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Electromagnetic Arc Stabilization System for Tube Mills
In the highly specialized area of industrial welding of stainless steel sheets, the top priority is to produce a superior weld seam quality. Tungsten Inert Gas (TIG) welding is the longest-established and most widely used method for these high-precision applications.
Nonetheless, a big issue in the case of robotized TIG welding is that the faster the welding, the more the arc, when it is in its free state, tends to "drag back" (arc lag or arc deflection) with respect to the direction of the steel tube. This problem becomes more and more serious with the increase in speed; the arc becomes unstable, and there is not enough penetration.
The resulting arc lag is a major cause of a wide range of welding defects, such as undercutting along the two edges (external and internal) of the weld seam, and also the creation of "hump" structures (normally called humped beads) on both the inner and outer surfaces of the weld (cf. Fig. 1). These flaws severely affect the strength and appearance of the weld, especially when it comes to industrial welded pipes and sanitary tubes.
When undercutting is not fixed, it can cause some liquid to get trapped in the remaining areas, thus rusting the steel pipe and creating possible points for stress corrosion cracking. Therefore, to avoid such problems and secure decent weld quality, machinists will typically have to slow down the weld speed as a trade-off for the output loss.
Function and Solution
In order to resolve these problems and, at the same time, increase the efficiency of the production line and keep the weld quality at the highest level, our company launched the advanced development of a new Electromagnetic Arc Stabilization System. The line-up of this new product is an easy one, as it mainly targets the key troubles of arc instability and poor penetration resulting from an arc lag.
The mechanism of the system is such that a specially regulated longitudinal electromagnetic field is created at the very center of the welding arc. By means of an electromagnetic force, the arc is thus made stable; it is either kept tightly in the central position or it is even moved forward. Such an electromagnetic stable arc cannot be shifted backward or laterally oscillated, as a result of which the voids or peaks of the humped bead surface, undercutting, have been totally eliminated (as can be seen in Figure 2).
Practical implementation in the production line has revealed a significant increase in welding speed by 20-30% while continuously maintaining top-notch weld quality.
In addition, the system features a variable electromagnetic force, which makes it possible to perfectly adjust to different welding currents and production speeds, thus providing flexibility and stable performance in different manufacturing scenarios.
System Components
The complete Electromagnetic Arc Stabilization System is made up of the major components:
Electromagnetic Controller: 1 unit – This is the main CPU, which decides, controls, and adjusts the power of the electromagnetic field depending on the welding parameters being used in real-time.
Electromagnetic Coil: 1 unit – The component that locates and produces the exact longitudinal electromagnetic field needed for the arc stabilization.
Water Cooling Seat: 1 unit – It is a heat dissipating unit that ensures efficient working of the electromagnetic coil by regulating the temperature of the surrounding area to the one that is best for the components, thereby extending their life.
Magnetic Boots: 1 set – Fixtures that are specially made to be integrated with the welding torch so as to easily output and direct the magnetic field to the arc.
Welding Gun: 1 unit – A welding torch that is compatible with TIG and whose design makes it easy to pair with the components of electromagnetic stabilization.
Comparison of effects: Metallographic diagram of φ 35 * 1.2mm and at speed of 3.5m/min is given below
The above picture shows a photo of argon arc welding leveling
The above picture shows the welding leveling photo after installing electromagnetic control in argon arc welding
About Us
Established: 2020
Core Expertise: Experienced in welded pipe equipment for over two decades.
Factory Size: With a modern production base and warehouse spanning over 20,000 square meters.
Technical Team: Maintained a team of over 20 professional technicians committed to R & D and innovation.
Core Products: Precision-welded pipe production lines, welding leveling equipment, bright solution equipment factory,
weld seam tracking systems, intelligent control systems, finishing rolling pipe bright solution equipment,
rotary annealing equipment, etc.
R & D Strength: Possesses more than 30 national patents and is constantly acquiring new patent authorizations.
Certifications: A national high-tech enterprise, certified with the ISO9001 quality management system, thus maintaining quality throughout the whole process from design to service.
Partners: Our continuous efforts in quality have led to the trust of numerous industry-leading companies, such as Juli, Wujin, Sanhua, Plymouth (USA), and Binner (India).
Market Coverage: The equipment is globally sold, exported to various countries and regions in Asia, the Americas, and Oceania, besides the Chinese market.
FAQ
Q1: Do you have your own?
A1: Yes, we are a Chinese manufacturer, and our factory is located in Yunfu, Guangdong, China.
Q2: Are your goods ISO9001 or CE certified ?
A2: Yes, we have an ISO certificate for all our products. All the machines are high-quality products.
Q3: How about the warranty?
A3: We offer a one-year quality warranty for all our products. Within the warranty period, spare parts replacement is free of charge. Besides, we offer technical support and other assistance for life.
Q4：What are the payment terms and delivery time ?
A4: For small machines: Payment terms are 100% T/T/ Western Union/Cash in advance.
· For big machines and big amounts: 40% deposit, 60% before shipment
(we will shoot the total delivery process for the customer's confirmation), and the related papers. You can pay by T/T,L/C, Western Union, or other ways.
The delivery period for the machine is within 45-90 working days.
Q5: Which countries have your products been exported to?
A5: We have sold our products worldwide, and our products have related certifications.
