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We receive plenty of questions about welding pipe. Whether it’s about welding high-pressure pipe, 60 Degree Elbow Pipe Fitting for food and beverage industries, or pipe for the oil and gas industries, there are a number of common elements we see in pipe welding and fabrication which lead to problems. These include anything from improper shielding gas and drive rolls to choosing 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, you should focus on many of these basic variables within the pipe welding process that can impact these efforts. In this article, we’ll look at 13 of the most common issues we see in pipe welding applications and how 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 must be removed just before welding, since the oxide often features a higher melting point compared to base metal. Once the arc gets hot enough to melt the oxide, it’s too hot for that base metal and can lead to burnthrough. The oxides can also remain in the weld and cause porosity, inclusions, absence of fusion and other defects. It is important that welders remember to grind the joint down to the parent material before welding, in addition to grind the inside and outside diameters from the pipe to eliminate these oxides and other potential contaminants.

2. Cutting corners with cutting

When welders work with materials very likely to distortion as well as the affects of higher heat input, such as stainless steel and aluminum, an inadequate cut can result in poor fit-up and create unnecessary gaps. Welders then compensate by putting more filler metal (thus, heat) to the joint to fill it up. This added heat can lead to distortion and, with corrosion-resistant pipe like stainless-steel, is able to reduce the corrosion-resistant qualities from the base metal. It may also cause 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 cut pipe found in critical process piping applications should look into buying dedicated orbital pipe cutting equipment to ensure cuts within mere thousandths of an inch in the specified parameters. This precision helps ensure optimum fit-up and keeps the quantity of filler as well as heat put into the joint at least.

3. Forgetting to cut out and feather tacks

Tacking is critical to suit-up, and best practices advise that the welder reduce and feather that tack to ensure the consistency of the final weld. Particularly in shops when a fitter prepares the Seamless Boiler Steel Pipe and then somebody else welds it, it’s essential that the welder knows just what is in the weld. Tacks left in the joint become consumed through the weld. If you have a defect inside the tack, or if perhaps the fitter used the incorrect filler metal to tack the joint, there is 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 than with Stick welding

Training welders is actually a main priority for most fab shops, and – for better or worse – many welders bring past experiences with them towards the new job. These experiences may be addressed with adequate training, but one common mistake we have seen is welders with Stick experience not discovering how to properly create a joint for wire processes common in pipe fabrication applications. Welders trained traditionally in Stick and TIG welding often prepare the joint with a heavy landing area and wish to keep your gap as narrow as possible. As pipe shops switch to easier, more productive MIG processes including 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 place is wider as opposed to those trained in Stick and TIG processes are employed to and can cause several problems: focusing a lot of heat in to the edges in the weld, too little penetration and insufficient reinforcement on the within the pipe. Shops should train their welders for the specifics of each application and be sure they understand different weld preparation and operational techniques before they start working.

5. More shielding gas is not always better

Some welders use a misconception that “more shielding gas is better” and definately will crank the gas wide open, mistakenly believing they may be providing more protection towards the weld. This technique causes several problems: wasted shielding gas (resources and price), increased and unnecessary agitation from the weld puddle, along with a convection effect that sucks oxygen to the weld and can cause porosity. Each station needs to be outfitted using a flow meter and every welder should learn how to set and adhere to the recommended flow rates.

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

We now have seen shops that, for a stainless-steel application that will require 75/25 % argon/helium, create a different tank of argon as well as a separate tank of helium and after that depend on flow regulators to bleed in the proper quantity of shielding gas. The truth is you really don’t know what you’re getting in a mix with this method. Buying cylinders of Black Weld Steel Pipe from reliable sources, or investing in a proper mixer, will guarantee you understand precisely what you’re shielding your weld with and that you’re implementing proper weld procedures/qualifications.

7. Welding power sources don’t cause porosity

It is far from uncommon to get a call coming from a customer who says “Hey, I’m getting porosity from the welder.” Plainly, welding power sources don’t cause porosity. We tell welders to recount their steps back from the stage where the porosity began. Welders will often find that it began just when a gas cylinder was changed (loose connections, incorrect gas used), a whole new wire spool was devote, when someone didn’t prep the fabric properly (oxides present in the weld), or if perhaps the fabric was contaminated somewhere else over the line. Most of the time the issue is brought on 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