Stage 1: Premium Material Selection
Our process begins with carefully sourced steel coils from certified mills. These coils undergo rigorous quality checks for chemical composition and mechanical properties before entering production. Using state-of-the-art uncoiling equipment, we gently unwind the steel while maintaining optimal tension to prevent material stress or deformation.
Stage 2: Precision Forming
The flat steel strip travels through our computer-controlled forming mill, where a series of precisely calibrated rollers gradually shape it into a cylindrical form. Our proprietary forming technology ensures perfect geometry while minimizing residual stress - a critical factor in pipe longevity. The edges are meticulously prepared for welding with our edge-trimming system that maintains perfect alignment.
Stage 3: Advanced Welding Process
At the heart of ERW production lies our high-frequency induction welding system. As the formed strip edges meet, they're heated to exact fusion temperature (typically 2,600-2,800°F) through electrical resistance, then forged together under controlled pressure. This creates a seamless bond stronger than the base material itself. Our real-time ultrasonic monitoring system ensures every inch of weld meets strict quality standards.
Stage 4: Precision Sizing & Shaping
Freshly welded pipe enters our sizing mill where computer-controlled rollers achieve perfect dimensional accuracy. This multi-stand reduction process precisely controls outer diameter, wall thickness, and roundness to meet exact specifications. Our advanced technology can produce pipes from 1/2" to 24" diameters with wall thicknesses from 0.5mm to 25mm.
Stage 5: Cutting & Finishing
The continuous pipe is cut to required lengths using our high-speed flying saws, capable of making perfect square cuts at production line speeds. Each length undergoes straightening, hydrostatic testing, and non-destructive examination. We offer various finishing options including varnish coating, galvanization, or beveling for specific applications.
Quality That Never Compromises
Every production batch undergoes rigorous testing including:
- Ultrasonic flaw detection
- Hydrostatic pressure testing
- Mechanical property verification
- Dimensional accuracy checks
Our ERW pipes deliver exceptional advantages:
✓ 15-20% stronger than comparable seamless pipes
✓ Consistent wall thickness for reliable performance
✓ Superior dimensional accuracy for easy installation
✓ Cost-effective production with minimal material waste
From residential plumbing to offshore oil platforms, our ERW pipes provide reliable performance in the most demanding environments. Contact our engineering team today to discuss how our precision-made ERW pipes can optimize your next project - visit our website for your customized piping solution.
Learn more about ERW Pipe Manufacturing Process and Applications