AWS Schäfer is a leading manufacturer of pipe forming machines, with over 2800 machines installed worldwide since 1959. Key developments include the first plate rolling machine capable of 120mm walls in 1980, largest hydroforming machine in 2006, and variable radius induction bending machines capable of tight radii. The company offers a wide range of pipe forming, bending, welding, and testing equipment for applications in oil/gas, automotive, nuclear, and construction industries.
2. From 1959 – 2013 WORLDWIDE more than 2800 Machines
1959 - 60 Startup by Mr. Schäfer‘s Grand Father with Handriven
Machines for Plate Rolling
1980 First Plate Rolling Machine up to wall 120 mm in the world
1987 First JCO Presses 6500 t
1988 Induction bending machines
1984 Fist T- Fitting Press
1989 First Cladding and Calibration press in the world
1970 – 1990 Plate Pre Forming, Welding and Cutting Machines
History of Schäfer Technologie
3. From 1959 – 2013 WORLDWIDE more than 2800 Machines
1980 Profile bending machines, Rollbending machines
1991 First Hydroforming machine for Automtive
1994 First worldwide complete Hydroforming Line for Automotive OPEL
2003 New Hydro-Mechanical Hydroforming Machine HFC 120
2006 Biggest Hydroforming Machine in the World HFC 380 (380,000 kN) for
Bi Metal Pipes and Calibration
2013 Induction Bending Machine SRBMI 1600
History of Schäfer Technologie
5. • Variable bending radius. The proposed technology enables manufacturing of elbows with
different radiuses within the length of the pipe, including radii less than 1.5 x D, using only
one set of tooling for the same diameter pipes. Bending radius can be anything from 1.5 to
40 DN
• Bending can be performed with preservation of some straight sections
length both before bending area and behind, as well as in between. It
reduces the number of welds in the system and prevents welding on
critical points (tangential), which can not be avoided in the manufacture of assembly
welding units
• High quality of elbow, low wall thinning and ovality, high performance
• Minimal required set of tools does not require large amounts of the expensive stamping
equipment as in the manufacture of stamped elbows.
• CNC system based on an industrial PC in combination with Hydraulic power and thanks to
a special algorithm of coordinated movements of the inductor and the pipes for great
quality with minimal human intervention
The advantage of the induction
bending
13. Stamped elbow of two pieces Ø 1020
x 32 mm R= 1,5 X D, 90°
Induction bent Ø 1020 x 32 mm
R= 1,5 X D, 90°
At least 17 different manufactoring processes
Costs intensive manufactoring process
High amount of specialist is required
Pressure keeping 2,0 of nominal
Delivery time 1 pc. approx. 7-10 days.
Only 5 different manufactoring processes
Low costs manufactoring process
Low amount of specialist is required
Pressure keeping 3,0 of nominal
Delivery time 1 pc.approx. 0,5 day. ( at least
6,5 days faster than stamped technology)
Induction bents vs stamped technology
14. Pipe diameter Ø 57 mm – 1660 mm
Pushing force up to 5000 kN
Bending moment up to 10.000 kNm
Wall thickness 4 mm till 120 mm
Radius from 1,0 x D till 10 m
Bending speed 3-150 mm/min
S355 - P92,
austenitic steel
ferrititc steel
Technical Specifications
15. One Machine = Three Functions:
1. Pipe Clading
2. Pipe Calibration
3. Hydro Static Testing
AWS Bi-Metal/Clad Pipe Technologies
16. 0 1
2 3
Tool
Calibration Inner Pipe To Outer Pipe
Outer
Pipe
Inner Pipe
Cladding Process
Bi-Metal/Clad Pipe Forming Process
20. Sizes: 90 240 320 380 480 520
Pipe Ø: - 200 mm - 355 mm - 457 mm - 508 mm - 610mm - 650 mm
Wall-
thickness:- 5 mm - 17 mm - 20 mm - 20 mm - 22 mm - 25 mm
Pipe Length: Any Length / Standard: 6 m – 12 m
Machine Range
Bi-Metal/Clad Pipe Calibrationmachine
21. SHFC 320 Pipe Length 12 m SHFC 380 Pipe Length 12 m
Bi-Metal/Clad Pipe Calibrationmachine
22. Outer Diameter Wallthickness
4" 8.56 mm
6" 10.97 mm
8" 17.7 mm
10" 15.09 mm
12" 17.48 mm
14" 19.5 mm
16" 20.0 mm
20" 20.0 mm
Pipe Diameter Wall Thickness Ratio
23. Outer Pipe Material Inner Pipe Material
Type Yield
(MPa)
Norm
X42 290 API 5L
X52 359 API 5L
X60 414 API 5L
X65 448 API 5L
X70 483 API 5L
X80 552 API 5L
L 360QB 360 DIN EN 10208-2
L 415QB 415 DIN EN 10208-2
L 450QB 450 DIN EN 10208-2
L 485QB 485 DIN EN 10208-2
UNS Type Cr M o N i N PRE
S41000 410 12 — 0,5 — 12
S32100 321 18 — 9,0 — 18
S31603 316L 17 2,5 11,0 — 24
S31703 317L 18 3,0 11,0 0,05 29
N08904 904L 21 5,0 25,0 0,10 39
N08825 Alloy 825 22 3,0 40,0 — 32
N06625 Alloy 625 22 9,0 60,0 — 52
N06059 Alloy 59 23 16,0 59,0 — 75
C70600 CuNi10Fe — 10,0 — —
C71500 CuNi30Fe — — 30,0 —
N08926 Alloy 926 20 6,5 25,0 0,20 45
N08367 Alloy 367 20 6,5 24,0 0,22 45
PRE: Value for pre resistance corossion, (0 - Protection for Steel)
Pipe Material Combinations
24. High Quality In Repeatability, In Roundness, In Tolerances
Cost Effective And Flexible Production
Corrosion Protection
Abrasive Protection
Life Time 10 x Higher Then Carbon Steel Pipes
Advantages of AWS Cladding Machines
26. Steel T-fittings with diameter
from 114 mm till 1067 mm
made of austenitic and ferritic grades of steel
Elbows with small radius with diameter
from 114 till 630 mm made of austenitic and ferritic
grades of steel
Reducers with diameter
from 114 mm till 1220 mm made of austenitic and
ferritic grades of steel
AWS Machines For Tees
27. Machine Closing Filling with water
Horizontal cylinder
advance
Control water pressure
Holding cylinder controlled
Pressure release
Press open part
removal
T – Forming Process
29. 1. Pipe stock 2. Pipe cutting 3. Sand blasting/Cleaning/Brushing
4. Lubrication 5. Hydroforming 6. Heat treatment
7. Cutting off the cap 8. End preparing 9. Marking
T-Fitting Line
30. Advantages of Hydroforming
Proposal for creation of high-efficiency, highly effective and flexible production of
pipeline fittings which guaranties:
Reduction of a work cycle of manufacture of a product - cost price advantage
Increasing mechanical characteristics of a tee at the expense of a cold hardening
and the subsequent heat treatment
High efficiency,
Manufacturing of products according to all standards like DIN, ANSI, Gost
Minimal production time, in comparison with other technologies
100 % repeatability of the sizes and properties of dimensions
Less influence of the human factor on the basic processes, as a consequence of the
high quality output
The minimum requirement of the highly skilled personnel
