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Articles tagged with "tube"

Results: 130

Increasing productivity on your cutoff saw: Considerations when sawing round and square tubing

All of the components of a tube cutting job—the workpiece, the blade, the saw, and the cutting fluid included—have to work together optimally to maximize your productivity.

Publish date: April 24, 2001

Tech cell: Sawing


Putting a spark into cutting productivity: Exploring the friction alternative

There are many ways to cut sheet, plate, tubing, and structural shapes, ranging from a hand hacksaw to power shears and lasers.

Publish date: September 4, 2001

Tech cell: Sawing


Making the cut: Array

By: Array
Array

Publish date: Array

Tech cell: Array


Boatmaker finds new saw for trailer production: Circular cold saw meets compound miter cut, setup requirements

At 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.

Publish date: April 24, 2003

Tech cell: Sawing


Take the old with the new - Selecting saw blades with new technologies in mind

New 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.

Publish date: May 29, 2003

Tech cell: Sawing


Tube Hydroforming Design Flexibility—Part I

Publish date: May 16, 2002

Tech cell: Hydroforming


The basic elements of tubular hydroforming

Many factors come into play when attempting to execute a production hydroforming operation, among them material selection, friction and lubricants, tube bending and preforming, and equipment. Many companies in the automotive sector are experiencing great success with the process, which can reduce weight, overall costs, and the number of parts per vehicle.

Publish date: March 5, 2001

Tech cell: Hydroforming


Hydroforming with end feeding

The 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.

Publish date: August 16, 2001

Tech cell: Hydroforming


Predicting failure in hydroforming prevent aluminum tubes: Strain variables require sophisticated analysis

This article discusses an approach to predicting failure in hydroforming prebent aluminum tubes. While strains are well researched for stamping sheet, this type of knowledge is lacking for hydroforming tubular components. Because the strains are different—prebent hydroformed tubular parts experience stress in the axial direction during bending, then in the circumferential direction during hydroforming—new methods for predicting failures are necessary. Researching these methods adds to the knowledge base of hydroforming, helping the technology gain further acceptance in manfacturing.

Publish date: March 14, 2002

Tech cell: Hydroforming


Hydroforming provides Rx for medical pumps: Fabriator adds economy to other benefits of titanium

This article relates how a Florida-based company used hydroforming to produce titanium housings for implantable pumps for a Massachusetts-based manufacturer.

Publish date: January 10, 2002

Tech cell: Hydroforming


Tube Hydroforming Design Flexibility—Part II

Publish date: October 10, 2002

Tech cell: Hydroforming


Hydroforming a new front automotive structure: How new methods can rise to old challenges

Hydroforming 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.

Publish date: October 25, 2001

Tech cell: Hydroforming


Material property variations in tubes used for hydroforming: Using the hydraulic bulge test to determine formability

As 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.

Publish date: October 10, 2002

Tech cell: Hydroforming


Hydroforming on a budget

You 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.

Publish date: July 12, 2001

Tech cell: Hydroforming


Fill'er Up: Using hydroforming to manufacture one-piece gas tank filler tubes

Hydroforming 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.

Publish date: March 27, 2003

Tech cell: Hydroforming


Tube Hydroforming Design Flexibility—Part III

Publish date: April 24, 2003

Tech cell: Hydroforming


Dealing with internal pressure in free hydraulic bulging: Predicting results with FEA

For hydraulic tube bulging, direct pressure control is the most commonly used process. Pressure control allows engineers to determine the correct capacity hydraulic system and, more importantly, prevent tube rupture. However, inflow control, or control of the volume of fluid inside the tube, theoretically could be another viable hydroforming process. Finite element analysis has shown that inflow control could allow engineers to more accurately predict deformation behavior and therefore enhance the hydroforming process.

Publish date: June 12, 2003

Tech cell: Hydroforming


Examining the effects of push assist on the formability of aluminum tubes

It is well-known that tube has become an important material for hydroforming hollow components. The increasing complexity of product structures, particularly in the automotive industry, often requires one or more forming operations before a tube actually is hydroformed. Prebending is one of these forming processes used to prepare tubes for the so-called prebent tube hydroforming.

