Ceramic Weld Rolls

For use in ERW (Electric Resistance Welding), UNIPRETEC manufactures a variety of silicon nitride ceramic weld rolls. By producing a forged weld, ERW is used to manufacture steel pipes and tubes, for example. The welding rolls (also known as squeeze rolls) in the ERW process provide pressure to the tube as the metal is heated, usually by high-frequency induction heating, resulting in a forged weld.

The welding roll material faces a variety of challenges as a result of this operation. High strength, thermal shock resistance, wear resistance, and electrical resistance are all required. Furthermore, since the pipe temperature may reach the metal's melting point, great thermal stability is needed. Material pick-up issues that are prevalent with high frequency welded tubes are eliminated with UNIPRETEC precision weld rollers. This is especially true for non-ferrous materials, where surface quality is crucial. Surface finishes of stainless steel, brass, and aluminum tubes may be significantly enhanced without the danger of rolling weld spatter or particles into the tube surface. Some mills have even switched to ceramic rollers across the whole forming area.

Sililicon nitride weld rolls are suitable for this application because they have good mechanical characteristics as well as chemical and thermal resilience. Si3N4 ceramic meets all of the above criteria, resulting in a number of significant advantages over traditional metal weld rolls, including improved pipe quality, reduced roll maintenance, reduced welding failures, and reduced cooling requirements due to the Si3N4 rolls' ability to operate at high temperatures. Si3N4 weld rollers have a lifespan of up to 10-20 times that of tool steel rolls.

Weld rolls made of technical ceramic have been proven to decrease HF weld power by up to 30% in practical testing. This also minimizes unwelcome "field" heating of nearby components including shafts, stands, and lubrication points. Upgrading to ceramic weld rollers may decrease the length of the weld vee, which is a significant advantage for small diameter tube producers. This allows for more effective placement of the induction coil and impeder, lowering the H.A.Z. (heat affected zone) and resulting in a more visually appealing product.

Material Properties

Note: Although we have no reason to doubt the accuracy of the data presented, this information is offered for comparison only. Exact properties will vary depending on the manufacturing method and part configuration, and can sometimes be tailored to meet specific requirements.

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