Barrel tank seam welder system

Abstract

An apparatus ( 10 ) for joining a predetermined geometrical profile shape from a sheet material (SM) includes a positioning assembly ( 12 ) including a base member ( 14 ) and a frame ( 16 ) that is operable to receive the sheet material (SM), to configure the sheet material in a predetermined orientation and to linearly translate the sheet material along a process direction ( 20 ). A Z-bar ( 22 ) is configured to guide a first longitudinal edge (FE) and second longitudinal edge (SE) of the sheet material (SM) into adjacent alignment along the process direction ( 20 ). A welding and forging assembly ( 60 ) welds and then forges a seam between the first longitudinal edge (FE) and the second longitudinal edge (SE) of the associated sheet material (SM).

1 . A method of joining overlapped end portions of one or more associated sheet materials, the method comprising:
 overlapping end portions of the one or more associated sheet materials;   welding the overlapped end portions with a welding assembly configured to apply a current to at least the overlapped end portions for at least partially bonding together the overlapped end portions; and   forging the overlapped edge portions with a forging assembly, the forging assembly configured to create a solid-phase bond between the overlapped end portions of associated sheet material.   
     
     
         2 . The method of  claim 1 , wherein the welding includes forming a transport weld for maintaining the overlapped end portions in position until the solid-phase bond is created during the forging step. 
     
     
         3 . The method of  claim 1 , wherein the welding includes applying a current with first and second weld wheels adapted to engage respective end portions of the associated sheet material on opposite sides thereof. 
     
     
         4 . The method of  claim 3 , wherein the weld current applied is between 5000 amps and 25000 amps, or the weld speed is between 50 inches/min and 600 inches/min, or the weld force is between 1000 lbs and 8000 lbs. 
     
     
         5 . The method of  claim 1 , wherein the forging includes applying pressure to the overlapped end portions with first and second forging wheels adapted to engage respective end portions of the associated sheet material on opposite sides thereof. 
     
     
         6 . The method of  claim 5 , further comprising heating the overlapped end portions by applying between 30 kW and 100 kW to an induction coil in proximity to the overlapped end portions, and the forging includes applying a force of between 3000 lbs and 15000 lbs to the overlapped end portions. 
     
     
         7 . The method of  claim 1 , further comprising heating the overlapped end portions of the associated sheet material with a heating unit after welding and before forging. 
     
     
         8 . The method of  claim 7 , wherein the heating includes heating the overlapped end portions of the associated sheet material to between 1400 degrees Fahrenheit and 2400 degrees Fahrenheit. 
     
     
         9 . The method of  claim 1 , wherein the sheet materials have a thickness, and wherein an overthickness of the overlapped end portions is reduced from 100% to 10% after the forging. 
     
     
         10 . The method of  claim 1 , wherein the overlapping includes overlapping terminal end portions of first and second rolls of sheet material. 
     
     
         11 . An apparatus for joining overlapped end portions of one or more associated sheet materials comprising:
 a positioning assembly including a base member and a frame that is operable to receive associated sheet material and configure end portions thereof in an overlapped configuration;   a welding assembly for applying a current to at least the overlapped end portions for at least partially bonding together the overlapped end portions; and   a forging assembly for creating a solid-phase bond between the overlapped end portions of associated sheet material.   
     
     
         12 . The apparatus of  claim 11 , further comprising a heating unit for heating at least a portion of the overlapped end portions of the associated the associated sheet material after welding and prior to forging. 
     
     
         13 . The apparatus of  claim 12 , wherein the heating unit includes an induction heating element configured to heat the overlapped end portions of the one or more associated sheet materials to a temperature of between 1400 degrees Fahrenheit and 2500 degrees Fahrenheit. 
     
     
         14 . The apparatus of  claim 13 , wherein the heating unit is configured to heat the overlapped end portions of the one or more associate sheet material by applying between 30 kW and 100 kW and the forging assembly is configured to apply a force of between 3000 lbs and 15000 lbs to the overlapped end portions. 
     
     
         15 . The apparatus of  claim 11 , wherein the forging assembly includes at least one pair of forging wheels configured to apply pressure to the each of the overlapped end portions of the associated sheet material. 
     
     
         16 . The apparatus of  claim 11 , wherein the welding assembly includes first and second weld wheels adapted to engage respective end portions of the associated sheet material on opposite sides thereof.