Publish date: July 10, 2003

Tech cell: Hydroforming


Tier 1 supplier builds four-stage competitive strategy

F & P Manufacturing Inc., a tier-one automotive components supplier, focused on four areas when it developed a hydroforming line for manufacturing Honda Accord engine cradles. These areas were eliminating end scrap, decoupling the bending machines from the manufacturing line, reducing cycle time, and palletizing parts.

Publish date: July 24, 2003

Tech cell: Hydroforming


A survey of presses for hydroforming tubes, extrusions: Presses, accessories offer options for hydroformers

Hydroforming 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.

Publish date: October 9, 2003

Tech cell: Hydroforming


Tube Hydroforming Design Flexibility—Part V

Publish date: February 26, 2004

Tech cell: Hydroforming


Developments in hydroforming: International conference highlights new equipment, industry trends

Commentary 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.

Publish date: March 25, 2004

Tech cell: Hydroforming


Part feature developments in hydroforming products: Hydroforming continues to make automotive inroads

Tube 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.

Publish date: March 25, 2004

Tech cell: Hydroforming


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.

Publish date: June 8, 2004

Tech cell: Hydroforming


Tube Hydroforming Design Flexibility—Part VI

Publish date: September 14, 2004

Tech cell: Hydroforming


Tube Hydroforming Design Flexibility—Part VIII: Dimensional Stability

Whether they are producing automobiles or hydroforming press parts, designers, manufacturers, and assembly personnel are very concerned about dimensional stability. Surfaces and holes must be located in a specified range and smaller is better. Concern escalates as the drive to improve quality and reduce build tolerances and problems increases.

Publish date: June 14, 2005

Tech cell: Hydroforming


Straining to understand bending?: Regression analysis predicts springback’s magnitude, variation

Before you can hydroform tube, you bend it. Then it springs back. You can compensate by overbending it, but first you have to predict the amount of springback.

Publish date: April 10, 2007

Tech cell: Hydroforming


Metallurgical aspects of tube production: Understanding the science, improving the manufacturing

Small-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.

Publish date: May 4, 2004

Tech cell: Metals/Materials


Using laser shock peening to increase pilger die life: Case-hardening for reducing tools

During 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.

Publish date: December 1, 2009

Tech cell: Metals/Materials


Putting a few end forming basics to work

Whether maintaining or changing the OD, knowing the basics of end forming—especially friction and lubrication—can help achieve a successful result.

Publish date: March 9, 2009

Tech cell: Roll Forming


Evaluating the Danger of Loud Noises in Tube and Pipe Shops: How OSHA's Rules Protect Your Employees

In 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.

Publish date: October 24, 2002

Tech cell: Safety


Achieving cost-effective environmental compliance: How outsourcing waste management can help

This 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.

Publish date: February 14, 2002

Tech cell: For CEOs


Learning to adapt: Fabricator adapts to changing manufacturing environment

Production Cutting Services opened for business in 1985 as a service

Publish date: September 1, 2009

Tech cell: For CEOs


Supply chain collaborates on bending project: Planning, cooperation keep project on schedule despite short time frame

Faced 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.

Publish date: March 1, 2010

Tech cell: For CEOs


All eyes on Dusseldorf: TUBE® expo hints at things to come

The timing of the previous TUBE expo in Dusseldorf was nearly perfect. The industrialized economies were growing, oil was around $100 per barrel, and capacity utilization was healthy across the board. A few signs indicated trouble ahead, but it was a successful expo nonetheless. Now it is time for the 2010 show, and again the timing is good. Most of the industrialized countries have rebounded from the biggest financial crisis in 80 years, and many economists expect 2010 to be a big improvement over 2009. In addition, the tradeshow organizer has reported increased registration compared with the previous expo, and the TUBE exhibition space is sold out.

