Imperial Weld Ring Corp.

Imperial Weld Ring, we recently demonstrated our ability to manufacture a custom sized product that fulfilled the stringent requirements of a power generation customer. To up the stakes, this high temperature alloy consumable insert was fabricated to rigorous nuclear quality assurance requirements, which even included on-sight inspections and audit procedures. After we designed the tooling, we used our custom-tooled roll formers, wire winders and straighteners, as well as metal shears to draw the 0.156" diameter weld wire per MIL-E-21562D, AM. 7, 1, Type ENRN62. Spooled to various diameters, the wire was 0.044" wide and 0.150" thick. Then we employed our optical comparator, precision gauges, and testing instruments calibrated to MIL-STD-45662 to inspect the dimensions of the wire, which was finally finished to 63 grit. Subsequently, the wire was fit into a custom shaped profile with precision tolerances of ±0.002 wide by ±0.002 to 0.003" thick and TIG welded.

abricate custom dissimilar metal weld spools-low alloy ferritic steel (T22) to austentic stainless steel (304H). These transition spool sections were designed to be used as superheater boiler tube replacements and upgrades. We were also required to engineer the inner diameters of the spools to project specifications, which enabled them to achieve desired steam flow. First, we used our CNC horizontal turning centers and performed external turning, boring, and profiling of the ASME SA-213 TP347H austentic stainless steel. We then drilled, swaged, and beveled the steel before it was deburred and polished to 63Ra max, confirmed by our custom gages and surface finish comparators. We then heat and lot marked the tubing, which was done with a combination of dot peen computerized marking heads, low stress dies, and an electrochemical etcher. Our staff end prep beveled the weld spools, which were 3" to 36" long, 0.740" thick, and 2.110" in diameter, to 37-12°. At Imperial Weld Ring, we fabricated the weld spools to precise tolerances of ±0.002" and followed with in-process dimensional inspections as well as gono-go gauging.

Imperial Weld Ring manufactures consumable inserts in both standard and custom sizes and styles that meet AWSASME 5.30 and MIL-I-23413 standards. Class 1, Class 2, Class 35, and Class 4 (A, J, K, and Y shapes, respectively) as well as Imperial's custom T-shape inserts are available in aluminum, carbon steel, stainless steel, titanium, chrome-moly, Hastelloy and Inconel alloys in unlimited diameters ranging as small as ¼" to larger than 100". Imperial's consumable weld inserts ensure a full penetration root pass and seamless inside diameter (ID) weld bead that meets the requirements of the most stringent weld procedures in critical applications. Imperial's consumable inserts increase the strength of the tube weld and provide a smooth surface on the inside of the weld joint for applications where unrestricted ID is crucial. Inserts can be used in any application where a strong, seamless joint is desired, and have successfully been used for decades.

At Imperial Weld Ring, we manufacture custom weld test pipe coupons, test plates, and backing strips for use in weld certification testing per ASME Section IX specifications, and in full compliance with ASME and Pipe Fabricating Institute (PFI) standards. They are designed for welder training and certification, mock fit-up, practice joints, and procedure qualification record (PQR) materials. All weld coupons are available in steel, carbon steel, stainless steel, chrome-moly, Hastelloy, aluminum, nickel alloys, titanium, and virtually any material or grade. Regardless of material type, full traceability is available as well as mill certification. All of our pipe, plate, and test coupons are precision machined transverse to grain - never flame cut. Weld coupon dimensions are typically 4” to 6” in length, but can be fabricated to any length required, and to tolerances as tight as ±1°. We provide unlimited customization, including the fabrication of single and or double end-bevel, and in almost any quantity.

Imperial Weld Ring manufactures precision weld rings (also known as backing rings or chill rings) in both standard and custom sizes. Our weld rings ensure the proper root gap to allow full weld penetration in pipe or tube welding and expedite the welding process by eliminating the need for manual fit-up or spacer blocks. Machined to ±0.003", this precision fit prevents weld contamination inside of the pipe that could inhibit proper internal flow. We offer multiple standard spacer styles including long removable type spacers that compensate for the highest degree of pipe misalignment, short spacers that are readily consumed in the initial root pass, pressed type spacers that offer a root gap setting without the addition of foreign material and can be furnished on rings of all material types including non-ferrous metals (ex. Aluminum) on which stud welding is ineffective. Rings may also be supplied without spacers ("plain") which allows the welder to have more control over the size of the root gap. Our custom weld rings can be machined to fit any standard or non-standard pipe or tube dimensions. We offer a variety of profiles that are designed to meet multiple pipe welding applications.