We get a lot of questions regarding welding pipe. Whether it’s about welding high-pressure pipe, Rectangle Steel Pipe 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. Included in this are everything from improper shielding gas and drive rolls to selecting 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 essential to concentrate on a few of these basic variables within the pipe welding process that could affect these efforts. In the following paragraphs, we’ll look at 13 of the most common issues we see 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 towards the cut edge. This oxide layer must be removed prior to welding, since the oxide often features a higher melting point compared to the base metal. When the arc gets hot enough to melt the oxide, it’s too hot for the base metal and can cause burnthrough. The oxides may also remain in the weld and cause porosity, inclusions, lack of fusion along with other defects. It is crucial that welders remember to grind the joint right down to the parent material just before welding, in addition to grind the inside and outside diameters from the pipe to eliminate these oxides as well as 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, like stainless steel and aluminum, an inadequate cut can lead to poor fit-up and make unnecessary gaps. Welders then compensate by putting more filler metal (thus, heat) in to the joint to fill it up. This added heat can cause distortion and, with corrosion-resistant pipe like stainless, is able to reduce the corrosion-resistant qualities from the base metal. It can 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 reduce pipe found in critical process piping applications should look into buying dedicated orbital pipe cutting equipment to guarantee cuts within mere thousandths of an inch in the specified parameters. This precision helps ensure optimum fit-up and keeps the volume of filler and heat placed into the joint at the very least.

3. Forgetting to slice out and feather tacks

Tacking is critical to suit-up, and best practices recommend that the welder reduce and feather that tack to guarantee the consistency of the final weld. Particularly in shops when a fitter prepares the Line Pipe then another person welds it, it’s essential that the welder knows precisely what is within the weld. Tacks left inside the joint become consumed by the weld. When there is a defect within the tack, or maybe the fitter used the incorrect filler metal to tack the joint, you will find a risk for defects within the weld. Eliminating 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 main concern for most fab shops, and – for better or worse – many welders bring past experiences together towards the new job. These experiences may be addressed with adequate training, only 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 having a heavy landing area and wish to keep the gap as narrow as is possible. As pipe shops switch over to easier, more productive MIG processes such as 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 area is wider as opposed to those trained in Stick and TIG processes are utilized to and can result in several problems: focusing a lot of heat into the edges of the weld, an absence 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 is not always better

Some welders possess a misconception that “more shielding gas is better” and will crank the gas wide open, mistakenly believing they may be providing more protection towards the weld. This procedure causes several problems: wasted shielding gas (resources and price), increased and unnecessary agitation of the weld puddle, and a convection effect that sucks oxygen into the weld and can result in porosity. Each station should be outfitted having a flow meter and each and every welder should learn how to set and adhere to the recommended flow rates.

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

We have seen shops that, for any stainless steel application that needs 75/25 percent argon/helium, setup a different tank of argon and a separate tank of helium and after that rely on flow regulators to bleed within the proper amount of shielding gas. The truth is you truly don’t understand what you’re getting in a mix with this method. Buying cylinders of X80 Carbon Ssaw Steel Pipe from reliable sources, or buying a proper mixer, will guarantee you know precisely what you’re shielding your weld with which you’re sticking with proper weld procedures/qualifications.

7. Welding power sources don’t cause porosity

It is far from uncommon to obtain a call coming from a 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 stage where the porosity began. Welders will usually discover that it began just each time a gas cylinder was changed (loose connections, incorrect gas used), a brand new wire spool was devote, when someone didn’t prep the fabric properly (oxides contained in the weld), or maybe the content was contaminated somewhere else across the line. Usually the issue is brought on by an interruption or trouble with 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