Orbital welding equipment can handle intense use, but even the most reliable machines can wear down over time. Recognizing malfunctions can prevent job delays, costly repairs, or potential safety hazards. Here are five signs your orbital welding equipment is failing.

1. Decreased weld quality

If your welds suddenly look inconsistent, it’s time to investigate the cause. Orbital welding machines are precise, so any drop in quality could signal defective components or calibration issues. You may notice weak joints more often. Keep an eye out for irregular bead patterns, excessive spatter, or poor penetration in your welds.

2. Unusual noises

An orbital welding machine should operate smoothly. If you hear grinding, clicking, or whining when you use your equipment, they may indicate mechanical issues. Bearings, motors, or other internal parts could be degrading, and ignoring strange sounds could lead to bigger problems.

3. Erratic power supply

A welding machine that powers off unexpectedly or struggles to operate consistently is hazardous. Power fluctuations can result from deteriorating electrical components or a problem with the power source. Erratic power can cause failed welds or damage your equipment.

4. Excessive overheating

All machinery generates heat, but excessive or sudden overheating is a different story. If your orbital welding equipment feels unusually hot to the touch, or if it shuts down mid-operation, the cooling system may be malfunctioning. Overheating often leads to damage, so acting fast can save your equipment.

5. Calibration errors

When was the last time you calibrated your welding machine? Misalignment or loss of calibration will negatively affect weld quality. Persistent calibration issues or setting drifts indicate that some components are due for replacement. Performing regular maintenance keeps your orbital welding equipment in top condition and prevents calibration from becoming an ongoing struggle.

Know when it’s time for repairs

Your orbital welding equipment can’t perform perfectly forever—every machine has its limits. Detecting these signs that your orbital welding equipment is failing can save you from headaches. Frequent inspections and routine maintenance will extend its life, but you should act quickly at the first sign of trouble. Addressing small problems now can prevent breakdowns and injury.

If you notice any issues, report them to your supervisor or consult a welding equipment technician. Experts can safely resolve problems and keep your projects on track.