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Heat Exchanger Welding — Every Tube Joint Identical

A heat exchanger lives or dies at the tube-to-tubesheet joint. Hundreds of them per bundle, each one a potential leak. Machine welding makes every joint the same — that is the whole product.

Heat Exchanger Welding

Leak-tight joints, joint after joint after joint

Heat exchanger tubesheets are the purest repetition problem in fabrication: the same fillet joint, hundreds of times per bundle, each one a potential leak path. Manual welding drifts across the sheet as hours pass. The HLGB25-108 centres itself in each bore and repeats one proven parameter set for every joint.

  • Tube-to-tubesheet joints on heat exchangers, condensers, coolers and heaters
  • Tube inner diameter Ø25–108 mm, carbon steel and stainless tubes
  • Expanding (clamp) head customized to your tube diameter and wall thickness
  • Production counter, weld-count display and reset on the PLC screen
What we recommend: HLGB25-108 automatic tube-to-tubesheet machine, with the expanding head made to order for your tube gauge. Standard configurations ship in about 7 days with commissioning guidance included.
The difference: The head centres itself in the bore, the machine welds, the operator moves to the next hole. Ships within 7 days with commissioning guidance included, so a new machine stops being the bottleneck of the assembly schedule.
See the HLGB25-108
HLGB welding head on a heat exchanger tubesheet — real photo Automatic tube-to-tubesheet welding machine — head and control cabinet
Seam Types We Cover

Which Carriage Welds What in Heat Exchangers

Typical joint / seamRecommended machine
Tube-to-tubesheet fillet joints, Ø25–108 mmHLGB25-108 tube-to-tubesheet machine
Shell & channel circumferential seamsCX-III-Q1 magnetic crawler
Baffle & support plate filletsJJ fillet carriage
Long flange & channel seamsZG-III-Q1 straight-track carriage
Watch It Work

Tube-to-Tubesheet Welding on an Exchanger Bundle

HLGB25-108 automatic tube-to-tubesheet welding — real footage
FAQ

Heat Exchangers Welding — Common Questions

What tube protrusion above the tubesheet does it need?
5–20 mm of tube standing proud of the tubesheet, which is the standard condition for the fillet (outside corner) joint the machine produces. If your bundles are flush-mounted, tell us — we will review whether the joint can be adapted before you order.
How do you guarantee joint 200 matches joint 1?
The servo-driven spindle, PLC-timed ignition and fixed rotation speed make the joint a stored program rather than a hand skill: rotation speed, welding delay, arc-out delay and wire retract are all set once on the touch screen and repeated per joint. The production counter confirms how many joints each shift actually made.
What is included when it ships?
Main unit, control cabinet with integrated air compressor, wire feeder and water cooling, the 5 m aviation-plug cable bundle, the dedicated 350 A torch, cable suspension bracket, tool kit, documents and an export wooden case (820 × 620 × 1720 mm, 140 kg). Commissioning guidance is included; standard configurations ship in about 7 days.

Building Exchanger Bundles?

Send us the tube gauge and tubesheet layout — we will configure the expanding head and quote within 24 hours.

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