In many metal production processes and applications, structural metal tubing is a vital component. Metal tubing is widely utilized as it combines strength with weight and affordability with solid metal stocks. These Tubes are available in two main types available: welded tubing and seamless tubing. This article looks more closely at the manufacturing process of welded tubes.
What are Welded Tubes?
Welded tubes are a form of metal tubing with a welding seam along its length axis. It may essentially be built of any sort of metal or metal alloys, such as carbon steel, stainless steel, alloy steel, and aluminum. The welded metal tube is typically available in the following shapes:
How are Welded Tubes Made?
Manufacturing welded tubing on a large scale is a complex process that involves several steps.
- The thickness of the metal coil is chosen initially, as it will subsequently match the thickness of the final tube wall. The coil also has to be wide enough to produce the appropriate circumference and diameter.
- The coil is formed by feeding it through a series of dies. This brings the coil width’s two edges closer together until a tube forms with one edge touching the other.
- These two edges are joined together via a welding technique.
- The extra weld reinforcement may be removed at this point, depending on the welded tube production procedure. Depending on the necessary requirements, the newly formed tube may additionally undergo a heat-treatment process.
- The tube is then cut to the desired length.
What Type of Welds are Used to Make Welded Tube?
- Electric Resistance Welding (ERW)
- High-Frequency Welding
- Laser Beam Welding
- Gas Tungsten Arc Welding (TIG welding)
- Plasma Arc Welding
- Submerged Arc Welding
Why are Different Welding Processes Used to Manufacture Welded Tubes?
There are a variety of reasons why one welding method is preferred over another when producing welded tubes. High-frequency welding is perhaps the most frequent technique. A high-frequency welding power source is used to produce a welded tube using high-frequency welding. Leads from the power source that are positioned near the formed but unwelded tube begin to produce high-frequency radiation once the power source is turned on. This energy stimulates the molecules in the tube until they reach a temperature where they can join together. The two heated edges of the unwelded tube are pushed together through another die at this point, resulting in a weld.
High-frequency welding is popular because it is a well-established, repeatable technique that is both cost-effective and capable of handling poor fit-up better than other tube welding methods. It is also carried out in a continuous manner, similar to almost all large-scale welded tube production processes, allowing for great levels of productivity.
Other welding methods are used in place of high-frequency welding for different reasons. Laser beam welding may be used for metals that are more difficult to weld than mild steel. Examples include titanium, stainless steel, and other non-ferrous alloys. Gas tungsten arc welding and plasma arc welding are sometimes used in place of laser welding because of their reduced equipment cost and complexity; however, they typically provide slower travel speeds and larger heat-affected zones. Resistance welding is occasionally used instead of high-frequency welding for medium diameter carbon steel tubing. For welded steel tubing with thick walls, submerged arc welding is used.
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