Publish date: March 1, 2010

Tech cell: For CEOs


Don't underestimate India: TPA tours the country that could overtake U.S. by 2050

TPA 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.

Publish date: June 12, 2007

Tech cell: Industry Trends and Analysis


Troubleshooting your stamping operation

A common thread runs through all effective troubleshooting approaches: the skill of observation. Learn to use it to your advantage.

Publish date: April 24, 2001

Tech cell: Press Technology


Using NDT systems to monitor welded tube production: Two methods are better than one

This article discusses the capabilities and limitations of the two most common online tube monitoring test methods -- eddy current and ultrasonic. It discusses the types of flaws that each is capable of detecting, and shows photographs of three typical flaws -- one that was detected by ultrasonic, one by eddy current, and one by both. It concludes by showing that both methods should be used to provide the most comprehensive testing of welded tube.

Publish date: November 15, 2001

Tech cell: Testing and Measuring


Technology modernizes CMMs: Hardware, software progress to enhance these shop tools

Coordinate measuring machines have progressed since their inception in the 1970s.

Publish date: July 11, 2002

Tech cell: Testing and Measuring


Rockwell hardness and Brinell testing of tube and pipe: Special factors merit attention to ensure proper results

The 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.

Publish date: November 15, 2001

Tech cell: Testing and Measuring


Monitoring the quality of welded tube and pipe

An 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.

Publish date: September 17, 2001

Tech cell: Testing and Measuring


Do you use checking jigs and fixtures?: An ounce of prevention is worth a pound of cure

How do you check tube fabrications to ensure they meet quality standards? Do you ship parts without checking them and hope that the next time the phone rings it isn't a prelude to a tirade from a disgruntled customer? Or do you check finished parts only to realize that your scrap rate is too high and wish you had checked them at earlier stages of the manufacturing process?

Publish date: July 10, 2003

Tech cell: Testing and Measuring


Error-free tube fabrication: Electronic sensing devices provide an ounce of prevention

Manufacturing processes are prone to variances, resulting in manufactured products that do not conform to specifications. Dozens of types of electronic sensors and measurement systems are available that fabricators can use to verify that their products are not defective. Understanding what types of sensors are available and how they work are the first two steps in implementing electronic sensing devices for quality control.

Publish date: March 13, 2007

Tech cell: Testing and Measuring


A primer on titanium tube and pipe: Applications abound for this versatile metal

This 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.

Publish date: May 16, 2002

Tech cell: Tube and Pipe Fabrication


Forming exhaust components with an alternative lubricant: Manufacturer cleans up with gel

Switching 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.

Publish date: September 12, 2002

Tech cell: Tube and Pipe Fabrication


Reviewing forming, expansion, and bending applications for welded tube

Tube used in production processes that form a part by expanding or bending the tube

Publish date: September 18, 2001

Tech cell: Tube and Pipe Fabrication


Focusing on tube cutting lasers: Tube fabricators, producers see the light

State-of-the-art laser technology for cutting metal tubes includes capabilities for cutoff, beveling, and cutting an infinite variety of shapes such as holes, slots, and notches. In this article, manufacturers of laser cutting equipment discuss the state of advancements such as automated loading and unloading of parts; simplified programming; automatedinspection of finished parts; and lights-out operation.

Publish date: November 7, 2002

Tech cell: Tube and Pipe Fabrication


CPR for your old CNC bender: Before you junk it, try rebuilding

In the 1980s, when CNC machinery evolved, tube fabricators made the transition from manually forming each part to allowing a machine to form the parts unassisted. Now in the age of Windows®-based computers and brushless electric servo drives, these machines can seem like relics. But don't take them to the scrap heap just yet.

Publish date: February 27, 2003

Tech cell: Tube and Pipe Fabrication


Quenching and tempering of welded carbon steel tubulars: Minimal process variations to obtain a uniform product

The quenching and tempering of tubes include a number of variables that can have a profound effect on the process and the finished product.

Publish date: July 29, 2001

Tech cell: Tube and Pipe Fabrication


Using precision abrasive wheel technology: Narrow niche, small parts, tight tolerances

Precision 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.

