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Articles tagged with "pipe"
Results: 89
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Making the cut: ArrayArray
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Boatmaker finds new saw for trailer production: Circular cold saw meets compound miter cut, setup requirementsAt its factory in Vonore, Tenn., MasterCraft builds boats and trailers in adjacent bays. It offers the option of a trailer with every ski boat it sells.
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Take the old with the new - Selecting saw blades with new technologies in mindNew methods for cutting tube and pipe have been introduced to welding shops in the last few years—methods designed not only to cut metal, but also to cut costs.
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Making hands-free straight, saddle, and miter cutsRovanco Piping Systems Inc. designs and fabricates piping systems for applications such as water (hot and cold), steam, and jet fuel. It sells fabricated pipe—typically with straight or miter end cuts—up to 36 inches in diameter. It provides preinsulated, high-temperature, low-temperature, and containment systems.
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Hydroforming with end feedingThe list of applications for hydroforming with end feeding is growing all the time. Maybe you should check into how this technology could benefit your operation.
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Hydroforming provides Rx for medical pumps: Fabriator adds economy to other benefits of titaniumThis article relates how a Florida-based company used hydroforming to produce titanium housings for implantable pumps for a Massachusetts-based manufacturer.
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Hydroforming a new front automotive structure: How new methods can rise to old challengesHydroforming the parts in a vehicle structure can be of immense benefit on several counts, as a review of a recent project at the author's company can attest.
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Material property variations in tubes used for hydroforming: Using the hydraulic bulge test to determine formabilityAs tubular hydroforming becomes a competitive process for the mass production of automotive parts, a tube's material properties must be consistent. To predict variations in material properties, many tube producers use the uniaxial tensile test. Because the specimens for the tensile test are collected before a tube is bent and welded, they are not always accurate. To predict variations in tube property accurately, it should be tested under a biaxial state of stress.
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Hydroforming on a budgetYou can use several strategies for starting a hydroforming operation on a limited budget. Review your alternatives for selecting a press, fluid intensification system, and developing the tooling necessary for your operation before you take the plunge.
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Fill'er Up: Using hydroforming to manufacture one-piece gas tank filler tubesHydroforming is gaining ground in the manufacture of many automotive components,such as pillars, frame rails, and engine cradles. Automakers are finding hydroforming advantageous for forming many smaller parts also. The process is useful for manufacturing an automobile fuel filler tube, which is the expanded portion of a fuel filler assembly where a fuel nozzle is inserted.
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A survey of presses for hydroforming tubes, extrusions: Presses, accessories offer options for hydroformersHydroforming is one of the most important fields in production manufacturing. In recent years many single presses, groups of presses, and entire production plants for internal high-pressure (IHP) hydroforming of tubes and extrusions have been installed, especially in the Americas and in Europe. The driving force behind this development has been the efficient production of automotive parts.
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Developments in hydroforming: International conference highlights new equipment, industry trendsCommentary from the people interviewed at the International Conference on Hydroforming (Oct. 2003) indicate that trends include an increasing interest in forming aluminum and other lightweight materials; more use of tailored tubes; and that sheet hydroforming is expected to grow faster than tube hydroforming.
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Part feature developments in hydroforming products: Hydroforming continues to make automotive inroadsTube hydroforming technology continues to develop in ways that improve part utility, economy, or process robustness. Auto parts that have recently been produced by hydroforming include roof rails, radiator enclosures, a front-end structural module, and roof rails.
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Hydroforming tapered engineered tubes: Are they more formable than uniform-thickness tubes?Hydroforming often results in localized thinning. Using engineered tubes--tubes that have a thicker wall where the tube is most prone to thinning--can result in a stronger finished component.
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Tube Hydroforming Design Flexibility—Part VI |
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Metallurgical aspects of tube production: Understanding the science, improving the manufacturingSmall-diameter tubing plays a crucial role in many markets, including aerospace, nuclear, medical, and industrial. From coronary stents to hydraulic aircraft controls, each application has unique requirements. To meet the requirements of customers in these industries, well-designed processing steps and adequate control are critical.
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Using laser shock peening to increase pilger die life: Case-hardening for reducing toolsDuring pilgering, the dies endure extreme amounts of stress. Shot peening is a conventional, economic process for hardening the tooling, but its benefits are limited. Supplementing shot peening with laser shock peening where the stress is highest can help to extend the service life of the tools.
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Putting a few end forming basics to workWhether maintaining or changing the OD, knowing the basics of end forming—especially friction and lubrication—can help achieve a successful result.
