There Electric Welding Positioners?
Yes, in fact, most weld positioners are driven either by electricity or by pneumatic hydraulics; the latter being the classic.
A pneumatic hydraulic weld positioner
Because of their industrial usage and utility, electrically powering them up became the norm.
More, if not all welding positioners sold today are already run by electricity.
The Most Popular Weld Positioners of 2020
If you are to ask the most popular welding positioners of this year, based on customer demand, they are:
WDBWJ-3 Welding Automatic Positioner (with 110 V input power)
10″ Chuck + 265-770 LBS Welding Positioner (with a 35 to 88 A output range)
TECHTONGDA 50KG Rotary Welding Positioner (with a 105A output range)
YaeTek 10KG Rotary Welding Positioner (with a 115 V input power)
These are the most popular and the most sought after positioners of the year in any order. They easily became the best because of their functionalities.
One problem, though – their rates and prices might not be fit for what their features are.
Is a Welding Positioner the Same as Welding Manipulators?
A lot of people have the misconception that they’re the same – but they’re different.
They have the same goal: to produce better quality welds and reduce welder fatigue. But how do they differ?
Welding manipulators are machines that help by moving the weld material to the workpiece. On the other hand, welding positioners move the workpiece, to assist the welder.
Technically, the difference is with the particular variable moved in the process.
Are Welding Positioners Automatic?
When purchasing welding positioners, you can choose from the following processors:
Manual Weld Positioners
Semi-Automatic Weld Positioners
Automatic Weld Positioners
You can ask your manufacturer which ones they offer so you don’t get confused.
Types of Welding Positioners
There are different types of welding positioners, as well as differences on how they’re categorized.
But, the most common would be through the following:
2-axis weld positioners
Multi-axis weld positioners
Tailstock or headstock weld positioners
Turning rolls or welding rotators
You can choose any of these types, depending on the type of work you require.
What is a Multi-Axis Welding Positioner?
This is a weld positioner that moves in many different directions.
Compared to a 2-axis positioner that moves in two (2) directions; and a 3-axis positioner that moves in three (3) directions, a multi-axis weld positioner moves in multiple directions.
They’re perfect for welds that are complex as well as those that have many angles.
What are 3-Jaw Welding Chucks?
They’re known as a surface, a part of a welding positioner that could properly hold hexagonal and round workpieces.
3-jaw welding chucks can firmly clutch on the workpiece, keeping it in place while it’s rotated.
What Advantages Can You Get From Using Welding Positioners?
You can find many benefits from utilizing weld positioners, some of which include:
Faster and Speedier Welding Processes
Can Save You Money (Less Labor Hours, Less People Needed)
Consistency of Welding (For Bulk Welding)
Higher and Better Productivity
More Accurate and Precise Welds
Using weld positioners can get you these advantages, and many more! Depending on what project you have would be the benefits you can get from using them.
Applications of Welding Positioners
There are many applications of weld positioners, scattered throughout different industries.
But, to give you the ones that are the most common, here they are:
Mounting of heavy welding equipment
Welding of wheels, piping and tubing, shafts, etc.
And many more
What are Benchtop Welding Positioners?
Benchtop weld positioners move and rotate the workpiece, passing the welding arc.
This would allow the welder to stay in a single position; preventing the need to move around and maneuver in difficult positions.
What are Rotary Welding Positioners?
Rotary welding positioners rotate workpieces in a 360-degree angle – either vertically or horizontally.
What are Pipe Welding Positioners?
They’re welding positioners that can spin and rotate pipes and tubes in a full 360-degree angle.
How Does a Welding Positioner Function?
A welding positioner functions by clutching to a valve or a point to hold the workpiece.
Then, depending on the goal, it would revolve and rotate the work material. It will spin on a specific axis based on the specifications of the welder.
Why Use a Weld Positioner?
Using weld positioners is not just for the benefit of the welder. As a matter of fact, it’s helpful for the quality of the work as well.
Here are some of the best reasons why you should use a weld positioner:
You Keep Yourself and Your Welders Safe
Weld positioners maximize the safety of your welders.
The workpiece would be anchored and attached well to the positioner, it wouldn’t move. No chains, slings, and cables – you’re going to mount it safely to your positioner.
You Decrease the Stress and Fatigue of the Welder
Your welders would remain on the surface level during welding. They wouldn’t have to duck, go overhead, or achieve complex positions while welding.
Better and Higher Quality of the Weld
Gathering all of its uses, it would guarantee a higher quality of work. Everything’s going to be more accurate, more precise, and the motion of the workpiece will be more controlled.
By using a welding positioner, you can expect to achieve and complete a project faster.
If you compare it to manual handling, it’ll be faster, more effective, and it’ll have a higher quality.
What are Pipe Welding Positioners?
They are welding positioners that accommodate the welding of pipes and tubes.
