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Shijiazhuang Faith Machinery Co., Ltd integrates multiple technological measures to maintain consistent weld quality in ERW pipe production. The process begins with precise edge preparation and continues through advanced monitoring systems.
Material Preparation and Forming
Strip edges are milled to achieve clean, parallel surfaces free of oxides and contaminants. This ensures uniform electrical resistance during welding. The forming section gradually shapes the material using sequenced rolls that maintain consistent edge alignment. Optical sensors monitor strip position, automatically adjusting guide rolls to prevent misalignment that could cause weld defects.
Welding Process Control
High-frequency current (100-400 kHz) generates localized heat through contact or induction methods. The system maintains optimal vee length (distance between electrode contact and weld point) through servo-controlled pressure rolls. Copper alloy electrodes require precise cooling to maintain stable electrical characteristics. Water cooling systems maintain electrode temperature within 65-75°C to prevent resistance variations.
Post-Weld Treatment
Immediate heat treatment normalizes the weld zone. Induction coils raise the seam to 900-950°C followed by controlled cooling. This process refines the grain structure and eliminates stress concentrations. Temperature profiles are monitored using infrared pyrometers with closed-loop control systems.
Non-Destructive Testing
In-line inspection systems include:
Eddy current testing for surface defects
Ultrasonic examination for subsurface imperfections
Automated visual inspection using high-resolution cameras
Periodic hydrostatic testing at 1.5 times working pressure
Maintenance Protocols
Scheduled maintenance includes electrode replacement every 800 operating hours, roll alignment checks every 400 hours, and calibration of monitoring instruments weekly. Documentation systems track weld parameters for each production batch, ensuring complete traceability.
