Electric Resistance Welding Pipe Edge Tapering for Penetrator Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric resistance welding processes face challenges in achieving optimal weld toughness and strength due to the presence of oxides, known as penetrators, which are not effectively discharged during the welding process, leading to reduced manufacturing efficiency and poor weld characterization.
Innovation Solution
The proposed solution involves shaping the lateral edges of the strip with a two-stage or three-stage tapering configuration using cutting or shaving rolls, with specific angle and length adjustments to ensure effective discharge of melting steel and removal of penetrators, thereby enhancing weld quality without compromising manufacturing efficiency across varying strip thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric resistance welding is performed without edge shaping, then the welding process is simple and fast, but penetrators remain in the weld causing reduced toughness and strength
Solution Approach 1:
The patent applies preliminary action by shaping the lateral edges of the strip with tapering (at angles of 10-45 degrees) before the welding process. This pre-shaping of the edges ensures that penetrators can be effectively discharged during welding, improving weld toughness and strength without requiring complex equipment modifications during the welding itself.
Solution Approach 2:
The patent changes the geometric parameters of the strip edges by introducing specific tapering angles (10-45 degrees) and lengths (5-50mm). This parameter modification enables effective penetrator discharge during welding, resolving the contradiction between weld quality and equipment complexity by using simple geometric changes rather than complex welding process modifications.
2Reliability
If edge tapering is applied to improve penetrator discharge, then weld quality improves, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent optimizes the tapering parameters (angles of 10-45 degrees and lengths of 5-50mm) to achieve effective penetrator discharge within a reasonable processing time. These parameter ranges balance the need for adequate tapering to remove penetrators with the constraint of maintaining manufacturing efficiency, avoiding excessive processing time while ensuring weld quality.
Solution Approach 2:
The patent applies local quality by tapering only the lateral edges of the strip where penetrators form, rather than processing the entire strip. This localized edge shaping minimizes the additional manufacturing time and complexity while effectively addressing the penetrator discharge issue at the critical welding locations.
3Object-generated harmful factors
If the lateral edges are shaped with adequate tapering, then melting steel discharges effectively removing penetrators, but the edge shaping process requires additional equipment and process steps
Solution Approach 1:
The patent applies local quality by using cutting or shaving means that process only the lateral edges of the strip (5-50mm width) where penetrators form, rather than processing the entire strip. This localized approach effectively removes penetrators while minimizing the complexity and cost of the edge shaping equipment required.
Solution Approach 2:
The patent uses preliminary action by shaping the lateral edges with tapering before the welding process. This pre-shaping ensures that when welding occurs, the melting steel can effectively discharge and remove penetrators. The cutting or shaving means are positioned to process edges in advance of the welding operation, improving weld quality without requiring complex equipment during the welding itself.
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 results in electric resistance welding pipes with improved weld toughness and strength, as demonstrated by higher Charpy impact values and lower brittle fracture surface ratios, ensuring reliable product performance.
Implementation Method 1
apparatus for inductively heating lateral edges of the roll-formed strip
Implementation Method 2
electric resistance welded pipe is formed by welding without using weld metal
Data Source
Figure 1~3B
Figure 4A~5C
Figure 6A~7
AI summary
Manufacturing equipment of electric resistance welding pipes is provided, in which lateral edges of a strip for an electric resistance welding pipe is shaped with appropriate tapering immediately before electric resistance welding so that welding quality is kept excellent. (1) Cutting or shaving means 3 is provided after a leveler 2. (2) At least one finpass forming stand 4 is provided, which includes a fin having tapering having at least 2 stages. The manufacturing equipment of electric resistance welding pipes satisfies at least one of the above (1) and (2).