Patrik Vlašić

Robotic pipe welding represents a key and rapidly evolving technology for the automation of pipe and pipe-joint welding processes with standard, intersecting, and complex geometries. This review analyses 84 studies published over the past three decades, categorising them into four primary research areas: general pipe welding, intersecting pipes, boiler and tube-to-tubesheet welding, and control and modelling. Two separate comparative analyses were conducted: one within intersecting pipe research and another within the control and modelling category. The aggregated findings reveal consistent, complementary patterns: simulation and laboratory experiments clearly dominate validation methods, while industrial-scale evaluations remain scarce. The results further demonstrate that control strategies, sensor integration, and validation levels are strongly interconnected, collectively determining system performance, reliability, and practical applicability. Despite significant progress, challenges remain, including system integration complexity, limited robustness in variable industrial environments, insufficient real-time adaptive control, and inconsistent quantitative performance evaluation. Further research should prioritise the development of digital twins, human–robot collaboration, multi-sensor fusion, reinforcement learning-based adaptive control, and scalable industrial deployment. This review provides an overview of current progress and outlines key directions for developing intelligent and reliable robotic pipe welding systems.