Seamless tube manufacturing process- know about all process in brief

In this article, you will learn about the manufacturing of seamless tube manufacturing. The introduction of the advance rolling mill technology and its growth during the first 19th century also placed in the tube manufacturing industries. Toward the end of the century, different types of process are available for manufacturing of seamless tubes, hence the production process became available for the manufacturers. The production volume of tubes has increased due to its vast demand in the industrial and engineering sectors.

Below are some manufacturing processes of seamless tubes:

1# mandrel mill process

In this type of manufacturing process, a steel billet is heated and pushed to a forging process in the rotary furnace. It is induced in the cylindrical hollow which is also known as mother hollow. this is produced from the help of rotary piercer. The set of roller arrangement keeps piercer at the center of the steel billet. The OD is same approx that of the inside diameter of the finished tube. Due to the secondary roller arrangements outside diameters and thickness are achieved. In order to maintain temperatures, tubes are processed for reheating furnace that increases the temperature of the tubes.

2# forging process to manufacture seamless tube manufacturing:

In a Forging operation, a billet is heated and placed in forging die that has a somewhat larger diameter than a finished tube.  The hydraulic press has a forging hammer have the same inside diameter of the tube that is used to create cylindrical forging. After the forging operation, it is machined to achieve the desired dimension. Generally, the forging operation is used to produce large diameter stainless steel 304 seamless tubes that cannot be manufactured using standard operations. The forged tubes are used for high heating applications.

3# Extrusion operation for seamless tube manufacturing process:

It is the same as the forging operation, the heated billet is placed between the die. The hydraulic ram pushes the steel billet against the piercing mandrel. Hence, the billet passed from the cylindrical cavity between die and mandrel. This operation produces the billet to the tube. In some cases, tubes manufactured with a high thickness which is known as mother hollow cavity. Many manufacturers used the mother hollow to manufacture tube with the different dimension with extrusion operations.

4# Plug mill process:

This process was invented by German engineer Mannesmann. The main difference between a mandrel and plug mill process is that in mandrel process used to achieve the inside diameters. On the other hand, by plug mill process multi-stage reduction is possible. So the greater thickness reduction is achieved. In this process, the heat treatment process is performed.

The manufacturing material is processed from different heat treatment process such as normalizing, quenching, tempering, solution Annealing, stress relieving, and other combination of the heat treatment process. The finished tubes are processed from various quality test stages for quality assurance. Those tests include a hardness test, leakage test, compression test, mechanical test, PMI test, radiographic test, and IGC test. Other tests are pitting corrosion test, destructive test, ultrasonic test and more.

This is all about the manufacturing of seamless tubes.

Know about nickel Alloys and its resistance to corrosive environments

In 1751, the nickel (Ni) was discovered in Stockholm, Sweden by A.F Cronstedt and added to the periodic table. Nickel is a silver whitish metal that is found on sulfide and arsenic ores. It is derived by roasting to NiO and reducing the carbon elements. Carbonyl process is used to manufacture pure nickel grade. On the other hand, the impure nickel grade reacts with carbon monoxide to form Ni (CO) 4. This is subsequently decomposed at 200 deg C to succumb nickel alloy.

The pure nickel grade has resistance to corrosion in water or air. Thus, it is used as a protective coating. The nickel grade is malleable, ductile and readily soluble in dilute acids, however, the alkalis will not affect it.

The nickel grades are widely used, ranging from industrial to engineering applications. Mainly, the nickel grade is used as a constituent of different types of alloys. Additionally, these are utilized as a protective coating in the food and chemical processing industries. It is known as a carcinogen. Nickel is also an allergen to certain individuals. However, it is a part of many dietetic constituents, and hence cannot be removed easily.

The brief description of nickel alloy:

It is a commercially pure (CP) grade having the properties that are ideal for several fields, mainly in chemical processing and electronics applications. It has great resistance to many reducing chemicals and is matchless resistance to caustic alkalies. The commercially pure nickel has high thermal and electrical conductivity. The nickel alloys have higher core temperatures and also possess good magnetostrictive properties. In the annealed condition the nickel grade has a low hardness and good ductility and malleability. These properties are joined with great readability makes it highly fabricable.

Nickel Alloy is divided into 2 grade 200 and 201. Nickel alloy 200 Round Bars has a relatively low work hardening rate; however, it can be cold worked to achieve moderately high strength and maintains ductility. The nickel alloys have good mechanical properties and outstanding resistance to many corrosive environments. Some other salient features of an alloy are its magnetic properties, low gas content, low vapor pressure, and more.

The corrosion resistance of nickel alloys makes it particularly useful for maintaining product purity in the handling of synthetic fibers, and other demanding media. These are used in the structural applications where corrosion resistance is the prime issue.

The nickel alloy is considered as the superalloy due to its features offers to any application. These are easily alloyed with any types of alloying elements and enhance their properties. The nickel alloys offer great resistance to pitting and crevice corrosion cracking in the environments that contain warm chlorides. These can be exposed to elevated temperatures without any elongation and distortion.

The nickel grade offer service in the exposure of harsh chemicals such as nitric acids, sulfuric acids, phosphoric acids, and other harsh acids. Advantageously, these are inherent to the application in organic and inorganic compounds. In the mild cyclic environments, nickel alloys offer service while retaining its structure and offering less erosion. These are well suited for the chromium carbide precipitation range.

Types of steel pipes and uses in piping industries

 Since the manufacturing process has greatly changed and has become more complex. The industries are involved in producing a variety of ranges of pipes that suits the demands and requirement of the clients. There are many types and range of steel pipes available in the market that is offered by the companies.  All these types of steel pipes have different features and properties that make it useful as per its suitability.

Talking about the steel alloy, these consider carbon and iron including with a small percentage of other metals like aluminium, chromium, and nickel. Combining with other elements these steel pipes forms other ranges and types. Here are the types of steel pipes mention below-

Carbon Steel Pipes – These are a range of steel pipes that are designed from the proportion of carbon content adding up with iron content.  Similarly, carbon steel exhibits superior resistance to corrosion and durability. Apart from these are further categorized into four types based on the amount of carbon included in the alloy. These are low carbon steel, medium carbon steel, high carbon steel, and very high carbon steel. These pipes are extensively used in many industries basically in oil, gas transmission, automobiles, etc.  This pipe holds superb workability, ductility, strength and is safe to use.

Alloy Steel Pipes– By its name it suggests that these pipes are formed with a specified amount of other elements. The major alloying element, it includes is manganese, chromium, nickel, titanium, aluminium, and copper. This alloy steel pipe is considered a workhorse of many industries due to its extensive availability, inexpensive cost, and ease of processing.  Due to its exceptional performance properties, these are used in oil refineries, power generations, petrochemicals, chemical plants and in sugar mills. The addition of elements imparts superior corrosion resistance to pipes. Furthermore, it possesses good strength, ductility, mechanical properties and durability that enable to withstand in high-temperature circumstances.

Stainless Steel Pipes- These steel pipes have belonged to the family of steel that generally comprises 10 to 30% of chromium in addition to low carbon content. Furthermore, these include molybdenum, titanium, copper, nitrogen, aluminium and nickel content. This addition of content imparts superior useful properties that enhance superior resistance to corrosion and formability.  Therefore on the surface of the steel, the presence of chromium content creates a thin layer of the oxide that is known as the passive layer that provides great prevention from further corrosion.

These stainless steel 321H pipes exhibit superior resistance to crevice and stress corrosion cracking in elevated temperatures. To increase impact resistance and strength of the pipes these are properly heat treated. These pipes are used in various industrial applications such as pharmaceutical, oil and gas applications,  food production and in power generations.

 The manufacturing of these ranges of steel pipe is done with the use of high quality of raw material and with highly advanced machinery. These are the most common types and range that is utilized worldwide and are highly appreciable by the clients.

Temperature range of Stainless Steel 304 Vs 316

Stainless steel has good strength and good corrosion resistance ability in higher temperature environments. The most searched SS grade is 304 and 316, due to the prominent features it offers to the applications. These grades are extensively used in many application ranges from moderate temperatures to high temperatures such as superheaters, heat exchangers, valves and other heating applications. However, their heat capacities differ from each other that vary its properties.

Temperature range of 304 grades:

SS 304 grade is from the 300 series of austenitic stainless steel modified with controlled carbon chemistry for increased strength up to 1500 deg F. UNS S30400 is a unified numbering system of 304 grades. Generally, it is the modified version of 18/8 chromium and nickel base austenitic alloy. The carbon content present on it about 0.04 % to 10 % that increases its strength above 800 deg F. It is the most cost-effective and versatile alloy suitable for a wide range of applications.

