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Manufacturing Butt Weld Fittings

The most appropriate manufacturing method of a product will be decided with consideration of its material, sizes, shape, use, standards and other properties.

There are numerous processes for manufacturing Elbows alone, several examples listed as follows.

ELBOWS: Mandrel method (Hot Forming)

One of the most common manufacturing methods for manufacturing Elbows from pipes. After heating the raw material, it is pushed over a die called "mandrel" which allows the pipe to expand and bend simultaneously. Applicable to a wide size range.

Manufacturing Butt Welding ELBOWS

ELBOWS: Extrusion method (Cold Forming)

Using raw material with the same diameter as finished product, pipe is pushed through a die and formed into its desired shape. Usually applied to stainless steel, small to medium sizes.

Manufacturing chart-ELBOWS: Extrusion method (Cold Forming)

ELBOWS: UO method

After raw material plate is cut out into a specially designed shape, it is shaped first into an U-shape using a die and then into an O-shape (tubular form) using another die, finished with a single weld. Usually applied to stainless steel and non-steel material, small to medium sizes.

Manufacturing chart-ELBOWS: UO method

ELBOWS: "Monaka" method

One of the most common method for manufacturing Elbows from plates. After two pieces of raw material plates are cut out symmetrically, each piece are press formed and welded together, which somewhat reminds us of the Japanese delicacy, "Monaka." This method is applicable to various materials and can even be applied to large items with diameters over 1 meter. Has two seams and special welding technology is in use to meet various standards required by our clients (electricity, gas pressure vessels, etc.,) from whom Steel Tubes products continue to receive high acclaim.

Manufacturing chart-ELBOWS: "Monaka" method

ELBOWS: Hot Forming Die Bending method

After heating raw material pipe, it is press formed and corrected using different dies. The process may be repeated as needed to obtain the required shape, size, wall thickness, etc. Usually applied to thick-wall items that cannot be bent on a mandrel die.

TEES: Hydraulic Bulge method (Cold Forming)

After cutting and placing raw material into a die, the pipe is pressed as hydraulic pressure pushes out the branch. The Tee is pressed against the die, leaving the finished product to have a truly smooth outer surface.

Manufacturing chart-ELBOWS: "Monaka" method

TEES: Extrusion method (Hot Forming)

Using raw material with a bigger diameter than the finished product, the branch outlet is extruded from pipe while the main body is being pressed. The outlet's wall thickness can also be adjusted as needed. Applied to Tees with large diameters, heavy wall thickness and/or special material with challenging workability that cannot be manufactured using the hydraulic bulge method.

TEES: Steel Plate Welding method

Manufacturing methods for Elbows, using steel plates as the raw material. Includes UO-method, Monaka method and Throat-welding method.

UO method: After raw material plate is cut out into a specially designed shape, it is shaped first into an U-shape using a die, then the branch pipe is formed and then shaped into an O-shape (tubular form) using another die, finished with a single weld on the opposite side of the branch pipe. Usually applied to large diameter items used in severe conditions. 
"Monaka" method: Two pieces of raw material plates cut out symmetrically are press formed and welded together. Usually applied to large-diameter items.
Throat-welding method: Mainly used for stainless and non-metal items, this method is similar to UO-method but with the weld on the same side as the branch pipe and the "branch throat." Usually applied to low-pressure, corrosion-resistant items.

REDUCERS: Outer Die method

One of the most common method for manufacturing Reducers, using an outer die. Raw material pipe is cut and pressed in an outer die, compressing one end of pipe into a smaller size.

Manufacturing chart - REDUCERS: Outer Die method

REDUCERS: Plate Forming method

Plates can also be used to manufacture Reducers. In an UO method, plate is cut in a specially designed shape which is formed into an U-shape and an O-shape respectively, then finished with a single weld seam. The "Monaka" method for Tees is similar to that of Elbows, using two symmetrically cut plates formed and welded together with two seams. Both methods are used for large diameter items.

CAPS: Deep Drawing method

One of the most common manufacturing methods for caps, where plate is cut out in a circle and formed by deep drawing.

LAP JOINTS / STUB ENDS: Flare method

One of the most common manufacturing methods of Lap Joints / Stub Ends. One end of the raw material pipe is spread out to form the brim. There are other methods, where the brim is welded onto the end of a cut pipe or where the whole product is machined from block.

