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Cored Wire Tube Production Line

Cored wire tubes are manufactured using cold-rolled low carbon steel strips, filled with single or composite functional powders such as calcium, aluminum, silicon, and titanium. By precisely controlling the feeding rate and insertion depth, the core material is released into molten steel, where it reacts with impurity elements like oxygen (O) and sulfur (S), forming stable compounds (e.g., CaO, CaS). This reaction effectively modifies inclusions and purifies the steel.

The production of cored wire tubes is a high-precision, high-efficiency cold roll forming process. The core challenge lies in ensuring uniform filling, consistent sealing, and continuous stable operation. The entire process integrates automated machinery with advanced control systems to meet the strict requirements of metallurgical refining.

Product Details

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Product Details

Product Description

1. Production Process

1. Steel Strip Decoiling
  Premium cold-rolled low-carbon steel strips (typically 0.3–0.6 mm thick) are uncoiled and fed into the forming system.
2. Steel Strip Cleaning (Optional)
  Surface cleaning or degreasing may be applied to enhance bonding and weld quality.
3. Pre-forming Stage
  The strip is gradually bent into a "U" shape by rollers to prepare for core filling and sealing.
4. Precise Core Filling
  Pre-blended metallic powders such as Ca, Al, Ti, Si, CaCO₃, or rare earths are dispensed into the U-shaped strip via a precision dosing system.
5. Tube Forming and Sealing
  The filled strip is progressively formed into a closed tube. Sealing can be achieved through mechanical crimping or welding, ensuring no leakage.
6. Straightening and Compacting
  Tubes are straightened and compacted to ensure dimensional consistency and core density.
7. Cut-to-Length
  Tubes are cut into fixed lengths (e.g., 3m, 5m) or left continuous for coiling. Cutting tolerance is controlled within ±1%.
8. Coiling (if applicable)
  Tubes are coiled into reels for efficient handling, transportation, and on-site feeding.
9. Quality Inspection and Packaging
  Each batch undergoes visual inspection, weight verification, chemical sampling, and fill uniformity checks before final packaging.

2. Technical Parameters

Tube Specifications:	Φ9mm, Φ13mm, Φ16mm, Φ20mm (customizable)
Wall Thickness:	0.3 mm – 0.6 mm
Filling Ratio:	10%–35% depending on application
Production Speed:	30–80 m/min (up to 100 m/min under stable operation)
Coil Weight:	150–500 kg per spool
Length Tolerance:	±1%

3. Performance Standards After Use

Cored wire tubes are designed to deliver the following metallurgical performance:
- Inclusion Control: Inclusions are refined and spheroidized, meeting ASTM E45, DIN 50602, and GB/T 10561 standards
- Sulfur Content: ≤0.003%, compliant with ultra-low sulfur steel specifications
- Total Oxygen (T.O): ≤0.0025%, meeting high-purity steel requirements
- Enhanced steel workability, cutting performance, and fatigue resistance

Typical Application

- Ultra-low sulfur structural steels
- High-strength alloy steels
- Pipeline steel, spring steel
- Marine steel, automotive steel, premium-grade welded pipe steel

Additional Notes

Full production line equipped with a PLC-based control system for real-time monitoring and feedback
Optional in-line weighing systems to ensure consistent core material dosing
Custom solutions available including weld inspection units and laser measurement modules

The Technical Flow of the Production Line

{Steel Tape}→→ Double-head un-coiler →→Strip-head Cutter and welder→→Spiral accumulator→→Forming section（Flattening unit +Main driving unit +Forming unit +Guide unit +squeeze roller）+ De-burr frame →→Cooling unit →→ Sizing unit and straightener →→Recoiler

ored Wire Tube Production Process

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Cored Wire Tube Production Line FAQS

What is the function of the core powder in cored wire tubes?

The core powder—usually a mix of calcium, aluminum, silicon, titanium, and other active elements—reacts with impurities like oxygen and sulfur in molten steel to form stable compounds (e.g., CaO, CaS). This effectively refines the steel by modifying non-metallic inclusions and enhancing purity, improving steel quality and performance.

How do I select the right filling material for my application?

Selection depends on your metallurgical goals. For example: Calcium-based cores are ideal for sulfur removal and inclusion modification. Aluminum or Titanium are used for deoxidation. Rare earths are chosen for grain refinement and special alloy properties. We provide consultation services to help you determine the most suitable formula based on your steel grade and process requirements.

What are the benefits of using cored wire tubes over traditional bulk additives?

Higher reaction efficiency due to targeted delivery. Reduced material waste and better control of chemical reactions. Cleaner steel with improved mechanical properties. Automated feeding ensures consistency and safer handling.

How long can the cored wire be stored, and what conditions are recommended?

Cored wire tubes should be stored in a dry, covered environment away from moisture and corrosive substances. Under proper storage, the shelf life can exceed 6–12 months. For extended storage, sealed packaging or vacuum packing is recommended.

What’s the typical delivery form—straight lengths or coils?

Both options are available: Coiled form (spool/reel) is commonly used in continuous feeding systems. Straight lengths (e.g., 3m, 5m) are also offered for manual or semi-automatic applications. Custom formats can be provided based on your equipment setup.

What should I do if the core powder leaks during use?

Leakage can be caused by: Improper sealing during production. Rough handling or bending during transport/storage. Excessive feeding speed or friction during use. We recommend checking the feed system alignment, ensuring smooth unwinding, and selecting properly sealed wires. If issues persist, contact our service team for troubleshooting support.

What maintenance is required for the production equipment?

Key maintenance practices include: Regular cleaning of forming rollers and filling nozzles. Checking wear of sealing units and straightening components. Ensuring PLC system calibration and backup. Routine inspection of feeding accuracy and filler integrity. We provide a detailed maintenance manual and offer remote or on-site technical support if needed.

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