Press release
The Complete ERW Pipe Manufacturing Process Explained Step-by-Step
Introduction
Electric Resistance Welded (ERW) pipe [https://www.cortecsteel.com/erw-electric-resistance-welding-pipe-product/] has become an essential part of modern industry due to its strength, uniformity of properties, and ease of production. However, how does a flat strip of steel become a high-integrity pipe with no filler metal? This guide will take you through the modern High-Frequency ERW manufacturing process and explain essential processes with key parameters, and quality-checking at each stage.
ERW Manufacturing: Key Stages and Quality Control
Stage
Step-by-Step Process
Critical Parameters / Quality Checks
1. Uncoiling & Slitting
A master steel coil is unrolled and cut by rotary knives into narrower strips of a precise width.
Strip Width Tolerance ( plus-minus 0.2mm); Edge Quality (No burrs).
2. Forming
The flat strip is passed through a series of rollers that progressively bend it into a round, open-seam tube.
OD and Roundness Control; Seam Gap Alignment.
3. Welding
A high-frequency (HF) current (100-800 kHz) is induced on the strip edges, heating them to a plastic state.
HF Power & Frequency; Welding Temperature Monitoring.
4. Forging
Squeeze rollers apply immense pressure, forging the heated edges together into a homogenous weld seam.
Squeeze Pressure; Upset Formation.
5. Seam Treatment
Internal and external weld beads (upset) are removed (scarfed) by cutting tools for a smooth surface.
Scarfing Tool Condition; Surface Finish Inspection.
6. In-line NDT
The weld seam is immediately scanned by an in-line Ultrasonic or Eddy Current testing unit.
100% Weld Seam Inspection for Defects.
7. Sizing & Straightening
The pipe passes through more rollers to achieve final, precise diameter and straightness.
Final OD Tolerance (e.g., plus-minus 0.5%); Straightness (
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