Publish date: March 13, 2003

Tech cell: Tube and Pipe Fabrication


Heating P91 boiler pipe: Induction heating gives contractor faster, more consistent results

In 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.

Publish date: March 13, 2003

Tech cell: Tube and Pipe Fabrication


Expanding Their Reach: Expandable Casing Pipe Helps Oil Companies Drill to New Depths

Expandable-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.

Publish date: June 27, 2002

Tech cell: Tube and Pipe Fabrication


Comparing materials for high-temperature steam piping: The use of X20 and P91 in power stations

Of 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.

Publish date: January 16, 2003

Tech cell: Tube and Pipe Fabrication


Say 'no!' to burrs, dimples: Competitors, customers drive finishing requirements

As 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.

Publish date: July 11, 2002

Tech cell: Tube and Pipe Fabrication


The basics of roll form tooling design: Understanding tube forming's not-so-distant cousin

You 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.

Publish date: March 27, 2003

Tech cell: Tube and Pipe Fabrication


Specifying the sulfur content of 316L stainless steel for orbital welding: Weldability versus surface finish

The 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.

Publish date: March 27, 2003

Tech cell: Tube and Pipe Fabrication


Making the connection: Substituting tube end forms for machined connectors

Hundreds 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.

Publish date: April 10, 2003

Tech cell: Tube and Pipe Fabrication


The anatomy of a monster truck

It drives right over nearly every obstacle in its path and splits nearly every eardrum in its vicinity. It's supercharged, oversized, and extraordinary. It stands more than 10 feet tall, develops more than 1,500 horsepower, and can leap over a 727 jet airliner in a single bound.

Publish date: April 24, 2003

Tech cell: Tube and Pipe Fabrication


Coating fabricating tooling

Tube fabricators all over the country are starting to see some major benefits from new coating technology. Many coatings-both those that are time-proven and new ones just hitting the market-can provide many benefits for many tube fabrication processes, including extended tooling life, better finished parts, and less stress on machinery.

Publish date: April 24, 2003

Tech cell: Tube and Pipe Fabrication


Producing holes in tubing: Comparing the piercing and punching methods

Need to put a hole in a tube? This article provides an overview of tube punching and tube piercing, exploring the different variations of each method and comparing the two methods on cost, safety, and flexibility.

Publish date: May 15, 2003

Tech cell: Tube and Pipe Fabrication


Inspecting welds on complex tube forms: Manual eddy current options

Many 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.

Publish date: May 15, 2003

Tech cell: Tube and Pipe Fabrication


Batter up! Turning an aluminum tube into a baseball bat

The roar of the crowd, the shouts of the umpire, the crack of the bat hitting the ball—these are the unmistakable sounds of a baseball game. Over the last few decades, however, one of those sounds has changed; now the bat tends to make a ping that resonates when it hits the ball. It's the sound of aluminum rather than wood making contact with the ball.

Publish date: May 29, 2003

Tech cell: Tube and Pipe Fabrication


Automotive motives - Tips for cutting per-piece prices for automotive customers

Today's automotive industry is more competitive than ever. To compete with the European, Mexican, and Asian markets, the U.S. market must become more aggressive in finding ways to cut costs.

Publish date: May 29, 2003

Tech cell: Tube and Pipe Fabrication


Waste not, want not: Array

By: Array
Array

Publish date: Array

Tech cell: Tube and Pipe Fabrication


The little-known life of the scarfing tool: Focusing on a small device to see the bigger picture

Who cares about scarfing tools? There are more important things in life. When the beauty pageant contestant is asked what problem she would like to solve, she's more likely to answer "I'd like to establish world peace" than "I wish I could find ways to help scarfing tools last longer."

Publish date: June 26, 2003

Tech cell: Tube and Pipe Fabrication


Designing an off-road sport truck

The main component in any off-road sport vehicle is the frame. Frames for mass-produced vehicles usually are stamped and welded. These are suitable for most drivers' needs, but for intense off-road driving and competitions, a sturdier frame is necessary.