The Standards Of Pipe Fittings

Butt Welding Fittings Manufacturer

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Standard Code  Standard Name
ASME B16.9 Factory-made wrought steel butt-welding fittings
ASME B16.5 Pipe flanges and flanged fittings
ASME B16.11 Forged fittings socket-welding and threaded
ASME B16.47 Steel flanges
ASME B16.28 Wrought steel butt-welding short radius elbows and returns
MSS-SP-43 Wrought stainless steel butt-welding fittings
MSS-SP-44 Steel flanges
MSS-SP-75 Specification for high test wrought butt welding fittings
MSS-SP-79 Socket-welding reducer inserts
MSS-SP-83 Class 3000 steel pipe unions socket-welding and threaded
MSS-SP-95 Swage nipples and Circle plugs
MSS-SP-97 Integrally reinforced forged branch outlet fittings-socket welding, threaded and butt-welding ends
ANSI/AWWA C207 Steel Pipe Flanges For Waterworks Service

 


Grades available with Steel Tubes

Butt Welding Fittings Manufacturer India

Nickel - Monel® - Inconel® - Incoloy® - Hastelloy® - Alloy 20 - Duplex

Nickel Alloy Butt Welding Fittings

ASTM / ASME SB 336 UNS 2200 ( NICKEL 200 ) , UNS 2201 (NICKEL 201 ) , UNS 4400 (MONEL 400 ) , UNS 8020 ( ALLOY 20 / 20 CB 3 ) , UNS 8825 INCONEL (825) , UNS 6600 (INCONEL 600 ) , UNS 6601 ( INCONEL 601 ) , UNS 6625 (INCONEL 625) , UNS 10276 ( HASTELLOY C 276 )

COPPER Alloy Steel Butt Welding Fittings

ASTM / ASME SB 111 UNS NO.C 10100 , C 10200 , C 10300 , C 10800 , C 12000, C 12200, C 70600 , C 71500
ASTM / ASME SB 466 UNS NO.C 70600 ( CU -NI- 90/10) , C 71500 ( CU -NI- 70/30)

Stainless Steel Butt Welding Fittings

ASTM / ASME SA 403 GR WP "S" / "W" / " WX" 304 , 304L, 304H, 304N, 304LN, 309, 310H, 316, 316H, 317, 317L, 321, 321H, 347, 347 H

Duplex Steel Butt Welding Fittings

ASTM / ASME SA 815 UNS NO.S 31803, S 32205, S 32550, S 32750, S 32760

Carbon Steel Butt Welding Fittings

ASTM / ASME A 234 WPB, WPC
ASTM / ASME A 860 WPHY 42, WPHY 46, WPHY 52, WPH 60, WPHY 65 & WPHY 70

Alloy Steel Butt Welding Fittings

ASTM / ASME A 234 WP 1, WP 5, WP 9, WP 11, WP 12, WP 22, WP 23, WP 91

 

Materials used:

Butt Welding Fittings Manufacturer India

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Alloy steel
Carbon steel
Stainless steel
Cast iron
Rubber
PVC
Thermoplastics
Aluminum
Brass
Bronze etc.


Where Steel Tubes India export?

Iran, Iraq, Italy, UAE, Bahrain, Indonesia, Australia, Kuwait, Saudi Arabia, South Africa, Germany, UK, Denmark, Canada, USA, Peru, Brazil, Nizeria, Mexico, Venezuela (Latin America), South America

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Butt weld Long radius elbow 90° Sch. 10S
Butt weld Short radius elbow 90° Sch. 10S
Butt weld Long radius elbow 45° Sch. 10S
Butt weld Equal Tees Sch. 10S
Butt weld Reducing Tees Sch. 10S
Butt weld Concentric Reducers Sch.10S
Butt weld Eccentric Reducers Sch.10S
Butt weld Caps Sch. 10S
Butt weld Stub Ends MSS Type A Sch. 10S
Butt weld Long radius elbow 90° Sch. 40S
Butt weld Short radius elbow 90° Sch. 40S
Butt weld Long radius elbow 45° Sch. 40S
Butt weld Equal Tees Sch. 40S
Butt weld Reducing Tees Sch. 40S
Butt weld Cocentric Reducers Sch. 40S
Butt weld Eccentric Reducers Sch. 40S
Butt weld Caps Sch. 40S
Butt weld Stub Ends MSS Type A Sch. 40S

 


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