TPT March 2025

The international magazine for the tube & pipe industries

ISSN 0953-2366

MARCH 2025

VOL 38 NO 2

US$33

Tube inspection, testing and quality control Advances in tube measuring and marking

The international magazine for the tube & pipe industries

ISSN 0953-2366

MARCH 2025

VOL 38 NO 2

US$33

max

min

4–8 Number of cameras

5 Min. object diameter (mm)

540 Max. object diameter (mm)

2000 Scan rate (scans/s)

10+ Years Over 10 years of successful PROFILEMASTER implementations

PROFILEMASTER® High Speed

Benefits:

Best measuring accuracy thanks to temperature-stabilized measuring systems New algorithms for surface inspection and defect detection Defect detection based on multiple maps and surface properties (reflectivity and intensity) Detects process problems at an early stage Quick maintenance and easy cleaning Profile measuring solutions with global references

In-Line Profile Measurement Systems for Hot / Cold Steel Applications with increased sampling rate up to 2kHz.

Zumbach Electronic AG | Hauptstrasse 93 | 2552 Orpund | Switzerland Phone: +41 (0)32 356 04 00 | sales@zumbach.ch | www.zumbach.com

INDEX Editorial

Alleima................................................ 50

Hexagon.............................................. 37

Sica..................................................... 20

AM-SYS GmbH & Co KG....................34

Friedrich Kocks GmbH & Co KG...........8

Sikora AG................................35, 40, 43

Boehlerit Group...................................21

Linsinger Maschinenbau.....................20

Sofratest.............................................. 31

Bültmann GmbH.................................19

Magnetic Analysis Corporation...........30

STHEMMA Srl.....................................19

Controle Mesure Systemes.................32

Metalube Group..................................17

Strohm. ............................................... 54

Corinth Pipeworks...............................50

Optris. ................................................. 36

TechnipFMC........................................ 51

CRC Evans.........................................27

Paul Leibinger GmbH & Co KG..........38

Tecnar................................................. 28

Dietronic Srl........................................10

Peninsular de Vástagos......................14

TRUMPF............................................. 23

ENRX.................................................. 18

Pipelife International GmbH................52

Unison Ltd...........................................14

Exel Composites Plc...........................55

Rafter Equipment Corporation............12

Welding Alloys.....................................57

Fives. .................................................... 9

RSA Cutting Technologies GmbH.......10

Xiris Automation..................................41

FOBA Laser Marking + Engraving......43

Scleros SpA........................................16

Zumbach Electronic AG................33, 37

Fraunhofer Institute.............................34

Septentrio............................................ 37

Zwick Armaturen GmbH......................51

Fronius................................................ 22

Severance Tool Industries Inc.............24

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MARCH 2025

PIPE BEVELLING MACHINE RFM FOR SPIRAL TUBES AND LSAW PIPES SIMULTANEOUS ON BOTH ENDS

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Inner copying tools Low-burr bevelling Simple, low-cost bevel geometry change-over #TRUST THE INVENTOR

CONTENTS

Editor

Rory McBride

Design & production

Lisa Wright

Sales & marketing

Jason Smith UK, Italy, USA, Canada, India & ROW jason@intras.co.uk Tel: +44 1926 834684 Linda Li Asia 亚洲 linda@intras.co.uk Tel: +44 1926 834685

2 Editorial index 8 Industry news 9 Diary of tube events 18 Technology news

Advertising co-ordinator

Liz Hughes

Subscriptions

Louise Jennings

Accounts manager

Louise Jennings

Web Design/Developer

Andrew Barnes

Social Media Administrator Milly Harrison

28 Tube inspection, testing and quality control 36 Advances in tube measuring and marking 44 Interview: Owen Gao, vice-president FD Machinery Company 64 Advertisers index 49 Tube Products INTERNATIONAL www.read-tpi.com The trade magazine for tube and pipe products www.read-tpi.com March 2025

Founder

John C Hogg

All rights reserved – © Intras Ltd ISSN 0953-2366

Published by Intras Ltd Unit 32, Tangent Business Hub,

Shirebrook, Nottinghamshire NG20 8RX UK Tel: +44 1926 334137 • Fax: +44 1926 314755 Email: tpt@intras.co.uk • Website: www.read-tpt.com

Intras USA Danbury Corporate Center, 107 Mill Plain Road, Danbury CT 06811, USA Tel: +1 203 794 0444 • Email: doug@intras.co.uk

This publication and its full contents of layout, text, images, and graphics is copyright protected. No part of this publication may be reproduced in any form or by any means, electronic or mechanical including photocopying, recording or any other storage or retrieval system without the publisher’s written permission. The publisher, owners, agents, printers, editors and contributors cannot be held responsible for and hereby exclude all liability whatsoever for errors, omissions or the accuracy and claims printed or inferred in the editorial or advertisements published in this, previous or subsequent editions or for any damages, costs or losses caused thereby. Tube & Pipe Technology reserves the right to edit, reword and subedit all editorial submissions in accordance with editorial policy. Tube & Pipe Technology expressed graphically or by text is a registered name and style trademark of Intras Ltd, UK. All matters relating to this disclaimer are governed by the laws of England. US Copies only: Tube & Pipe Technology (ISSN No: 0953-2366, USPS No: 023-507) is published six times a year: January, March, May, July, September and November by Intras Ltd and distributed in the USA by Asendia USA, 701 Ashland Ave, Folcroft PA. Periodicals postage paid at Philadelphia, PA and additional mailing offices. POSTMASTER: send address changes to Tube & Pipe Technology, 701 Ashland Ave, Folcroft PA 19032.

