Pipe fabricators often introduce new processes for producing seamless pipes. Whether they produce hot-rolled or cold-drawn seamless tubes, these processes are helpful. New processes allow them to find out the most suitable method of pipe production. Besides, it also improves the quality of the products.
Rotary piercing is one such process that manufacturers use to produce seamless tubes that we can use in aerospace, automobile, petroleum, etc., industries. Engineers use rotary piercing to transform solid round steel billets into precision tubes.
To understand the intricate process, we must understand the steps and principles of rotary piercing.
What rotary piercing is:
At its core, manufacturers use rotary piercing, a metalworking process for creating seamless tubes. Rotary piercing gives seamless tubes the strength, reliability, and uniformity they are popular for. It makes them ideal for high-pressure applications where welded seams may pose a risk.
Rotary piercing involves piercing solid steel billets to create hollow shells. Seamless tube manufacturers then elongate the pipes while reducing their diameter. It is integral to achieving the seamless nature of these tubes. We have discussed the primary steps involved in rotary piercing below:
Selecting the base material:
The process begins with the selection of the appropriate steel billet. The material choice depends on the explicit requirements of the final product. Common materials engineers use for seamless tubes include carbon steel, alloy steel, and stainless steel. Manufacturers consider the material’s composition, mechanical properties, and suitability for the intended application.
Heating the billets:
Once suppliers choose the pipe material, they start with the piercing process. They heat the steel billets to a precise temperature in a furnace. The purpose of this heating is to make the steel more malleable. Besides, heating the billets also reduces the risk of cracking during the piercing process for producing seamless tubes and pipes. The specific temperature and heating duration depend on the steel type and the final tube’s desired characteristics.
As a seamless pipe manufacturer, we also make fluid pipes used in water, air, heating steam, gas, and other low-pressure fluid delivery. Some of our standard fluid pipes include- ASTM A53-98, JIS G3452-1998, JIS G3454-1998, ASTM A106, DIN 1629-1984
We are one of the seamless pipe manufacturers specialized in manufacturing high-pressure boiler tubes and Low-medium pressure boiler tubes like ASTM A179, ASTM A106, and JIS G3454.
The process of piercing:
Once the billet reaches the optimal temperature, operators place them into the piercing mill. The mill consists of a rotating cone-shaped roll. In manufacturing language, we know it as the “piercer plug.” They also use a stationary die called the “piercer mandrel.” They place the billet in the center of the mill.
As they push the billet through the mill, the piercer plug makes contact with the billet’s surface and exerts pressure. It initiates the piercing process by creating a small hole in the billet’s center, forming a “bloom.”
The process of rotary piercing:
After the initial piercing, seamless tube manufacturers rotate the billet while the piercer plug applies pressure. The rotation, along with the axial movement of the billet, elongates the bloom and further refines its inner diameter. Rotary piercing is a critical step that ensures the inner surface of the tube is uniform and defect-free.
Following rotary piercing, suppliers start the elongation and sizing process. They pass the tube through a series of dies. These die progressively reduce the tube’s diameter while increasing its length. The elongation and sizing process continues until engineers achieve the desired dimensions and thickness.
Cooling, straightening, and finishing:
Once manufacturers produce seamless tubes, they cool them to relieve residual stresses. They send the tubes to the straighteners to maintain their straightening standards. Straightening the seamless tubes and pipes is especially crucial for precision applications.
Once manufacturers straighten the pipes entirely, they cut them into desired lengths. Engineers may further process the ends to ensure the pipes fit their desired locations. Pipe fabricators also finish the cut ends of the pipes and tubes. Based on their intended applications, pipe operators use processes like threading, bevelling, chamfering, etc.
Inspection and quality control:
Quality is something that manufacturers absolutely do not compromise with. Hence, they use various processes to test the quality of the products. They use non-destructive testing processes, like ultrasonic testing, eddy current testing, etc. These tests detect any internal or surface defects that may affect the tube’s integrity.
Seamless Steel Pipe (SMLS Pipe)
As one of the leading seamless pipe manufacturers, we manufacture cold-drawn seamless steel pipes and hot-rolled seamless steel pipes in standards of API 5L, ASTM A53, ASTM A106, ASTM A335, ASTM A213, ASTM A179, ASTM A192, ASTM A210, ASTM A333, ASTM A519, DIN 17175, DIN 1629, DIN 2391, EN 10216, EN 10210, BS 3059, JIS G3454/3455/3456
Besides manufacturing seamless steel pipes, we also manufacture structure tubes applicable in the general and mechanical structures in standards of ASTM A53, ASTM A106, ASTM A500-98, ASTM A501-98, ASTM A519-98, JIS G3441-1994, JIS G3444-1994, BS EN 10210-1
As one of the well-known line pipe manufacturers, we manufacture API 5L PLS1/2 Line pipe for oil and gas transport. Our line pipes are made of superior quality carbon steel per industry standards and are very reasonably priced. That is why we are considered one of the leading line pipe manufacturers in India.
Such a wide variety of equipment allows us to produce marine pipes, line pipes, mechanical and automobile pipes, machining tubes, high-pressure boiler tubes, high-strength oil pipelines, and petroleum machinery parts.
The maximum length of our pipes and tubes is 12.8 meters. Apart from stainless steel, we also produce cold-drawn carbon steel seamless tubes. As an experienced seamless pipe company, we can make seamless tubes and pipes following ASTM, GB, JIS, DIN, and other specifications & standards. All our products are widely used in various industries, including – metallurgy, chemicals, machinery, construction, coal & gas, petroleum, electricity, and others.
Rotary piercing for seamless tubes:
Rotary piercing is a complex but essential manufacturing process in producing cold-drawn seamless tubes. Manufacturers can choose from various available materials. They select steel billets that they heat to the right temperature. Then, they use a series of processes to produce precise piping solutions. Rotary piercing helps manufacturers produce defect-free, leak-free pipes and tubes.
Rotary piercing produces robust, durable, and uniform pipes and tubes. Hence, they are critical in many industries for transporting fluids and energy. Engineers use various steps of rotary piercing to ensure they meet the highest industry standards.