Analysis of the whole production process of high frequency welded steel pipe
As a leading enterprise in the steel pipe manufacturing industry in North China, Hebei Huayang Steel Pipe Co., Ltd. has been deeply involved in the production of high-frequency welded steel pipes for more than 20 years with the core concept of "technology drives development and quality wins the future". We rely on international advanced production technology, intelligent manufacturing system and strict quality control standards to provide high-precision and high-performance steel pipe products to customers all over the world. The following will take you into the high-frequency welding workshop of Huayang steel pipe and reveal the birth journey of each high-quality steel pipe.
Raw material inspection: quality begins at the source
We adhere to the quality concept of "raw materials are products", and all incoming steel products are tested by spectral analyzer to ensure that the chemical composition meets domestic and international standards such as GB/T 3091 and ASTM A53. 100% internal defects of the base material are detected by ultrasonic flaw detector, and the thickness tolerance of the plate is monitored in real time with laser thickness gauge to prevent unqualified raw materials from flowing into the production line from the source.
Forming technology: precisely shaping the beauty of geometry
The continuous progressive deformation of sheet metal is realized by using 28-stand high-precision cold bending forming unit and digital control technology. The intelligent optimization system of forming parameters independently developed by us can automatically match the best roll profile combination according to different pipe diameters, ensuring that the roundness deviation of steel pipes is ≤0.5% and the straightness reaches 1/1000mm standard. Specially configured pre-bending device of plate edge can effectively eliminate the problem of forming stress concentration and lay a solid foundation for subsequent welding.
High frequency welding: the art of electric energy conversion
High-frequency welding equipment imported from Germany is used to realize instantaneous Joule effect at the frequency of 300-450kHz by using 120kW solid-state induction heating power supply. Our technical team has created a "three-stage temperature control method", which can monitor the temperature curves of welding zone (1350-1450℃), normalizing zone (900-950℃) and tempering zone (700-750℃) in real time through infrared thermometer, and cooperate with water cooling system to accurately control the crystallization process of weld, so that the weld strength can reach more than 105% of the base material.
Welding seam treatment: details determine success or failure
Using double milling cutter flash device, the high-precision treatment of weld burr residue ≤0.1mm is realized. Specially configured online polishing system for welding seam ensures that the surface roughness Ra of welding seam is less than 3.2 μ m through robot flexible polishing technology. For products with special requirements, we can provide weld induction annealing treatment to eliminate welding residual stress and improve the comprehensive mechanical properties of steel pipes.
Non-destructive testing: technology creates a security line
Establish a "three-level inspection system": for the first inspection, the GE digital ultrasonic flaw detector of the United States is used for 100% weld inspection, for the middle inspection, the X-ray real-time imaging system is used to monitor the internal quality, and for the final inspection, the 5.5MPa pressure holding test is carried out by a hydraulic testing machine (far exceeding the national standard of 3.0MPa). All test data are automatically uploaded to the cloud database, which realizes the quality traceability of the whole product life cycle.
Post-processing technology: finely crafted into fine products
The residual stress of steel pipe is eliminated by an eight-high precision straightener, and the cutting accuracy of ±0.5mm is realized by a laser cut-to-length cutting system. The surface treatment adopts automatic shot blasting derusting line to ensure that the steel surface reaches the Sa2.5 standard, and the supporting environment-friendly spraying line can realize various coating processes such as epoxy resin and polyethylene to meet the anti-corrosion requirements under different working conditions.
Intelligent warehousing: technology empowerment and delivery efficiency
Built the first intelligent steel pipe storage center in North China, equipped with AGV logistics system and WMS storage management system. Through the two-dimensional code traceability technology, the intelligent control of the whole process from finished product warehousing to customer delivery is realized, ensuring that each batch of products can be delivered within 48 hours, and urgent orders can realize 24-hour expedited production.
summary
Hebei Huayang Steel Pipe has always integrated the "artisan spirit" into every production link, and has obtained 32 national pate nts and passed the authoritative certifications such as ISO 9001 and API Spec 5L. Our high-frequency welded steel pipe products are widely used in national key projects such as west-to-east gas transmission and Sichuan-to-east gas transmission, and exported to more than 40 countries and regions such as Europe, America and Southeast Asia. In the future, we will continue to promote the "intelligent+green" two-wheel drive strategy to provide better steel pipe products and service solutions for customers around the world.
