Welded profile applications have been increasing over the past 10 to 15 years, mainly driven by the automotive industry. Although there are many welding techniques used by pipe mills, three are at the forefront:
1. Tungsten inert gas shielding (TIG), such as gas tungsten arc welding (GTAW).
2. Laser beam welding (LBW).
3. High frequency induction (HFI), such as resistance seam welding (RSEW-I).
These welding techniques for roll forming machines can be divided into two categories, fusion welding and forge welding. GTAW and laser are fusion welding techniques, and HFI is forge welding techniques.
1. Fusion welding process:
The fusion welding process in a roll forming machine is a general term for welding processes that rely on melting to join materials with similar compositions and melting points.
GTAW creates an arc between a non-consumable tungsten electrode and the workpiece to create a weld.
The welding area is protected from atmospheric contamination by shielding gas (single gas or gas mixture). GTAW is sometimes referred to as a "collapse" melting method, which means that the molten pool collapses on its own as it solidifies. Therefore, the effect of gravity is a concern for two reasons.
Laser Beam Welding (LBW): It provides a concentrated heat source, allowing for narrow, deep welds and relatively high welding rates. Like GTAW, LBW is a fusion process. The three main components in a laser system are the beam generator, beam delivery system, and focusing optics.
2. Forging welding process:
Forge welding on a roll former uses heat and a hammering or pressing process to create the joint.
HFI welding uses the same principles as induction heating. It is the process of heating a conductive object (usually a metal) by electromagnetic induction, where eddy currents are created within the metal and the resistance to this current causes the metal to heat.
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