Manufacturer of tube and pipe production equipment Thermatool Corporation has announced the release of its HAZControl technology for high-frequency tube and pipe welding.
The company notes that the tool helps oper- ators understand the effects of frequency on the heat-affected zone of a weld. Frequency is an important factor in weld quality and by controlling this, manufacturers are able to control the depth of penetration of the heat during welding.
Decreasing the frequency increases the heat penetration for induction and contact welders.
HAZControl technology includes software that requires operators to enter values, such as intended speeds, outside diameters and wall thicknesses. It then uses a graphical interface to help the user understand how the different factors relate and provides a guide for selecting the best frequency to improve the process.
If any changes occur, for example, an increase in mill speed, the HAZControl technology suggests to the operator the changes which should be made to power or frequency to maintain the weld quality.
Operators can store the settings once an optimum configuration has been established. These settings can be reloaded for future production runs.
HAZControl features a durable control cabinet, touch-screen monitor and all the necessary attachments for linking it with a Thermatool welder.
Meanwhile, small-diameter, heavy-wall mechanical tubing applications continue to increase, particularly in the automotive, recreational vehicle, agriculture and garden machinery sectors.
Typical applications include the manufacturing of car headrest restraints, seat frames and side-impact systems. Commercial considerations are such that this type of tube needs to be produced at mill speeds that are economically viable.
“Often considered to be the hardest tube to weld, many producers simply have no option other than to apply excessive weld power to achieve a weld. “This is far from ideal and will deliver ‘blue’ tube at best, or a major increase in scrap in extreme cases.”
‘Blue’ tube refers to a whole tube section being heated, rather than just the weld area.
“This is not the case for mills that feature the latest-generation Thermatool high-frequency welders fitted with patented HAZControl technology, which is designed to provide precise, independent control of weld power and weld frequency on each and every mill run,” states Thermatool.
To achieve higher mill speeds and increased productivity, the weld conditions must also be improved and the correct selection and positioning of both the work coil and the impeder are essential, as is the installation of correctly sized squeeze rolls.
HAZControl technology enables the mill operator to store product process parameters for all types of tube, including small-diameter or heavy-wall tubes, providing quick and easy automatic operation on future mill runs.
The technology is suitable for difficult-to-weld products, such as small-diameter or thick-wall tube. It enables mill operators to start at a higher weld frequency and then reduce it to a point where the most appropriate weld properties are obtained, or to just above the point where the impeder begins to lose its magnetic properties.