1. Welding Quality Issues
1.1. Weld Joint Cracking:
Cause: Stress concentration at the weld joint or poor welding quality, such as improper welding heat control and mismatched welding speeds.
Solution: Optimize the weld joint design, strengthen welding process control, control welding heat, and preheat the weld joint.
1.2. Weld Inclusion:
Cause: Metal oxides or other impurities are not completely removed during welding and are trapped in the weld.
Solution: Adjust welding parameters to ensure effective removal of molten metal and oxides; regularly inspect and maintain equipment to ensure a clean welding environment.
1.3. Insufficient Fusion:
Cause: Insufficient welding heat or excessive welding speed, resulting in incomplete fusion of the weld.
Solution: Increase welding heat, reduce welding speed, and ensure complete fusion of the weld.
1.4. Gas Porosity:
Cause: Gas is not completely removed during welding and remains in the weld, forming porosity.
Solution: Improve the welding environment to ensure smooth gas exhaustion; adjust welding parameters to reduce the opportunity for gas generation.
1.5. Overlap Welding:
Cause: Misalignment bonding formed when the two edges of the tube billet overlap, potentially caused by axial movement of the extrusion roller, bearing damage, bending of the extrusion roller shaft, or excessive extrusion pressure.
Solution: Check and adjust the positioning and condition of the extrusion roller, replace damaged bearings, select appropriate hole shapes and roller gap allowances, and adjust the extrusion amount.
2. Equipment Failure Issues
2.1. Motor Failure:
Cause: Motor overload, overheating, or aging.
Solution: Regularly inspect the motor status and promptly replace damaged motor components; ensure that the motor load is within a reasonable range.
2.2. Mechanical Component Wear:
Cause: Long-term operation of the equipment results in mechanical component wear.
Solution: Regularly replace worn components, strengthen equipment maintenance; reasonably arrange production plans to avoid overloading the equipment.
2.3. Oil Pump Failure:
Cause: Oil pump clogging, oil leakage, or pump body damage.
Solution: Regularly inspect the oil pump status and promptly clean blockages; replace damaged pump bodies or seals.
3. Process Control Issues
3.1. Improper Welding Parameter Settings:
Cause: Unreasonable settings for welding current, voltage, speed, and other parameters.
Solution: Reasonably set welding parameters according to welding materials and specifications; regularly calibrate and inspect welding equipment to ensure parameter accuracy.
3.2. Misplaced Induction Coil and Impedance:
Cause: The induction coil and impedance are not positioned at the optimal location, affecting welding effectiveness.
Solution: Adjust the position of the induction coil and impedance to their optimal working states; regularly inspect and maintain equipment to ensure stable positioning.
3.3. Raw Material Issues:
Cause: Unstable mechanical properties of steel strips, surface defects, or large geometric dimensional deviations.
Solution: Choose qualified raw material suppliers, strengthen raw material inspection and acceptance; return and replace unqualified raw materials.
