Pipe fittings are piping component that helps in changing the direction of the flow such as elbows, tees; changes the size of the pipe such as reducers, reducing tees; connect different components such as couplings and stop the flows such as caps, fittings.

1. Pipe Fittings Manufacturing Process
Introduction
Pipe fittings are piping component that helps in changing the direction of the flow such as elbows,
tees; changes the size of the pipe such as reducers, reducing tees; connect different components
such as couplings and stop the flows such as caps, fittings.
Pipe fittings are manufactured from stainless steel seamless pipes, carbon steel seamless pipes and
from welded pipe with filler material. Large diameter fittings are manufactured from plate.
Various methods used for manufacturing pipe fittings are shown in the below diagram: -
PipeFittingManufacturing
Process
Butt-Welding
Elbow
Mandrel Method/Hot
Forming
Extrusion Method/Cold
Forming
"UO" Method Welding
Hot Forming Die
Bending Method
Tee
Hydraulic Bulge Method
(Cold Forming)
Monaka Method
Hot Extrusion Method
Reducer
Outer Die Method
Plate Forming Method
Cap Deep Drawing Method
StubEnd Flaring Method
Forged Fittings
Open Die Forged
Fittings
Closed Die Forged
Fittings
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Our Specialties:
1) Largest Stock for Seamless Pipes in Stainless Steel, Carbon Steel & Alloy Steel
2) Pipe Fittings Manufacturing
3) Leading Manufacturer of Instrumentation Tubes & Fittings
4) Plates, I Beams, H Beams, Angles, & Structural Steel Products Available at Lowest Prices
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2. Butt-Welding Manufacturing Processes
1. Elbow Manufacturing Process
a. Mandrel Method/Hot Forming Method
 One of the most common manufacturing methods for manufacturing elbows
from pipes.
 After heating the raw material, it is pushed over a die called "mandrel"
which allows the pipe to expand and bend simultaneously. Applicable to a
wide size range.
 Characteristics of mandrel bending strongly depend on the integrated shape
and dimensions of the mandrel.
 Elbows manufactured by using hot mandrel bending have advantages of
small thickness deviation and shorter bending radius than those of any other
bending method type.
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3. b. Extrusion Method/Cold Forming Method
 In the cold extrusion method, a pipe with the same diameter as a finished
product is pushed through a die and formed into its desired shape. Usually
applied to stainless steel small to medium sizes elbows.
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4. c. “UO” Method (Welding)
 In this method the plate is cut out into a specially designed shape, it is
formed first into a U-shape using a die and then into an O-shape or tubular
form using another die, that is why this method is known as UO method.
Once the fittings formed in tumbler shaped it is welded from inside and
outside of the closing seam. A cut plate is 1st from in U shape and then in O
shape
d. Hot Forming Die Bending Method
 In this method the pipe is
been inspected before any
process. Then after cutting
out pipe into specified
length, it goes under elliptical
forming using a die shown in
the picture. For producing a
specified radius for elbow, it
bends in another die. In the
next step the elbow goes
under heat treatment. In the
end shot blasting, cleaning,
bevelling and coating are
done respectively to finalize
the product.
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5. 2. Tee Manufacturing Process
a. Hydraulic Bulge Method (Cold Forming)
 Cut piece of Pipe is placed in hydraulic die and liquid is fill inside the pipe,
Hydraulic pressure pushes out the branch, in the fixed opening in the die.
 This method gives the good surface finish. However, higher thickness Tee
cannot be manufactured by this method.
b. “Monaka” Method
 This manufacturing method is similar to Elbows, using steel plates as the raw
material.
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6.  In this method two pieces of raw material plates cut out symmetrically and
are press-formed and welded together.
c. Hot Extrusion Method
 Tee with large diameters, heavy wall thickness and/or special material with
challenging workability that cannot be manufactured using the hydraulic
bulge method are manufactured using hot Extrusion Method.
 In Hot Extrusion Method, normally bigger diameter pipe is used than the
finished product size; the branch outlet is extruded from the pipe with help
of extrusion tool.
 Other dimensions of body and branch can also be adjusted by pressing the
die if required.
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7. 3. Reducer Manufacturing Process
a. Outer Die Method
 One of the most common method for manufacturing Reducers is using an
outer die.
