Theoretical

Electric

Analysis
Resistance

of Current

Distribution

Welding*

By Michio SAI T 0, ** Hiroji KASAHARA,

and Shuxo WA TANABE ***

*** Hirotomo

Synopsis
In order to manufacture a fairly heavy walled pipe, the distribution of
the electric current in the strip edge of Vee apex zone was analyzed by
comparing the measured and calculated electric circuit constants in Vee
apex zone.
From the result of the analysis it can be concludedthat the current in
strip edgeshas a tendencyto flow uniformlyas the strip thicknessincreases
and, also, that the overheat at the corner of strip edges can be reduced to
an allowable level by employing a small apex angle and mild welding
condition.
In addition, it is found that the large amount of upset is needed to obtain a sound quality of welding. So, the proper welding conditions of
heavy wall are selectedto be as follows, mild weldingcondition, i.e., slow
welding speed, small apex angle and large amount of upset. A fairly
heavywalled ERW pipe with large outside diameter of 2I inch c x 19.05
are manufacturedby applying theproper conditions. The toughnessof the
weld part is proved to have excellenttoughness.

I.

Introduction
Recently, the demand of High Frequency Electric
Resistance Welding (HFERW) pipes for line pipe and
OCTG has been expanded to large out diameter,
heavier wall thickness and higher grade pipe. One
of the best idea to cope with this problem is to investigate forming and welding processes in order to prevent edge wave, weld defects, etc.
In ERW process, high frequency current is introduced through sliding contact electrodes to edges of
a strip, which is formed into a tubular shape. The
edges are selectively heated to a welding temperature
by skin effect and proximity effect of high frequency
current. The heated edges of the strip are pressed
together by the squeeze rolls to form a welded pipe.
In the process, the welding phenomena was dif.
ficult to be analyzed, because the measurement of the
parameters such as temperature, welding current, etc.,
was interrupted by the noise due to high frequency,
high voltage, bad atmosphere with cooling water and
high welding velocity.
However, the welding phenomena have recently
been clarified by various methods. It has been considered that the corners of the strip edges are more
easily heated than the middle surface of the strip
edges, because the high frequency current is concentrated at the corners of edges. Haga et a1.' pointedd
out that the selective heating at the corner of the strip
edges was proportional to the wall thickness of pipes.
The available wall thickness has been about 16 mm
so far. However, the demand for line pipes has re*

**
***

in

TOMINAGA***

cently increased toward heavier walls over 16 mm.

Authors have made it possible to manufacture pipes
of fairly heavy wall thickness by investigating the basic
characteristic of ERW and applying the results to the
manufacturing process.
This report deals with the welding phenomena and
the weld quality of fairly heavy walled pipes.
II.

Investigation Method
The self inductance and resistance of Vee apex zone
in ERW changes depending on the current distribution in the zone, so the current distribution can be
presumed through the measurement of self inductance
and resistance by taking them the other way round.
The self inductance and the resistance were measured at 400 kHz by LCR meter, using quasi Vee apex
specimens with various thickness and Vee apex angle,
as shown in Fig. 1.
Though Vee apex zone in making a pipe shows
three-dim.entional shape, it is considered that Vee apex
zone as shown in Fig. 1 is validly used in order to
investigate the effect of the shape on the current distribution in the zone. Vee apex angle is 3 to 6 deg.
The self inductance (L) and resistance (R) of Vee
apex zone under various current distribution were calculated respectively by Eqs. (1) and (2). Equation
(1) is derived by assuming that the electric current is
concentrated in the corners of strip edges, as is shown
in Fig. 2. The deviation of the equation is explained
in detail at Chap. III.

Fig.

1.

Quasi Vee

apex

zone

specimen.

Based on the papers presented to the 105th ISIJ Meeting, April 1983, S369, at The University of Tokyo in Tokyo and to the 106th
ISIJ Meeting, October 1983, S1220, at Akita University in Akita. Manuscript received on August 26, 1985; accepted in the final
form on March 4, 1986. 19861SIJ
Chita Research Department, Iron & Steel Research Laboratories, Kawasaki Steel Corporation, Kawasaki-cho, Chita 475.
Chita Works, Kawasaki Steel Corporation, Kawasaki-cho, Handa 475.

