​Can High Frequency Pipe Welding Machine Achieve Zero-Defect Welding for 16mm Thick Stainless Steel Tubes?

When industrial aesthetics meet ultimate precision

        At the construction site of petrochemical storage tanks in Qingdao Port, ten blue welded pipe machines marked with the TENYES logo are roaring. These devices, specially designed for thick-walled stainless steel pipes, are rolling 16-millimeter-thick 316L stainless steel into perfect round pipes at a speed of 1.2 meters per minute. The blue light flashing at the weld seam testifies to a new breakthrough in China's high-end equipment manufacturing.

        "Three years ago, when we took on an order for cooling tubes at a nuclear power plant in the Middle East, the customer explicitly required that the X-ray inspection pass rate of the welds must reach 99.997%." Wang Jianjun, the chief engineer of TENYES, stroked the pipe that had just come off the production line. "At that time, the industry average was 98.5%. This 0.5% gap was like being separated by the Milky Way." This seemingly minor gap prompted the R&D team to re-deconstruct the physical process of high-frequency welding and ultimately achieve a revolutionary breakthrough in the design of induction coils.

        The predicament of traditional pipe welding machines is particularly prominent in thick-walled materials. A certain shipping group once reported: "When welding stainless steel over 8 millimeters with ordinary equipment, either the penetration depth is insufficient, leading to leakage, or overheating causes intergranular corrosion." TENYES 'solution adopts a three-stage dynamic focusing technology - the pre-heating zone uniformly heats the material to 650℃, the core melting zone precisely controls the gold temperature of 1450℃, and the post-holding zone prevents stress concentration through gradient cooling. This temperature curve control accuracy reaches ±3℃, which is equivalent to precisely throwing a ping-pong ball into a basket in a car traveling at 120 kilometers per hour.

        In the simulated extreme environment tests conducted in the Suzhou laboratory, the new equipment delivered an astonishing performance report: after continuously welding 2,000 meters of 16-millimeter stainless steel pipes, only two 0.03-millimeter micro-pores were found, and the defect rate was reduced by 98% compared to the industry standard. More importantly, all these tiny defects occur within a 5-millimeter range of the weld seam edge and can be eliminated through simple grinding, truly achieving "repairable zero defects".

        "We polish each welding parameter as if it were a work of art." Wang Jianjun opened the control cabinet, revealing a dense array of sensors. "This system collects 3,200 sets of data per second and can adjust 17 variables such as current, frequency and pressure in real time. Last year, at the pre-salt oilfield project in Brazil, the equipment worked continuously for 4,380 hours in an environment with a temperature of 55℃ and a humidity of 95%, and the strength of the weld seam remained at 112% of the base material."

        TENYES 'expectations for this device go far beyond technological breakthroughs. When our machines can stably produce aerospace-grade pipes, "Made in China" will truly have the say in high-end equipment. General Manager Chen Feng said at the commissioning ceremony. Behind him, a large screen was playing the inspection video of the German TUV certification body. In a liquid nitrogen environment of -196℃, the pipes welded by TENYES withstood 2,000 pressure cycle tests, and the crack growth rate was only one fifth of the EU standard.

The actual usage feedback confirms the value of the technology

        When CIMC Rafuji was building a semi-submersible drilling platform, it adopted the TENYES equipment. The welding of 2,000 meters of thick-walled pipes, which originally took 15 days, was shortened to 7 days and passed the acceptance of Det Norske Veritas in one go. Even more astonishing is the energy consumption data. "Project Director Li Wei pointed at the report," The power consumption per meter of welding has dropped from 4.2 kilowatt-hours to 1.8 kilowatt-hours. Calculated based on an annual output of 200,000 meters, the electricity bill alone can save 4.56 million yuan."

        In TENYES 'digital exhibition hall, a running pipe welding machine caught the attention of overseas customers. When the induction coil precisely sweeps over the stainless steel strip, the shape of the molten pool on the monitoring screen presents a perfect parabola. This is the digital twin system we have developed. "Engineer on-site demonstration," Customers can enter the virtual workshop through VR devices to simulate the welding parameters of different materials and wall thicknesses in advance, reducing the trial-and-error cost to zero." This technology has helped customers in 17 countries shorten the commissioning cycle by more than 60%.

        "We are taking on more difficult tasks." Chen Feng disclosed that the R&D team is currently working on the automated welding of 25-millimeter titanium alloy pipes. "This material costs more than gold per kilogram, and any minor defect can cause huge losses." But I am confident that within three years, TENYES 'equipment will enable titanium alloy pipes to be welded as reliably as ordinary steel pipes.

        Standing at a desk piled high with test reports, Wang Jianjun opened a yellowed notebook, which contained the parameters of the first-generation high-frequency welded pipe machine that he had recorded twenty years ago. At that time, we couldn't even afford temperature sensors. We had to rely on the experienced workers to judge the color of the weld seams with the naked eye. He gently closed the notebook. "Now our machine can sense a temperature change of 0.01℃. This is the romance of Chinese engineers - using the most cutting-edge technology to achieve the ultimate perfection."