Clad Steel Pipe Forming for Continuous Corrosion-Resistant Welding
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Solution Overview
Problem
Conventional high-frequency longitudinal welding of clad steel pipes requires subsequent non-continuous processes for repair welding to maintain corrosion resistance at the weld, which hinders continuous and efficient production.
Innovation Solution
The method involves bending both sides of the clad steel plate towards the base layer side before forming, allowing the clad layer to be on either the inner or outer surface, facilitating continuous high-frequency welding without the need for additional repair processes, ensuring corrosion resistance and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-frequency longitudinal welding is used to produce clad steel pipes, then production efficiency and continuity are improved, but the clad layer at the weld is extruded and scraped off, reducing corrosion resistance
Solution Approach 1:
The clad steel plate is pre-formed with the clad layer positioned on the inner surface before welding. This preliminary configuration ensures that during high-frequency welding, the clad layer remains protected on the inner surface and is not extruded or scraped off, maintaining corrosion resistance while enabling continuous production
Solution Approach 2:
The invention applies different surface quality requirements to different locations: the inner surface maintains the clad layer for corrosion resistance, while the outer surface allows for burr formation and removal. This localized quality approach enables continuous welding without compromising the corrosion-resistant clad layer
2Reliability
If repair welding is performed to maintain corrosion resistance at the weld, then corrosion resistance is improved, but the continuous production process is interrupted
Solution Approach 1:
The clad steel plate is pre-formed with the clad layer positioned on the inner surface before welding. This preliminary configuration ensures that during high-frequency welding, the clad layer remains protected on the inner surface and is not extruded or scraped off, maintaining corrosion resistance while enabling continuous production
Solution Approach 2:
By pre-positioning the clad layer on the inner surface and designing the welding process to accommodate this configuration, the invention eliminates the need for interrupting production for repair welding. The useful action of corrosion protection is maintained continuously throughout the welding process
3Shape
If the clad layer is positioned on the outer surface after forming, then surface quality is improved, but the weld area is reduced and corrosion resistance is compromised
Solution Approach 1:
The clad steel plate is pre-formed with the clad layer positioned on the inner surface before welding. This preliminary configuration ensures that during high-frequency welding, the clad layer remains protected on the inner surface and is not extruded or scraped off, maintaining corrosion resistance while enabling continuous production
Solution Approach 2:
Instead of positioning the clad layer on the outer surface for aesthetic purposes, the invention inverts the conventional approach by positioning it on the inner surface. This inversion prioritizes functional integrity (corrosion resistance and weld area) over external appearance, as the inner surface positioning protects the clad layer during welding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, maintains corrosion resistance at the weld, and enhances the efficiency of clad steel pipe production by eliminating the need for off-line repair welding, while maintaining mechanical properties through sufficient weld area.
Implementation Method 1
the clad steel pipe is produced by a high-frequency longitudinal welding pipe unit
Implementation Method 2
both sides of the clad steel plate are bent towards the base layer side of the clad steel plate
Data Source
AI summary
A method for manufacturing a clad steel pipe is provided, wherein the clad steel pipe is manufactured by using a clad steel plate as a raw material. The clad steel plate comprises a base layer (1) and a clad layer (2) roll-bonded with the base layer (1). The method for manufacturing a clad steel pipe comprises the steps of forming, welding, and deburring; both sides of the clad steel plate are bent towards the base layer (1) side of the clad steel plate, then the forming step is carried out, and after the forming step, the opening faces of the resultant pipe blank are all in a form of the clad layer (2). According to the method for manufacturing a clad steel pipe, a clad steel pipe is manufactured by using a clad steel plate as a raw material. Thus, continuance and high efficiency of a high-frequency longitudinal welding pipe unit is fully utilized, subsequent non-continuous processes are not necessary, and the corrosion resistance at the weld of the clad steel pipe is ensured.