What is Electric Resistance Welded tube (ERW)?
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.
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.
What is the Electric Resistance Welded Tube manufacturing process?
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.
How is ERW Made?
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:
What Are The Types of Resistance Welding?
ERW tube production uses electric resistance welding, but there are several types of resistance welding for various applications:
- Resistance Spot Welding: Commonly used in the automotive industry, this method joins metal components by applying electric current through copper electrodes.
- Resistance Seam Welding: Produces a continuous welded seam, often used for fuel tanks and other leak-proof containers.
- Resistance Projection Welding: Focuses electricity and pressure on specific points to weld thicker materials.
- Resistance Butt Welding: Joins rods or wires by applying heat and pressure simultaneously, forming a strong bond.
- Flash Butt Welding: Uses high resistance heat to join components, creating a forge weld without melting metal at the joint.
What are the Shapes of ERW Tube?
ERW (Electric Resistance Welded) tubes come in various shapes to meet the demands of different industries and applications. These shapes include:
- Round: The most common and versatile shape, round ERW tubes are used extensively in structural supports, piping, and machinery components.
- Square and Rectangular: These shapes provide greater rigidity, making them ideal for construction, architecture, and manufacturing applications. They are easy to join and offer strong structural integrity.
- Oval: Oval-shaped ERW tubes are often chosen for aesthetic or functional purposes, particularly in industries like automotive manufacturing or furniture design.
- Flat-Sided Oval: This shape provides an ergonomic advantage, making it easier to grip. It's commonly used in applications like disabled equipment, where ease of handling is crucial.
- Elliptical Oval, D-Shape, and Trapezoidal: These shapes are used in specialised applications where unique profiles are required for both functionality and design.
Size and Dimension Versatility
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.
Custom Profiles
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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What is the Difference Between ERW Tube vs Seamless Steel?
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.
Key Differences
- Strength and Reliability:
The most notable advantage of seamless steel is its strength. With no welded joints, seamless steel tubes are free from potential weak points, making them highly reliable in demanding applications. On the other hand, while ERW tubes have welded seams, advancements in welding technology have significantly improved their strength and durability. - Corrosion Resistance:
Seamless steel tends to be more resistant to corrosion due to its smooth, uniform surface without weld lines. This makes it a preferred choice for industries where corrosion could be an issue, such as oil and gas. - Cost and Applications:
Seamless steel tubes are more expensive to produce due to the complexity of the manufacturing process. They are used in high-pressure and critical applications like oil exploration, refineries, and hydraulic cylinders.
ERW tubes, however, are more cost-effective and versatile. They are commonly used in everyday applications such as furniture, automotive components, construction, and general engineering projects. - Size and Shape Flexibility:
ERW tubes are available in a wider range of sizes and shapes, thanks to their manufacturing process. This versatility makes ERW tubes the go-to option for industries that require custom tube shapes or dimensions.
Choosing Between ERW and Seamless Steel
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.
INTRODUCTING
MAGNAtube BY TOP TUBES
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.
What Materials Can ERW Tube Be Made From?
What Materials Can ERW Tube Be Made From?
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.
What is Pre-Galvanised Tube?
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.
How Long Does Pre-Galvanised Steel Last?
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.
What is an Aluminised Tube?
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.
How Long Does Aluminised Tube Last?
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.
What is a Perforated Tube?
Perforated tubes are steel tubes with holes along their surface, designed for filtration, drainage, and acoustic control. They are widely used in industries such as automotive, chemical processing, and environmental protection.
How Long Does a Perforated Tube Last?
The longevity of a perforated tube depends on its material and environmental conditions. Regular maintenance can help prolong its operational life, especially in more demanding environments.
What is Semi Bright Steel?
Semi-bright tubes have a smooth, polished surface, making them suitable for applications where both appearance and durability matter. They are commonly used in industries like furniture manufacturing and automotive components.
How Long Does Semi Bright Steel Last?
With the right care, semi-bright steel tubes can last for many years, providing a reliable and aesthetically pleasing solution in applications that demand both strength and visual appeal.
What is Black Tubing?
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.
How Long Does Black Tubing Last?
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.
Conclusion
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.