Steinmüller Africa, in collaboration with engineering consultants eNtsa, has successfully pioneered the use of rotary friction welding in the repair of high-pressure steam generation equipment at the Tutuka power station in Mpumalanga. This marks a first in the industry, where the companies used a hybrid technique of rotary friction welding and friction hydro-pillar processing (FHPP) to attach heat exchanger nozzles to high-pressure headers.
The process was developed as an alternative to the traditional submerged arc welding method, which had previously led to defects in the first set of headers. By using the new hybrid welding approach, the companies were able to eliminate these defects and ensure the headers were 100% defect-free. Key advantages of this method include minimal distortion, a significant reduction in welding time (75% less compared to submerged arc welding), and the ability to produce consistent welds at no additional manufacturing cost.
The application of this advanced welding technique is expected to extend to the petrochemical, nuclear, and power generation industries, where high-strength nozzle-to-pipe welds are crucial. The technique, now part of the intellectual property portfolio of both Steinmüller Africa and eNtsa, is set to revolutionize welding in industries that rely on high-pressure equipment.
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