Publish date: August 28, 2003

Tech cell: Tube and Pipe Fabrication


Pour me a mandrel: Bending tubes, pipes, and other forms with low-melting-point alloys

To 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.

Publish date: September 25, 2003

Tech cell: Tube and Pipe Fabrication


Zero to sixty in the blink of an eye

The 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.

Publish date: November 20, 2003

Tech cell: Tube and Pipe Fabrication


Selecting a welding frequency: Research on the optimal frequency for tube production

Early 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.

Publish date: December 11, 2003

Tech cell: Tube and Pipe Fabrication


Is your bend good enough?: Standards for hot and cold bending

Bending 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.

Publish date: July 13, 2004

Tech cell: Tube and Pipe Fabrication


Bending and handling tube: Tailoring equipment to an application

Three 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.

Publish date: July 13, 2004

Tech cell: Tube and Pipe Fabrication


Tips for welding preparation: How machine, materials, and tool bits affect the results

The 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.

Publish date: August 10, 2004

Tech cell: Tube and Pipe Fabrication


Lean times call for mean tactics—Part 1: A tube bender’s tools of the trade

Ron 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.

Publish date: September 14, 2004

Tech cell: Tube and Pipe Fabrication


Thinking about an equipment upgrade?: Laser systems offer flexibility from prototyping to production

Products change, and so do manufacturing methods used to make products. In the tube and pipe industry, however, manufacturing changes have been few and infrequent over the past few decades.

Publish date: September 14, 2004

Tech cell: Tube and Pipe Fabrication


Welding zirconium and zirconium alloys: Array

By: Array
Array

Publish date: Array

Tech cell: Tube and Pipe Fabrication


Selecting a tube cutting process: Methods and applications, pros and cons

Tube fabricators use a variety of methods—sawing, lathe cutting, rotary cutting, supported shear cutting, dual-blade shear cutting, and laser cutting—to cut tubing from mill lengths into shorter pieces for use in final fabrication. No single method is optimal for cutting the broad range of tubular materials and tubular shapes produced by this industry.

Publish date: November 9, 2004

Tech cell: Tube and Pipe Fabrication


Managing rotary-draw tube bending: Best practices minimize variation and downtime

Editor's Note: This article is adapted from a conference presentation made by the author at a previous TPJ Symposium.

Publish date: March 8, 2005

Tech cell: Tube and Pipe Fabrication


The basics of rotary cutting: Finding the right machine type and options

The 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.

Publish date: April 7, 1999

Tech cell: Tube and Pipe Fabrication


Making the cut: Array

By: Array
Array

Publish date: Array

Tech cell: Array


Fact or Friction?: Understanding lubricant types is key to best selection

Array

Publish date: Array

Tech cell: Tube and Pipe Fabrication


Titanium trends: Energy demand, titanium demand grow hand-in-hand

Electricity 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.

Publish date: March 9, 2009

Tech cell: Tube and Pipe Fabrication


Focusing on bent tubing: Making measurements using photogrammetry

Measuring 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.

Publish date: June 29, 2009

Tech cell: Tube and Pipe Fabrication


Manufacturing motorcycle mufflers: Fabricator finds improvement with rotary swaging

Array

Publish date: Array

Tech cell: Tube and Pipe Fabrication


Shaping profits with a mandrel extractor: The basics of mandrel extractors and their applications

Array

Publish date: September 1, 2009

Tech cell: Tube and Pipe Fabrication


Welding zirconium and zirconium alloys Part II: Part II: Welding technique, procedures, and quality testing

Like 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.

Publish date: April 11, 2005

Tech cell: Tube and Pipe Fabrication


Making the cut - Understanding rotary cutoff blades and extending blade life

The 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.

