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Analysis of weld cracks and cold celding defects in high frequency welded pipe machine
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- Release time：2022-07-19 11:30
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【概要描述】Weld cracks and cold welding defects often occur when high frequency welded pipe machine is used to make pipes. These two problems will affect the quality of welded pipes in the production process of high frequency welded pipe machine. For this reason, we analyze these two problems. and solutions.
Analysis of weld cracks and cold celding defects in high frequency welded pipe machine
【概要描述】Weld cracks and cold welding defects often occur when high frequency welded pipe machine is used to make pipes. These two problems will affect the quality of welded pipes in the production process of high frequency welded pipe machine. For this reason, we analyze these two problems. and solutions.
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- Release time：2022-07-19 11:30
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Detail
Weld cracks and cold welding defects often occur when high frequency welded pipe machine is used to make pipes. These two problems will affect the quality of welded pipes in the production process of high frequency welded pipe machine. For this reason, we analyze these two problems. and solutions.
Weld
Most of the weld cracks appear in the weld part, showing a small hair shape, and most of them occur at the superficial part of the weld; some can be seen with the naked eye, while others need to be carefully identified or even enlarged to find.
The reasons for these tiny cracks are:
(1) Reflow slag inclusion caused by high welding temperature.
(2) The tube blank is thin and narrow and the extrusion force is low, and some oxides are not extruded from the weld, and non-metallic inclusions are formed after cooling. (3) There are lack of flesh and micro-cracks on the edge of the formed tube blank.
(4) The welded seam is V-shaped butt, the superficial fusion tissue is loose, and the cooling shrinkage stress will tear the loose fusion tissue.
(5) The chemical composition of the edge of the tube blank is segregated and the oxide layer is thick, resulting in non-metallic inclusions with high melting point.
Solution: High frequency welded pipe machine can be eliminated by appropriately increasing the opening angle, increasing the extrusion force, increasing the welding temperature, and improving the edge butt state.
Cold welding
The distinguishing feature of cold welding is that there is a visible (severe) or indistinct (slight) groove or dark line on the weld. Most cold welding occurs on the outer wall of thick-walled pipes, and sometimes also on the inner wall.
The principle of cold welding is that the metal crystallization of the weld is only completed in the part of the thickness direction of the tube blank, and although the other parts are also heated by high-frequency current, the metal crystallization is not completed due to some reasons, or the metal crystallization has not been reached. condition.
Cold welding is a serious quality defect. The reasons for the cold welding of the outer wall of the welded pipe are roughly as follows:
(1) Low temperature welding
(2) Insufficient extrusion force
(3) The welding speed is too fast
(4) The magnet bar is demagnetized, the welding speed is slowly reduced, and the operator is not aware of it in time
(5) The edge of the formed tube blank is deformed, and the upper edge of the extrusion roller hole is severely worn, resulting in a sharp V-shaped butt on the edge of the tube blank
(6) Improper spraying of coolant, spray directly onto the V-shaped loop of the heating tube blank
The reasons (1) (3) (4) (6) are related to each other, the core is insufficient welding heat.
Solution: Adjust the electrical equipment of the high frequency welded pipe machine, reduce the welding speed, increase the welding heat, detect the state of the magnetic rods (cooling and arrangement), and avoid direct spraying of the coolant on the V-shaped loop of the heating tube blank.
The core of the solution is ①to reach the melting conditions of the tube blank metal. ②Increase the extrusion force and observe the burr state. ③ Strengthen the shape of the edge of the tube blank, and be sure to realize the I-shaped butt joint of the welded edge of the tube blank.
The dark line at the weld position is often misjudged as the scratch mark left by the removal of the outer burr. The first identification method is to wipe with sandpaper, and after wiping off the surface layer, the black line is still seen as cold welding; the second is to do a side flattening test.