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Evaluating the Danger of Loud Noises in Tube and Pipe Shops: How OSHA's Rules Protect Your EmployeesIn work environments that generate noise that exceed 85 dB or with impact noises exceeding 140dB, such as found in tube and pipe, OSHA requires a hearing conservation program.
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Achieving cost-effective environmental compliance: How outsourcing waste management can helpThis article provides information on waste management, with specific focus on outsourcing. Topics include determining waste generator status, waste identification and minimization, safety training for employees, and "green" products.
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Learning to adapt: Fabricator adapts to changing manufacturing environmentProduction Cutting Services opened for business in 1985 as a service
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Supply chain collaborates on bending project: Planning, cooperation keep project on schedule despite short time frameFaced with a daunting bending contract and a short timeframe, Rick Williams of Rockford Process Control (RPC) sought cooperation from a tubing supplier, bending machine manufacturer, and a tooling supplier at the beginning of the project. The information exchange enabled RPC and its supply chain partners to develop a process, deliver a bender, and engineer and manufacture tooling without the benefit of tubing samples.
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Don't underestimate India: TPA tours the country that could overtake U.S. by 2050TPA recently hosted a tour of eight tube and pipe producers and fabricators throughout India. Although the country is not advanced, this tour and a recent report by Goldman Sachs reveal where it stands and where it is likely to go in the near future. Its capabilities are modernizing and Goldman Sachs expects its economy to overtake the U.S. economy by 2050.
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Rockwell hardness and Brinell testing of tube and pipe: Special factors merit attention to ensure proper resultsThe article discusses special considerations that must be kept in mind when hardness testing tube and pipe. Rockwell and Brinell are covered. Special considerations include surface finish, wall thickness, deflection, and internal supports.
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Monitoring the quality of welded tube and pipeAn eddy current flaw detection system is suitable for detecting discontinuities in tube and pipe during the production process. Understanding about eddy current system principles and this technology's capabilities and limiatations can help tube and pipe producers learn how to use such a system.
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A primer on titanium tube and pipe: Applications abound for this versatile metalThis article discusses titanium—how it is processed; the types and grades of pure titanium and alloys that are available; and applications for titanium tube and pipe. Discusses manufacturing and testing titanium tube and pipe to ASTM standards for specific applications.
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Forming exhaust components with an alternative lubricant: Manufacturer cleans up with gelSwitching from an oil-based lubricant to a water-based gel lubricant helped an exhaust-system components manufacturer, Zeuna Starker, reduce costs and cycle time. After studying several types of lubricants, the company chose a water-based gel that was less prone to spilling onto the floor and did not produce smoke during the welding process. The company reaped benefits in decreased housekeeping and disposal costs, and found that it did not need to wash the lubricant residue from semifinished parts before welding.
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Using precision abrasive wheel technology: Narrow niche, small parts, tight tolerancesPrecision abrasive wheel cutting is a small but important niche in the abrasive cutting field. It can be used to cut many types of parts, including metal rods, tubes, extruded shapes, and even wire. It is most useful in operations characterized by small parts, hard-to-cut materials, and tight tolerances.
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Heating P91 boiler pipe: Induction heating gives contractor faster, more consistent resultsIn the power piping industry, turnaround time on a boiler pipe project typically is from 20 to 36 weeks. But J.F. Ahern Co. (JFA), Fond du Lac, Wis., a company ranked as one of the Midwest's top 10 mechanical contractors according to the May 2002 Contractor magazine, isn't typical. Neither were the results JFA achieved when it switched to induction technology for pipe preheating.
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Expanding Their Reach: Expandable Casing Pipe Helps Oil Companies Drill to New DepthsExpandable-casing pipe is being used by some aggressive OCTG players, causing oil companies to look at deep water and land based wells in a whole new light.
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Comparing materials for high-temperature steam piping: The use of X20 and P91 in power stationsOf all the materials used for high-temperature steam piping, X20 (12 percent chromium, 1 percent molybdenum, 1/4 percent vanadium) and P91 (9 percent chromium, 1 percent molybdenum, 1/4 percent vanadium) stand out because of their very high creep rupture properties, even at elevated temperatures.
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Say 'no!' to burrs, dimples: Competitors, customers drive finishing requirementsAs tube mill speeds increase, tube end cut quality suffers. Meanwhile, customer requirements for end cut quality continually increase. Tube producers are turning to dedimpling and deburring machines to enhance tube cut quality and improve worker safety.
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Selecting the right temporary coating: Choices abound for tube and pipe applicationsTube and pipe manufacturers should consider carefully environmental laws, cost, quality, and the cost of a coating line before deciding on a temporary coating for their products.
