1.Raw Material Inspection and Cutting: Raw steel bars and forging blanks are inspected with material certificates. Defective materials with cracks, inclusions or corrosion are rejected. Qualified blanks are cut to fixed dimensions with burr-free ends and marked clearly to prevent material mixing.
2.Heating and Hot Forging:
Prepared blanks are heated to the standard forming temperature according to material grades. Hot closed-die forging is performed with dedicated molds to form standard pipe cap blanks with qualified wall thickness and regular arc shape.
3.Trimming and Heat Treatment:
Forged blanks are cooled, trimmed to remove flashes, and shape corrected. Professional heat treatment including normalization, annealing or solution treatment is conducted to eliminate forging stress, stabilize microstructure and avoid deformation and cracking.
4.CNC Precision Machining:
Finish machining is carried out on socket end, inner hole, end face and welding groove by CNC lathes. All dimensional tolerances are strictly controlled to ensure precise fitting and welding compatibility with pipes.
5.Surface Treatment:
Surface polishing and deburring are implemented to remove tool marks and oxide layers. Stainless steel caps are pickled and passivated; carbon steel caps are sandblasted and anti-rust treated to improve corrosion resistance.
6.Full Dimensional Inspection:
Key dimensions including outer diameter, inner diameter, wall thickness and socket depth are fully verified with precision measuring tools. Non-conforming products are sorted out for rework or scrapping.
7.NDT and Hydrostatic Test:
UT and MT non-destructive testing is performed to detect internal defects. 100% inspection is applied for high-pressure products. Standard hydrostatic pressure test is conducted to ensure no leakage, swelling or cracking.
8.Marking and Cleaning:
Qualified products are laser marked with material, specification, pressure class, batch number and production date for full traceability. All finished parts are thoroughly cleaned and surface protected.
9.Classification and Packaging:
Products are classified by specification and material. Standard moisture-proof and shockproof packaging is adopted, with qualified certificates and test reports attached.
10.Final Inspection and Delivery:
Final verification of product appearance, dimension and documents is conducted before shipment. All quality records are filed for traceability and delivery.