March issue • Business & market news • Wider tubes offer greater possibilities: how composites are advancing wide diameter tube development • Emerging tech shaping the landscape for European tube welding manufacturers

Photo credit: Racool Studio

60 ARTICLE

The latest trends in high frequency contact tube welding By Olexandra Tupalo, manager, Thermatool Labs

Tube & Pipe Technology magazine is available in print and online. Go to www.read-tpt.com for more information.

The Professional Publishers Association Member

When you have finished with this magazine please recycle it

The March Issue Welcome to the latest issue of

March 2025 Vol 38 No 2

Tube & Pipe Technology magazine. In this March issue we have features on tube inspection, testing & quality control; and advances in tube measuring & marking. We also have an interview with Owen Gao, who is the vice-president of FD Machinery Company.

Rory McBride – Editor

Mr Gao offers some fascinating insights into how the company was formed and some of the challenges it has overcome in recent years. He also talks about the many automation innovations the company has developed and offers advice to those who are just starting their career in the tube industry. You can read more on page 44. This month's technical article is from regular contributor Olexandra Tupalo from Thermatool Labs who writes about the latest interesting trends in high frequency contact tube welding (see page 60). The deadline for the forthcoming May issue is 10 April. We have features on tube mills & rollforming; tube bending, end forming & swaging; and environmentally friendly tube production. The Tube Products INTERNATIONAL section will have a focus on copper & aluminium tubes; and small diameter, high precision tubes. Please send any editorials or articles you would like to be included in the May 2025 issue of TPT magazine to: rory@intras.co.uk I hope that you enjoy the magazine.

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The international magazine for the tube & pipe industries

On the cover . . . Guild International offers a complete line of coil joining and end welding machines for almost any steel processing, tube producing or stamping application. Its line of patented equipment includes laser welders, arc welders and resistance welders. The Shearwelders™, Zipwelders™ and Laser Welders are some of the most technically advanced welding machines on the market. Guild International also produces a full line of tube mill VOL 38 NO 2 MARCH 2025

US$33

ISSN 0953-2366

entry equipment including uncoilers, speed funnels, flatteners and accumulators. Each one of these machines is designed and manufactured to improve the productivity of any strip processing line requiring coil handling and coil end joining and welding. Guild’s team of engineers are dedicated to helping customers assess and determine their coil end joining needs to ensure proper equipment design and compatibility with existing equipment. With thousands of installations around the globe, Guild International has the experience, know-how and manufacturing capability to help its customers stay competitive in today’s manufacturing environment.

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INDUSTRY

The Kocks PWW 530/4 for voestalpine Tubulars with 4-roll stands

Rolling mill for the production of seamless hollow sections supplied to tube company VOESTALPINE Tubulars, based in Austria, has successfully commissioned a profile rolling mill engineered by Friedrich Kocks GmbH & Co KG.

Following the completion of all work and successful commissioning, the new equipment is now fully integrated into the hot tube rolling mill at the Kindberg site in Styria. The award of the contract was preceded by an intensive technological discussion on the design and construction of a solution for rolling seamless hollow sections. The centrepiece of the profile rolling mill, called PWW 530/4, consists of four consecutive 530mm stands, each equipped with two horizontal and vertical rolls facing each other. These four rolls in the stands are individually driven. Based on Kocks’ proven 3-roll stand design, they feature calibre adjustment and allow for fast roll changes, providing high flexibility in production planning. The scope of supply also included the corresponding equipment for the roll shop. voestalpine Tubulars, with its extensive experience in the production of seamless round tubes, is now also capable of producing seamless, hot rolled square and rectangular hollow sections up to large formats and wall thicknesses. The Kocks Group, headquartered in Germany, is a global supplier of rolling mill equipment for sizing applications and was founded in 1946.

Friedrich Kocks GmbH & Co KG www.kocks.de

The Kocks 4-roll stand with individually driven rolls

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DIARY OF EVENTS

High performance OTO tube mills supplied for renewable

2025

energy market METALOGALVA, a leading European company in the steel industry, has strengthened its long-standing partnership with Fives to help it produce high performance tubes for the renewable energy and structural markets. As part of its medium-term sustainability strategy, the company entrusted Fives to design, supply and commission two OTO tube mills and a high-speed OTO cut-off for its MSS Steel Tubes production subsidiaries in Portugal and the USA. The first OTO tube mill was commissioned in March 2022 at the MSS Steel Tubes plant in Vila Nova de Famalicão, Portugal. The technology enabled the customer to produce high quality structural and solar tubes at a constant productivity speed. To further increase its efficiency, the company also ordered a high-speed OTO cut-off in 2023, which will be installed in the coming months. “This project is in line with Metalogalva’s strategic and sustainable development in the renewable energy industry, which is booming

11-14 March Global Industrie Lyon, France www.global-industrie.com 9-12 April Tube Eurasia Istabul, Turkey www.tube-eurasia.com

worldwide. Fives’ technologies have exceeded our expectations in terms of engineering and reliability. “That’s why we continue investing, not only in Portugal but also in the US, where demand is growing, with a preference for local production,” said Nuno Guimarães, purchase and logistic, Metalogalva. Thanks to these excellent results, Metalogalva once again entrusted Fives to supply a new OTO tube mill for its MSS Steel Tubes plant in Memphis, USA. The first tube was successfully produced in November 2024, marking an important milestone. “Our long-term partnership with Fives led us to again choose its fully automated solutions to achieve maximum productivity and ensure high quality standards. The collaboration between the teams has been excellent – from sales, project management, commissioning and after-sales. We are proud to have delivered another successful project together,” added Mr Guimarães.

