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We get a lot of questions about welding pipe. Whether it’s about welding high-pressure pipe, Brass 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 that lead to problems. Included in this are everything 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 in the pipe welding method that can affect these efforts. In this article, we’ll look at 13 of the most common issues we have seen in pipe welding applications and the way to resolve them.

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

Both oxyfuel and plasma cutting processes put in a layer of oxide to the cut edge. This oxide layer has to be removed before welding, since the oxide often has 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 cause burnthrough. The oxides may also stay in the weld and cause porosity, inclusions, insufficient fusion along with other defects. It is important that welders be sure you grind the joint down to the parent material before welding, along with grind the outside and inside diameters from the pipe to eliminate these oxides and other potential contaminants.

2. Cutting corners with cutting

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

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

3. Forgetting to reduce out and feather tacks

Tacking is crucial to match-up, and best practices recommend that the welder eliminate and feather that tack to be sure the consistency of the final weld. Specifically in shops when a fitter prepares the Used For Transmission Pipeline then another person welds it, it’s essential that the welder knows just what is within the weld. Tacks left in the joint become consumed from the weld. If there is a defect in the tack, or if the fitter used a bad filler metal to tack the joint, there exists a risk for defects within the weld. Removing and feathering the tacks helps eliminate this potential problem.

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

Training welders is really a top priority for most fab shops, and – for better or worse – many welders bring past experiences with them for the new job. These experiences could be addressed with adequate training, only one common mistake we have seen is welders with Stick experience not finding out how to correctly prepare 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 would like to keep the gap as narrow as possible. As pipe shops transition to easier, more productive MIG processes including Regulated Metal Deposition (RMD™), we prefer welders take that landing area as a result of a knife’s edge and space the joint at approximately 1/8-inch. This place is wider compared to those trained in Stick and TIG processes are used to and can result in numerous problems: focusing excessive heat in to the edges in the weld, a lack of penetration and insufficient reinforcement on the inside the pipe. Shops should train their welders towards the details of each application and be sure they understand different weld preparation and operational techniques before they go to work.

5. More shielding gas may not be better

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

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

We have seen shops that, to get a stainless application that requires 75/25 percent argon/helium, set up another tank of argon along with a separate tank of helium and then depend on flow regulators to bleed in the proper level of shielding gas. The reality is you truly don’t understand what you’re getting in a mix with this particular method. Buying cylinders of Carbon Spiral Welding Steel Pipes from reliable sources, or purchasing a proper mixer, will guarantee you already know just what you’re shielding your weld with and this you’re implementing proper weld procedures/qualifications.

7. Welding power sources don’t cause porosity

It is not uncommon to obtain a call from the customer who says “Hey, I’m getting porosity out of 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 often find that it began just each time a gas cylinder was changed (loose connections, incorrect gas used), a brand new wire spool was put in, when someone didn’t prep the content properly (oxides present in the weld), or if the material was contaminated elsewhere along the line. More often than not the issue is brought on by an interruption or downside to the gas flow. Tracing back your steps will usually 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