Publish date: May 1, 1999

Tech cell: Tube and Pipe Fabrication


Manufacturing motorcycle mufflers - Fabricator finds improvement with rotary swaging

Array

Publish date: September 1, 2009

Tech cell: Tube and Pipe Fabrication


Making a workhorse run: Getting the best performance from a vertical compression bender

Publish date: Array

Tech cell: Tube and Pipe Fabrication


No need for annealing: Tube benders find success with unannealed material

Publish date: February 10, 2010

Tech cell: Tube and Pipe Fabrication


Producing quality ASTM A249 and ASME SA 249 pressure tubes

Details are everything when you're manufacturing stainless steel pipe to exacting specifications.

Publish date: March 26, 2001

Tech cell: Tube and Pipe Production


Increasing tube mill welding speed: Examining technology for tube producers

This 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.

Publish date: October 25, 2001

Tech cell: Tube and Pipe Production


Accumulating strip before the mill: An introduction to entry end equipment

Publish date: September 4, 2001

Tech cell: Tube and Pipe Production


Exploring the welded tube making process: The basics for fabricators

This article is aimed not at tube producers, but at fabricators of tubing, to provide an overview of the process.

Publish date: May 30, 2001

Tech cell: Tube and Pipe Production


Skelp edge preparation for manufacturing ERW pipe

Preparing 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.

Publish date: May 30, 2001

Tech cell: Tube and Pipe Production


Maintaining a RF Tube and Pipe Welding Generator: How to find trouble spots

This article separates the RF generator into seven major subassemblies and then gives tips for finding and preventing problems in each subassembly.

Publish date: September 4, 2001

Tech cell: Tube and Pipe Production


Mastering the tool selection process: How to minimize production costs with the proper equipment

Need 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.

Publish date: October 11, 2001

Tech cell: Tube and Pipe Production


Presenting coil to a tube mill: Preparation of material for continuous operation

Tubemakers looking to improve operations at the front of the mill should consider factors such as coil preparation before feeding it into the tube mill—end joining, removal of overthickness, burr up/down condition, and accumulation.

Publish date: September 4, 2001

Tech cell: Tube and Pipe Production


Boosting efficiency in solid state welders: Improving weld mechanicals can make the difference

This 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."

Publish date: September 4, 2001

Tech cell: Tube and Pipe Production


Automated tube welding of heat exchangers: Converting from a manual process allows one company to increase production, expand projects

Harris 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.

Publish date: April 24, 2001

Tech cell: Tube and Pipe Production


Solving the mysteries of the fin pass—Part 1: Uncovering where, why and how

By: W.B.
The 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.

Publish date: April 10, 2003

Tech cell: Tube and Pipe Production


Solving the mysteries of the fin pass—Part 2

Editor's Note: This article is the second part of a two-part series about fin passes. Part I, which appeared in the March issue, discussed their location, what they do, and how they do it. Part II focuses on troubleshooting.

Publish date: May 15, 2003

Tech cell: Tube and Pipe Production


Minimizing wall thickness variation in seamless tubing

All mechanical steel tubing has some amount of wall thickness variation. Wall variation in welded tubing results from the strip manufacturing and tube welding processes. Seamless tube, which is created from a hot billet of solid steel, has wall variation that results from tooling wear, bearing and shaft variation, and normal hot-process variation. The wall thickness in seamless tubing varies in the cross section and along the tube's length.

Publish date: August 28, 2003

Tech cell: Tube and Pipe Production


Measuring tube as it grows and shrinks: Using girth changes to set up a tube mill

Publish date: August 28, 2003

Tech cell: Tube and Pipe Production


Six-axis tube laser adds new dimension to job shop

Since its founding in 1988 as a stamping job shop, the Kooima Co.'s equipment and services have evolved to meet the changing demands of its customers—always with the goal of providing them with one-stop shopping for all their primary metal fabricating needs.

Publish date: November 20, 2003

Tech cell: Tube and Pipe Production


Laser tube processing: Ten out-of-the-box techniques save money, spur innovation

The introduction of lasers to the manufacturing process has changed the fabrication of tubing. Today, many manual processes can be replaced with laser processing techniques. Using the flexibility afforded by lasers, a bundle of raw tubing can be loaded into a laser tube cutter; parts can be cut with high accuracy, quality, and speed; and then finished parts from the machine can be sent directly to the final assembly.