Using Weld Positioners vs. Manual Handling
Manual handling is the classic or the traditional welding approach. However, it’s tiring for the welder.
You can also produce inaccurate welds because of the workpiece’s unpredictable movement.
Utilizing weld positioners can free you from all the stress you’re experiencing.
Once mounted, you can specify how the workpiece would turn. Everything is automated and you wouldn’t have to do the lifting of the material you’re welding!
What are the Areas of Application of Weld Positioners?
Weld positioners are famous for a lot of uses. However, you can choose to use weld positioners for:
Mounting Welding Equipment and Machinery
Parts Rotation for Assembly
Positioning of Rotary
Rotating Workpieces With Huge Loads of Offset
Pipes, Wheels, Shafts, and Others of the Same Kind of Welding
The Most Common Welding Positioner Options
There are a lot of styles and options that you can do for welding positioners.
The most common and sought after units are:
Rotary Welding Positioners
Pipe Welding Positioners
Gripper Welding Chucks
General Welding Positioners
Tailstock & Headstock Positioners
Benchtop Welding Positioners
What are the Usual Capacities of a Welding Positioner?
Welding positioners, on a usual basis, can withstand weight that ranges from the lightest of 50 lbs., to 200,000 lbs.
Welding Positioner Prices
The prices of welding positioners would depend on certain factors including:
Its weight capability
The overall weight of the machine
Type of the machine
Features and functions of the welding positioner
To know accurate details of pricing, contact the manufacturer you wish to do business with. They’ll give you a quote or an estimate of he positioner you need for your project.
What are the Advantages of Using Welding Positioners?
To name a few of the most recognizable benefits of using weld positioners:
Better Weld Quality
Less Welder Fatigue
Higher Input and Production Ratio
Automated; Needs Less Supervision
Higher Capacity Load
Parts of Welding Positioner
Different weld positioners have distinct parts.
But, if we were to name the most general parts of welding positioners, they would include:
Motor Control (Processing Unit)
What is Rotary Welding?
It’s a type of welding that uses a welding positioner, oscillating the torch to the surface.
Oftentimes, the torch is fixed or is specified to move back and forth. The purpose is to fill a bigger area with the bead.
What are Rotary Welding Positioners?
They’re the type of positioners you’ll need to use if you need a rotating weld.
It moves a full 360 degrees and will enable you to stick on surface level welding.
What are Benchtop Welding Positioners?
These types of machines are best for smaller design frames that need intricate detail.
They’re not difficult to mount and their main purpose is to mount heavy artillery; not disregarding the design and the details.
What is a Welding Turntable?
In the simplest terms, they’re machines that can help you with your welding project.
Welding turntables are the equipment that could rotate a workpiece on its own. It can be controlled (manually), or could be set on automatic.
How Do You Use Welding Positioner Turntables?
Using a welding positioner turntable is neither hard nor challenging to do. In fact, it can be summed up in these steps:
Load the workpiece onto the table before you start welding.
It is then held onto the table by chucks and bolts.
Using the controller or the pedal, the rotation would begin – it would depend on the speed and the pace you select.
If you’re using a manual welding turntable, you’d have to hold the filler metal and/or the weld head. Otherwise, you can set them to perform at the pace you want
Once complete, you can unload the workpiece from the machine; the weld is completed.
You can think of it as a machine that would give you two free hands off of the workpiece.
Are Welding Floor Turntables Automatic?
There are different processing types of welding turntable.
You can choose from manual turntables, semi-automatic turntables, and automatic turntables. Most of the welding turntables now are automatic. However, some welders are more comfortable in making their own pace.
Different Pipe Welding Position
In using these welding positioners, you can take advantage of a few pipe welding positions available.
There’s the 1G position, the 2G position, the 5G position, and the 6G position.
The 1G position is known to be the most basic welding position. It’s where the pipe sits on its horizontal plane; and it’s rotated along its own horizontal axis.
The welding you’ll perform would be on top of the pipe.
2G is the welding position that’s opposite of the 1G position.
It’s the position where you’ll weld the pipe or the workpiece on the side because it’s sitting at a vertical position; on its vertical axis.
The 5G welding position is the one exactly the same with 1G.
However, it’s a position where the pipe cannot be moved, turned, spun, or rotated; the pipe is just fixed at a specific horizontal position.
Last but not the least is the 6G welding position.
This is the position where the pipe welding positioner tilts the pipe at exactly 45 degrees (either on the horizontal or the vertical axis).
Akin to the 5G welding position, the workpiece is fixed permanently; it cannot be moved, spun, turned, or rotated.
The 6G position is suggested for welders that have reasonable and dependable experience in welding.
What Types of Workpieces Can Be Loaded in Pipe Welding Positioners?
Regular pipes aren’t the only things you can load and work on with pipe positioners.