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Application of high precision steel pipe produced by pipe welding machine in modern industry
Time of issue : 2025-02-11
1. The characteristics of high-precision steel pipe
High dimensional accuracy: small outer diameter, wall thickness tolerance (usually up to ±0.05mm), low ellipticity.
Excellent surface quality: smooth weld without burrs, surface finish Ra≤0.8μm.
Stable mechanical properties: weld strength close to the base material, uniform compressive/tensile properties.
Applicable materials: stainless steel (304/316L), carbon steel, alloy steel (such as API series), etc.
2. Core production process
(1) Type of pipe welding machine
High-frequency welding (HFW) : high efficiency, suitable for medium thin wall pipe (Φ10~Φ600mm), need to cooperate with precision forming unit.
Laser welding: small heat affected zone, narrow weld (0.1~0.3mm), suitable for ultra-thin walls (such as 0.3mm) or special alloys.
TIG welding: For high alloy steel or thick wall pipe, higher weld purity.
(2) Key process links
Forming process: multi-roll continuous cold forming, dynamic adjustment of roll parameters to compensate for rebound.
Welding control:
High frequency welding: precise control of current frequency (100~400kHz) and extrusion amount.
Laser welding: focus position accuracy ±0.05mm, real-time depth monitoring (such as CCD vision).
Online detection:
Eddy current inspection (ET) : Detection of surface cracks.
Ultrasonic inspection (UT) : detection of internal defects (sensitivity Φ0.5mm equivalent flat hole).
Laser caliper: Outer diameter closed loop control (accuracy ±0.01mm).
3. Post-processing technology
Heat treatment: bright annealing (hydrogen nitrogen protection atmosphere) to eliminate stress, hardness fluctuation ≤3HRC.
Straightening: multi-roll precision straightening, straightness ≤0.5mm/m.
Surface treatment:
Electrolytic polishing (EP) : For medical/food grade stainless steel tubes, Ra up to 0.2μm.
Coating: hot dip galvanizing (zinc layer ≥80μm) or electroless nickel plating (uniform thickness ±2μm).
4. Typical application areas
Automobile manufacturing: fuel injection pipe (tolerance ±0.03mm), hydraulic pipe.
Semiconductor equipment: Ultra-high clean gas delivery pipe (inner wall EP treatment, particle ≤Class 5).
Medical instruments: endoscopic catheter (Φ1~5mm, wall thickness 0.1mm).
Energy industry: Instrument tubes for nuclear power plants (SA213-TP347H material, intergranular corrosion test passed).
5. Quality control standards
International standard:
ASTM A269 (Universal Seamless and Welded Austenitic Stainless Steel Pipe)
EN 10305-4 (Precision welded pipes for hydraulic systems)
Industry certification: ISO 9001, PED 2014/68/EU (Pressure Equipment Directive).
6. Technological trends
Intelligent production: AI algorithm optimizes welding parameters, and the yield is increased to more than 99.5%.
Composite process: laser + arc composite welding, both efficiency and quality (speed increased by 30%).
Green manufacturing: low energy high frequency power supply (efficiency ≥90%), waste acid recovery ≥95%.
Through the above process optimization and strict quality control, the high-precision steel pipe produced by the pipe welding machine can meet the demanding requirements of size, performance and reliability in high-end industrial fields. In actual production, the process route needs to be customized according to the material characteristics and uses, for example, medical tubes need to undergo additional passivation treatment and biocompatibility testing.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
1. The characteristics of high-precision steel pipe
High dimensional accuracy: small outer diameter, wall thickness tolerance (usually up to ±0.05mm), low ellipticity.
Excellent surface quality: smooth weld without burrs, surface finish Ra≤0.8μm.
Stable mechanical properties: weld strength close to the base material, uniform compressive/tensile properties.
Applicable materials: stainless steel (304/316L), carbon steel, alloy steel (such as API series), etc.
2. Core production process
(1) Type of pipe welding machine
High-frequency welding (HFW) : high efficiency, suitable for medium thin wall pipe (Φ10~Φ600mm), need to cooperate with precision forming unit.
