Electromagnetic Arc Stabilization System for Tube Mills
In the specialized field of industrial stainless steel welding, achieving superior weld seam quality is paramount. Tungsten Inert Gas (TIG) welding stands as the most mature and preferred process for these high-precision applications.
However, a significant challenge arises in automated TIG welding: as welding speeds increase, the arc, in its free state, tends to "drag back" (arc lag or arc deflection) relative to the steel tube's travel direction. This phenomenon becomes more pronounced with higher speeds, leading to an unstable arc and insufficient penetration.
This detrimental arc lag commonly results in various weld defects, including undercutting along both the external and internal edges of the weld seam, as well as distinct "hump" formations (often referred to as humped beads) on both the inner and outer surfaces of the weld (as illustrated in Figure 1). These imperfections critically impair the weld's integrity and aesthetic quality, posing particular challenges for industrial welded pipes and sanitary tubes.
Unaddressed undercutting can lead to residual liquid entrapment, promoting corrosion of the steel pipe and creating potential stress corrosion points. Consequently, traditional industrial welding practices often necessitate a reduction in welding speed to mitigate these issues and ensure acceptable weld quality, thereby compromising throughput.
Function and Solution
To overcome these limitations and simultaneously enhance production line efficiency while maintaining excellent weld quality, our company has developed an advanced Electromagnetic Arc Stabilization System. This innovative solution directly addresses the problems of arc instability and inadequate penetration caused by arc lag.
The system operates by introducing a precisely controlled longitudinal electromagnetic field within the central region of the welding arc. Through the application of electromagnetic force, the arc is effectively stabilized, either held firmly in its central position or actively propelled forward. This electromagnetic stabilization prevents the arc from deflecting backward or oscillating laterally, thereby eliminating the occurrence of undercutting and humped bead defects (as depicted in Figure 2).
Practical implementation in production environments has demonstrated a remarkable 20-30% increase in welding speed while consistently upholding superior weld quality.
Furthermore, the system offers adjustable electromagnetic force, allowing for optimal adaptation to varying welding currents and production speeds, ensuring versatility and consistent performance across diverse manufacturing requirements.
System Components
The complete Electromagnetic Arc Stabilization System comprises the following key components:
