Electric Resistance Welded tube, commonly known as ERW tube, is a type of steel tubing that’s produced through the process of electric resistance welding. This method involves passing an electric current through the edges of a steel strip, heating them to a molten state. Pressure is then applied to join the edges together fusing the two edges and thereby forming a solid tube.
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ERW tubes are known for their high strength and durability, making them suitable for a wide range of applications. ERW tubes are also utilised in the automotive industry for manufacturing components like exhaust systems and frames.
One of the key advantages of ERW tubes is their cost-effectiveness. The electric resistance welding process allows for the production of large quantities of tubes at a relatively low cost. Additionally, ERW tubes have a smoother interior surface compared to other types of welded tubes.
This uniformity is achieved due to the precision and control of the electric resistance welding process. In addition to their mechanical strength, ERW tubes offer an excellent surface finish, enhancing their aesthetic appeal and making them a preferable option for visible architectural applications.
At Top Tubes, we specialise in manufacturing ERW tubes that adhere to strict quality standards made from our very own ERW mills, ensuring our products meet the diverse needs of our clients across various industries. With our state-of-the-art technology and commitment to innovation, we strive to deliver ERW tubes that are not just cost-effective but also exceed performance expectations.
Electric Resistance Welded (ERW) tubes are integral to many industries, offering strength, cost-efficiency, and reliability. From construction to plumbing, ERW tubes have become the go-to solution for steel pipes. This blog explores the step-by-step process of creating these essential components.
ERW tubes, or Electric Resistance Welded tubes, are made by heating steel using an electric current to form a welded seam. Here’s a breakdown of the ERW tube manufacturing process:
The journey begins with high-quality steel coils, often carbon steel, known for its strength. The choice of steel grade depends on the final application of the Electric Resistance Welded tubes.
Next, the steel coil is uncoiled and its edges straightened to prepare for the subsequent processes. This ensures a smooth feed into the machinery.
The flat steel strip, known as skelp, is rolled into a cylindrical shape. Forming rolls help create the desired shape while preparing the edges for welding.
This is the key stage where the ERW tube takes shape. High-frequency induction welding fuses the edges of the skelp by generating heat through an electric current. This process forms a strong weld seam, ensuring durability and a nearly seamless finish.
Once the weld is made, excess material (the weld bead) is trimmed off the inner and outer surfaces to create a smooth tube. This step improves the tube’s appearance and functionality.
The welded tube then passes through a series of rolls to achieve the required dimensions. It can be shaped into round, square, or rectangular profiles based on specific requirements.
After shaping, the tube is cooled rapidly using water or air. This process ensures the ERW tube achieves the necessary hardness and strength. Once cooled, the tube is cut into desired lengths.
For applications requiring specific ends, processes like beveling, threading, or grooving are carried out. These finishing touches make installation and connections smoother.
Quality control is vital for Electric Resistance Welded tubes. Each batch undergoes rigorous inspections and tests to meet industry standards. Tests include:
The final step involves applying protective coatings like zinc or epoxy to enhance corrosion resistance. Once complete, the tubes are bundled, packaged, and prepared for distribution.
ERW (Electric Resistance Welded) tubes come in various shapes to meet the demands of different industries and applications. These shapes include:
ERW tube production uses electric resistance welding, but there are several types of resistance welding for various applications:
ERW tubes are not limited by shape alone; they come in various sizes, from thin-walled tubes for lighter applications to thick-walled ones for heavy-duty use. Additionally, they can be cut to custom lengths, offering flexibility for installation and design.
Beyond standard shapes, custom profiles can also be produced to meet specific requirements. This adaptability makes ERW tubes a preferred choice for industries that require innovation and flexibility in design.
At Top Tubes, we offer ERW tubes in a wide range of shapes and sizes, tailored to meet the unique specifications of our customers. Our advanced manufacturing processes ensure each tube meets the highest standards of quality and performance, regardless of its shape or application.
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When comparing ERW (Electric Resistance Welded) tube to seamless steel, the differences in production methods, strength, and applications are significant.
ERW Tube ERW tubes are manufactured by rolling a steel strip into a cylindrical shape and welding the edges together using electric resistance. This welding creates a durable tube with a nearly invisible seam, making it suitable for a wide range of applications.
Seamless Steel In contrast, seamless steel tubes are produced by piercing a solid steel billet and elongating it to form a tube without any welding or joints. This process results in a completely smooth surface and a structure free from weld lines, offering superior strength and reliability.
With advanced welding techniques, the gap between the two has narrowed, making ERW tubes a reliable option for many non-critical and medium-pressure applications.
At Top Tubes, we specialise in high-quality ERW tubes, using cutting-edge technology to ensure strength, durability, and precision in every product. Our commitment to quality means you can rely on our ERW tubes to meet the demands of a variety of industries, while maintaining cost-efficiency.
MAGNAtube® sets a new benchmark for corrosion-resistant steel tubes, providing up to 20 times the corrosion resistance of standard galvanised tubes. With its innovative zinc/aluminium/magnesium coating, MAGNAtube® is designed to endure even the harshest environments, including alkaline and ammonia-rich conditions. Tested by leading UK laboratory Rotech, MAGNAtube® has demonstrated a lifespan equivalent to 100 years without significant deterioration.
This cutting-edge tube also features MAGNAfusion® weld repair technology, which guarantees 100% protection inside and out, ensuring extreme longevity. The scratch-resistant surface and environmentally sustainable properties make MAGNAtube® an excellent choice for industries requiring superior durability and corrosion protection.
ERW tubes can be made from a variety of materials to suit different needs:
MagnaTube: Tube manufactured from double sided premium zinc/aluminium/magnesium coated coil. MAGNAfusion weld repair then offering unmatched corrosion protection
Pre-galvanised Tube: A type of steel tube coated with a layer of zinc to prevent corrosion.
Aluminised Tube: Coated with a layer of aluminium, providing heat resistance with corrosion protection.
Perforated Tube: Features holes throughout its structure, suitable for exhaust silencers.
Semi Bright Steel Tubes: These have a smooth, pickled and oiled finish.
Black Tubing: Untreated with aself-colour appearance.
Pre-galvanised tubes are made from steel coated with zinc before being formed into a tube shape. This zinc coating acts as a protective layer, preventing rust and corrosion, which makes pre-galvanised ERW tubes ideal for applications like plumbing, heating systems, and outdoor structures where long-lasting durability is essential.
The lifespan of pre-galvanised steel can span several decades, depending on environmental conditions. In indoor or mildly corrosive settings, the zinc coating offers a strong barrier against rust, ensuring extended durability with proper care and maintenance.
Aluminised tubes are steel tubes coated with aluminium on both sides, providing excellent resistance to heat and corrosion. These tubes are commonly used in high-temperature environments such as automotive exhaust systems, furnaces, and water heaters.
Aluminised tubes typically last between 20 and 50 years, depending on the environment and upkeep. Known for their ability to resist corrosion and withstand high temperatures, they are a durable solution for challenging applications.
Black tubing is made from untreated carbon steel, which gives it a dark finish. It is known for its strength and durability, making it suitable for structural applications like gas lines and outdoor installations where appearance is less critical.
Black tubing can last for decades with proper installation and maintenance. Its longevity is influenced by exposure to moisture, chemicals, and temperature fluctuations, which can affect its performance over time.
At Top Tubes, we provide ERW tubes in a wide range of materials, tailored to meet the unique demands of various industries. Our advanced processes and quality control ensure that each tube meets the highest performance standards, regardless of the material.
Contact us today to learn more about how we can support your projects with our precision, quality, and expertise.
Are you looking for the best steel pipes for your project? You have recently heard about ERW steel pipes that can help you meet high and low-pressure requirements. These rounded steel pipes are mostly used for oil, natural gas, and other vapour-liquid transportation. Therefore, other engineering applications can also use these round structural steel pipes for fencing, scaffolding, line pipes, etc.
No doubt, it has become more popular in the transportation pipe & construction tube industry. Learn how ERW steel pipes are manufactured and the advantages of using them.
What is ERW Steel Pipe?
Electrical Resistance Welded ( ERW) Structural Steel Pipe is made of carbon steel coil, which has low strength and hardness properties. Also, the durability is increased by the weld seam that runs parallel to the pipe.
At APL Apollo, ERW structural steel pipes and tubes are manufactured by transforming cold flat steel strips into rounded tubes and passing them through a set of forming rollers to produce a longitudinal seam. The two edges of a seam are heated with a high-frequency resistance and pressed together to form a bond.
No metal filling will be needed for the longitudinal ERW as impurities in the heat zone are extruded during the welding process. Thus, this process makes electro-welded steel pipe more durable.
Five Key Advantages of Apollo ERW Steel Pipes
Steel ERW pipes are formed from hot rolled steel plates through repeated shaping, bending, welding, heat treatment, sizing, straightening, cutting, and heat treatment.
1) High dimensional accuracy: Electrical-resistance welded pipes are rounded pipes with a small diameter and thin width of the wall. It is made with high-frequency induction welding to achieve accurate dimensions.
2) Good mechanical properties: Manufacturers can control the strip rolling of ERW steel pipe effortlessly because of its innovative welding technology. ERW Steel pipes can be rolled effortlessly because of its innovative welding technology, which enables manufacturers to control the strip rolling process. The welded part is also passed through online heat treatment technology to improve its performance. Hence, it helps to reduce material wastage.
3) Higher Elongation: Straight seam welded steel pipe can elongate 8% -10% higher than traditional seamless steel pipes. Besides, an electric-welded steel pipe consumes less carbon than other steel tubes and pipes.
4)Uniform wall thickness: ERW steel pipe has high concentricity and uniform thickness after heat treatment. Its microstructure makes the steel pipe more durable and resistant to collapse. Also, it offers higher elongation compared to other seamless steel pipes.
5) Longitudinal resistance: Welded steel tubes undergo rigorous heat treatment to ensure their durability. It will not collapse during transit and can provide high resistance to all external forces. This is why it can be used to manufacture small diameter thin-walled pipes, commonly used in the city to transport gas and crude oil.
Summing Up! Only the best ERW steel pipes will offer you all the advantages mentioned in the list. APL Apollo manufactures structural steel pipes and tubes with higher resistance to heat and temperature. They are easy to install and have a long service life. Click here to know more.
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