Laser welding: small heat affected zone, narrow weld (0.1~0.3mm), suitable for ultra-thin walls (such as 0.3mm) or special alloys.
TIG welding: For high alloy steel or thick wall pipe, higher weld purity.
(2) Key process links
Forming process: multi-roll continuous cold forming, dynamic adjustment of roll parameters to compensate for rebound.
Welding control:
High frequency welding: precise control of current frequency (100~400kHz) and extrusion amount.
Laser welding: focus position accuracy ±0.05mm, real-time depth monitoring (such as CCD vision).
Online detection:
Eddy current inspection (ET) : Detection of surface cracks.
Ultrasonic inspection (UT) : detection of internal defects (sensitivity Φ0.5mm equivalent flat hole).
Laser caliper: Outer diameter closed loop control (accuracy ±0.01mm).
3. Post-processing technology
Heat treatment: bright annealing (hydrogen nitrogen protection atmosphere) to eliminate stress, hardness fluctuation ≤3HRC.
Straightening: multi-roll precision straightening, straightness ≤0.5mm/m.
Surface treatment:
Electrolytic polishing (EP) : For medical/food grade stainless steel tubes, Ra up to 0.2μm.
Coating: hot dip galvanizing (zinc layer ≥80μm) or electroless nickel plating (uniform thickness ±2μm).
4. Typical application areas
Automobile manufacturing: fuel injection pipe (tolerance ±0.03mm), hydraulic pipe.
Semiconductor equipment: Ultra-high clean gas delivery pipe (inner wall EP treatment, particle ≤Class 5).
Medical instruments: endoscopic catheter (Φ1~5mm, wall thickness 0.1mm).
Energy industry: Instrument tubes for nuclear power plants (SA213-TP347H material, intergranular corrosion test passed).
5. Quality control standards
International standard:
ASTM A269 (Universal Seamless and Welded Austenitic Stainless Steel Pipe)
EN 10305-4 (Precision welded pipes for hydraulic systems)
Industry certification: ISO 9001, PED 2014/68/EU (Pressure Equipment Directive).
6. Technological trends
Intelligent production: AI algorithm optimizes welding parameters, and the yield is increased to more than 99.5%.
Composite process: laser + arc composite welding, both efficiency and quality (speed increased by 30%).
Green manufacturing: low energy high frequency power supply (efficiency ≥90%), waste acid recovery ≥95%.
Through the above process optimization and strict quality control, the high-precision steel pipe produced by the pipe welding machine can meet the demanding requirements of size, performance and reliability in high-end industrial fields. In actual production, the process route needs to be customized according to the material characteristics and uses, for example, medical tubes need to undergo additional passivation treatment and biocompatibility testing.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
The relationship between pipe welding machine and automobile frame manufacturing
Time of issue : 2025-02-08
1.The role of pipe welding machine in the manufacture of automobile frame
Pipe production: The welding pipe machine is used to manufacture high-precision welded steel pipes, which constitute the longitudinal beams, beams, anti-collision beams and other key components of the automobile frame. High frequency welding (HFW) or laser welding technology can produce steel pipes with uniform wall thickness and strength of more than 800MPa to meet the needs of lightweight.
Customized processing: Through flexible forming technology, the welding machine can produce special-shaped cross section pipes (such as rectangular, trapezoidal), adapt to the topology optimization design of different models of frames, improve space utilization and impact energy absorption efficiency.
2.The core requirements of the welding pipe process for automobile frames
Material properties: DP600/DP800 duplex steel or 22MnB5 thermoforming steel should be used, and online heat treatment (such as induction annealing) should be carried out after welding to ensure the microstructure consistency between the weld zone and the base material and avoid HAZ (heat affected zone) softening.
