Although robotic welding is often considered a relatively new and modern process, it has been around since the 1960s when it was first introduced into the industrial sector. Today, it is becoming an increasingly accepted element within mainstream manufacturing, with the market forecast to double by 2026 compared to 2018 levels.
Robots are now common in many aspects of manufacturing, but robotic welding is growing faster than other applications. This is largely because the process is highly suitable for automation and because rapid global industrialisation has created demand levels that human resources alone cannot meet.
Robotic welding is particularly effective for short welding operations that are repeated in large volumes. It is most often used on production lines where high quality, accuracy, and fast processing are essential.
The Process of Robotic Welding
Robotic welding is an automated process carried out by specialised industrial robots, commonly used on production lines where the same operation is repeated across many components.
Each welding robot comprises two main components:
- Mechanical unit: Stationary or rail-mounted, with a robotic arm that moves in multiple directions. The arm incorporates a welding torch, which produces extreme heat to melt metal supplied by a wire feeder or from the workpieces themselves.
- Controller: Provides instructions to the arm to move precise distances, perform welds at specific points, and follow pre-programmed tasks. Some systems incorporate machine vision to guide welding, or a combination of pre-programming and vision.
The robot applies molten metal to join components, then moves to a cleaning device to remove excess material before repeating the cycle. Most robotic welding systems are fully automatic, moving components along conveyors and welding them in place. Semi-automatic systems require an operator to position and remove components between cycles.
The Different Types of Robotic Welding Processes
Robotic welding can be carried out using several different methods, including:
- Arc welding: Uses an electric arc at temperatures up to 3,595°C to melt and bond metal. Ideal for high-accuracy, high-volume tasks.
- Resistance welding: Passes an electric current between two metal pieces to create a molten pool that bonds them together.
- Spot welding: A form of resistance welding, commonly used in the automotive industry to join sheet metal where other welding types are unsuitable.
- Tungsten inert gas (TIG) welding: Creates an arc between a tungsten electrode and the metal. It delivers high precision but is slower, making it suitable for complex products.
- Metal inert gas (MIG) welding: Continuously feeds a wire into the weld pool, offering speed and simplicity, best for high-output environments.
- Laser welding: Uses laser light delivered through fibre optics for extreme accuracy and throughput, often in automotive, medical, and jewellery applications.
- Plasma welding: Highly versatile, with adjustable temperature and gas flow rates for different applications.
The Benefits of Robotic Welding
The rise of robotic welding is driven by its many advantages over manual welding, including:
- Labour savings: Skilled human welders are costly and scarce. Robotic welding allows one operator to oversee multiple robots simultaneously, reducing labour costs.
- Increased productivity: Robots work 24/7 with no breaks, fatigue, or absences, delivering predictable output and faster production cycles.
- Reduced waste: Extreme accuracy means cleaner seams, less material usage, fewer defects, and lower scrap levels.
- Versatility: Robotic welders are programmable for many applications and can reach areas difficult for humans to access.
- Cost efficiency: While expensive upfront, robots save on labour, reduce waste, and improve productivity, lowering per-unit costs over time.
- Improved safety: Welding is dangerous due to high heat and molten metal. Robots reduce human exposure and can operate safely in hazardous environments.
The Future of Welding
Despite its growth, robotic welding will not eliminate the need for manual welders. Human welders remain essential for one-off and low-volume jobs, unique challenges, and programming and supervising robotic systems.
Future developments include collaborative robots with advanced sensors for adaptive welding, and even experimental ideas like mind-controlled welding robots that respond to brain signals. While these are not yet practical, collaborative robotics is already emerging, combining automation with human oversight.
Welding has evolved dramatically, with robotic welding now common in industries such as automotive manufacturing. With its many benefits, robotic welding is set to remain a key part of industrial production for years to come.