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Keywords
Electric Resistance Welding, High Frequency Welding, Tube
Welding, Proximity Conductor, Induction Coil, Induction
Current, Impeder, Seam Annealing
DC
60 HZ AC
KiloHertz AC
High Frequency
High Frequency
Induction Welding
Induction Coil
HF
HF
Strip Butt
HF
T-Joint
HF
Induction
Coil
Projection Seam
HF
HF
Pipe Butt
Bar Butt
Frequency KHz
Meter
Control Devices
Input Voltage Regulation
SCRs control input voltage constant
Filters used on rectifier output to reduce ripple
Variations cause intermittent fusion stitching
Speed Control
Feedback Control on weld power as a function of mill speed
Reduces scrap on start and stop
Weld Temperature Control
Optical Pyrometer aimed at v adjusts weld power
460 V
60 Hz
DC
Reduce
Ripple
50 - 65% Efficient
Solid State
>80% Efficient
HF Resonance
Circuit
Ep
AC/DC Converter
Grid
Feedback
Circuit
Ip=Plate Current
Ig= Grid Current
Ep= Plate Voltage
Ip
Ig
Eff
Ip (onload) Ip (offload)
Ip (onload)
HF Resonance
Circuit
Ep
AC/DC Converter
Grid
Feedback
Circuit
Ip
Ig
Proper Matching
Relationship between the plate voltage and plate current; and
the relationship between plate voltage and grid current are
nearly coincident with the rated impedance line.
HF Resonance
Circuit
Ep
AC/DC Converter
Grid
Feedback
Circuit
Ip
Ig
Overload Matching
Occurs when load impedance is too small in comparison
with the rated impedance
Increase the turns ratio
of current transformer
Reduce tank
capacitance
Ishizaka, HF Resistance Seam Welding,
The Fabricator, Nov 1993
HF Resonance
Circuit
Ep
AC/DC Converter
Grid
Feedback
Circuit
Ip
Ig
Insert Impeder
Impeder Mass Closer to Tube
Cool Impeder
Power = E*I
B = Fixed Power (losses etc)
A*Sp = Weld Power
Induction Coils
Cu Tubing or Bar
Normally water cooled
Surround = efficiency
Mag. Strength reduces
with distance = 1/8 - 1
inch between coil and
work
Contacts
Cu or Hard Cermets
0.25 - 1 in2
500 - 5000 Amps
Cooling required
5 - 50 lbs force
Life = 1K - 300K feet
Impeders
(Current Flow Around inside Surface of
Tubes can cause reduced efficiency. The
impeder increases the inductive
reactance around inside wall of tube.)
Ferritic Material
Cooled: keep below Curie Temp
Extend from v to 1 1/2 tube
diameters upstream of v
Mandrels
Used to treat inside weld bead shape or scarfing
Nonmagnetic Material like Austenitic SS (Impeders also needed)
Seam
Annealing
Advantages of High-Frequency
Welding
Produce welds with very narrow heat-affected zones
High welding speed and low-power consumption
Able to weld very thin wall tubes
Adaptable to many metals
Minimize oxidation and discoloration as well as
distortion
High efficiency
Limitations of High-Frequency
Welding
Special care must be taken to avoid radiation
interference in the plants vicinity
Uneconomical for products required in small quantities
Need the proper fit-up
Hazards of high-frequency current
HF Welding