Stainless Steel 304 Tubes has good resistance to atmospheric corrosion and many organic and inorganic compounds in moderately oxidizing to severe reducing conditions. It has the highest chromium content that provides resistance to oxidizing agents such as nitric acids up to 176 deg F temperature.

This grade also opposes harsh organic acids like acetic acids. In addition to the nickel, it offers resistance to moderate reducing solutions like phosphoric acids even in the higher concentration too. This grade can offer service in caustic solutions free of chlorides at nominal temperatures.

The hot working temperature of this grade is between 1652 deg F to 2102 deg F, the same temperature is recommended for the hot working process. In order to acquire maximum corrosion resistance, this grade is subject to the annealing process and quenched with water.

A higher concentration of chlorides, it is susceptible to pitting and crevice corrosion. The high molybdenum content is needed for the successful performance in the most severe conditions.  

Temperature range of 316 grades:

Alloy 316 (UNS S31600) /S31603) is chromium, nickel, and molybdenum austenitic stainless steel. It is designed for improved corrosion resistance in the high temperatures. These are often utilized in the process streams that contain halides and chlorides. In addition to molybdenum, its resistance ability to corrosion and pitting is enhanced. 316 grades provide excellent properties such as stress to rupture strength and tensile strength even in the hoisted temperatures. This grade is weldable with more standard techniques.

These are not corroded in process streams. SS 316 performs well in sulfur-containing environments such as that encountered in industries. This alloy can be utilized in higher concentrations at temperatures up to 120 deg F.

The working temperatures of this alloy are ranging from 1700 deg F to 2200 deg F. These are also subject to the hot working process at the same temperatures. The annealing process is performed at 1900 deg F to acquire higher corrosion resistance. These are also quenched with water.

So, these are the temperature ranges of stainless steel 304 and 316. Choose one as per your application suitability.

Phosphor Bronze: Its Properties and Characteristics

Phosphor Bronze, also known as tin bronze, is alloys made up of copper, tin and phosphorous and known for its strength, low coefficient of friction and toughness. The phosphor bronze contains between 0.5 and 11% tin and 0.01 to 0.35 % phosphorous. The addition of tin increases the resistance to corrosion and strength of the alloy. The phosphorous increases the resistance to wear and stiffness of the alloy. The phosphor bronze has superb spring qualities, resistance to high fatigue and corrosion, excellent formability and solderability. They are basically used for electrical products, corrosion resistant bellows, diaphragms, and spring washers. The phosphor bronze has to grades UNS C50100 through C54200. Leaded phosphor bronze combines good strength and resistance to fatigue, corrosion and wears along with good machinability.

Copper alone is not suitable for use in connectors because it is not elastic enough and loses its strength when held at the operating temperature of most electrical switchgear. Therefore Copper, in the form of an alloy has to be strengthened without unnecessary loss of electrical conductivity.

To remove oxygen Phosphorus is added to molten copper. The product of this deoxidation- Phosphorus pentoxide, is readily removed from the melt during the refining process. Any excess phosphorus goes into solution in the copper, where it provides some strengthening when the copper is cast and worked to a sheet. But phosphorus in solution reduces electrical conductivity dramatically. As little as 0.25% phosphorus will reduce conductivity to only 30% IACS, (International Annealed Copper Standard for the pure metal).  During the hot rolling stage of sheet production, too much phosphorus also causes problems. It is, therefore, a challenge, to maintain the amount of phosphorus at an optimal value to remove oxygen but keep it low enough to enable the material to be worked down to a sheet and still retain a relatively high electrical conductivity.

To strengthen the alloys Tin is added to conventional phosphor bronze. Like phosphorus, tin goes into solution in the molten copper and remains in solution in the solidified alloy. The maximum tin concentration that can be retained in solid solution is about 16%.