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The basics of roll form tooling design: Understanding tube forming's not-so-distant cousinYou can successfully roll-form a profile more than one way. In fact, many roll form designers take different approaches to design and development. Also, because the roll forming process has a seeming limitless capacity to produce complex profiles with just as many variables, many roll form designs are one-of-a-kind; therefore, theory can go only so far.
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Specifying the sulfur content of 316L stainless steel for orbital welding: Weldability versus surface finishThe widespread use of autogenous (fusion) orbital gas tungsten arc welding (GTAW) in the high-purity semiconductor and biopharmaceutical industries, combined with modern steel refining technology, has made it both desirable and practical to supply type 316L stainless steel with a restricted range of elemental sulfur.
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Making the connection: Substituting tube end forms for machined connectorsHundreds of types of machined end connectors are used to transmit fluid in fabricated tube and hose assemblies. In recent years manufacturers and end users of these connectors have been developing new methods and processes that eliminate machined connectors and the associated joining operation. Eliminating connectors and joining operations can help save both money and time.
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Inspecting welds on complex tube forms: Manual eddy current optionsMany manufacturers are familiar with using eddy current systems to inspect their sheet and tubular products. Eddy current testing (ECT) is a nondestructive electromagnetic test that offers a rapid examination to detect surface-breaking flaws or cracks. It can be applied easily to straight sections of both seamless and welded tubing. Tests can be performed online as part of the manufacturing process or offline as part of a supplier or customer quality assurance check.
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The Bold in Arches: Pipe fabricator uses induction bending to create roof truss assembliesThe phraseobstructed viewis probably most connected with older sports stadiums. For example, at Wrigley Field in Chicago, depending on where your seat is, watching Sammy Sosa in action in right field might be replaced by a view of a rusting steel girder.
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Pour me a mandrel: Bending tubes, pipes, and other forms with low-melting-point alloysTo reduce weight and cost for all types of products, design engineers often specify tubes and pipes with thinner walls instead of the previously used heavier-walled tubes and pipes. Shorter tube or pipe lengths also achieve the same objectives, but usually they require sharper or more complex bends. These designs make the tube bender's task more difficult.
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Zero to sixty in the blink of an eyeThe engine roars to life, and Bruce Van Sant inches the motorcycle forward, stopping about 25 feet from the starting line. Alan Geetings, crew member of the Van Sant racing team, sprays the asphalt with water. Bruce revs up the engine. The engine's torque breaks the rear tire's grip on the asphalt and it spins furiously. The air is suddenly filled with a cloud of smoke and the smell of burning rubber. After heating the tire, Bruce approaches the starting line.
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Selecting a welding frequency: Research on the optimal frequency for tube productionEarly power supplies for contact and induction welding for tube production, which were introduced in the 1950s, operated at 300 to 400 kHz. Modern power supplied, introduced in the 1990s, are variable from 200 to 400 kHz. While using any frequency in this range can produce acceptable welds for most applications, finite element analysis can be helpful for finding the optimal frequency for a particular gauge and material.
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Is your bend good enough?: Standards for hot and cold bendingBending tube or pipe so the finished product conforms to one of two bending standards can help to reduce rejects and improve relations between fabricators and their customers. The standards can facilitate the use of bending terms, and promote an understanding of bending tolerances and acceptable defects before starting a bending project.
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Bending and handling tube: Tailoring equipment to an applicationThree main types of tube bending equipment are dedicated, CNC, and automated bending cells. Understanding the advantages of each is crucial to deciding which type to purchase.
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Tips for welding preparation: How machine, materials, and tool bits affect the resultsThe increasing use of advanced equipment and applications (such as orbital welding for high-purity systems) requires better weld preparation. A thorough understanding of equipment, tool bits, and materials—including advanced alloys—helps to achieve better end prep.
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Lean times call for mean tactics—Part 1: A tube bender’s tools of the tradeRon Stange looks back on his 50 years in the tube-bending industry and provides his insight on the one thing tube bender operators must know to be successful: Ironclad rules for successful bending do not exist. Tube bender operators must start with guidelines and incorporate their own experience to be successful.
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Welding zirconium and zirconium alloys: ArrayArray
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Managing rotary-draw tube bending: Best practices minimize variation and downtimeEditor's Note: This article is adapted from a conference presentation made by the author at a previous TPJ Symposium.