6-9 May Lamiera Milan, Italy www.lamiera.net 6-8 May Made In Steel Milan, Italy www.madeinsteel.it

10-12 May China (Guangzhou) International Metal & Metallurgy Exhibition Guangzhou, China www.julang.com.cn

6-8 September Tube Middle East Africa Cairo, Egypt www.tube-mea.com 8-11 September FABTECH Chicago, IL, USA www.fabtechexpo.com 10-11 September UK Metals Expo Birmingham, UK www.ukmetalsexpo.com 17-19 September Tube Southeast Asia Bangkok, Thailand www.tube-southeastasia.com

Fives www.fivesgroup.com

Metalogalva once again entrusted Fives to supply a new OTO tube mill for its MSS Steel Tubes plant in Memphis, USA

22-27 September EMO Hanover, Germany www.emo-hannover.de

All shows are correct at the time of going to print, but are subject to change. Please check to ensure the event is going ahead

www.read-tpt.com

INDUSTRY

Coolant dryer system for clean tubes and profiles supplied by Dietronic

system offers a more efficient solution. The Coolant Dryer System consists of a rugged steel frame housing 4 x adjustable manifolds, 2 x in the vertical plane and 2 x horizontal. The manifolds create a uniform sheet of high pressure air across their entire length ensuring a completely dry surface on the product prior to oil application. Air supply to the manifolds is delivered from a PLC controlled blower. The blower is a special design that generates a series of vortexes from the centrifugal thrust of the impeller. No rotating parts inside the blower are in contact with the casing meaning internal lubrication is not required. The result is uncontaminated, oil free air is delivered directly to the manifolds. The system is quiet and vibration free. The blower system is recommended for the Antirust 12 model or for any mill predominantly producing square and rectangular profiles.

The system is an alternative to using conventional air knife technology to dry the pipe or profile prior to application of rust prevention oil. Round air knives are not as effective for square/rectangular profiles and larger pipe diameters, this is where the manifold blower

DIETRONIC offers multiple solutions for surface preparation and drying prior to the application of lubricant on the surface of metal products. This includes the removal of emulsion from the surface of pipes and profiles in-line and prior to cutting the product to length.

The system is an alternative to using conventional air knife technology to dry the pipe or profile prior to application of rust prevention oil

Dietronic Srl www.dietronic.eu

RSA Cutting Technologies acquires high precision sawing specialist

more comprehensive solutions and combine the innovative strength of both companies. With this acquisition, we will further consolidate our market position and guarantee customers of both companies a seamless continuation of the proven service,” he added. Spontan Trenn- und Entgrattechnik is known for its high precision and efficient sawing systems and deburring systems, which are used in various industries, including conveyor technology, steel stockholding and shop fittings. As part of this realignment, RSA is assuming responsibility for customer relationships and continuing its product development. Having acquired Schwarz Maschinenbau in 2024, RSA is continuing its growth with this strategic acquisition. RSA Cutting Technologies GmbH www.rsa.de

will remain the same for existing customers including the contact person, the companies said. Spontan Trenn- und Entgrattechnik GmbH will therefore continue to operate as an independent company in future. However, Spontan Trenn- und Entgrattechnik will benefit from RSA’s large modular system and will offer modules such as measuring, washing and various robot solutions in future. Both companies have been active in the same industry for many years and have established strong reputations. “The acquisition of Spontan is a logical step for us to expand our position in the market and utilise synergies resulting from previous collaboration,” said Thomas Berg, managing director of RSA cutting technologies GmbH. “The integration will enable us to offer our Spontan customers even

RSA CUTTING technologies GmbH, a manufacturer of deburring and sawing systems for metal processing, has acquired Spontan Trenn- und Entgrattechnik GmbH. The takeover builds on a previous collaboration when RSA and Spontan worked together successfully. Everything

Thomas Berg, managing director of RSA (right) at the signing of the contract

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SST Forming Roll, Inc. 1318 Busch Parkway, Buffalo Grove, IL 60089-4507 USA TEL: +1 (847) 215-6812 info@sstformingroll.com

INDUSTRY

Rafter Equipment Corporation merges with tube handling and finishing company to expand options for customers

RAFTER Equipment Corporation has merged with the Kraft Werks Group, which is an Ohio, US-based capital equipment manufacturer of tube and pipe handling and finishing

systems. It also offers heavy equipment used in the global power generation sector. The companies have joined forces to provide expanded tube and pipe equipment and installation solutions for their customers. By combining the complementary product offering Rafter now offers its customers a broad range of tube and pipe mill and roll forming equipment, including cut-off machines and tube and pipe handling and finishing equipment. In addition, by leveraging Kraft Werks’ expertise in large scale capital equipment installations and project management services, Rafter will be able to provide a complete turn-key solution to its customers, all under one roof and all based in the USA. Founded in 1917, Rafter’s aims to provide the highest quality tube mill and roll forming systems and after sales service and support possible.