Research

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( 461)

2a

( 462)

Transactions

L= - 2

ISIJ,

Vol.

26,

1986

02: angle L PBC.

Magnetic flux d~b0,caused by the current in one
side of the strip edges in an infinitesimal part dr of
Fig. 3 is given by Eq. (4).

P0
-a2 tan-i li tan fl +ali tan O
~rb' tan 0
a

+ (li tan 0)2 tan'

li tan

-a11 tan U

x In (li tan 0)2 + 1 + (a-b')2 tani-li tan l

a2
a-b'
-(a-b')li

tan 0-(li tan 0)2tan-i li tan 0

a-b'
+(
ll tan2 0
a-b')litandln
(b')2 +l
...............(1)

where, dl: length of parallel edge

dr : infinitesimal part at distance r from one
side edge.
Therefore, total magnetic flux `YO
in the subdivided
portion, generated by the current in one side of the
strip edges can be derived by summing up d~b0generated by each infinitesimal part. Equation (5) gives
the results.

where, Po : the magnetic permeability (=1.26 x 10

H/m)
b' : the current separate depth from inner or
outer surface
0 : Vee apex angle
2a: wall thickness
1,: the distance from V convergency point
to contact tip.
R =p

2li
bxb'

III.

Theoretical Analysis of Self Inductance in

Vee Apex Zone
To derive the equation of self inductance, both
edges of Vee apex zone were subdivided along the
longitudinal direction and the subdivided portion was
assumed parallel as is shown in Fig. 3. Magnetic
field Hx of point P at distance r from one side of strip
edge in the subdivided portion is represented by Eq.
(3),2) on the assumption that the current in strip edge
flows separately within depth b' from both surface
and the current penetration depth b from. strip edges
is considerably small as compared with wall thickness.

Hx=-_!(01_02)
I0:

total

current

D1:

angle

L PAB

c5

p010dl R
_ 2Trb'
(O1-H2)dr
R a
R 2
= - 1i010d1
2ir6, R tan' a - 2 In 1+ -a

........................(2)

where, S: cross sectional area of current path

b : current penetration
depth from strip
edges
p: specific resistance.
The current distribution was discussed by cornparing the measured results with the calculated results.

where,

-1i010d1
2
rb' (0i - U2)dr ...............(4)

dJ0 _

where,

tan

0i = a

tan

B2 =

a-b'
R : distance between both strip edges.
Magnetic flux d, caused by the current in one side
of the strip edges in a subdivided portion dl of Fig. 4
is given by Eq. (6), on the assumption that the Vee

(3)
Fig.

3.

Vee

apex

zone

subdivided

in the

tion.

Fig.

2.

Research

Quasi current path of Vee apex zone.

Article

Fig.

4.

Vee

apex

zone.

longitudinal

direc-

Transactions

apex

angle

B is very

small.
2

do _

2 P0; x xtan-1
- a In 1 +
2rb tan B
a
2
-x tan-1

x
ab,
-

+ a 2

In

1+

x
a

a-bx ,

...........................(6)
(R=x=lltanO)
Total
by the
derived
divided

magnetic flux ~bin Vee apex zone, generated

current in one side of the strip edges can be
by summing up d~b generated by each subzone. Equation (7) gives the results.

~'-

_ 2

010
li tand
x
x tan-1-rrb' tan o
a
'x2
x

a
2
a-b'

XIn 1+a )J_xtanl

- a-b'+ 2x In 1+

b,dx

...........................(7)

Therefore, the self inductance L of Vee apex zone

is represented by above-mentioned Eq. (1), because
L is 201.
Iv.

Vol.

26,

1986

(463)

apex zone. As may be seen from Fig. 5, Lm has a

tendency to approach to Lc1, as wall thickness increases.
The measured and calculated self inductance are
shown in Figs. 6(a) and (b), when B is 3 deg and l1
is 200 mm. The self inductance is calculated by
changing b' and 2a. The mean depth of b' can be
estimated by comparing the measured self inductance
with the calculated. Figure 6(b) shows the comparison of the measured and calculated results. As
is shown in Fig. 7, the mean value of b' has a tendency
to increase with an increase in wall thickness.
Therefore, it is quite all right to conclude that the
separation rate (b'/a) of current in strip edge varies
with the wall thickness of pipe, and namely current
shows a tendency to flow uniformly in the strip edge,
as wall thickness increases.
Photograph 2 shows the cross section of Vee apex
specimens which are picked up directly after welding.
From the shape of the HAZ, it is confirmed that the
current in thicker strip edge has a tendency to flow
more uniform and wider near the Vee apex point, but

