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Straight seam steel pipes(LSAW or ERW steel pipes) are widely used across various industries, but their production can face several challenges. Effective fault handling ensures high-quality outputs and minimizes waste. Below are common faults encountered in the manufacturing process, their causes, and solutions.
1. Misalignment
Misalignment is a frequent issue during pre-welding. If it exceeds tolerance limits, it can lead to downgrading or scrapping of steel pipes. Strict control of misalignment is crucial.
Causes and Solutions:
(a) Full-length or widespread misalignment:
Causes:
Improper adjustment of the seam opening.
Misaligned joint rollers (incorrect circumferential angle, asymmetry in left and right rollers, or inconsistent radial extension).
Inadequate pre-bending of the plate edges, leaving edges uncurved.
Solutions:
Check and adjust the seam opening parameters.
Align and calibrate joint rollers properly.
Ensure the plate edges are pre-bent to the required specifications.
(b) Head or tail misalignment:
Causes:
Incorrect positioning of inlet and outlet rollers.
Misaligned center of the ring frame.
Inconsistent rounding of joint rollers or positional errors in a single roller.
Poor forming, such as large concave or convex deformation at tube ends.
Excessive seam opening width (greater than 150mm).
Hydraulic system pressure fluctuations.
Solutions:
Correct the roller positions and frame alignment.
Adjust forming parameters for better rounding.
Address hydraulic system stability.
2. Back Weld Nodules and Burn-Through
Back weld nodules, if left unremoved, hinder internal welding formation and seam tracking. Burn-through affects both internal and external welding, requiring additional repairs.
Causes:
Loose joints or low hydraulic system pressure.
Poor forming with significant roundness errors.
Incorrect pre-welding parameters, such as mismatched welding current, arc voltage, and welding speed.
Solutions:
Tighten joints and stabilize hydraulic pressure.
Optimize forming processes for better roundness.
Adjust welding parameters, ensuring proper line energy and speed balance.
3. Porosity
Porosity in pre-welding welds leads to internal defects that compromise subsequent welding.
Causes:
Poor protective gas quality (e.g., water contamination, low pressure, or insufficient flow).
Partially blocked welding machines causing uneven gas coverage and harmful gas mixing.
Presence of rust or oil on the groove.
Solutions:
Use high-quality protective gas with appropriate pressure and flow.
Maintain welding equipment and ensure proper gas hood formation.
Clean grooves thoroughly to remove rust and oil.
4. Poor Weld Formation
Poor weld formation affects welding seam tracking, process stability, and overall weld quality.
Causes:
Improper line energy caused by imbalances in welding current, arc voltage, and welding speed.
Occurrence of pores in the weld.
Solutions:
Optimize welding parameters to balance penetration and width.
Address porosity issues to improve weld consistency.
5. Spatter
Spatter during pre-welding can burn the surface or groove of the steel pipe, affecting weld quality and surface appearance.
Causes:
Incorrect composition of protective gas.
Improper technical parameters.
Solutions:
Adjust the protective gas composition, particularly the argon proportion.
Fine-tune welding parameters to reduce spatter.
Conclusion
Addressing these common faults in straight seam steel pipe production requires meticulous attention to process parameters, equipment maintenance, and material preparation. By implementing targeted solutions, manufacturers can enhance product quality, reduce waste, and ensure reliable performance in the final products.
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