19. What problems are likely to occur in the production of high-frequency welded round tubes? How to solve it?

19.1. Welding quality problems
19.1.1. Cracking of weld joints:
Causes: Stress concentration at the welded joint or poor welding quality, such as improper welding heat control, mismatch welding speed, etc.
Solution: Optimize the design of welded joints, strengthen the control of welding process, control the welding heat, preheat the welded joints, etc.
19.1.2. Weld inclusions:
Cause: During the welding process, metal oxides or other impurities are not completely discharged and are trapped in the weld.
Solution: Adjust the welding parameters to ensure that the molten metal and oxides can be effectively discharged; Regularly inspect and maintain equipment to ensure a clean welding environment.
19.1.3. Insufficient Fusion:
Cause: Insufficient welding heat or too fast welding speed, resulting in the weld not fully fused.
Solution: Increase the welding heat, reduce the welding speed, and ensure that the weld is fully fused.
19.1.4. Stomatum:
Reason: During the welding process, the gas is not completely discharged, and the residue forms pores in the weld.
Solution: Improve the welding environment to ensure that the gas can be discharged smoothly; Adjust welding parameters to reduce the chance of gas generation.
19.1.5. Lap Welding:
Reason: The misalignment bonding formed by the two edges of the pipe billet stacked together may be caused by the axial tandem of the extrusion roller, the damage to the bearing, the bending of the extrusion roller or excessive extrusion force.
Solution: Check and adjust the positioning and status of the extrusion roller, replace the damaged bearing, select the appropriate hole type and roll seam retention, adjust the extrusion amount, etc.
19.2. Equipment failure problems
19.2.1. Motor failure:
Causes: Motor overload, overheating or aging, etc.
Solution: Regularly check the status of the motor and replace damaged motor components in time; Make sure the motor load is within a reasonable range.
19.2.2. Mechanical Component Wear:
Cause: Long-term operation of the equipment leads to wear and tear of mechanical components.
Solution: Regularly replace worn parts and strengthen equipment maintenance and maintenance; Reasonably arrange production plans to avoid overloaded equipment.
19.2.3. Oil Pump Failure:
Causes: clogged oil pump, oil leakage or pump body damage, etc.
Solution: Check the status of the oil pump regularly and clean up the blockage in time; Replace damaged pump body or seals.
19.3. Process control problems
19.3.1. Improper Welding Parameter Setting:
Reason: The welding current, voltage, speed and other parameters are unreasonable.
Solution: According to the welding material and specifications, the welding parameters should be set reasonably; Regularly calibrate and inspect welding equipment to ensure accurate parameters.
19.3.2. Improper Position of Induction Coil and Impedo:
Cause: The position of the induction ring and impedance is out of the optimal position, affecting the welding effect.
Solution: Adjust the position of the induction coil and impedance to make it in the best working condition; Regularly inspect and maintain equipment to ensure stable positioning.
19.3.3. Raw material issues:
Reasons: unstable mechanical properties of steel strips, surface defects or large deviations in geometric dimensions, etc.
Solution: Select qualified raw material suppliers and strengthen raw material inspection and acceptance; Return and exchange of unqualified raw materials.