Morgan Advanced Materials uses their advanced ceramic materials to manufacture high performance welding rolls and guides for high frequency electric resistance welding (HF-ERW) in continuous steel tube production.
Morgan Advanced Materials’ welding rolls and guides are designed using Nilcra™ Zirconia, a robust monolithic ceramic material that maintains strength and hardness even at high temperatures, making it extremely resistant to wear, galling, deformation and corrosion. It has a low coefficient of friction and even abrasive materials have marginal effect on its surface. Nilcra™ Zirconia is suitable for use in ERW applications as it is non-conductive and is not influenced by the resistance-welding field that runs in close proximity to the rolls.
By using Nilcra™ Zirconia rolls and guides, the surface finish of the tube is improved and scrap rates are reduced. Manufacturers gain from decreased down time, superior process efficiency, and better yields. Investment in tooling inventories can be similarly scaled down too. In contrast to steel rolls, Nilcra™ Zirconia rolls do not draw power from the ERW equipment, so they stay cooler, which improves the bearing life and minimizes energy consumption.