The tin content in this alloy determines the corrosion resistance and also gives it strength. Tin in solution produces two conflicting effects. Due to solid-solution strengthening, it increases the strength of the copper significantly. But the more the content of tin in solid solution the lower is the electrical conductivity. Fortunately, the effect of tin on electrical conductivity is less severe than in the case of phosphorus, and 1% of tin only reduces the conductivity to 60% International Annealed Copper Standard (IACS). Again, there has to be a balance, which depends on the cost of the material and the properties required.  If the tin content is above 2.5% the alloy becomes too expensive to process; if the content of tin below 1.5% the alloy lacks strength and the ability to retain strength at its operating temperature.

Hence, conventional phosphor bronze is a compromise, with optimum additions of phosphorus and tin to give as high strength as possible coupled with a relatively high electrical conductivity.

Properties and Characteristics

• Strength and resilience – phosphor bronze is an alloy which is resistant to fatigue. It holds up exceptionally well to wear. The inclusion of tin is what gives Phosphor bronze its added strength.
• Corrosion resistance – phosphor bronze is typically used in applications where it will have exposure to corrosive chemicals and/or physical elements.
• Electrical conductivity – the use of Phosphor bronze in electrical components is perhaps its most well-known application.
• Excellent elasticity – the fine grain size of this alloy enables the material to have a greater degree of spring back.

Features and Uses of Stainless Steel 316 Round Bars

Stainless steel 316 round bars are also known as UNS S31600 grade bars. It is chromium, nickel and austenitic SS build to provide enhanced resistance in moderately corrosive environments. These are often used in process streams containing halides and chlorides. It has some amount of molybdenum improved general corrosion and chloride pitting resistance. These bars provide higher stress to rupture, tensile strength and higher creep strength at hoist temperature too. It's common practice for 316 grade to dual certified. It has a lower carbon composition with the addition of nitrogen enable to meet the mechanical properties.

Stainless steel 316 round bars resist atmospheric corrosion in moderately oxidizing and reducing environments. These bars also resist corrosion in polluted salty waters. This grade has outstanding resistance to intergranular corrosion in welded condition too. These possess excellent strength and down the toughness at cryogenic environments. When these are annealed becomes non-magnetic in nature. However, it becomes slightly magnetic in nature when these are cold worked or welded.

These are easily weldable and processed by standard shop fabrication process. In most applications, this alloy has superior corrosion resistance to other conventional grades. In the cyclic mild environments, these are not corroded. Once exclusion, it is highly oxidizing such as nitric acid where it contains molybdenum content. These bars perform well in sulfur-containing environments that are encountered in paper processing industries. Alloy 316 can be utilized in higher concentration temperature up to 38 degrees C. These have good resistance to pitting in acetic and phosphoric acids. These perform well in 20% boiling phosphoric acids.

This grade is non-toxic and bio-compatible makes it ideal for food and pharmaceutical process industries. It is utilized to handle fatty acids and hot organic acids that lower product contamination.

Stainless steel 316 round bars performs well in fresh water even that contain a high level of chlorides. The higher composition of molybdenum content makes it superior pitting resistance to traditional grades in the application, including chloride solutions, particularly in adverse environments. For instance, the corrosion resistance level will be roughly equal to reducing climates. However, in a mild environment, it has sufficient resistance that causes intergranular corrosion of welds in the heat affected zone that is due to its lower carbon amount.

SS round bars are formed with hot or cold forging methods. The hot working temperature ranges between 927 to 1204 degree C. To achieve maximum corrosion resistance it is annealed at 1038 degree C and rapidly quenched with water or air. These bars are quite ductile and form easily. The cold working method will enhance its hardness and strength. These are easily weldable by most standard process. Post-welding heat treatment is not required. 316 bars are subjected to work hardening during manufacturing that leads in chip breaking. The best machining results are gained by slower feeds, speeds, lubrication and powerful tool.

Fabricated stainless steel 316 round bars are undergone with several testing for the maximum factor of safety. Some of those are buckling or crushing test, destructive/nondestructive test, mechanical test and more.

A Complete Guide on WHEEL BRUSHES for Car Operators

We all have seen that when dust gets to sit on car wheel for an extended period of time, the entire coating gets eaten up and this pit the metal. In this case, wheel brushes which are a tool that consists of bristles made of supple and soft wire get used. Some brushes make use of steel wire that is very springy and hard with high carbon content. Modern brushes are held together using staples, bindings, and epoxy. This is either followed by plastic or wood handle so as to form the base for usage on pistol-grip motors, angle grinders, bench grinders, and power tools.