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The basics of rotary cutting: Finding the right machine type and optionsThe rotary cutting process rotates a tube or pipe and cuts it with a rotating blade. Because it is a chipless cutting method, it does not waste any material and reduces or eliminates subsequent deburring and cleaning operations. Although it can be used on any metal, it is not suitable for every application. The cutting action produces a slight chamfer on the end of the workpiece, so it is not useful for applications that require a square end. Machine types include manual and pneumatic. Accessories include cutter block assemblies that support the workpiece during the cut; length gauges for repeatable cut lengths; and feed systems that store and feed the material into the cutting machine.
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Making the cut: ArrayArray
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Fact or Friction?: Understanding lubricant types is key to best selectionArray
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Titanium trends: Energy demand, titanium demand grow hand-in-handElectricity demand grew an average of 15,000 megawatts per year from 1995 to 2006, and this trend will undoubtedly continue. The Energy Information Administration predicts that meeting future demands will require the equivalent of more than 20 new 500-MW power plants per year over the next 20 years or so. A critical component in power plant construction is titanium tubing, which is favored for its high strength and corrosion resistance.
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Focusing on bent tubing: Making measurements using photogrammetryMeasuring the bends and straight sections of a bent tube can be tricky and time-consuming, especially if the tube has a large number of bends in several directions. Photogrammetry, also known as optical measurement, uses a booth equipped with several digital cameras to make a digital image of the part, allowing fast, easy measurements.
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Manufacturing motorcycle mufflers: Fabricator finds improvement with rotary swagingArray
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Shaping profits with a mandrel extractor: The basics of mandrel extractors and their applicationsArray
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Welding zirconium and zirconium alloys Part II: Part II: Welding technique, procedures, and quality testingLike welding of other metals, welding zirconium successfully depends on correct application of electrical characteristics, wire feed, interpass cleaning, preheating, and heat input. Understanding the resulting surface color is key in knowing whether the weld was performed successfully or if it requires repair.
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Making the cut - Understanding rotary cutoff blades and extending blade lifeThe rotary cutting process rotates a tube or pipe and cuts it with a rotating blade. The blades are beveled to various angles and produce a chamfered end on the workpiece. Selecting the right bevel angle is the key in getting an optimal combination of end finish and production rate. Proper alignment and clearance, the use of a lubricant, frequent inspections, and proper sharpening are the keys to long blade life.
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Manufacturing motorcycle mufflers - Fabricator finds improvement with rotary swagingArray
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Making a workhorse run: Getting the best performance from a vertical compression bender |
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Increasing tube mill welding speed: Examining technology for tube producersThis article reviews processes that were technological advances in tube welding years ago but still have a bearing on how tube producers do their jobs today.
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Accumulating strip before the mill: An introduction to entry end equipment |
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Skelp edge preparation for manufacturing ERW pipePreparing the edge of a metal strip properly before it enters an electric resistance welding tube mill makes a huge difference in the quality of the final product. Make sure your prep methods match your quality requirements.
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Piping in Productivity: Construction company uses orbital welding on underground pipelineUsing orbital welding equipment led to productivity gains in one of the nation's first fusion-welded underground pipelines.
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Maintaining a RF Tube and Pipe Welding Generator: How to find trouble spotsThis article separates the RF generator into seven major subassemblies and then gives tips for finding and preventing problems in each subassembly.
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Mastering the tool selection process: How to minimize production costs with the proper equipmentNeed a tutorial on how to select the proper tube mill tooling for all kinds of jobs? Getting the right tools in place for a particular product can make a world of difference in the final product.
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Boosting efficiency in solid state welders: Improving weld mechanicals can make the differenceThis article, reprinted from the January/February 1999 issue of TPJ-The Tube & Pipe Journal, is based on excerpts from Thermatool Corp.'s "High Frequency Pipe & Tube Welding Manual."
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Automated tube welding of heat exchangers: Converting from a manual process allows one company to increase production, expand projectsHarris Thermal Transfer Products, Newberg, Oregon, is an American Society of Mechanical Engineers (ASME)-code shop that focuses mainly on the production of shell and tube heat exchangers.
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Solving the mysteries of the fin pass—Part 1: Uncovering where, why and howThe fin pass was not the first time your father gave you five bucks for your allowance. The fin passes are those forming passes that immediately follow the breakdown or initial forming stages on a tube mill. Their role is paramount in the successful final presentation of the formed tubular section to the welding process.
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Keeping stainless steels stainless: How important is passivation for SS?Stainless steels are inherently resistant to surface attack in mildly corrosive environments. However, when corrosion does occur, it can result in the formation of pits on the surface or within crevices of the part. Why does this situation develop, and what can be done to prevent catastrophic failure?