Results and Discussion

1. Current Distribution in VeeApex Zone

The measured self inductance (Lm) by LCR meter
and the calculated self inductance (Lc1, Lc2) by Eq.
(1) are shown in Fig. 5, when Vee apex angle (B) is
3 deg and the distance from Vee apex point to contact tip (l1) is 300 mm. Lc1 is calculated on the assumption that the current in strip edge flows uniformly (b' = a). Lc2 is calculated on the assumption
that the current in strip edge flows separately within
one-fourth of strip thickness from both surface (b'=
2a). Lm is approximate to Lc2, which is smaller than
Lc1.
Therefore, it is supposed that the current in the
Vee apex zone flows separately in the corner of strip
edge. This phenomenon is confirmed by four heated
lines in Photo. 1, which shows the appearance of Vee

Fig.

'SIT,

5.

Relationship
ance

of Vee

between
apex

zone.

wall

thickness

an d self-in duct-

Photo.

Fig.

1.

6.

Heating

and

Relationship
ance

of Vee

weldin

between
apex

g phenomenon

wall

thic kness

(165.2x11

.Ot).

an d self-in duct-

zone.

Research

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26,

1986

the edge corner is overheated. Also, Haga et al.3~reported that the melt layer width at edge corner increased with an increase in wall thickness, as is shown
in Fig. 8.
The measured resistance (Rm2,Rm5) by LCR meter
and the calculated resistance (Rc2, Rc5, Rmc5) by Eq.
(2) are shown in Fig. 9, when Vee apex angle e is 3
deg and the distance from Vee apex point to contact
tip (l,) is 300 mm.
Rm2 and Rc2 is the resistance at 20 C, and Rm5,

Fig . 7.

Relationship
separate

Fig.

8.

Influence
amount
between

between

wall

thickness

and

current

depth.

of

frequency

of the

melt

current

and
layer

supplying

at

plate

thickness

edge

corner

point

and

on

an

produced
Vee

apex

Fig.

point.

Article

Relationship
perature

Photo.

Research

9.

2.

Macrostructure

of Vee

apex

zone.

among
and

resistance

wall

thickness,

of Vee

apex

specimen
zone.

tern-

Transactions

Rc5and Rmc5is the resistance at 500 C. Rm5 is measured by heating the quasi Vee apex specimen to
500 C in a electric furnace. On the calculation of
Rc2 and Rc5 by Eq. (2) the current separate depth
(b') is estimated from Fig. 7 and the current penetration depth (b) at each thickness is assumed equal to
that of 6.4 mm thickness.
Rmc5is calculated as follows. The cross sectional
area (b.b') of current path is derived from the Eq.
(2) by using the measured resistance (Rm2) at 20 C.
Assuming that the cross sectional area does not change
by the temperature, specific resistance at 500 C is
substituted in Eq. (2) to obtain the estimated resistance Rmc5.
It is expected that the cross sectional area (b. b') of
current path becomes smaller as thickness increases,
because Rm2 becomes larger than Rc2. The decrease
in the cross sectional area of current path is depending on the current penetration depth from strip edge,
because the current separate depth b' becomes larger
as the wall thickness increases.
Generally, the Vee apex angle increases with the
increase of wall thickness of pipes partly due to the
low mill modulus of squeeze stand and, also, to the increase of rigidity of formed pipes themselves. Figure
10 shows the measured changes of Vee apex angle
with wall thickness. When the Vee apex angle increases, the proximity effect decreases which resulted
in the large penetration depth (b) and small current
separation depth (b') as guessed by Fig. 11. Photograph 2 shows the variation of HAZ. The penetration depth (b) increases and the current separation
depth (b') decreases with the increase of thickness. In
order to reduce the over heating of the corner, it is
necessary to increase the current separate depth (b')
by making Vee apex angle small.
As shown in Fig. 9, Rm5 becomes smaller than
Rmc5as thickness increases, and the ratio of calculated
value and measured value (Rc/Rm) at 500 C is larger
than at 20 C.
Therefore, the cross sectional area (b . b') of current
path in Vee apex zone of heavy walled pipe increases

Fig.

