Architects and engineers are designing structures with new and innovative shapes due in part to new steel chemistries and improved flat rolling technologies. To meet these ever-changing requirements, manufacturers may turn to solid-state, high-frequency electric resistance welding (HF ERW) to produce engineered structural sections at high speeds with unlimited beam profiles and higher structural performance at lighter weights.
By controlling welding power and frequency, manufacturers of engineered structural sections (ESS) are welding different materials successfully, including carbon steel, stainless steel, advanced high-strength steel, weathering steel, titanium, and aluminum.
Welded Pipe Making Machine Production Line includes: Uncoiler, Pinching & Leveling, Shear & Welder, Cutting Saw, Straightening Machine, End-Facing Machine, Hydro Testing Machine, Forming & Sizing Mill, Storing Accumulator, Auto-packing Machine and other equipment.
Until recently structural sections have been limited to the standard catalog of symmetrical shapes and sizes that are practical to produce by rolling hot ingot metal to the required shape. Designers, architects, engineers, and manufacturers, however, are looking for new ways to lower costs, improve product performance, and reduce lead-times.
Weld Quality. Solid-state, high-frequency welding for ESS in general requires minimal heat input, produces a narrow heat-affected zone (HAZ), and results in improved weld properties. The solid-state weld process uses less heat input because high-frequency (150-400 kHz) electromagnetic energy is used in conjunction with high pressure to join two materials. The material is joined under heat and pressure instead of melted together with a filler material. Controlling key welding process parameters, such as frequency, enables you to control the time and temperature, resulting in a narrow HAZ and improved weld properties in the weld zone.
The strength of the weld zone in solid-state welded structures is near that of the parent material, whereas the strength of fusion weld zones is approximately 70 percent that of the parent material for typical steels.
Flexibility. HF ERW has the flexibility to weld low- and high-strength materials, dissimilar metals, and various sizes and shapes.
Efficiency. With this process, producing ESS inline enables you to yield greater operational efficiencies when compared to traditional hot rolling lines.
Production Rates. The process can accommodate speeds from 15 to 30 meters per minute.
No Restraightening. Through the control of key parameters such as time and temperature, you can produce sections that are straight as produced off the line.
Welded beam has a degree of customization. In addition to asymmetric and custom geometries, since welded beam is processed continuously, it can be delivered cut to the required length, reducing the scrap, costs, and frequency of beam splices. This ultimately helps make fit-up easier while decreasing weld metal and labor time. The smaller tonnage requirements of high-frequency beam welding lines makes them more suitable for small- and medium-size beam markets. The flexibility of custom geometries helps producers meet various requirements of many different beam sizes in varying quantities.
In addition to custom sizing, the process helps reduce material costs because of the thinner cross-sectional area. These geometry changes have little impact on strength but dramatic impact on weight reduction.