Electric Resistance Welded Tubing

(Low Frequency Resistance Welding)

High Frequency Induction Welding

ERW & High Frequency Welding

Lesson Objectives
When you finish this lesson you will
understand:
The difference between low
frequency Electric Resistance Welding
and High Frequency Welding
Applications of each

Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. Do on-line
workbook
5. Do Homework

Keywords
Electric Resistance Welding, High Frequency Welding, Tube
Welding, Proximity Conductor, Induction Coil, Induction
Current, Impeder, Seam Annealing

Resistance Tube Welding (ERW)

W. Stanley, Resistance Welding

McGraw-Hill, 1950

The Making Shaping & Treating of Steel,

USS Corp, 1964

The Making Shaping & Treating of Steel,

USS Corp, 1964

Current Flow in a conductor as a

function of Frequency

DC

60 HZ AC

KiloHertz AC
High Frequency

High Frequency
Induction Welding

Appreciating Hig-Frequency Welding

Welding Journal, July 1996

Metals Handbook, Vol 6

ASM International, 1983

Impeder Inside the

Core Promotes
Path ADC

Linnert, Welding Metallurgy

AWS, 1994

High Frequency Welding

Applications
HF

Induction Coil

HF

HF

Tube Butt SeamTube Butt Seam

Tube Mash Seam

[Reference: Welding Handbook, Volume 2, p.653, AWS]

High Frequency Welding

Applications (CONT.)
HF
HF

Strip Butt
HF

T-Joint
HF

Spiral Tube Fin

Spiral Tube
[Reference: Welding Handbook, Volume 2, p.653, AWS]

High Frequency Welding

Applications (CONT.)
HF

Induction
Coil

Projection Seam

HF

HF
Pipe Butt

Bar Butt

[Reference: Welding Handbook, Volume 2, p.653, AWS]

AWS Welding Handbook

Typical Tube Welding Conditions for Steels

30 m/min (100 ft/min)at:

600 kW power for
12 mm-wall (1/2 in);
diameter of 200 - 1200 mm (8 - 48 in)

60 -240 m/min (200-800 ft/min)

100-400kW power
0.6 - 1.6 mm walls (0.025 - 0.065 in)
diameter of 25 - 50 mm (1 - 2 in)
Note high speed

Frequency KHz
Meter

Current Penetration Depth, in

Metals Handbook, Vol 6

ASM International, 1983

Circuitry & Control

Control Devices
Input Voltage Regulation
SCRs control input voltage constant
Filters used on rectifier output to reduce ripple
Variations cause intermittent fusion stitching
Speed Control
Feedback Control on weld power as a function of mill speed
Reduces scrap on start and stop
Weld Temperature Control
Optical Pyrometer aimed at v adjusts weld power

460 V
60 Hz

DC
Reduce
Ripple
50 - 65% Efficient

Solid State

Circuit Made of Three

Components
Filter
Tube or SS HF Converter
Tank Circuit

AWS Welding Handbook

>80% Efficient

HF Resonance
Circuit

Ep
AC/DC Converter

Grid
Feedback
Circuit

Ip=Plate Current
Ig= Grid Current
Ep= Plate Voltage

Ip
Ig

Eff

Ip (onload) Ip (offload)
Ip (onload)

If Efficiency is Below 55% Modifications are needed

Nominal Target =75%
Ishizaka, HF Resistance Seam Welding,
The Fabricator, Nov 1993

Efficiency Improvements Can Come From Two Sources

The Power Circuit

The Workpiece Arrangement

HF Resonance
Circuit

Ep
AC/DC Converter

Grid
Feedback
Circuit

Ip
Ig

Proper Matching
Relationship between the plate voltage and plate current; and
the relationship between plate voltage and grid current are
nearly coincident with the rated impedance line.

Ishizaka, HF Resistance Seam Welding,

The Fabricator, Nov 1993

HF Resonance
Circuit

Ep
AC/DC Converter

Grid
Feedback
Circuit

Ip
Ig

Overload Matching
Occurs when load impedance is too small in comparison
with the rated impedance
Increase the turns ratio
of current transformer
Reduce tank
capacitance
Ishizaka, HF Resistance Seam Welding,
The Fabricator, Nov 1993

HF Resonance
Circuit

Ep
AC/DC Converter

Grid
Feedback
Circuit

Ip
Ig

Light Load Matching

Reduce the turns ratio

of current transformer
Increase tank
capacitance
Ishizaka, HF Resistance Seam Welding,
The Fabricator, Nov 1993

Current flows more to edge when

Edges are closer
v length is shorter

Caution: Can get Premature Arcs

 Insert Impeder
Impeder Mass Closer to Tube
Cool Impeder

Effect of Weld Speed on Power and Performance

Power = E*I
B = Fixed Power (losses etc)
A*Sp = Weld Power

U=The relative power B:A

B has less of an effect at
higher travel speeds

Induction Coils
Cu Tubing or Bar
Normally water cooled
Surround = efficiency
Mag. Strength reduces
with distance = 1/8 - 1
inch between coil and
work

AWS Welding Handbook

Contacts
Cu or Hard Cermets
0.25 - 1 in2
500 - 5000 Amps
Cooling required
5 - 50 lbs force
Life = 1K - 300K feet

AWS Welding Handbook

Impeders
(Current Flow Around inside Surface of
Tubes can cause reduced efficiency. The
impeder increases the inductive
reactance around inside wall of tube.)

Ferritic Material
Cooled: keep below Curie Temp
Extend from v to 1 1/2 tube
diameters upstream of v

Mandrels
Used to treat inside weld bead shape or scarfing
Nonmagnetic Material like Austenitic SS (Impeders also needed)

Seam
Annealing

Robotron Web Site

Advantages of High-Frequency
Welding
Produce welds with very narrow heat-affected zones
High welding speed and low-power consumption
Able to weld very thin wall tubes
Adaptable to many metals
Minimize oxidation and discoloration as well as
distortion
High efficiency

Limitations of High-Frequency
Welding
Special care must be taken to avoid radiation
interference in the plants vicinity
Uneconomical for products required in small quantities
Need the proper fit-up
Hazards of high-frequency current

Some Products of High-Frequency

Welding

[Reference: Welding Handbook, Volume 2, p.665, AWS]

HF Welding