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Troubleshooting OCTG threading: Part II: Insert type impacts finished-surface quality, tool life, chip control |
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Optimizing your hydraulic cutoff press: Squeezing more out of your tube mill |
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MIAB welding of thick-walled pipe ends: Research finds ways to increase pipe thickness while maintaining quality |
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Certifying the quality of your tube and pipeIn a perfect world, quality assurance and certification of materials would not be issues. In the tube and pipe industry, however, flawless raw materials and finished goods are not givens.
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Tension control in tube and pipe production: Getting it right for smooth, steady mill operation |
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Tube and pipe loading:: How one manufacturer made the process less hazardousThis article discusses the hazards associated with manually loading and unloading tube and pipe. It describes one company's solution to making the process less hazardous.
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Tube mill cutoff die setup for square and rectangular profilesWhen properly selected and utilized, single-cut die sets can produce top-quality cut ends on square and rectangular tubing. This article discusses the criteria for selecting and using the die sets to achieve the best results.
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Cutoff die setup for dimple-free roundsWith the right equipment and proper setup, tube mills can produce dimple-free round tubing efficiently. A multistep process using a two shear blade makes a dimple-free cut, and an inline brush end finisher can be used to remove the ever-present clearance burrs, if needed
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Modern flying shear tube cutoff systems: ArrayArray
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Troubleshooting Guide for CleanersRust, wear, and dirt cost tube fabricators and producers millions of dollars annually, and they can be the bane of tube processes. Analyzing the criteria for selecting the lubricant, cleaner, and rust preventative can help provide maximum protection.
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Rotary straighteners for tube and pipe: An introduction to 6- and 10-roll straightening machinesAlthough six-roll straightening machines were the industry standard for decades, 10-roll machines provide twice as many bending moments and therefore turn out straighter, rounder tube.
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Shopping for a new tube mill coolant?: It takes more than comparing price tagsMany mill coolants are available today. Understanding the factors that drive selection and management of these fluids can help to minimize the costs of their use in welded tube production.
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Choices in flying cutoff saw blades: Friction versus carbideFriction saws are the conventional cutoff machines for tube and pipe mills. Drawbacks include hazards (noise and risk of breakage) and burrs they tend to generate. Tungsten-carbide-tipped (TCT) blades, which require more sophisticated sawing machines, run slower and safer, cut cleaner, and are less prone to breakage.
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Modern flying shear tube cutoff systems - Part I: MainframesModern flying shear tube cutoff systems comprise state-of-the-art mainframes, tools, and controllers. This article, Part I of a three-part series, discusses the different types of mainframes, their capabilities, and construction. It describes and includes images of the construction process from start to finish.
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Modern flying shear tube cutoff systems - Part II: Die set acceleratorsThis article, Part II of a three-part series, discusses the different types of die set accelerators found in flying shear tube cutoff systems. It presents an overview of earlier accelerator technologies still in use today —cam link, assisted lift target, and air/oil units. It also discusses three common closed-loop die set accelerators that represent newer technology —hydraulic servo valve, servomotor belt, and servomotor rack and pinion.
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Using AC for Al: How alternating current is employed in orbital GTAW |
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TIG for titanium tubing: Success hinges on filler metal selection, cleanness, gas coverageAlthough titanium has a reputation for being difficult to weld, it doesn't have to be problematic. Paying close attention to filler metal selection, cleanness, and use of the shielding gas are three steps to successful GTAW on titanium tube and pipe.
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Trends in offshore energy: Training, technology help overcome skill shortageThe welding industry is known for a persistent shortage of skilled workers, and the energy sector is no exception; meanwhile, offshore welding is getting more rigorous. The easiest-to-find oil sources were discovered long ago; with each passing year, energy companies go into harsher environments (deeper waters) to find petroleum and natural gas. Drilling into deeper waters means dealing with higher pressures and colder temperatures, and many companies have been switching too high-strength pipe, which tends to be more difficult to weld than common pipe.
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Simulating a robotic workcell: Taking the guesswork out of automationNot so long ago, setting up a robotic work cell was a trail-and-error affair. However, advances in simulation technology allow manufacturers to visualize a robotic work cell and sort out any problems before setting up the cell. Simulating the work cell's function helps to ensure the cell will yield the desired results and helps prevent costly mistakes and re-engineering.
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Don't throw away your profit margin |
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Examining electric resistance weld nuggets in tube and pipe: Using the microscope to study weld characteristicsAn in-depth examination of electric resistance welding nuggets as a quality control step in the manufacturing of high-strength tube and pipe used for pressure applications
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