Rafter Equipment Corporation www.rafterequipment.com

The RT-2000-7 HFI tube forming mill

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MAJOR PRODUCT: HIGH STRENGTH AND PRECISION STRAIGHT-SEAM WELDED PIPE MILL LINE WELDED SQUARE AND RECTANGULAR PIPE DIRECT-FORMING MILL LINE HIGH SPEED AND HIGH PRECISION SLITTING LINE

Add: Cross of Xinzhao Road and Shiji Road, R-1202 No.707, Lianmeng Road, Shijiazhuang, Hebei, China Website: www.kdsz.cc E-mail: info@hebeisz.com Tel: +86 311-85028506 Add: R-1202 No.707, Lianmeng Road, Shijiazhuang, Hebei, China Website: www.kdsz.cc E-mail: info@hebeisz.com Tel: +86 311-85028506

INDUSTRY

Unison invests in additional tube bend tooling capability to meet growing demand

bend tooling machinery to further increase our manufacturing capability. At full capacity, we can produce hundreds of individual tooling items each day, all ready for shipping. Fully tailored tooling agreements are prepared for customers to ensure the tooling they require is always available, while some £200,000 worth of tooling, including mandrel balls and wiper dies, is held in stock for immediate dispatch.” By holding pre-agreed stocks of consumable tooling on behalf of its customers, Unison ensures faster delivery times than for tooling that is made to order. Unison’s consumable tooling agreements enable customers to minimise the volume of tooling they would typically keep on site and benefit from the associated cost savings. On demand, next day and scheduled deliveries eliminate the risk of a tooling shortage stopping production and provide the opportunity to standardise for HVO plant PENINSULAR de Vástagos has successfully completed the supply of Hastelloy seamless tubes for heat exchangers for GALP’s hydrotreated vegetable oil plant in its Sines refinery in Portugal. The contract, which was awarded in July 2024, included the supply of more than 12 tons of Hastelloy UNS N10276 U-BENT seamless tubes worth more than €1mn. Peninsular de Vástagos was able to meet strict delivery time requirements and technical specifications to the customer’s satisfaction. Over the last 28 years, Peninsular de Vástagos has proved itself as a reliable partner by delivering customised products and solutions for the energy, automotive and hydraulic industries.

TWELVE months since launching its new bend tooling service, Unison Ltd, the UK’s leading manufacturer of tube and pipe bending machinery, has invested again to meet the increasing demand for its consumable and high precision bend tools from customers around the world. Introduced in 2023, following the creation of a £1mn bend tooling centre at the company’s Scarborough HQ, the aim of the service was to extend Unison’s tooling offering. Equipped with the latest manufacturing technologies, it has brought greater convenience to Unison customers, while also giving users of other makes of tube bending machines rapid access to Unison’s high quality consumable and long-life products. “Since commencing the new tooling service, uptake has been phenomenal,” said Unison’s sales applications engineer, Luke Gibson. “So much so, we have just invested a further £750,000 in specialist

tooling across different manufacturing sites. As part of the service, Unison also offers volume discounts and the convenience of easy budgeting through regular payment plans. As well as aluminium bronze consumable bend tooling, Unison also produces long-life precision tooling for the most challenging of tool manipulation applications.

Unison Ltd www.unisonltd.com

Peninsular de Vástagos completes tube contract

Peninsular de Vástagos www.peninsulardevastagos.es

Hastelloy seamless tubes for heat exchangers

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INDUSTRY

Scleros appoints Bond Metaltek to represent tube and bar processing products BOND Metaltek (BMT) has signed an agreement with Scleros SpA to represent its products in the UK, Belgium and Netherlands. For more than 70 years, from its plant in Northern Italy, Scleros has been designing and manufacturing high precision hard metal components used in the process of cold drawing of tubes and bars for the ferrous and nonferrous sector. It currently operates a state-of-the-art facility with high-tech modern machinery including multi-axis CNC, EDM and special grinding machines. All of these machines produce components to the closest tolerances and highest surface quality in different grades of tungsten carbide. Hard metal dies for tube and bar drawing offer unparalleled wear resistance and toughness to the most demanding drawing applications. Dies are available for round, square, rectangle, oval and special profiles. Special coatings are available for specific applications. Scleros is part of the OMCD group, a multinational company made up of 10 brands active in the field of hard metal, sintered copper/tungsten and precious metals. A centralised structure between all of the brands provides full control of the entire production process from the refining of raw materials to the micro-finishing operations. BMT has a long history of working in the tube and profile business with an extensive working knowledge of different processes. Its hands-on approach to customer requirements ensures that a close working relationship is formed with the focused objective of process improvement and improved efficiency.

