Automatic welding of pipes under a layer of flux (1974)

Large-diameter pipes.

Production line for such pipes.

Demonstration of automatic submerged arc welding of pipes.

Continuous supply of flux to the arc burning zone.

Cartoon explaining the welding process.

Feeding the welding wire to the welding site.

Cartoon explaining the effect of flux on the quality of welding.

Demonstration of pipes produced according to various automated technological schemes of automatic submerged arc welding.

Classification of pipes by type of seams.

Welding of pipes with one straight seam.

Magnetic loader transfers steel sheet to the welding line.

Roller table feeds the sheet into a nine-stand straightening mill.

In the straightening process, waviness and warping of the sheet are eliminated.

Straightened sheet is fed to the beveling machine.

In the planing process, the sickle-shaped side edges of the sheet are eliminated and strict parallelism is ensured.

In the last stand of the planing machine, four cutters remove chamfers for welding.

The sheet is cleaned of chips.

The sheet is fed to the edge bending mill.

In each of its three stands, the side edges of the sheet are gradually bent by rollers to a given radius.

Forming of tubular blanks on hydraulic presses.

Preliminary forming.

Final forming.

Edge offset parameters.

Formed blanks are fed to continuous welding mills.

Drive for advancing blanks at the welding speed to the welding mill.

Guide knife.

Side vertical rollers, which finish forming the blank, provide the gap size necessary for welding and the accuracy of the edge passage under the welding machine.

The welding machine of the mill feeds two electrodes into the welding zone.

Cartoon showing and explaining the welding process.

Seam defects when increasing the welding speed above 120 m/hour.

To prevent such defects, the first electrode is given oscillatory movements across the seam axis.

The welded joint is performed in two stages.

The outer seam is welded.

Cartoon explaining this stage of welding.

The pipe with the welded external seam enters the cleaning unit, where the seam is cleaned of slag crust and flux residues.

The pipe is transported to a through-pass mill for welding the internal seam.

A double-arc welding machine is fixed to the console of the mill.

The cartoon demonstrates welding of the internal seam.

After welding is completed, the pipe is fed to a hydraulic unit for cleaning the internal surface of slag crust and flux residues.

Finishing section.

Sheet metal products in the forming section.

Formed semi-cylinders are transported to the assembly section.

In the assembly unit, each pair of semi-cylinders is aligned along the length, aligned along the side edges and fed by a pusher to a continuous mill for welding the first external seam.

Three-arc welding machine.

Cartoon explaining the operation of such a machine.

After welding the first seam, the workpiece goes to the tilter.

Then it is fed to another mill for welding another external seam.

A through mill, where the internal seams are welded one by one by a two-arc machine.

The welding modes are the same as for pipes with one seam.

Finished pipes are sent for finishing.

Welding of pipes with a spiral seam.

Rolled metal products are fed to the pipe welding unit.

The unit's uncoiler, where the end of the strip is separated from the roll by a hydraulic knife.

The end is tucked into the straightening mill and fed to the guillotine shears.

After trimming along the transverse edge, the strip is fed to a moving welding machine, where the end of the previous strip and the beginning of the next strip are aligned along guides and secured with hydraulic clamps.

The machine's automatic welding unit joins the ends of the strips along the transverse edge on the move using submerged arc welding.

When welding is complete, the hydraulic clamps are lifted.

The machine returns to its original position, and the strip is moved to the edge trimming unit.

Disc shears trim the craters of the butt seam and the crescent shape of the side edges of the strip, and mechanical crumblers crush the trim.

The chamfers for the seam are removed with milling cutters.

The strip is cleaned of chips and dirt.

A four-roll feed machine with a hydraulic clamping device creates a force for deforming the strip into a pipe blank.

Cartoon explaining the forming of a pipe.

Roller-roller forming unit and rotary platforms providing the required forming angle, in combination with a powerful feed machine allow forming and welding pipes up to 1420 mm in diameter at a speed of up to 120 m/hour.

Welding unit.

Cartoon explaining pipe welding with three welding machines.

Plasma cutter for cutting pipes to measured lengths.

The pipe is sent for finishing.

Workshop where finishing operations are carried out.

Plasma cutters cut the ends of straight-seam pipes.

A single-cutter semiautomatic machine removes chamfers on the ends of pipes.

The ends of straight-seam pipes subject to calibration are processed on milling machines.

Pipe calibration on hydraulic expander presses.

Cartoon explaining calibration.

Pipes with a spiral seam.

Such pipes are tested for maximum pressure.

Spiral and straight-seam pipes made of special steels undergo heat treatment, during which internal stress in the metal is removed, the structure of the near-weld zone and the weld is improved.

X-ray unit.

Continuous quality control of welded joints is carried out.

Defects are marked with paint markers.

Acceptance of pipes by the quality control department.

Each pipe is weighed, marked, and sent for shipment to the consumer.

Alternation of personnel from pipe production.