10.

Relationship
Vee
mill.

apex

between
zone

wall

measured

th iekness
in

26

inch

and

width

ERW

ISIJ,

Vol.

26,

1986

(465)

as temperature rises. This can be explained by Eq.

(8). The specific resistance and specific permeability,
which affects penetration depth of high frequency current become larger and smaller, respectively.

P = 5O3/_4-

.....................(8)

where, P: penetration depth

tel: specific permeability
f : frequency
p : specific resistance.
Photograph 3 shows the cross section of Vee apex
zone of the pipe (thickness 14.27 mm, diameter 600
mm), which was manufactured at fairly slow welding
speed to get a wide HAZ and a high temperature. It
is recognized that the strip edge is not overheated at
the corner but melted uniformly.
It turns out that even a heavy walled pipe can be
welded without any defects owing to the uniform current: flow and the moderate welding conditions.
2.

Design of SqueezeRoll Stand

It is necessary to keep the width of outside bond
less than 0.15 mm in order to secure good weld quality
from our experience. Figure 12 shows the relationships among the wall thickness of pipe, the width of
outside bond and the relative amount of upset. I t
is understood from Fig. 12 that the large upset is necessary for a fairly heavy walled pipe to obtain a constant width of outside bond. The width variation
near Vee apex point is caused by large bending rigidity of formed pipes themselves and a lack of mill
modulus to cope with the decrease of necessary set-up
gap of squeeze rolls.
Therefore, it is necessary to strengthen the rigidity
of squeeze roll stand in order to upset heavy walled
pipe and maintain the width of outside bond less than
0.15 mm. As the side rolls were supported only from
bottom, the mill spring modulus was small.
So, the design of the squeeze roll stand has improved to support them on both top and bottom sides.
As a result, the mill spring modulus was doubled.

of
pipe

Fig.

11.

Relationship
inductance

between
of Vee

apex

Vee

apex

angle

D and

self-

zone.

Research

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ISIJ,

Vol.

26,

1986

Table

1.

Chemical

composition

of

used

steel.

quality of the pipe was examined by 90 deg flattening

test, Charpy impact test and DWTT test. The chemical composition of used pipe is shown in Table 1.
The result of Charpy impact test is shown in Table
2 and the DWTT transition curve is shown in Fig.
13. It is clear that every pipe has excellent strength
and toughness.

Fig.

12.

Relationship
of upset

3.

among
and

width

wall

thickness,

of outside

relative

amount

bond.

Quality of ER W Pipe with Fairly Heavy Wall

Thick-

ness4~

Heavy walled pipe of 24 finch x 19.05t mm were

manufactured
by the 26 inch ERW pipe mill. The

V. Conclusions
The welding phenomena and the weld quality
heavy walled pipe have been investigated in the laboratory and 26 inch ERW pipe mill. The results
are as follows:
(1) The current in the strip edge of the Vee apex
zone has a tendency to flow uniformly in the strip
edge, as thickness increases. However, current penetration depth from strip edge become shallower as
thickness increases.
(2) The cross sectional area of current path in
Vee apex zone of heavy walled pipe increases as ternperature rises.

Transactions

Table

2.

Results

of Charpy

im pact

ISIJ,

Vol.

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(467)

1986

tests.

(3) The strip edges can be heated uniformly with

little overheat at strip edges in the moderate
heat
conditions.
(4) The technical improvements in welding and
of
squeeze roll stand have enabled the manufacture
heavy walled pipe with large outside diameter which
has excellent toughness.
REFERENCES
1) H. Haga, Y. Watanabe, S. Yamada and K. Sakurai :
Tetsu-to-Hagane, 69 (1983), A73.
2) S. Takeyama : Theory of Electric Magnetic Phenomena,
Maruzen, Tokyo, (1962), 253.

Fig.

13.

Relationship
area

3)
4)

test

between

temperature

and

shear

of DWTT.

H. Haga and
51369.
H. Tominaga,
S. Minamiya
51220.

N.

Mizukami

Y.

Yoshimoto,

and

M.

Saito

T etsu-to-Hagane,
S. Watanabe,

T etsu-to-Hagane,

M.

70 (1984),

Shibagaki,
69 (1983),