Laser Welding Solution for a Turkish Stainless Steel Corrugated Pipe Manufacturer

Overview of the Project

Our client, a leading stainless steel corrugated pipe manufacturer in Turkey, approached SteviS Tech via LinkedIn after watching our video demonstration of the latest laser welding machine for stainless steel pipe production lines. Recognizing the significant advantages of laser technology over traditional welding processes, they sought to upgrade their production capabilities to meet growing market demand and enhance product quality.

Client Background and Challenges

About the Turkish Manufacturer

• Industry: Manufacturing of stainless steel corrugated pipes for industrial and commercial applications
• Location: Turkey
• Core Requirement: Replace the traditional TIG/MIG welding setup with a more efficient, precise laser welding process to:
  1. Increase production throughput
  2. Reduce weld defects on corrugated pipe seams
  3. Lower overall operational costs

Client Background and Challenges

About the Turkish Manufacturer

• Industry: Manufacturing of stainless steel corrugated pipes for industrial and commercial applications
• Location: Turkey
• Core Requirement: Replace the traditional TIG/MIG welding setup with a more efficient, precise laser welding process to:
  1. Increase production throughput
  2. Reduce weld defects on corrugated pipe seams
  3. Lower overall operational costs

Existing Production Pain Points

1. Inefficient Traditional Welding:
   • Frequent rework due to inconsistent welds on thin-walled corrugated tubes
   • Lengthy cycle times slowed down the production line
2. High Labor and Consumable Costs:
   • Skilled welders required for manual TIG/MIG processes
   • Constant spending on filler wire and gas
3. Limitations in Weld Quality and Repeatability:
   • Inability to maintain tight tolerances on corrugated geometries
   • Surface discoloration and heat-affected zones affecting end-product appearance

Solution: SteviS Tech’s Laser Welding System

Automatic Laser Welding Machines for Corrugated Pipes Processing

1. Laser Welding Machine for Endless Stainless Steel Tube Mill
   • High-Precision Welding: Galvo-controlled laser head for consistent seam tracking on corrugated profiles
   • Speed and Efficiency: Up to a 50% increase in welding speed compared to traditional methods
   • Minimal Heat Input: Reduces distortion, producing clean, “no-touch” welds with virtually zero spatter
   • Turnkey Integration: Designed to slot seamlessly into existing stainless steel pipe production lines
2. Handheld Laser Welding Machine for Joint Welding
   • Portable Flexibility: Ideal for secondary operations, such as welding corrugated pipe connectors and fittings
   • Intuitive Operation: Lightweight ergonomic design allowing operators to handle complex joint geometries
   • Consistent Quality: Precise energy control ensures uniform weld penetration and superior aesthetics

Project Scope and Implementation

1. Consultation & Needs Assessment
   • Detailed requirements analysis via LinkedIn discussions and on-site visits
   • Labs tested sample corrugated tubes to validate weld parameters
2. Equipment Delivery & Installation
   • Delivery Timeline: Equipment shipped to Turkey within four weeks of order placement
   • On-Site Support: SteviS Tech engineers dispatched immediately upon arrival to perform turnkey installation, alignment, and system calibration
3. Operator Training & Commissioning
   • Comprehensive training session for the client’s production team on machine operation, safety protocols, and basic maintenance
   • Final commissioning proved that the system met all throughput and quality benchmarks

Results and Benefits

Enhanced Production Efficiency

• Throughput Improvement: Achieved a 40% increase in daily output of corrugated pipes
• Reduced Cycle Time: Average weld time per pipe decreased from 45 seconds (TIG) to 25 seconds (laser)
• Lower Reject Rate: Weld defect rate dropped by more than 80%, ensuring more first-pass yield

Cost Savings and ROI

• Labor Savings: Reduced dependency on manual TIG/MIG welding, allowing skilled welders to focus on higher-value tasks
• Consumables Reduction: Virtually eliminated filler material and shielding gas costs for primary seam welding
• Energy Efficiency: Laser source delivers higher energy conversion rates, reducing overall power consumption by 20%

Improved Weld Quality and Consistency

• Superior Aesthetics: Minimal discoloration and precise seam tracking minimize post-weld polishing
• Consistent Process Control: Digital parameter storage ensures repeatability across large production batches
• Versatility: Handheld laser welding machine allows fast, reliable welding of corrugated pipe joints and fittings

Conclusion and Future Plans

Summary of Success

By adopting SteviS Tech’s laser welding machine for stainless steel corrugated pipe production and our handheld laser welding machine for secondary operations, the Turkish manufacturer has upgraded its entire welding workflow. The combined solution delivered substantial gains in production efficiency, reduced costs, and improved end-product quality—positioning them to capture new market share both domestically and internationally.

Next Steps

• Expansion of Production Line: The client is exploring adding a second laser welding cell to further increase throughput.
• Ongoing Support: SteviS Tech will continue to provide remote monitoring, software updates, and periodic maintenance inspections to guarantee long-term reliability.

Call to Action

If you are a stainless steel pipe manufacturer or an industrial fabricator looking to boost production efficiency and eliminate traditional welding bottlenecks, contact SteviS Tech today to learn how our laser welding solutions can transform your operations