Scleros SpA www.scleros.it

Hard metal dies for tube and bar drawing offer unparalleled wear resistance and toughness

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INDUSTRY

Metalube appoints product manager for tube and hot rolling products

Mr Mallet’s appointment is a result of Metalube’s commitment to continuous growth and innovation within the industrial lubricants sector. By dedicating resources to these product lines, Metalube aims to provide even better support, enhanced customer care and an expanded global reach. Metalube’s flagship product ranges – Tubol™, Metarol™ and Alumol™ – are recognised for offering cutting-edge lubrication and protection solutions for copper and aluminium drawing, tube drawing and hot rolling applications. The addition of Mr Mallet to the team reinforces its dedication to delivering advanced technologies to customers worldwide. Metalube distributes high-performance

METALUBE, a manufacturer of industrial lubricants, has appointed Sébastien Mallet as product manager for tube, hot rolling and sub-sea products. Mr Mallet joins the UK commercial team at the Manchester, UK headquarters, bringing with him over a decade of experience in the oil and lubricants industry. Mr Mallet said: “I am excited to hit the ground running at Metalube and get to know our customers in the tube, hot rolling, and sub-sea industries across the globe. “With my experience in the lubricants industry, I am confident we can take our comprehensive range of specialist lubricants to the next level and expand our export sales even further afield.”

Sébastien Mallet

lubricants for industrial applications. Headquartered in Manchester, UK, Metalube serves customers in more than 95 countries worldwide.

Metalube Group www.metalube.co.uk

Speeding up tube and pipe production The Weldac is not like any other welder. Unrivalled energy efficiency and un matched performance make it a standout choice. It has automatic load matching for hassle-free operation. Short-circuit-proof, safe and reliable operation means more uptime, which again translates to more output. And, for further peace of mind: The advanced inverter technology is covered by a 5-year warranty.

Choose from a wide power range, from 50 kW to 2200 kW, with a single-cabinet option up to 1100 kW. Visit enrx.com to learn more.

THE RIGHT ENERGY CAN TAKE YOU ANYWHERE | ENRX.COM

TECHNOLOGY

Mastering the challenges of boron steel tube welding

and advanced wel- ding techniques has enabled ENRX to develop innovative solutions that deliver precision, efficiency and reliability.

RENOWNED for its unmatched strength, durability and lightweight performance, boron steel has become a cornerstone of modern manufacturing. Yet, its unique properties also pose significant challenges for tube welding, requiring advanced technology and expertise. Boron steel has emerged as a game changer in industries where strength, durability and precision are essential. Known for its ultra high strength properties and good formability when hot formed, boron steel is widely used in vehicle safety structures, lightweight engineering and other applications requiring complex shapes and outstanding wear resistance. However, welding this material demands cutting edge technology that ensures consistent performance while preserving its unique properties. “‘This is where our Weldac tube welders truly excel,” said Morten Lavergren, in-line manager at ENRX. As an expert in induction-based tube welding, ENRX is at the forefront of helping manufacturers unlock the full potential of advanced materials like boron steel. This success is driven by the expertise of ENRX’s highly skilled team, including PhDs and industry veterans who have dedicated their effort to solving the complex challenges of boron steel welding. Their in-depth knowledge of metallurgy, heat treatment

Boron steel tubing is prized for its exceptional strength, hardness and wear resistance

challenges with precision and efficiency. By combining advanced induction technology with ENRX’s expertise in welding systems, Weldac provides tube manufacturers with a reliable solution that meets the demands of boron steel and beyond. “Our welders are built with superior heat management systems,” Mr Lavergren said. “This ensures optimal heat input during welding, which helps preserve the material’s structural integrity while minimising the risk of defects.” “Reliability is another key strength of Weldac,” he added. “Our systems are engineered with advanced controls and tight tolerances to deliver consistent weld quality across batches. Manufacturers can count on unmatched repeatability.” ENRX has been delivering advanced boron steel welding solutions to manufacturers worldwide for several years, helping them overcome the unique challenges associated with this high performance material. One notable example is their partnership is with Zhida Precision Pipe Manufacturing Co Ltd. Zhida has relied on ENRX’s welders to produce high quality boron steel tubes that meet the rigorous demands of automotive and industrial applications. The consistent performance and superior weld quality provided by Weldac systems have made them an indispensable part of Zhida’s production process. “At ENRX, we are committed to pushing the boundaries of what’s possible in tube welding,” said Mr Lavergren. “As the demand for advanced materials like boron steel continues to grow, our Weldac technology is ready to support manufacturers with precision, reliability and efficiency.”

“Over the years, we’ve collaborated closely with leading line builders and manufacturers to deepen our expertise,” Mr Lavergren says. “Today, we’re proud to offer optimised Weldac welders specifically designed to meet the unique challenges of boron steel welding.” Boron steel tubing is prized for its exceptional strength, hardness and wear resistance, making it ideal for creating lightweight yet robust structures. Its ability to combine strength and formability makes it indispensable in industries such as automotive and construction. For example, the exceptional strength of boron steel opens opportunities to replace traditional solid bars with hollow tubes, significantly reducing weight and material usage without compromising on performance. This shift not only enhances design flexibility but also supports more sustainable manufacturing practices by lowering material consumption and overall emissions. Welding boron steel, however, is no small task according to Mr Lavergren. “Its properties demand much more precise control than carbon steel in order to prevent microcracking, distortion and other defects,” he explained. “And the need for tight dimensional tolerances and consistent performance across batches adds another layer of complexity.” Boron steel presents a unique set of challenges. Achieving optimal results requires an advanced welder, capable of precise control over critical parameters such as frequency and power output with the right quality system. Any deviation from these finely tuned settings can compromise the final product, leading to defects or weakened performance. ENRX Weldac tube welders are specifically designed to tackle these