If you travel too much and frequently then your car might have experienced tear and wear, this could decrease the productivity of the wheel. This article is the essence of Wheel Brushes. You will get to know what are they exactly, how they work and what are the advantages of it. In addition to these, type of brushes is also enclosed in it. So, read it till the end and buy the one that suits your need the most.

What are wheel brushes exactly?

·         Wheel Brushes are detailed brushes also known as rim brushes with durable bristle loop along with extra scrubbing for deep cleaning. The soft and supple brush bristles offer a gentle and smooth cleaning. The scrubber is used to lifts caked present on the debris. They contain a non-slippery handle that facilitates beaded thumb rest. The handle contains a hole for hanging or easy storage. It also offers a secure grip. There are many wheel brushes with rubber bumpers that assist the prevention and protection of vehicle while the cleaning process gets executed.

Modern technology and machine tools have presented wheel brush with different bristle length (in), product depth (in) and handle length (in) and height (in), width (in) respectively. Car wash brushes can be designed on the automotive part type of vehicle. This helps in deciding the bristle stiffness, bristle material color, and cleaning tool type.

All the wheel brushes present in the market is offered with a certificate and warranty period so that in case anything goes wrong, the user can directly claim for it.

Additional information on Wheel brushes-

Wire wheel brushes have a diameter in various ranges. It is the most widely and renowned wheel brush in carbon steel family and it has customizable sizes. They are supplied in numerous sizes based on the work as well as the finishing type the user requires. It has been manufactured for a long time from the tempered wire as it can sustain longer compared to un-tempered wheel brushes. The arbor hole of wire brush can be adjusted based as per standard hole. In addition to this bore size can be customized.

It can be supplied in stainless steel wire, brass wire in various sizes in accordance with specifications and drawing. It has the following applications- removes paint, rust, corrosion, and offers a clean surface. There are a lot more applications of it.

Basic use of wheel brushes:

It is solely incorporated as abrasive equipment that gets used only for removing paint and cleaning rust. The sole idea to use a wheel brush is to clean the surface and helps in the creation of a conductive area so as to perfectly attach electrical connections. The electrical connections may include connectors, car battery posts that quickly build or accumulate dirt and grime.

It is recommended to use a stainless steel brush when cleaning the steel rim. This is due to the fact that carbon steel brush has the ability to contaminate and this can result in rust spot appearance. On the soft surfaces, brass bristle brushes are made use of. It is necessary to wash all the hard dust and dirt so that no marring gets occurred. The wheel brushes are also utilized under the supervision of a flammable environment so that non-sparking tool requirement exists.

Wheel brushes have an application such as cleaning teeth of rims, casting paint. The origin of brushes is believed to originate from the Romans.

How to select a wheel brush?

Give below is a list of things that would enable you to know how you can pick up a good and reliable brush.

Material- Cross contamination is considered one among the biggest and deadliest concerns. It is advisable to use a carbon steel brush when the wheel is made of steel. On the other hand, stainless steel can be used on steel surfaces. For example, if you make use of carbon brush instead of stainless steel which is required, then the rimmed steel starts contaminating as well as oxidizes so as to form rust.

It is recommended to use a color- code and fabricated brush so as to make sure you don't make use of the wrong kind of brush. There are color-codes that indicate whether the particular brush type is carbon or stainless steel type.

Brush diameter and shape- wheel brush works awesomely on cleaning between the passes. Confined spaces can be cleaned up easily. The holes and other things can be cleaned easily. A good wheel brush would have a near-perpendicular or direct contact with the wheel surface that avoids chances of failure. The wire arrangements are done in such a way that can easily flare. This enables no hindrance in cleaning efficiently. Flaring can be controlled because the designer has built the wheel brush in that way.

Wire diameter- if you want a brush that resists fatigue and is flexible then a wire with a diameter up to 0.014 inches is the best. On the other hand, if you want a stiffer wire brush then go with a brush with a 0.025-inch diameter.

Wire style- the market is full of different wire brush types. Knotted or twisted and crimp style Brushes are some of those. You can as per the application and usage chose from any of the two.

Trim length- for more aggressive action, a short wire brush can be used. It is because it keeps the wire around circumference and dust can be easily removed.

Online suppliers of the wheel brushes are the best example of great brushes. If you wish to buy a high geometrical brush with lots of features, then visit online.