Publish date: November 20, 2003

Tech cell: Tube and Pipe Production


Pulling taffy and producing tube: Proper tension is a key to success for both processes

Publish date: December 11, 2003

Tech cell: Tube and Pipe Production


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?

Publish date: May 4, 2004

Tech cell: Tube and Pipe Production


Troubleshooting OCTG threading: Part II: Insert type impacts finished-surface quality, tool life, chip control

Publish date: May 4, 2004

Tech cell: Tube and Pipe Production


Optimizing your hydraulic cutoff press: Squeezing more out of your tube mill

Publish date: June 8, 2004

Tech cell: Tube and Pipe Production


MIAB welding of thick-walled pipe ends: Research finds ways to increase pipe thickness while maintaining quality

Publish date: July 13, 2004

Tech cell: Tube and Pipe Production


Certifying the quality of your tube and pipe

In 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.

Publish date: October 12, 2004

Tech cell: Tube and Pipe Production


Tension control in tube and pipe production: Getting it right for smooth, steady mill operation

Publish date: April 11, 2005

Tech cell: Tube and Pipe Production


Innovative die setup and maintenance methods for tube mill cutoff

Publish date: April 11, 2005

Tech cell: Tube and Pipe Production


Tube and pipe loading:: How one manufacturer made the process less hazardous

This 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.

Publish date: July 12, 2005

Tech cell: Tube and Pipe Production


Tube mill cutoff die setup for square and rectangular profiles

When 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.

Publish date: September 13, 2005

Tech cell: Tube and Pipe Production


Cutoff die setup for dimple-free rounds

With 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

Publish date: December 13, 2005

Tech cell: Tube and Pipe Production


Modern flying shear tube cutoff systems: Array

Array

Publish date: Array

Tech cell: Tube and Pipe Production


Troubleshooting Guide for Cleaners

Rust, 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.

Publish date: May 15, 2006

Tech cell: Tube and Pipe Production


Rotary straighteners for tube and pipe: An introduction to 6- and 10-roll straightening machines

Although 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.

Publish date: September 25, 2009

Tech cell: Tube and Pipe Production


Shopping for a new tube mill coolant?: It takes more than comparing price tags

Many 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.

Publish date: September 2, 2009

Tech cell: Tube and Pipe Production


Choices in flying cutoff saw blades: Friction versus carbide

Friction 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.

Publish date: December 2, 2009

Tech cell: Tube and Pipe Production


Modern flying shear tube cutoff systems - Part I: Mainframes

Modern 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.

Publish date: April 11, 2006

Tech cell: Tube and Pipe Production


Modern flying shear tube cutoff systems - Part II: Die set accelerators

This 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.

Publish date: August 8, 2006

Tech cell: Tube and Pipe Production


Using AC for Al: How alternating current is employed in orbital GTAW

Publish date: April 11, 2005

Tech cell: Arc Welding


TIG for titanium tubing: Success hinges on filler metal selection, cleanness, gas coverage

Although 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.

Publish date: October 28, 2008

Tech cell: Arc Welding


Trends in offshore energy: Training, technology help overcome skill shortage

The 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.

Publish date: July 28, 2009

Tech cell: Arc Welding


Robots and dials and knobs—oh my!: GMAW power sources have evolved over time

In the late 1950s, the U.S. Navy wanted to find a way to join heavy aluminum structural sections used to fabricate motor torpedo boat hulls.

Publish date: May 29, 2003

Tech cell: Automation and Robotics


Simulating a robotic workcell: Taking the guesswork out of automation

Not 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.

Publish date: March 8, 2005

Tech cell: Automation and Robotics


Don't throw away your profit margin

Publish date: April 6, 2004

Tech cell: Consumables


Examining electric resistance weld nuggets in tube and pipe: Using the microscope to study weld characteristics

An 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

Publish date: April 24, 2001

Tech cell: Resistance Welding