Dimensional accuracy: Diameter tolerance should be controlled within ±0.2mm, ellipticity ≤0.5%, to ensure the matching accuracy of the assembly and stamping parts (clearance <0.5mm).
3.Key technology breakthrough point
Laser-MAG composite welding: the penetration depth can reach 8mm, the welding speed is increased to 6m/min, the heat input is reduced by 30%, and the welding deformation of the frame is significantly reduced (≤1.5mm/m).
Online quality monitoring: high-speed CCD vision system (sampling rate 2000fps) with eddy current detection, to achieve real-time detection of weld defects, miss rate <0.01%.
4.Cost-performance balance
Compared with the stamping and welding structure, the welded pipe frame can reduce the weight by 15-20%, the material utilization rate is increased to 95%, and the manufacturing cost of the bicycle is reduced by about 1200 yuan. However, it is necessary to increase the investment in roller forming molds (about 2 million yuan/set).
5.Industry Application Cases
- An independent brand pure level station adopts 3D variable cross-section welded pipe subframe, with torsional rigidity increased to 27000Nm/°, 40% higher than the traditional structure, and the battery pack space utilization increased by 12%.
Conclusion
The penetration rate of welded pipe technology in the field of automotive frames is growing at a rate of 8% per year, and future development directions include:
Intelligent welded pipe system (digital twin model real-time control molding parameters)
Magnesium alloy /CFRP composite pipe welding process
Topological optimization driven continuous forming technology for variable thickness pipes
It is recommended to pay attention to the update of the ISO 15614 standard and the latest certification requirements for automotive welded pipe processes in ASME BPVC Section IX to ensure technical compliance.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
1.The role of pipe welding machine in the manufacture of automobile frame
Pipe production: The welding pipe machine is used to manufacture high-precision welded steel pipes, which constitute the longitudinal beams, beams, anti-collision beams and other key components of the automobile frame. High frequency welding (HFW) or laser welding technology can produce steel pipes with uniform wall thickness and strength of more than 800MPa to meet the needs of lightweight.
Customized processing: Through flexible forming technology, the welding machine can produce special-shaped cross section pipes (such as rectangular, trapezoidal), adapt to the topology optimization design of different models of frames, improve space utilization and impact energy absorption efficiency.
2.The core requirements of the welding pipe process for automobile frames
Material properties: DP600/DP800 duplex steel or 22MnB5 thermoforming steel should be used, and online heat treatment (such as induction annealing) should be carried out after welding to ensure the microstructure consistency between the weld zone and the base material and avoid HAZ (heat affected zone) softening.
Dimensional accuracy: Diameter tolerance should be controlled within ±0.2mm, ellipticity ≤0.5%, to ensure the matching accuracy of the assembly and stamping parts (clearance <0.5mm).
3.Key technology breakthrough point
Laser-MAG composite welding: the penetration depth can reach 8mm, the welding speed is increased to 6m/min, the heat input is reduced by 30%, and the welding deformation of the frame is significantly reduced (≤1.5mm/m).
Online quality monitoring: high-speed CCD vision system (sampling rate 2000fps) with eddy current detection, to achieve real-time detection of weld defects, miss rate <0.01%.
4.Cost-performance balance
Compared with the stamping and welding structure, the welded pipe frame can reduce the weight by 15-20%, the material utilization rate is increased to 95%, and the manufacturing cost of the bicycle is reduced by about 1200 yuan. However, it is necessary to increase the investment in roller forming molds (about 2 million yuan/set).
5.Industry Application Cases
- An independent brand pure level station adopts 3D variable cross-section welded pipe subframe, with torsional rigidity increased to 27000Nm/°, 40% higher than the traditional structure, and the battery pack space utilization increased by 12%.
