ERW pipes are among the most often utilised building materials. They must be long-lasting in order to endure various environmental changes that could result in a significant shift in pressure or temperature. As a result, a variety of production procedures exist to produce industrial-grade pipes. One of these ways is the ERW steel pipe manufacturing process. ERW pipes offer exceptional strength and endurance for fluid transmission and other structural applications by doubling down on the many qualities of steel.
What is ERW?
Electric resistance welding, or ERW, is a term used to describe a specific process of pipe manufacture. Two uncoiled rolls of steel sheets are bonded together without the use of welding filler wire or metal in this procedure. Instead, the sheets are joined together with the use of an electrical current and a continuous push. ERW pipe construction does not begin with a billet that is rolled before being polished by a piercer point, as is the case with other techniques of pipe fabrication.
Tube Trading is a well-known ERW Pipe distributor in Gujarat.
The Process of Creating ERW Pipes
- Cold-forming.
- Passage of current.
- Forming.
- Welding.
- Sizing and cutting.
Step 1 – Cold-forming:
Working or forging a metal specimen, for example, steel, in a room-temperature environment is known as cold-forming. This means that the forging takes place at a lower temperature than the recrystallization temperature of the steel, which aids in the removal of impurities. When this happens, the grain structure of steel changes, becoming finer and less coarse, resulting in a hardened material with little machining waste.
One of the most important steps in the production of ERW pipes is this. A cylindrical shape is created from a sheet of steel that has been cold-rolled or shaped. Cold-forming is significantly quicker and appropriate for high-speed manufacturing since it does not require any additional heat-processing processes. Before the welding stage, the permanent hardening of the cold-forming process results in a significantly stronger steel specimen.
Step 2 – Passage of current:
ERW pipe formation is a continuous process that takes place in a machine that is continually moving. Despite this, the many steps that make up the process may still be recognised and described. After the cold-forming process, an electrical current flows between the cylindrical steel’s resultant edges. With the aid of an induction coil and a smooth pressure roll, they are progressively linked together by the current, maintaining the cylindrical shape.
Tube Trading is an excellent and distinct ERW Pipe supplier in Gujarat.
A non-contact technique of heating the material is created by using an induction coil. It is usually placed around the induction-sensitive steel specimen. An impeder is used in the ERW machining process to regulate the amount of electrical current that is dispersed throughout the material. This implies that the energy is redirected to fusing the steel joints.
Step 3 – Forming: which
Another step in the ERW manufacturing process is forming. As previously said, the steel coils that pass through the ERW-making machine produce cylindrical-shaped sheets that must be welded using electrical current. To better demonstrate this, the sheets appear to be in the shape of a U, with numerous open welded seams, or edges, as they’re known.
The equipment guarantees that the resultant U-shaped steel maintains this shape throughout the process, preventing flaws and inconsistencies in the ERW pipe manufacturing. Before being subjected to gauge forming, the steel sheet goes through rolling components, resulting in a uniformed U-shaped cross-section.
Tube Trading is the most distinguished ERW pipe provider in Gujarat.
Step 4 – Welding:
When comparing seamless and non-seamless pipes to ERW pipes, it’s clear to see where the production processes begin to diverge. Although seamless pipes resemble ERW pipes in appearance, the latter employs a non-contact electrical current. Seamless pipes do not require welding, resulting in a continuous smooth surface with no apparent edges or seams. Seamed pipes, on the other hand, may employ welding filler, which is not present in the ERW welding process.
Manufacturers of welded pipes usually make sure that their products may be used in a variety of applications, such as HVAC systems or petrochemical facilities. Even with strict quality control, there is a chance that uneven welding pressure will occur in seamed pipes. Pipe leakage or damage are two issues that may arise, although they are considerably less prevalent with ERW pipes because to their consistent pressure and strength distribution.
Tube Trading is one of the most prominent ERW Pipe suppliers in Vadodara.
Step 5 – Sizing and cutting:
After welding the U-shaped joints together, the ERW pipe can now be subjected to post-processing methods to improve the material’s characteristics and usefulness even more.
Depending on the type of use, it is sized and cut to precise proportions. With this in mind, ERW pipes may be cut into a broad range of pipe sizes and lengths, with thickness, diameter, and length variations. It’s conceivable that the pipe ends can be further shaped with an end-facing machine to accept different fittings.