In fact, you can work on a wide variety of workpieces, some of the most common include:
Wheel and Shaft Pipes
And Many More
What are Pipe Positioner JAWS?
Also known as “chucks,” positioner jaws are tools to keep a workpiece in place.
They’re attached and mounted to the faceplate to clutch and make sure that the workpiece is held tightly.
What Advantages Can Pipe Turning Positioners Give You?
Pipe and tank positioners for welding can give you the following benefits and advantages:
Increased Welding Productivity
Higher Rates of Weld Deposition
Decreased and Reduced Welder Fatigue
Increased and Heightened Safety of Welders
Decreased Floor Space For Welding Production
Reduced Errors and Rejects
Reduced Welder Tiredness and Fatigue
What Are Different Types Of Welding Positioners?
Pipe positioners for welding can be categorized and differentiated in many different ways.
But, the most common would be through its automation: Manual, Semi-Automatic, and Automatic.
These are the machines that you can operate using levers and foot pedals to rotate the plate.
The speed and direction would depend on your manual control; it uses no robotics.
Semi-Automatic pipe positioners are machines that you can combine with accessories. This is done so you can achieve better and highly improved productivity.
One good example of an accessory would be a stationary torch; the positioner would move below or above the torch, depending on the position.
Automatic positioners are the positioners that utilize robots and highly intelligent machines. You’d want an automatic welding positioner if you’re going to perform large-bulk projects.
What are Pipe Roller Stands?
Pipe roller stands are tools or accessories that help a positioner hold the workpiece in place. They’re stationary accessories that supports or assists a pipe welding positioner.
You can choose from V-Heads and Roller Heads to hold your workpieces in place.
What is A Weld Positioner RPM?
RPM stands for Revolutions Per Minute. It’s the number of times the faceplate or the table spins or rotates within a minute.
Knowing it is important because this will determine how fast your welds can possibly be.
Also, most machines would only have a limit in their RPM; so you need to choose the one that fits your projects.
Where Can You Apply the Usage of Welding Turntables?
You can use welding positioner turntables in a wide variety of applications.
But, the most common ones include creation of equipment and components in the following industries:
Shipbuilding and Shipyard Industries
Power and Generation Industries
Oil & Gas Industry
And Many More
These aren’t the only options you got – there are a lot more! Oftentimes, it’s more used in welding round or cylindrical objects as they’re more challenging to work with.
How Can You Benefit From Using Rotating Welding Tables?
You can find a lot of different benefits and advantages from using welding turntables.
Among the most common ones that you can consider include:
Faster and Shorter Positioning Time
One of the main advantages and benefits you can get from using it would be speed; speed in terms of positioning and productivity.
The automation that it offers will allow your welders to gain better welding positions faster. They wouldn’t have to experiment because the workpiece would be laid out flat.
Due to this, you can expect faster welding durations and timeframes for results.
If you are to use a welding turntable, you’ll only need one (1) welder or operator. Once the workpiece has been loaded to the table, it’s as easy as the alphabet from there.
If your machines are semi-automatic or automatic, the welder can allow it to operate by itself.
Safety and Security of Your Welders
Going back to the point above, it promotes the safety and the security of your welders. You wouldn’t have to worry about dangers in handling the workpiece – even if it’s too heavy.
Better and More Accurate Results
Last but definitely not the least is that it can provide promising results. The ease of the welding projects you have will allow you to yield better outputs.
Final Verdict: More Savings
All these advantages point towards one thing – more and better savings for your operational and maintenance costs!
These are just the most common advantages you can get from using welding turntables. Others and more specific ones would depend on the workpiece and the project you have.
What to Look For in a Welding Positioner Manufacturer?
If you’re to work with a welding positioner company, you need to be clear about your needs.
You need to be wary of the following:
The proof of the jobs and workpieces they’ve finished
Where Can You Get the Best Welding Positioners?
There are a lot of manufacturers of welding positioners across the globe, so how do you pick?
The Chinese are famous for creating and for manufacturing the best and the highest quality of weld positioners; whether you need a rotary welding positioner, a benchtop weld positioner, even a tailstock welding positioner.
Here in the country, there’s no other company trusted but us here at Waldun.
For more than a decade, we’ve continuously provided our clients with the best and highest quality of weld positioners.
Why Choose Our Welding Positioners?
Waldun’s weld positioners are complete with all composites that make up the product. In fact, you wouldn’t have any problems or troubles with it.
When you choose our welding positioners, you can enjoy the following perks:
A Complete 1-Year Warranty
20-Day Delivery Wherever You Are (Maximum)
Strong and Durable
Rotational Speed of 0.1 – 1.2 RPM
Capacity That Can Exceed 5,000 pounds
And Many More!
You will find many welding positioners for sale in the market. However, only at Waldun can you get the solutions you need for your welding requirements!
Get your free quote by contacting us! Acquire the weld positioner you’ve always wanted!