Inconel / Incoloy Welded Pipe

WWhat are Inconel and Incoloy welded pipe, and what are their main characteristics and applications?

Inconel and Incoloy welded pipes are high-performance alloys renowned for their exceptional strength, corrosion resistance, and high-temperature capabilities. Inconel is a registered trademark of Special Metals Corporation, while Incoloy is a registered trademark of the International Nickel Company. Both alloys are primarily composed of nickel, with the addition of chromium, iron, and other elements to enhance their mechanical and chemical properties.

The main characteristics of Inconel and Incoloy welded pipes include excellent resistance to oxidation, corrosion, and high-temperature environments. These alloys maintain their strength and integrity even at elevated temperatures, making them suitable for applications with thermal stress and mechanical strain. They exhibit remarkable resistance to various corrosive agents, including acids, alkaline solutions, and seawater, making them ideal for applications in chemical processing, power generation, and marine industries.

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Inconel and Incoloy welded pipes find extensive applications in various industries. They are commonly used in oil and gas exploration and production, where they withstand harsh drilling environments and corrosive fluids. These alloys are employed in aerospace and aviation industries for components exposed to extreme temperatures and aggressive conditions. In addition, Inconel and Incoloy welded pipes are utilized to manufacture heat exchangers, furnace components, chemical processing equipment, and nuclear reactors.

How does the welding process for Inconel or Incoloy pipes differ from other types of welding, and what are some key considerations for successful welding?

The welding process for Inconel and Incoloy pipes differs from other types of welding due to the unique properties of these high-performance alloys. One of the key considerations is the selection of appropriate welding techniques and filler materials to ensure a successful weld.

Inconel and Incoloy alloys have high melting points and are prone to cracking and distortion during welding. Therefore, precise control of the welding parameters, such as heat input and cooling rates, is crucial. Typically, Tungsten Inert Gas (TIG) welding or Gas Tungsten Arc Welding (GTAW) is preferred for welding Inconel and Incoloy pipes because it provides a stable and controlled welding environment.

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Electric Resistance Welding (ERW) Process

Pipe is created using the Electric Resistance Welding (ERW) process by cold-forming a flat steel sheet into a cylindrical shape. The steel is then heated to a degree at which the edges of the steel cylinder are pressed together to establish a bond without the use of welding filler material.
Several Electric Resistance Welding (ERW) processes are available for pipe production. The two main types of ERW are:
. High Frequency Welding
. Rotary Contact Wheel Welding.

High Frequency Welding

In high frequency induction welding, a work coil is placed in front of the weld spot and acts as a conduit for the weld current to reach the material. Work coil does not come into contact with pipe. Through the magnetic fields that surround the pipe, an electrical current is induced into the pipe's substance. When changing pipe size, high frequency induction welding avoids contact marks and requires less setup time.

Rotary Contact Wheel Welding

The electrical current is passed through a contact wheel at the weld spot in rotary contact wheel welding. A portion of the forge pressure required for the welding process is also applied by the contact wheel. AC, DC, and square wave are the three primary types of rotary contact wheel welders. Electrical current is transferred in all three power supplies by brush assemblies that interact with slip rings attached to a revolving shaft that holds the contact wheels. The current is sent to the strip edges through these contact wheels.

Submerged Arc Welding (SAW) Process

A constantly fed bare wire electrode and the workpiece form an arc during the submerged arc welding (SAW) process. To produce protective gases, slag, and to add alloying components to the weld pool, the procedure requires a flux. Using a shielding gas is not necessary. Excess flux is recycled via a hopper as the arc advances along the joint line. After welding, any remaining layers of fused slag are simple to remove. The arc is generally invisible during welding because the flux layer totally covers it, and heat loss is also very minimal. In contrast to the manual metal arc's 25% thermal efficiency, this one can reach 60%.
There are two types of Submerged Arc Welding (SAW) processes:
. Longitudinal Submerged Arc Welding (LSAW) Process
. Spiral Submerged Arc Welding (SSAW) Process

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