1. Raw Material Preparation & Inspection Select stainless steel or carbon steel round bars that comply with industry standards as raw materials, and conduct comprehensive inspections on chemical composition, mechanical properties, and surface defects to ensure they meet the manufacturing requirements of socket weld crosses.2. Cutting & Blank Preparation Use band saws or CNC cutting machines to cut the raw material round bars into blanks of preset weight and dimensions, then remove burrs and sharp edges from the cut surfaces to avoid affecting subsequent processing.
3. Hot Forging Heat the blanks to the optimal forging temperature (1100–1250°C) in a heating furnace, then use a forging press or die forging machine to shape the blanks into cross-shaped rough parts with socket structures through multi-pass forging, ensuring uniform distribution and consistent size of the four ports.
4.Heat Treatment Perform normalizing or quenching and tempering treatment on the forged rough parts to eliminate internal stress caused by forging, refine the metal grain structure, and enhance the product's mechanical strength and toughness.
5. Precision Machining - Socket Machining: Use CNC lathes to machine the socket at each port of the cross, strictly controlling the socket size, depth, and taper to conform to socket weld connection specifications. - Port Finishing: Process the end faces and outer circles of each port to ensure end face flatness and outer diameter tolerance accuracy. - Deburring: Remove all machining burrs and sharp edges to prevent damage to welding joints and pipelines during installation.
6. Weld Groove Machining (Optional) For products requiring pre-weld grooves, machine grooves of specified angles and sizes at the socket openings to improve welding seam fusion quality and structural stability.
7. Surface Treatment - Pickling & Passivation (for Stainless Steel): Treat the surface with a mixed acid solution (nitric acid + hydrofluoric acid) to remove oxide scale and form a dense passivation film, improving corrosion resistance. - Anti-rust Treatment (for Carbon Steel): Carry out anti-rust painting or galvanizing according to customer requirements to prevent rust during storage and use.
8. Quality Inspection & Testing - Dimensional Inspection: Use calipers, micrometers, and gauges to inspect all dimensions of the cross to ensure compliance with design drawings.
- Pressure Testing: Conduct hydraulic pressure tests in accordance with standards to check for leakage and verify that the pressure-bearing capacity meets requirements.
- Surface Defect Inspection: Check for surface defects such as cracks, pores, and scratches, and reject unqualified products.
9. Marking & Packaging Mark the product model, material grade, pressure rating, and batch number on qualified crosses, then package them with anti-rust paper and plastic film before warehousing.
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