With the continuous innovation of industrial technology, titanium tees, as a key fluid connection component, are increasingly widely used in petrochemical, aerospace, medical equipment and other fields. Their excellent corrosion resistance and high strength-to-weight ratio make them a core component for ensuring the stable operation of complex industrial systems. As the performance requirements for materials in industrial systems continue to rise, the manufacturing process of titanium tees has become a focus of industry attention.
I. Plastic forming process
Hydraulic bulging process
Using a straight pipe blank with the same diameter as the titanium tee, synchronous pressure is applied to both ends of the pipe blank through a hydraulic press, driving the metal to flow towards the branch pipe direction under the high pressure of the internal liquid. This process requires a balanced convex die to support the formation of the branch pipe and is suitable for materials such as carbon steel, stainless steel, and titanium. It can achieve uniform wall thickness of the branch pipe and is highly efficient.
Hot pressing process
A pipe blank larger than the diameter of the tee is flattened and then heated and punched. Radial compression is used to drive the metal to flow towards the branch pipe direction, and the branch pipe is formed through die drawing. This process has low requirements for equipment tonnage and is suitable for materials with poor high-temperature plasticity such as titanium, but it requires precise control of heating temperature and deformation rate.
Filling extrusion process
An incompressible medium is filled in the straight pipe blank, and the metal and the filling material are simultaneously extruded from the radial holes of the die by bidirectional top rods to form the branch pipe. This method can avoid mechanical scratches on the inner wall, and the extrusion height can reach 2-3 times the pipe diameter. It is suitable for scenarios with high requirements for inner wall quality.
II. Machining process
End reduction method
A pipe blank with a diameter 15%-30% larger than the finished product is used. The ends are locally heated and reduced in diameter to form a middle protrusion, and then holes are drilled and flanged in the protruding part. This method is suitable for large-sized titanium tees with DN50-DN600, but the process is complex, the yield rate is low, and the wall thickness distribution needs to be strictly monitored.
Machining method
Directly cut, forge, and machine the bar or plate material through processes such as turning and drilling to form the tee. This method is suitable for small batches or special-sized titanium tees, with low material utilization but high dimensional accuracy, and is often used for small-sized pipe fittings with DN25 or less.
III. Welding process
Equal diameter welding process
After opening a hole in the main pipe, a saddle-shaped groove is designed, and the branch pipe and the main pipe are welded using a flux-cored wire CO₂ gas shielded welding. The swing amplitude of the welding torch and the length of the repeated weld beads need to be controlled, and the triangular unfilled area at the intersection of the abdominal welds needs to be carefully treated to ensure the uniformity of the weld and the pressure resistance strength.
IV. Process selection basis
Material properties: Titanium has poor room-temperature plasticity, and hot pressing or end reduction methods are mostly used for DN50 and above specifications; small-sized products can use cold extrusion or machining methods.
Specification requirements: Hydraulic bulging is suitable for batch production of standard parts, while welding is suitable for irregular or customized requirements.
Quality grade: Plastic forming processes are preferred in high-pressure scenarios, while welding or machining solutions can be considered in low-pressure scenarios.
V. Quality control key points
Material pretreatment: The chemical composition and corrosion resistance of titanium pipes need to be strictly tested;
Heat treatment: Eliminate residual stress after forming and enhance structural strength;
Non-destructive testing: Conduct penetrant testing or radiographic testing on welds and formed parts.
The manufacturing process of titanium tees is a deep integration of materials science and precision processing. Every step from raw materials to finished products reflects the pursuit of "ultimate precision": rigorous material selection, diverse and innovative forming technologies, systematic thinking for performance optimization, and a zero-tolerance attitude towards quality inspection. This process not only supports the complex fluid networks of modern industry but also reflects the path of high-end manufacturing towards high performance, lightweight, and green transformation.