Conclusion
The penetration rate of welded pipe technology in the field of automotive frames is growing at a rate of 8% per year, and future development directions include:
Intelligent welded pipe system (digital twin model real-time control molding parameters)
Magnesium alloy /CFRP composite pipe welding process
Topological optimization driven continuous forming technology for variable thickness pipes
It is recommended to pay attention to the update of the ISO 15614 standard and the latest certification requirements for automotive welded pipe processes in ASME BPVC Section IX to ensure technical compliance.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
89 Pipe welding machine is used to produce steel pipes for highway fences
Time of issue : 2025-02-07
89 The working principle of the pipe welding machine 89 The pipe welding machine uncoils the steel strip, feeds and welds it into a round steel pipe, and then cools, straightens and cuts the steel pipe to the required length. The main steps include:
1. Uncoiling: Unroll the steel strip from the drum and level it through the straightener.
2. Forming: The steel strip is rolled into a tube shape through a series of roller wheels.
3. Welding: high frequency current is used to heat the joint of the steel strip, so as to weld the steel pipe.
4. Cooling: The welded steel pipe is cooled by cooling equipment.
5. Straightening and cutting: Finally, straighten and cut the steel pipe to the required length.
The main steel pipe used in the highway fence needs to have a certain strength and impact resistance, but also corrosion resistance. Specific features include:
1. High strength: the steel pipe must be able to withstand the impact to ensure the safety of the highway.
2. Corrosion resistance: steel pipes are usually galvanized to enhance their corrosion resistance and adapt to harsh outdoor environments.
3. Standard size: The steel pipe produced generally has strict size requirements to ensure the stability of the fixed connection of each fence.
The steel pipe produced by the 89 pipe welding machine plays a skeleton role in the highway fence, and its application is reflected in:
1. Guardrail: installed on both sides of the highway or in the middle, to prevent the vehicle from losing control of the road, to protect the safety of the driver.
2. Isolation belt: Set isolation belts between lanes in different directions to prevent vehicles from crossing lanes and reduce the incidence of accidents.
3. Sound barrier: The use of steel pipe frame to support the sound barrier plate to reduce the impact of road noise on the surrounding environment.
In short, the 89 pipe welding machine plays a key role in the production of steel pipes for highway fences, ensuring the stability, durability and safety of the fences, thus providing a reliable guarantee for the safe operation of the highways.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
89 The working principle of the pipe welding machine 89 The pipe welding machine uncoils the steel strip, feeds and welds it into a round steel pipe, and then cools, straightens and cuts the steel pipe to the required length. The main steps include:
1. Uncoiling: Unroll the steel strip from the drum and level it through the straightener.
2. Forming: The steel strip is rolled into a tube shape through a series of roller wheels.
3. Welding: high frequency current is used to heat the joint of the steel strip, so as to weld the steel pipe.
4. Cooling: The welded steel pipe is cooled by cooling equipment.
5. Straightening and cutting: Finally, straighten and cut the steel pipe to the required length.
The main steel pipe used in the highway fence needs to have a certain strength and impact resistance, but also corrosion resistance. Specific features include:
1. High strength: the steel pipe must be able to withstand the impact to ensure the safety of the highway.
2. Corrosion resistance: steel pipes are usually galvanized to enhance their corrosion resistance and adapt to harsh outdoor environments.
3. Standard size: The steel pipe produced generally has strict size requirements to ensure the stability of the fixed connection of each fence.
The steel pipe produced by the 89 pipe welding machine plays a skeleton role in the highway fence, and its application is reflected in:
1. Guardrail: installed on both sides of the highway or in the middle, to prevent the vehicle from losing control of the road, to protect the safety of the driver.
2. Isolation belt: Set isolation belts between lanes in different directions to prevent vehicles from crossing lanes and reduce the incidence of accidents.
3. Sound barrier: The use of steel pipe frame to support the sound barrier plate to reduce the impact of road noise on the surrounding environment.
In short, the 89 pipe welding machine plays a key role in the production of steel pipes for highway fences, ensuring the stability, durability and safety of the fences, thus providing a reliable guarantee for the safe operation of the highways.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
Purchase used pipe making machine
Time of issue : 2025-01-23
1.Supply channels:
Online marketplaces: For example, Taobao, Alibaba, Jingdong and other platforms can search and find used equipment.