Morten Lavergren

ENRX

www.enrx.com

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TECHNOLOGY

Semi-automatic bandsaw allows complete tube cutting cycle

which turns with the blade, guaranteeing excellent support for the material that is to be cut. This system prevents the blade from cutting the working table as is the case with some conventional bandsaws. A very large cast iron vice with handwheel and quick locking lever help to achieve this. The vice is equipped with a practical handle for rapid movement and is mounted on a rail to allow lateral displacement. The bandsaw offers the possibility of cuts from 0° to 60° to the right and to 45° to the left. Blade tension by handwheel and analogical pressure transducer is visualised on the display for the operator. The machine automatically stops in case of blade breakage or insufficient tension of the blade. The digital controller offers three different operating functions: • Semi-automatic cutting cycle: manual vice adjustment through handwheel – semi-automatic start through pedal switch or control panel switch – the

Bültmann tube testing lines for monitoring quality THE reliable recording and permanent monitoring of quality characteristics are an increasing challenge. This applies both to non-destructive testing units for tubes and bars in the eddy current and ultrasonic fields as well as to geometry, straightness and surface testing. Specially tailored Bültmann testing technology can be supplied, either with mechanical handling equipment com- bined with customer-supplied testing electronics or with Bültmann in-house developed measuring and testing units. Both stand-alone and connected in line systems are possible. The machine is practical and reliable for all the cutting needs of small and medium-sized ferrous materials. A large round working table “plateau” is used, THE semi-automated STHEMMA Srl bandsaw allows the user to make a complete cutting cycle without the constant presence of the operator through the original hydraulic control system for the descent of the saw frame. It also offers an infinitely variable blade speed through Inverter from 20 to 105m/min as well as analogic measurement of the starting position of the saw frame and blade tension. A limit switch is available to set the saw frame return just above the material to cut with a button for the rapid approach of the material to be cut. It features a centralised control panel at the front of the machine, including a luminous alarm system. It is automated and is controlled by safety relay. It also offers a highly efficiency hydraulic pump and low energy consumption for the customer.

machine carries out a complete cutting cycle including vice locking, sawframe downfeed, cut, sawframe return and vice opening. • Manual cutting cycle: manual vice adjustment through handwheel, material vice locking through switch key, sawband start through gripswitch, manual sawframe pull down and cut and material vice opening through switch key. The semi-automated bandsaw can perform a complete cutting cycle without the constant presence of the operator

STHEMMA Srl www.sthemma.com

The systems are connected to the corresponding production facilities and can also be interlinked with customer Level 2 systems in order to directly transmit and evaluate quality data online

testing systems; geometry measuring systems; surface measuring systems; straightness measuring system; and vibration measuring systems (developed in cooperation with an experienced partner). The focus is on practice-oriented solutions that also work reliably in industrial use under production conditions with corresponding ambient influences.

The systems are connected to the corresponding production facilities and can also be interlinked with customer Level 2 systems in order to directly transmit and evaluate quality data online in terms of Industry 4.0 requirements. The specialised department ‘Bültmann 4.0’ provides the developments for various measuring and testing technologies that can be used for different applications. The currently available (or soon to be available) technology includes: complete mechanics for non-destructive

Bültmann GmbH www.bueltmann.com

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TECHNOLOGY

Sica expands range of automatic tube coilers THE demand for automatic coilers has been steadily growing and Sica has expanded its product range by offering innovative, cutting-edge solutions. The setup is fully automatic and can be adjusted during the production without stopping the machine. reduces the consumption of film with respect to traditional systems available on the market (up to -30 per cent). They process diameters from 8 (1/8”) up to 40mm (1” 1/4) in short length coils covered with stretch film.

capacities and low running costs. Customers, such as the Swiss company Häusler, have trusted Linsinger’s expertise and technology for many years. In addition to the KSS sawing machines for steel billets and the KSA saws for seamless tubes, the BFMK strip edge millers and the Linsinger MC MultiCut parting saws have also proven effective in longitudinally welded pipe mills for several decades. The specialised portfolio for large diameter pipe mills is complemented by the PFM plate edge milling machines and the RFM pipe end bevelling machines. The PFM plate edge milling machine is used for preparation of Multilega 700, Multilega 700HS – automatic coilers for corrugated PVC, PE and PP pipes from OD16mm (3/8”) up to OD63mm (2”). Packaging with both heat sealed PP and PES straps. The new strapping system makes the Multilega 700HS even faster. Flash 450, Flash 600 automatic coilers for coiling corrugated PVC, PE and PP pipes – the coilers have two or three reels with centralised adjustment controls, a film dispenser with electronic tension control, universal film cutting systems and variable-geometry reel unloading device. The packaging method chosen

Its range of coilers includes models designed to ensure efficiency and reliability. The number of coilers ordered are growing and so are the models Sica can offer as seen below. Smartcoil 1200, Smartcoil 1400, Smartcoil 1700 and Smartcoil 2200 – automatic coilers with two-reel structure for flexible solid wall and corrugated PVC, PE and PP pipes. Packaging with both heat-sealed PP and PES straps. Their smart design consists of automatic format change, reliability and simplification of use and smaller footprint.

Flash 700E, Flash 700E HS, Flash 700E PLUS – automatic coilers for packing corrugated PVC, PE and PP pipes from OD16mm (3/8”) up to OD63mm (2”). Coils are wrapped along their diameter with bands of stretch film. This wrapping system allows the coil to maintain its shape even when pipe is pulled from its interior.

