Comprehensive Analysis of Six Major Steel Pipe Welding Processes

1. Core Process Performance Comparison

‌1. Spiral Submerged Arc Welding (SAWL)‌

‌Advantages‌:

Automated continuous welding with daily output up to 300 linear meters‌.

Weld strength exceeds base metal by 10%-15%, ideal for high-pressure transmission‌.

‌Limitations‌:

Suitable only for large-diameter pipes above Φ219mm‌.

Spiral seams increase inspection costs by 20% compared to straight seams‌.

‌2. High-Frequency Welding (HFW)‌

‌Advantages‌:

Welding speed reaches 60m/min, tripling traditional process efficiency‌.

Heat-affected zone (HAZ) limited to 0.5-1.2mm, minimizing material degradation‌.

‌Limitations‌:

Equipment investment exceeds ¥8 million, uneconomical for small batches‌.

Requires ultra-clean strip steel edges (impurities ≤0.01mm)‌.

‌3. Gas Tungsten Arc Welding (GTAW)‌

‌Advantages‌:

Smooth weld appearance without secondary polishing‌.

Compatible with titanium alloys and specialty materials‌.

‌Limitations‌:

Labor costs exceed 40%, with skilled welders producing only 15 meters daily‌.

2. Key Technical Parameters

3. Typical Application Scenarios

‌Offshore Drilling Platforms‌:

Prioritize SAWL for 18% higher circumferential stress capacity vs. straight-seam pipes‌.

Recommend X70+ high-strength steel to extend service life to 25 years‌.

‌Urban Gas Pipelines‌:

HFW reduces total costs by 32% compared to conventional methods‌.

Adopt 3PE anti-corrosion coating + HFW, achieving annual corrosion rate <0.03mm‌.

4. 2025 Industry Trends

‌Smart Manufacturing‌:

Weld tracking systems achieve ±0.02mm positioning, reducing defect rates to 0.15‰‌.

Digital twin technology cuts trial welding iterations by 70%‌.

‌Sustainability‌:

Low-fume welding wires reduce harmful emissions by 85%‌.

Waste heat recovery systems improve energy efficiency by 40%.