Professional used equipment market: Some areas have a special used equipment market, you can view the equipment situation on the spot.
Industry exhibitions: Participate in machinery, manufacturing related exhibitions, sometimes you can find suppliers to provide second-hand equipment opportunities.
Peers and recommendations: Ask peers and friends in the industry to obtain reliable equipment and supplier information.
2.Selection criteria:
Equipment condition: Carefully check the service life, maintenance records and running status of the equipment to ensure that the function is intact.
Brand and model: Choose well-known brands and reliable models, usually the quality is guaranteed, and the after-sales service is relatively perfect.
Price comparison: multiple inquiries to ensure reasonable prices to avoid buying inferior equipment at low prices.
Service and Accessories: Find out if the supplier provides after-sales service and accessories to ensure convenient maintenance in subsequent use.
3.Site inspection:
Equipment operation demonstration: The seller is required to perform equipment operation demonstration to observe the actual operation.
Technical Support: Evaluate the seller's technical support capabilities, including whether to provide installation and commissioning services.
Contract protection: Sign a detailed procurement contract to clarify the responsibilities of both parties, equipment specifications, payment methods, after-sales service and other content.
4.Trial Period:
Trial commitment: Try to strive for a certain trial period in order to find potential problems with the equipment during use.
Troubleshooting: During the trial period, pay close attention to the operation of the equipment, if there is a failure, contact the seller as soon as possible.
Through the above methods, you can better purchase a satisfactory second-hand pipe making machine.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
1.Supply channels:
Online marketplaces: For example, Taobao, Alibaba, Jingdong and other platforms can search and find used equipment.
Professional used equipment market: Some areas have a special used equipment market, you can view the equipment situation on the spot.
Industry exhibitions: Participate in machinery, manufacturing related exhibitions, sometimes you can find suppliers to provide second-hand equipment opportunities.
Peers and recommendations: Ask peers and friends in the industry to obtain reliable equipment and supplier information.
2.Selection criteria:
Equipment condition: Carefully check the service life, maintenance records and running status of the equipment to ensure that the function is intact.
Brand and model: Choose well-known brands and reliable models, usually the quality is guaranteed, and the after-sales service is relatively perfect.
Price comparison: multiple inquiries to ensure reasonable prices to avoid buying inferior equipment at low prices.
Service and Accessories: Find out if the supplier provides after-sales service and accessories to ensure convenient maintenance in subsequent use.
3.Site inspection:
Equipment operation demonstration: The seller is required to perform equipment operation demonstration to observe the actual operation.
Technical Support: Evaluate the seller's technical support capabilities, including whether to provide installation and commissioning services.
Contract protection: Sign a detailed procurement contract to clarify the responsibilities of both parties, equipment specifications, payment methods, after-sales service and other content.
4.Trial Period:
Trial commitment: Try to strive for a certain trial period in order to find potential problems with the equipment during use.
Troubleshooting: During the trial period, pay close attention to the operation of the equipment, if there is a failure, contact the seller as soon as possible.
Through the above methods, you can better purchase a satisfactory second-hand pipe making machine.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier：www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier（Please click the link→) :second-hand pipe mill
Contact information
Tel: +86-13392281699
Wechat: 13392281699
Email: zty@usedpipemill.com
Company address:No. A99, East Lecong Avenue, Lecong Town, Foshan City, Guangdong Province
Wechat: 13392281699
Email: zty@usedpipemill.com
Company address:No. A99, East Lecong Avenue, Lecong Town, Foshan City, Guangdong Province
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Tel (wechat): 13336487288
Wechat：+86 13336487288
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Email: zty@usedpipemill.com
Address: No. A99, Lecong Avenue East, Lecong Town, Foshan City, Guangdong Province
