What is a High Frequency Welded Solid Finned Tube
A high frequency welded (HFW) solid finned tube is a specialized heat transfer component widely used in industrial applications to enhance thermal efficiency. It consists of a base tube with solid fins (metal strips) welded radially or spirally onto its surface using high-frequency electrical currents.
The Key Features of High Frequency Welded Solid Finned Tubes
Structure:
- Base Tube: Typically made of carbon steel, stainless steel, or alloys.
- Fins: Solid metal strips (not hollow) welded tightly to the tube.
- Bonding Method: High-frequency welding creates a metallurgical bond between the fin and tube, ensuring minimal thermal resistance.
How It Works:
- High-frequency electrical currents generate localized heat, melting the fin and tube surfaces.
- Pressure is applied to fuse the materials, forming a seamless and durable joint.
The Manufacturing Process of High Frequency Welded Solid Finned Tubes
Material Preparation
- Base Tube Selection: Carbon steel, stainless steel (304/316), or seamless steel pipes are selected for their mechanical strength and compatibility with high-frequency welding.
- Fin Strip Material: Aluminum or steel strips (0.3–1.2 mm thickness) are precision-cut to match the base tube dimensions.
Pre-Treatment
- Surface Cleaning: Base tubes undergo degreasing and pickling to remove oxides, ensuring optimal welding surface conditions.
- Fin Strip Alignment: Strips are helically wound around the base tube with controlled tension to maintain uniform spacing.
High-Frequency Welding
- Induction Heating: High-frequency current (100–400 kHz) generates localized heat at the fin-tube interface, melting the fin strip edge and bonding it to the base tube.
- Pressure Rolling: Simultaneous mechanical pressure (10–30 MPa) ensures metallurgical bonding without filler materials.
The Advantages of High Frequency Welded Solid Finned Tubes
High Structural Integrity
- Continuous metallurgical bonding achieves fin-to-tube bond strengths of 60–80 MPa, outperforming embedded or wrapped fins by 30–40%.
Superior Heat Transfer Efficiency
- Direct metal-to-metal contact reduces thermal resistance, enabling 15–25% higher heat flux than extruded fins in boilers and heat exchangers.
Material Versatility
- Compatible with carbon steel, stainless steel (304/316), and copper-nickel base tubes, supporting diverse industrial applications.
Cost-Effective Production
- High-speed welding (1–3 m/min) lowers labor costs by 20–35% compared to manual brazing or soldering methods.
Dimensional Precision
- Laser-guided alignment ensures ±0.2 mm fin spacing accuracy, critical for high-density designs (5–7 fins/cm).
Durability in Harsh Conditions
- Solid fins withstand thermal cycling up to 400°C without loosening, ideal for power plant boilers and petrochemical reactors.
The Disadvantages of High Frequency Welded Solid Finned Tubes
Limited Material Compatibility
- Base tubes and fins must have similar melting points and thermal expansion coefficients (e.g., steel-steel or steel-copper). Aluminum fins are challenging to weld to steel due to metallurgical incompatibility.
Mechanical Stress Sensitivity
- Residual stresses from localized heating weaken fin roots, risking fatigue cracks under cyclic thermal loads (common in boilers and heat exchangers).
High Equipment Costs
- High-frequency power generators and precision alignment systems raise upfront investment (20–30% higher than extrusion or embedded fin methods).
Fin Height Restrictions
- Max fin height typically ≤20 mm due to uneven heat distribution during welding. Exceeding this limit reduces bond strength by 15–20%.
Process Complexity
- Strict parameter control (e.g., 200–400 kHz frequency, 10–30 MPa pressure) is required. Minor deviations cause defects like porosity or incomplete fusion.
Sizes and Materials of Our High Frequency Welded Solid Finned Tubes
| Base Tube Diameter | 16 to 350 mm | 3/8″ to 14″ NPS |
| Base Tube Wall Thickness | 2 to 30 mm | 0.08″ to 1.18″ |
| Base Tube Length | ≤32,000 mm | ≤92 ft |
| Base Tube Material | Carbon Steel (A106B, P235GH, A179, A210, A192, etc.) Alloy Steel (P5, T5, P9, T9, T11, T22, etc.) Stainless Steel (TP304, TP316, TP347, B407 800H/HT, etc.) | |
| Fin Pitch | 39 to 277 FPM | 1 to 7 FPI |
| Fin Height | 8 to 35 mm | 0.31″ to 1.38″ |
| Fin Thickness | 0.5 to 3 mm | 0.02″ to 0.12″ |
| Fin Material | Carbon Steel, 2.25Cr-1Mo, 5Cr-0.5Mo, 11-13Cr (409, 410), 18Cr-8Ni (SS 304), 25Cr-20Ni | |
| Fin Type | Solid | |
For other customized requirements, please contact us.
Our Production Capacity of High Frequency Welded Solid Finned Tubes
Total four high frequency welded spiral fin tube machines, monthly production capacity is 1200 tons in total.
High Frequency Welded Solid Finned Tubes Uses
- Finned Tube Heat Exchangers
- Finned Tube Radiator
- Finned Tube Cooler
- Finned Tube Evaporator
- Finned Tube Heater
- Finned Tube Radiation Heater
- Finned Tube Boiler
- Finned Tube Convector
- Finned Tube Economizer
- Finned Tube Condensers
- Finned Tube HVAC Systems
Comparison with Other Finned Tubes
| Type | Bonding Method | Fin Type | Typical Use |
|---|---|---|---|
| HFW Solid Spiral Finned Tube | Welded (HF current) | Solid metal | High-stress environments |
| Extruded Finned Tube | Mechanically bonded | Hollow fins | Moderate-temperature use |
| Embedded Finned Tube | Rolled into grooves | L-shaped fins | Low-pressure systems |
Why Choose Us
- a 16-year fin tube manufacturer. We are experts.
- solutions for all your needs
- the highest product quality
- the low lead times
- excellent customer service
