1. Welding Quality Issues
1.1. Cracking at Welded Joints:
Cause: Stress concentration at the welded joints or poor welding quality, such as improper control of welding heat or mismatched welding speed.
Solution: Optimize the design of welded joints, strengthen welding process control, control welding heat, and preheat the welded joints.
1.2. Inclusion in Welds:
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 results in incomplete fusion of the weld.
Solution: Increase welding heat and reduce welding speed to ensure complete fusion of the weld.
1.4. 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 venting; adjust welding parameters to reduce the likelihood of gas generation.
1.5. Lap Welding:
Cause: Misalignment bonding formed when the two edges of the tube blank overlap, possibly due to axial movement of the extrusion rolls, bearing damage, bending of the extrusion roll shaft, or excessive extrusion pressure.
Solution: Check and adjust the positioning and condition of the extrusion rolls, replace damaged bearings, select appropriate hole shapes and roll 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 replace damaged motor components in a timely manner; ensure the motor load is within a reasonable range.
2.2. Wear of Mechanical Components:
Cause: Long-term operation of the equipment leads to wear of mechanical components.
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 clean blockages in a timely manner; replace damaged pump bodies or seals.
3. Process Control Issues
3.1. Improper Setting of Welding Parameters:
Cause: Unreasonable setting of 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 accurate parameters.
3.2. Improper Positioning of Induction Coil and Impedance:
Cause: The induction coil and impedance are positioned away from the optimal location, affecting welding results.
Solution: Adjust the position of the induction coil and impedance to their optimal working state; 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: Select qualified raw material suppliers, strengthen raw material inspection and acceptance; return and replace unqualified raw materials.