 The pipe is cut and pressed in the outer die; compressing the one end of the
pipe into a smaller size. This method is useful for manufacturing of small to
medium size of reducers.
b. Plate Forming Method
 Plates can also be used to manufacture Reducers.
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8.  In an UO method, plate is cut in a specially designed shape which is formed
into a U-shape and an O-shape respectively, then finished with a single weld
seam.
4. Cap Manufacturing Process
a. Deep Drawing Method
 CAPs are manufactured by Deep Drawing method. In this method, Plate is
cut out in a circle and formed by deep drawing die.
5. Stub End Manufacturing Process
a. Flaring Method
 Stub Ends or Lap Joints Flange are manufactured by flaring method. Pipe
end is a flare or spared out to form flange face. Stub ends are also
manufactured by forging in which forge block are machined to final
dimension.
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9. Forged Fittings Manufacturing Processes
1. Open-Die Forging
Open die forging is the process of deforming a piece of metal between multiple dies that do
not completely enclose the material. The metal is altered as the dies “hammer” or “stamp”
the material through a series of movements until the desired shape is achieved. Products
formed through open forging often need secondary machining and refining to achieve the
tolerances required for the finished specifications. Open die forging is often used for short
run forgings of parts that are simple, rather than complex, in design, such as discs, rings,
sleeves, cylinders and shafts. Custom shapes can also be produced with open die forging.
The repeated working of the material through the deformation process increases the
strength of the grain structure. Some additional benefits of open die forging include
improved fatigue resistance and strength.
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10. 2. Closed-Die Forging
Closed die forging (also referred to as impression die forging) is a metal deformation process
that uses pressure to compress a piece of metal to fill an enclosed die impression. In some
closed die forging processes, a succession of impression dies is used to modify the shape of
the material into the final desired shape and form. The type of material, tightness of
tolerances, and need for heat treatment can determine the number of passes the product
requires through the dies.
Advantages and Disadvantages of Open Die Forging and Closed Die Forging
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11. Open Die Forging Closed Die Forging
Advantages
Better fatigue resistance and improved
microstructure
The internal grain structure formation
increases the tightness and strength of
the products
Continuous grain flow and finer grain size Economic for large runs of products
Valuable cost of savings Dimensions of tighter tolerances and net
shapes can be achieved
Less material waste No material limitation
Increased strength and longer part life Better surface finish
Reduced chance of voids Less or no matching required
Disadvantages
It is not capable of forming close
tolerance and higher precision parts
It is not very economical for short runs
due to high cost of die production
Machining is often required to achieve
accuracies and the desired features
Closed die forging presents a dangerous
working environment
The setup cost is very high as the
machines and furnaces are costly
Special building provisions must be in
place to cope with the powerful
vibrations
Types of Pipe Fittings
At Metallica, we are manufacturing a wide range of pipe fittings, for which we use seamless pipes
and welded pipes as a key raw material. In addition to being a pipe fittings manufacturer, we are
also one of the biggest seamless pipe manufacturer and supplier, enabling us to offer cost
advantages to our customers.
Fittings are divided into the following 4 groups:
 Buttweld (BW) fittings whose dimensions, dimensional tolerances etc. are defined in the
ASME B16.9 standards. Light-weight corrosion resistant fittings are made to MSS SP43.
 Socket Weld (SW) fittings Class 3000, 6000, 9000 are defined in the ASME B16.11 standards.
 Threaded (THD), screwed fittings Class 2000, 3000, 6000 as per ASME B16.11 standards.
 Flanges manufactured in compliance with ASME, DIN, and EN standards
 Double Ferrule Compression Fittings
 Instrumentation Tube Fittings
Metallica is a specialist manufacturer and supplier of steel pipes and various types of pipe fittings
in India such as butt-welding pipe fittings (both weld and no weld), socket welding and threaded
pipe fittings, and flanged pipe fittings. We are a professional manufacturer of carbon steel,
stainless steel, and alloy steel seamless butt-welding pipe fittings, forged fittings and flanges. We
have the CE PED & ISO etc. certificates.
If you are interested in purchasing high quality pipe fittings, please contact us now for prices and
product details. Email Us on sales@metallicametals.com | Call Us On +918928722715
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