Pipe Flange Hub Protrusion for Faster MAG Welding
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Solution Overview
Problem
High-pressure fluctuations in hydraulic applications lead to material fatigue in welded connections, such as the flange hub of pipes, necessitating costly and time-consuming ultrasound examinations and slow TIG welding processes.
Innovation Solution
A protrusion is created at the flange hub to prevent weld metal penetration into the pipe during welding, allowing for faster and less expensive MAG welding by forming a cover over the weld joint and serving as a centering aid and additional welding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If TIG welding process is used to ensure quality of welded connections, then welding quality is improved, but production time and cost increase significantly
Solution Approach 1:
A protrusion is created at the flange hub before welding to prevent weld metal penetration into the pipe. This preliminary structural modification eliminates the need for multiple welding layers and extensive quality assurance inspections, enabling single-layer MAG welding that is both faster and equally reliable
Solution Approach 2:
The welding process parameters are changed from TIG (tungsten inert gas) to MAG (metal active gas) welding. This parameter change, enabled by the protrusion structure, allows for single-layer welding instead of multiple layers, significantly reducing production time while maintaining welding quality through the controlled prevention of weld metal penetration
2Reliability
If multiple welding layers are applied to ensure complete coverage, then welding quality is improved, but production time increases
Solution Approach 1:
The protrusion is formed in advance at the flange hub to create a physical barrier that prevents weld metal penetration. This preliminary action allows for complete welding quality assurance in a single layer, eliminating the need for multiple welding layers and the associated time consumption
3Measurement precision
If ultrasound examinations are performed to detect material fatigue, then detection precision is improved, but production cost and time increase
Solution Approach 1:
The protrusion structure is created beforehand to prevent weld metal penetration into the pipe during welding. This preliminary preventive measure ensures welding quality from the start, eliminating the need for subsequent 100% ultrasound examination of welded connections and reducing both production cost and time
Solution Approach 2:
The protrusion provides preliminary anti-action by preventing the harmful effect of weld metal penetration before it can occur. This preventive design ensures welding quality without requiring extensive quality assurance inspections, reducing production costs while maintaining detection precision where needed
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 method significantly reduces production time by a factor of 10 compared to TIG welding, enabling a more efficient and cost-effective welding process for hydraulic pipes while ensuring precise alignment and preventing unwanted weld penetration.
Implementation Method 1
The protrusion contacts the inner wall of the oppositely disposed part on the joining together of the pipe and the flange part... The protrusion therefore forms a type of cover of the weld joint between the pipe and the flange part
Implementation Method 2
Both connecting parts, i.e. the flange part and the pipe, are welded to one another from the outside for this purpose
Implementation Method 3
the protrusion in accordance with a preferred embodiment, likewise serving as a centering aid on the joining together of the pipe and the flange part... an aligned positioning of both parts is ensured
Implementation Method 4
the protrusion can serve as an additional welding additive. Accordingly, welding additive is not only introduced into the weld joint from above, but the protrusion is rather thus equally heated and fused with the oppositely disposed part
Data Source
AI summary
The invention relates to a method of manufacturing a pipe having a connecting flange, wherein the flange part is welded to an end face pipe end and at least one protrusion of the pipe or of the flange part is provided in the region of the flange hub and contacts the inner wall of the other part on the joining together of the pipe and the flange part to cover the formed weld joint to the pipe interior; and wherein finally the pipe and the flange part are welded to one another.