Tapered Strip Edges for Electric Resistance Welding
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Solution Overview
Problem
Existing electric resistance welding methods for manufacturing pipes face challenges in achieving optimal toughness and strength of welds due to the presence of penetrators, which are not effectively discharged during the welding process, leading to reduced toughness and strength, especially in low-temperature applications.
Innovation Solution
The method involves shaping the lateral edges of the strip with predetermined tapering before welding, using a finpass forming process with multiple stages of tapering and specific angle configurations, and employing non-oxidizing gases during welding to enhance the discharge of penetrators and improve weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric resistance welding is performed on strips with rectangular edges, then the welding process is simple and fast, but penetrators remain in the weld causing reduced toughness and strength
Solution Approach 1:
The lateral edges of the strip are shaped with predetermined tapering before welding through a finpass forming process. This preliminary edge preparation creates a geometric configuration that facilitates the discharge of penetrators during welding, thereby improving weld toughness and strength without complicating the overall manufacturing process
Solution Approach 2:
The invention changes the geometric parameter of the strip edge from a rectangular shape to a tapered shape with specific angle configurations. This parameter change in edge geometry enables better penetrator discharge during welding, resolving the contradiction between weld quality and process simplicity
2Manufacturing precision
If multi-stage finpass forming with specific tapering angles is applied, then penetrator discharge is improved and weld quality increases, but the forming process becomes more complex
Solution Approach 1:
The finpass forming process is divided into multiple stages, each creating a specific tapering angle on different portions of the strip edge. This segmentation of the forming process allows precise control over edge geometry to optimize penetrator discharge, while the modular nature of multi-stage forming makes the complexity manageable and systematic
3Reliability
If strip edges are shaped with tapering to improve penetrator discharge, then weld toughness improves, but the additional forming step increases production time
Solution Approach 1:
The edge shaping operation is merged with the existing finpass forming process that is already part of the pipe manufacturing line. By integrating the tapering operation into the conventional forming sequence rather than adding a separate dedicated process, the invention improves weld toughness while minimizing the impact on overall production time
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 toughness and strength, as demonstrated by increased Charpy impact values and reduced brittle fracture surface ratios, ensuring higher reliability and performance, especially in low-temperature conditions.
Implementation Method 1
an electric resistance welder including an induction heating section 5 and a squeeze roll (electric resistance welding section) 6
Implementation Method 2
welded by electric resistance welding using an electric resistance welder including an induction heating section 5 and a squeeze roll (electric resistance welding section) 6
Data Source
AI summary
A method of manufacturing an electric resistance welding pipe is provided in which a lateral edge shape is made to be an appropriate shape immediately before electric resistance welding is performed, whereby penetrators are securely removed during the electric resistance welding and, consequently, an electric resistance welding pipe having excellent characterization of welded seam can be obtained. A fin shape in finpass forming is printed to lateral edges of a strip, whereby the lateral edges of the strip are shaped with predetermined tapering.