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We receive lots of questions regarding welding pipe. Whether it’s about welding high-pressure pipe, Ssaw Steel Pipe for food and beverage industries, or pipe for the oil and gas industries, there are a variety of common elements we see in pipe welding and fabrication which lead to problems. Such as everything from improper shielding gas and drive rolls to picking a MIG gun with too low of an amperage rating. As companies push to train new welders, work with new materials, increase quality and productivity, and improve safety, it is important to give attention to some of these basic variables in the pipe welding method that could affect these efforts. In this post, we’ll take a look at 13 of the most common issues we percieve in pipe welding applications and the way to resolve them.

1. Forgetting to grind the joint after oxyfuel or plasma cutting

The oxyfuel and plasma cutting processes add a layer of oxide to the cut edge. This oxide layer should be removed prior to welding, as the oxide often has a higher melting point than the base metal. Once the arc gets hot enough to melt the oxide, it’s too hot for the base metal and can lead to burnthrough. The oxides could also stay in the weld and cause porosity, inclusions, lack of fusion as well as other defects. It is important that welders make sure to grind the joint down to the parent material just before welding, in addition to grind the in and out of diameters of the pipe to get rid of these oxides along with other potential contaminants.

2. Cutting corners with cutting

When welders work together with materials more prone to distortion as well as the affects of higher heat input, including stainless and aluminum, a poor cut can result in poor fit-up and produce unnecessary gaps. Welders then compensate by putting more filler metal (thus, heat) in to the joint to fill it up. This added heat can lead to distortion and, with corrosion-resistant pipe like stainless-steel, is effective in reducing the corrosion-resistant qualities from the base metal. Additionally, it may lead to insufficient penetration or excessive penetration. Poor preparation also contributes to longer weld cycle times, higher consumable costs and potential repairs.

Shops currently using chop saws or band saws to slice pipe used in critical process piping applications should look into buying dedicated orbital pipe cutting equipment to guarantee cuts within mere thousandths of the inch from the specified parameters. This precision helps ensure optimum fit-up and keeps the amount of filler as well as heat put into the joint at the very least.

3. Forgetting to reduce out and feather tacks

Tacking is essential to match-up, and finest practices advise that the welder eliminate and feather that tack to guarantee the consistency in the final weld. Particularly in shops where a fitter prepares the 1000mm Diameter Steel Pipe then another person welds it, it’s crucial that the welder knows precisely what is within the weld. Tacks left within the joint become consumed by the weld. If there is a defect within the tack, or maybe the fitter used the wrong filler metal to tack the joint, there exists a risk for defects in the weld. Cutting out and feathering the tacks helps eliminate this potential problem.

4. Preparing a joint for MIG processes differs as compared to Stick welding

Training welders is really a main priority for many fab shops, and – for better or worse – many welders bring past experiences together for the new job. These experiences may be addressed with adequate training, only one common mistake we percieve is welders with Stick experience not discovering how to correctly create a joint for wire processes common in pipe fabrication applications. Welders trained traditionally in Stick and TIG welding often prepare the joint having a heavy landing area and wish to keep your gap as narrow as is possible. As pipe shops switch over to easier, more productive MIG processes like Regulated Metal Deposition (RMD™), we prefer welders take that landing area right down to a knife’s edge and space the joint at approximately 1/8-inch. This area is wider as opposed to those trained in Stick and TIG processes are employed to and can lead to a number of problems: focusing excessive heat into the edges of the weld, a lack of penetration and insufficient reinforcement on the within the pipe. Shops should train their welders to the details of each application and make sure they understand different weld preparation and operational techniques before they start working.

5. More shielding gas might not be better

Some welders possess a misconception that “more shielding gas is better” and definately will crank the gas wide open, mistakenly believing they are providing more protection to the weld. This technique causes numerous problems: wasted shielding gas (resources and expense), increased and unnecessary agitation in the weld puddle, as well as a convection effect that sucks oxygen in to the weld and can lead to porosity. Each station should be outfitted using a flow meter and every welder should discover how to set and adhere to the recommended flow rates.

6. Buy mixed gas – don’t depend on mixing with flow regulators

We have now seen shops that, for a stainless-steel application that will require 75/25 % argon/helium, create a separate tank of argon as well as a separate tank of helium and then depend on flow regulators to bleed within the proper amount of shielding gas. The reality is you really don’t understand what you’re getting in a mix with this method. Buying cylinders of Erw Line Pipe from reliable sources, or purchasing a proper mixer, will guarantee you know exactly what you’re shielding your weld with and this you’re adhering to proper weld procedures/qualifications.

7. Welding power sources don’t cause porosity

It is not uncommon to get a call from a customer who says “Hey, I’m getting porosity from your welder.” Plainly, welding power sources don’t cause porosity. We tell welders to recount their steps back from the point where the porosity began. Welders will usually find that it began just whenever a gas cylinder was changed (loose connections, incorrect gas used), a new wire spool was invest, when someone didn’t prep the content properly (oxides contained in the weld), or maybe the fabric was contaminated elsewhere over the line. More often than not the issue is caused by an interruption or problem with the gas flow. Tracing back your steps will frequently lead dkmfgb the variable that caused the porosity.

Rise Steel consisted of subsidaries of Cangzhou Spiral Steel Pipe Factory, Hebei All Land Steel Pipe Factory, Hebei Yuancheng Steel Pipe Factory, Cangzhou Xinguang Thermal Insulation Pipe Factory .The company is located in Tianjin port, the largest comprehensive port and an important foreign trade port, engaging in the management of steel pipe production nearly 20 years.The company is a high-tech enterprise intigrated with independent production and sales business.We are committed to the concept of “innovation, technology and service”.

Rise Steel consisted of subsidaries of Cangzhou Spiral Steel Pipe Factory, Hebei All Land Steel Pipe Factory, Hebei Yuancheng Steel Pipe Factory, Cangzhou Xinguang Thermal Insulation Pipe Factory .The company is located in Tianjin port, the largest comprehensive port and an important foreign trade port, engaging in the management of steel pipe production nearly 20 years.The company is a high-tech enterprise intigrated with independent production and sales business.We are committed to the concept of “innovation, technology and service”.

Contact Us:
Address: APT. 1202 BLDG. B Kuang Shi Guo Ji Plaza, Tianjin Free Trading Testing Zone (Business Center), Tianjin, China.
Hamer Chen:[email protected]
Eason Gao: [email protected]
Miao lin: [email protected]
Amy Shi: [email protected]
Hamer Chen:+86 18202505824
Eason Gao: +86 18622403335
Miao lin: +86 13251845682
Amy Shi: +86 18630426996