Stainless tubing fabrication is a demanding process where precision, efficiency, and durability are essential. However, issues like bushing wear and welding defects can delay production and increase costs. Discover how AMPCO® 25 helps overcome these challenges and increases production in real world applications.
The Fundamentals
In high-volume stainless-steel flexible tube manufacturing, every component in the production line plays a crucial role. Tube Butt Welding (TBW) bushings that wear out too quickly lead to welding defects, tube inconsistencies, and costly downtime. Several leading manufacturers face these challenges firsthand.
Numerous companies have turned to AMPCO® 25 as the solution to these challenges. With superior wear resistance and thermal conductivity, these bushings significantly improved production efficiency and quality. Our article explores the key issues in flexible tube production and how AMPCO® 25 provides a lasting solution.
TBW bushings made from AMPCO® 25
The Process of Flexible Steel Tube Fabrication
This is a multi-step production method that requires rigorous attention to detail at every stage. Even minor inconsistencies can lead to defects, making reliable tooling and materials essential for maintaining efficiency and product quality.
The manufacturing process typically follows these key stages:
- Tube Forming – Flat stainless-steel sheets are shaped into a cylindrical form.
- Tube Welding – The edges are fused together to create a strong, continuous seam.
- Tube Corrugation – The welded steel tube undergoes shaping to achieve flexibility.
- Tube Calibration – Dimensions are refined to meet strict tolerances and ensure consistency.
- Washing – Surface residues from welding and fabrication are removed.
- Coiling – The final tubing is wound up for storage or transport.
Sometimes precise and well optimized manufacturing steps are not enough. Certain recurring issues can disrupt production and impact overall efficiency.
Flexible tube welding process using AMPCO® 25 TBW bushing
Difficulties Occurring during Tube Manufacturing
Large-scale stainless-steel tube fabrication leaves little room for error. Each component in the process, from forming to welding, must perform flawlessly to maintain speed and accuracy. However, small inefficiencies in tooling can disrupt production, reduce quality, and increase costs.
One of the most persistent challenges of flexible tube manufacturing is bushing wear. Even though these components are small, they play a substantial role in the process. They are used to guide the tubing during welding, ensuring proper geometry and seam integrity. When they wear out too quickly, manufacturers face various issues:
- Frequent replacements – Leading to costly downtime.
- Welding defects – Increasing scrap rates and rework.
- Inconsistent tube dimensions – Affecting product uniformity.
- Unstable heat control – Compromising weld strength.
To stay competitive, manufacturers require more durable and high-performance materials that minimize interruptions and maximize efficiency.
Detail of corrugated flexible stainless-steel tube
Improvements Provided by AMPCO® 25
AMPCO® 25 is a high-strength, wear-resistant copper alloy designed for demanding applications where durability and thermal conductivity are essential. Its superior mechanical properties make it an ideal choice for components subjected to high friction and extreme operating conditions.
TBW bushings made from this material have proven to be a superior solution, addressing the most persistent challenges in stainless-steel tube manufacturing.
Key benefits observed with AMPCO® 25 include:
- Extended bushing lifespan – The exceptional wear resistance of AMPCO® 25 significantly reduces the frequency of replacements.
- Minimized downtime – Less frequent bushing changes lead to smoother operations and uninterrupted production.
- Improved quality – Superior thermal conductivity helps create stronger, more consistent welded steel tubing, reducing defects.
- Consistent tube geometry – AMPCO® 25 maintains its structural integrity over time, ensuring precision in tube dimensions.
- Enhanced efficiency and cost savings – With fewer process interruptions and reduced material waste, manufacturers achieve higher productivity and lower operational costs.
Close-up of AMPCO® TBW welding bushings
Resulting Numbers
To give a better description of the actual improvements provided by the AMPCO® 25 TBW bushings, two sets of trials were conducted at the facilities of our customers who are leading manufacturers of flexible stainless-steel tubing.
One set of trials has led to an approximately 46% longer bushing lifespan at 4400 meters of tubing produced compared to the average 3000 meters. The other set of trials, which is also the focus of our case study, has led to a 53% longer bushing lifespan and even no rejected parts!
Companies that have adopted AMPCO® 25 have reported significant improvements in performance, reliability and production. The full case study reveals the exact procedure with all the necessary details. Download it for free to discover how you can leverage AMPCO® 25 TBW bushings to your advantage.