Sica www.sica-italy.com

Large diameter pipe mills upgraded by Linsinger Maschinenbau

welding edge profiles. The machine works with height copy milling units and is capable of maximum cutting efficiency combined with minimum consumable tooling costs. Simultaneous milling of both longitudinal sides saves time and money. The profile milling tools made by Linsinger enable virtually any geometry to be milled with high precision and speed. The RFM pipe end bevelling machine enables simultaneous chamfering of both pipe ends by a single operator. The chamfered pipe surpasses API specifications and the long tool life ensures the lowest possible running costs. The movable milling units chamfer a range of pipe lengths and the internal copy tools guarantee consistent chamfer geometries. The RFM pipe end bevelling machine chamfers diameters between 16" and 90" with practically no burr. The backlash free Linsinger patented DPD double power drive transmission system uses twin motors, small flanges and high torque for absolute precision. Linsinger’s modular approach and innovation continue to set high standards for large diameter pipe manufacturing, ensuring high quality and cost efficiency for customers.

FOR more than 80 years Linsinger has prided itself on offering high quality machines and being able to meet even the strictest deadlines of customers in the large diameter pipe industry. “Linsinger has continuously optimised and improved machine performance. This has been backed up by high levels of R&D investment and a balanced in house sourcing policy,” said Linsinger CEO, Günter Holleis. Producers of large diameter pipes demand customised solutions – whether for pipe cutting, longitudinal seam preparation or pipe-end chamfering. These solutions must ensure high precision, ambitious production

Pipe end bevelling machine RFM

Linsinger Maschinenbau www.linsinger.com

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MARCH 2025

TECHNOLOGY

Boehlerit GmbH presents new brazed saw blades

with manufacturing techniques. This enables a high cutting quality with minimal wear, resulting in an increase in productivity and a reduction in downtimes in the application. Thorsten Almer, product manager bar peeling and sawing, said: “Our brazed saw blades have been specially developed for use in heavy duty industrial sectors where, in addition to performance, a long service life and consistent cutting quality are also required. With our many years of experience in tool development, we are once again setting new standards with this new product range.” Sawtec brazed saw blades offer high resistance to abrasion and overheating, which extends the service life of the tools and guarantees high performance over the entire work cycle. Particularly in metalworking and applications that require precise cuts, the new saw blades offer high stability and durability, even innovative

BOEHLERIT GmbH & Co KG, a manufacturer of high precision cutting tools, is launching a new product line – Sawtec brazed. This product range has been developed for demanding applications in metalworking and other industrial sectors and aims to offer a combination of tool life, precision and cost-effectiveness. Boehlerit is responding to the demands in modern manufacturing processes for the highest cutting quality and long tool life. The brazed design, in which the saw teeth are firmly connected to the saw blade body by means of high performance brazing systems, ensures a stable connection and high resistance to the extreme forces that occur during the cutting processes. The new brazed saw blades are characterised by their first-class precision and the careful selection and processing of high quality materials in combination

The new Sawtec brazed saw blades are suitable for a wide range of applications

under extreme conditions. The new brazed saw blades from Boehlerit are suitable for a wide range of applications and cover a broad spectrum from soft to harder materials. To meet the specific needs of different industries, Boehlerit offers the saw blades in a diameter range of 250 to 460mm and with a cutting width of 2 to 2.8mm. Other dimensions and cutting widths are available. Boehlerit Group is a manufacturer of protection solutions and cutting tools for machining metal and composite materials that has been in operation since 1932.

Boehlerit Group www.boehlerit.com

DRAWING STRAIGHTENING PEELING

BARS TUBES PROFILES

Bültmann GmbH www.bueltmann.com

Contact us: +49 2394 180 info@bueltmann.com

TECHNOLOGY

Boosting welding quality with robot assistance WIRESENSE, TouchSense and

A reversing wire movement, which takes place at around 100Hz, causes the electric motor in the drive unit to scan the metal surface with the wire. It is this high frequency scanning of the workpiece that provides the necessary levels of precision. Even if the surface being scanned is uneven, such as the sheets lying at an angle, the edge can still be detected and measured without any difficulty. “Our WireSense technology uses the scanning function of the reversing CMT wire movement to determine the exact position of the component and edge as well as air gap heights. Steel, stainless steel and aluminium sheets from 0.5 to 20mm thick can be scanned quickly and precisely,” added Mr Schlor. Every raising and lowering operation on the component can be recorded accurately relative to a reference point specified at the start of the scanning process. In just seconds the robot has compared the taught positions with those measured, or in other words it has checked the stored values against the actual position data. If it detects any differences, the course of the seam is adjusted accordingly in the robot’s coordinate system and the weld is produced in the right place. With WireSense the wire electrode becomes a height sensor, allowing air gaps to be determined on lap joints using the precisely measured sheet edge height. To achieve perfect results it is possible to specify in advance which jobs stored on the Fronius welding system should be called up for different air gap sizes. This allows the robot to always respond appropriately and weld with the welding parameters that are ideal for the air gap dimension in question, preventing welding errors. The key to high quality lies in teaching the correct welding path. The tried and-tested TeachMode assistance system helps the welder set the weld seam positions on the robot, making the programming process extremely easy. The reversing wire movement prevents the wire from bending in the event of contact with the component and saves the user from having to remove the deformed wire or re-measure the stickout.

