WELDING PROCESS IN ROLL FORMINGMACHINE

Types of welding process in the roll forming machine:

Welded profile applications have been steadily increasing over the last 10 to 15 years, driven mainly by the automotive industry.As they look for ways to increase strength and reduce weight, automobile engineers continually research materials and forming processes to find the best combinations of part design, weight, and strength. To get a piece of this growing pie, roll formers need to consider manufactur ability and reliability. though many welding technologies use on tube and pipe mills, three have come to the front:

1.   tungsten inert gas (TIG) ，such as gas tungsten arc welding (GTAW)

2.  laser beam welding (LBW)

3.   high-frequency induction (HFI) ，such as resistance seam welding (RSEW-I). 

tungsten inert gas (TIG)	laser beam welding (LBW)	high-frequency induction (HFI)

These Welded technologies can divide into two groups, fusion welding and forge welding.    GTAW and laser are fusion welding technologies and HFI is a forge welding technology.

Fusion Welding Process: 

A fusion welding process in roll forming machine is a generic term for welding processes that rely on melting to join materials of similar compositions and melting points.For roll forming applications, a filler metal typically is not used.

1.GTAW generates an electric arc between a non-consumable tungsten electrode and the workpiece to produce the weld.  The weld area is protected from atmospheric contamination by a shielding gas, either a single gas or a mixture of gases.  GTAW sometimes call a "collapse" melting method, which implies that the weld puddle collapses back on itself as it solidifies.  Because of this, the effect of gravity is a concern for two reasons. 

2.Laser beam welding (LBW): it provides a concentrated heat source, allowing for narrow, deep welds and relatively high welding rates.   Like GTAW, LBW is a fusion process.   The three main components in a laser system are the beam generator, the beam delivery system, and the focusing optics.

Forge Welding Process:

Forge welding uses heat and a hammering or pressing process to make the joint.Although it is not necessary to actually melt the metal being joined, it is necessary to have sufficient forging squeeze pressure.

3.HFI welding uses the same principles as induction heating. It is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, where eddy currents are generated within the metal and electrical resistance to this current flow leads to heating of the metal.

Method Comparisons:

GTAW：The decision to use GTAW is driven by a few key points. First, the weld seam must be continuous and at the 12 o'clock orientation. If the limited speed capability is acceptable and equipment cost is a concern, then GTAW is generally the right choice. It is important to note that a GTAW mill can be upgraded to LBW without too much trouble. GTAW can be considered an intermediate step before transitioning to LBW. It's also possible to set up the mill so that it can be changed back and forth between GTAW and LBW.

LBW：LBW is the preferred method in situations where a continuous seam is not possible, where the seam is not oriented at 12 o'clock, or the joint required is not a butt joint. LBW is also useful in situations where GTAW speeds are too slow. LBW is clearly the most versatile method.

HFI：welding's biggest advantage is speed. If a continuous seam is possible and no other factors limit the welding speed, then generally HFI is the right choice, especially if the application calls for high-volume production.

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