ORBITALSERVICE®

Tube-to-Tubesheet weld heads

TTS 40, TTS 90, TTS Flex Station, TTS-Autoline
Products
Orbitalservice-Rohr_in_Boden_Schweisskoepfe-tube_to_tube_sheet_weld_heads
Orbitalservice-Rohr_in_Boden_Schweisskoepfe-tube_to_tube_sheet_weld_heads

ORBITALSERVICE®

Tube-to-Tubesheet weld heads

TTS 40, TTS 90, TTS Flex Station, TTS-Autoline

Products

Suitable welding heads for every project

Here you can find an overview of our tube-to-tubesheet weld head range. We will be glad to advise you on which model best suits your application.

From our compact, easy-to-use weld heads without cold wire, ideal for stainless steel, titanium, and nickel-based alloys, to our rotating tube-to-tubesheet weld heads with cold wire feeder for TIG-DC welding, we offer the right solution for every project. For mechanized applications, our TTS Flex Station combines the TTS 40 or TTS 90 weld head with an articulated arm, providing smooth, precise and stable positioning for efficient tube-to-tubesheet welding.

TTS40-Rohr-in-Boden-Schweisskopf-Tube-to-tubesheet_weld_head

TTS 40

Our small, handy and easy operable tube-to-tubesheet weld head without cold wire for stainless steels, titan and nickel-based-alloys.

  • Tube-to-tubesheet weld head without cold wire
  • Area of application: Stainless steels, titan or nickel-based-alloy
  • Small, handy and easy operable
  • Easy self-centering clamping-cartridge
  • Clamping of the cartridge with a clamping mandrel with extension-lever
  • Improved water cooling system for high duty cycle

  • Tube ID from 16 to 38 mm / 0.63″ to 1.5″
  • Electrode diameter: 1.6 and 2.4 mm / 0.063″ and 0.078″
  • Weight: 3,5 kg / 8 lbs (without hose package)
  • Hose package length: 12 m / 40 ft
  • Article number: TTS40

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TTS90-Rohr-in-Boden-Schweisskopf-Tube-to-tubesheet_weld_head

TTS 90

Our tube-to-tubesheet weld head with cold wire feeder (rotating version) is equipped with a pneumatic clamping system. Thanks to the eroded clamping mandrels and the elastic force of the pneumatic system, even overhead welding operations can be carried out with ease.

  • With cold wire feeder (turning) for TIG-DC-welding
  • Continuous rotation without twisting of the cold wire possible
  • Pneumatic clamping system
  • Erorded clamping cartridge
  • Weld head can be mounted on a balancer
  • Suitable for steel, stainless steel and nickel-based-alloy
  • For justified, back shifted (1 mm) and overlaying (5 mm) tubes

  • Tube ID from 12 to 90 mm /0.47″ to 3.54″ (bigger diameters available on request)
  • Electrode diameter: 1.6 and 2.4 mm /0.063″ and 0.078″
  • Welding wire diameter: 0.8 mm – 1 mm
  • Weight: 13 kg / 28 lbs (without hose package)
  • Hose package length: 8 m / 26 ft
  • Article number: TTS90mD100

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TTS40 Flex Station
TTS90 Flex Station

TTS Flex Station

The TTS Flex Station is a self-balancing articulated arm designed to support and position TTS tube-to-tubesheet weld heads ergonomically and precisely. Used with the TTS-40 or TTS-90, it makes positioning around the entire tubesheet easier while significantly reducing operator effort and fatigue.

Designed for demanding tube-to-tubesheet welding applications, the Flex Station combines a gas-spring-balanced articulated arm with precise positioning and secure locking.

The arm carries the welding head virtually weightless in all positions, allowing smooth and effortless movement. Its radial and tilting joints provide 360° movement, giving the operator easy access across the tubesheet while maintaining precise torch positioning.

Depending on the configuration, manual or pneumatic turning and tilting brakes allow the arm to be locked individually or simultaneously on all axes. This provides a stable and repeatable welding position during production.

The robust construction is designed for industrial environments and allows rigid or flanged mounting of the TTS-40 or TTS-90 weld heads. The Flex Station is particularly suited to boiler and heat exchanger fabrication, where a large number of repetitive tube-to-tubesheet welds require consistent positioning and reduced operator strain.

Key Features

  • Self-balancing, gas-spring-assisted articulated arm
  • Ergonomic positioning with minimal manipulation effort
  • 360° movement of both radial and tilting joints
  • Manual or pneumatic turning and tilting brakes
  • Rigid and repeatable mounting of TTS-40 or TTS-90 weld heads
  • Up to 35 kg gross load capacity, depending on configuration
  • Suitable for repetitive tube-to-tubesheet welding applications
  • Designed for industrial environments
  • Made in Germany

  • Load capacity: Up to 35 kg / 77 lbs, depending on configuration
  • Maximum reaction torque – vertical work: Up to 650 Nm / 479 ft·lb
  • Maximum reaction torque – horizontal work: Up to 250 Nm / 184 ft·lb
  • Maximum reaction torque – any angle: Up to 250 Nm / 184 ft·lb
  • Manipulation resistance: Approx. 0.5 kg / 1.1 lbs
  • Vertical reach: Approx. 1070 mm / 42.1″
  • Horizontal reach: Approx. 1725 mm / 67.9″
  • Balancing system: Gas spring with pneumatically assisted control, depending on brake and lock configuration
  • Power fluid: Compressed air
  • Operating pressure: 0.5–0.7 MPa / 5–7 bar / 73–102 psi
  • Operating temperature: −10 °C to +50 °C / 14 °F to 122 °F
  • Maximum relative humidity: 70%, for indoor industrial environments
  • Brake options: Manual or pneumatic turning and tilting brakes
  • Article numbers:
    • TTS40FlexStation – Articulated arm for TTS-40, without welding head
    • TTS90FlexStation – Articulated arm for TTS-90, without welding head

TTS-Autoline-Rohr-in-Boden-Schweisskopf-Tube-to-tubesheet_weld_head

TTS-Autoline

By using TTS-Autoline as an accessory for TTS-90, you are able to work without a balancer. Thanks to adjusting its weight and hight of the linear guide unit perfectly for the TTS-90, it can be moved by hands very easily.

TTS-Autoline offers multiple benefits:

  • No patrons and mandrels, no clamping, no damage of the inner pipe surface, no deterioration of the eroded collets, etc.
  • You can weld pipes with an inner diameter of 1 mm (0.03937”) minimum.
  • Easy handling: Clamp all three axes by using just one shifter.
  • Easy adjusting of the whole construction(elevating screws at its feet, turning devices at its weld head attachment with toggle levers.

  • Measurements (from the ground)
    • X axis: 600 mm / 23.62’’
    • Y axis: 1500 mm / 59.06’’
    • Z axis: 1000 mm / 39.37’’
  • Weight: 230 kg / 507.06 lbs
  • Dimensions: 2080 x 1010 x 1080 mm / 81.89 x 39.76 x 42.52 in
  • Article number: TTSAutoline

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Do you have questions about our products or would you like an individual offer? Please do not hesitate to contact us.

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You would like to recommend our products? With pleasure.