The TouchSense assistance system has been specially developed for fillet welds. Before each weld, the robot automatically touches the sheets being joined at the start and end of the weld. It does not matter whether it is the wire electrode or gas nozzle that makes contact: the signal is always clearly assigned and correctly transferred. The low sensor voltage creates a short circuit when the torch touches the workpiece, which enables the robot to precisely determine the weld position and adjust the welding parameters dynamically. Another helpful feature is the immediate warning issued if a spatter bridge forms between the contact tip and gas nozzle, allowing this to be cleaned promptly to increase precision and quality in production. “Adding special controller software to our highly sensitive and dynamic CMT drive turns the welding wire into a sensor that can identify contours or air gap deviations on the component,” said Philipp Schlor, strategic product manager, industrial welding solutions, at Fronius International. To ensure precision control of the welding wire, the Fronius welding system simply needs to be equipped with a CMT-ready system. The Welding Package – the Cold Metal Transfer (CMT) welding process itself – is not required. CMT-ready systems consist of a wirefeeder on a wire drum or wire spool, a wire buffer, and a CMT Robacta Drive, in other words a second wirefeeder on the torch itself.

TeachMode are patented assistance systems for robotic welding designed by Fronius to improve weld quality and increase efficiency. The welding wire acts as a precise sensor for the robot and simplifies welding path programming or detects deviations in the component position as well as air gaps over the course of the seam. Using this data, the robot can then correct the weld path – adjusting it precisely based on the identified position points – to save material, time and costs, as rework and component rejects are no longer an issue. Despite increasingly advanced robot technology and almost seamlessly interconnected systems, inaccuracies and deviations repeatedly occur in industrial production. In some cases, minimal material differences or imprecise clamping devices can have a negative influence on the welding result and potentially cause time-consuming rework, costly component rejects, or huge cycle time losses. Integrators often resort to using optical measuring systems to avoid having to make time-intensive manual readjustments. But laser and camera systems are expensive to buy and maintain, plus require space, which restricts access to the component. Fronius has the answer in the form of high-tech solutions for the intelligent iWave, TPS/i and TPS/i TWIN welding systems that require neither a camera nor manual readjustment.

Fronius www.fronius.com

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TECHNOLOGY

Laser investment boosts tube and sheet processing company BY investing in a TruLaser Weld 5000 laser welding cell from TRUMPF, brothers Kevin and Marcel Kempf took an entrepreneurial risk. They only had a few parts optimised for the new process. However, their employees were motivated to change this in a short space of time and the results were so good that many customers now only want laser welded parts. “If we only ever took the bare cost calculations as the basis for our decisions, we wouldn’t have been allowed to buy some of our machines in recent years,” explained Kevin Kempf. “But we like looking at the big picture. We cannot offer our customers technologies which we do not have the machines for. And that means we are missing out on business.” As is the case with the decision to invest in an automated laser welding cell from TRUMPF. The technology has long fascinated the brothers. When the TruLaser Weld 5000 with the FusionLine option came onto the market, things got interesting for them. The FusionLine option makes it possible to compensate for inaccuracies in a component and thus automatically process components that are not optimised for laser welding. Gaps up to one millimeter wide can be closed easily without compromising the quality and strength of the weld seam. “That was what convinced us,” said Marcel Kempf. “We ordered the system in 2018.” The family business, with its headquarters in Baden Württemberg, is a contract manufacturer for sheet metal and tube technology. The company currently supplies around 500 customers from sectors including machine and systems engineering, fixture construction, medical and rehabilitation technology as well as the automotive and electrical industries. The brothers invested in the expansion of the welding shop in 2017. In addition to the standard TIG, MIG and MAG welding processes, it was time to try automated laser welding. “Everything fell into place,” explained Kevin Kempf. “With FusionLine, TRUMPF has lowered the previously extremely high demands on component accuracy in preparation for laser welding. What’s more, it is no longer necessary to invest thousands in milled fixtures. And last but not least, the shortage of skilled workers, which is also a problem for us, has made it clear how important automated production processes are. The issue has become even more acute since Covid-19.” When commissioning the TruLaser Weld 5000, the Kempf brothers initially encountered the same problem that still prevents many sheet metal fabricators from purchasing laser welding systems: they didn’t have the right parts. The prospect of a new process is often rejected by customers. “Many people think only a thick seam can be stable. Although we have destroyed components and proven that it is the material rather than the delicate laser weld seam that tears, this evidence is often not enough to convince people,” said Marcel Kempf. The Kempf employees were initially not too keen on redesigning components for laser welding and building the devices required. “That’s when we came up with the idea of offering a bonus for every laser weld optimised part,” said Kevin Kempf. “This piqued the interest of our employees. The

The automated laser welding process is highly productive, delivering 100 per cent reproducible quality and reducing employee workload

specifications were simple: they had to present a processing program, the appropriate fixture and documentation of the new process. And, of course, they needed to be able to win over customers with their idea. “The work was worthwhile for both sides,” said Kevin Kempf. “For the employees, their ideas paid off. And we have also profited: 80 per cent to 90 per cent of our parts are now optimised for laser welding.” Marcel Kempf concluded: “We have components that took us over an hour with TIG welding and the necessary post processing. We can do it in ten minutes with laser welding. We can do in one shift what used to take us a whole week.”

TRUMPF www.trumpf.com

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