scholarly journals Development of Welding P92 Pipes Using the Reduced Pressure Electron Beam Welding Process for a Study of Creep Performance

2014 ◽  
Author(s):  
Nick Bagshaw ◽  
Chris Punshon ◽  
John Rothwell
Keyword(s):  
Electron Beam ◽  
Heat Input ◽  
Power Plants ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Pipe Material ◽  
Reduced Pressure ◽  
Type Iv ◽  
Type Iv Cracking

Boiler and steam piping components in power plants are fabricated using creep strength enhanced ferritic (CSEF) steels, which often operate at temperatures above 550°C. Modification of alloy content within these steels has produced better creep performance and higher operating temperatures, which increases the process efficiency of power plants. The improved materials, however, are susceptible to type IV cracking at the welded regions. A better understanding of type IV cracking in these materials is required and is the basis of the Technology Strategy Board (TSB) UK funded VALID (Verified Approaches to Life Management & Improved Design of High Temperature Steels for Advanced Steam Plants) project. In order to study the relationship between creep performance and heat input during welding, several welds with varying amounts of heat input and resultant HAZ widths were produced using the electron beam welding process. The welding parameters were developed with the aid of weld process modeling using the finite element (FE) method, in which the welding parameters were optimized to produce low, medium and high heat input welds. In this paper, the modeling approach and the development of electron beam welds in ASTM A387 grade P92 pipe material are presented. Creep specimens were extracted from the welded pipes and testing is ongoing. The authors acknowledge the VALID project partners, contributors and funding body: Air Liquide, Metrode, Polysoude, E.ON New Build & Technology Ltd, UKE.ON, Doosan, Centrica Energy, SSE, Tenaris, TU Chemnitz, The University of Nottingham, The Open University and UK TSB. Paper published with permission.

scholarly journals Effect of Electron Beam Welding Parameters on Temperature and Stress Field of AISI P20 Tool Steel in Vacuum Roll-cladding Process

2021 ◽  
Author(s):  
lanyu mao ◽  
Zongan Luo ◽  
Yingying Feng ◽  
Xiaoming Zhang
Keyword(s):  
Electron Beam ◽  
Stress Field ◽  
Tool Steel ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Welding Current ◽  
Temperature Fields ◽  
Welding Parameters ◽  
Aisi P20

Abstract Vacuum roll-cladding (VRC) is an effective method to produce high quality ultra-heavy AISI P20 plate steel. In the process of VRC, reasonable welding process of electron beam welding (EBW) can significantly avoid welding cracks and reduce the cost. In this paper, the electron beam welding process of AISI P20 tool steel was simulated by using a combined heat source model based on finite element method, and the temperature field and stress field under different welding parameters were studied respectively . The results showed that welding parameters have a greater effect on weld penetration than that of weld width, which making the aspect ratio increases with the increase of welding current, and decrease with the increase of welding speed. The weld morphologies were consistent with those of the modeling and the measured thermal heat curves were good agreement with those of simulated, which was verified the feasibility and effectiveness of temperature fields. The results of stress fields under different welding parameters indicat ed that lower welding speed and higher welding current resulting in lower residual stress at welded joint, which means lower risk of cracking after EBW. The results of this study have been successfully applied to industrial production.

Finite Element Modelling of Reduced Pressure Electron Beam Stainless Steel Plate and Pipe Welds

2012 ◽  
Author(s):  
Benjamin M. E. Pellereau ◽  
Paul R. Hurrell ◽  
Christopher M. Gill ◽  
Kevin Ayres
Keyword(s):  
Finite Element ◽  
Electron Beam ◽  
Welding Process ◽  
Welding Parameters ◽  
Fe Modelling ◽  
Reduced Pressure ◽  
Butt Weld ◽  
Mixed Hardening ◽  
Full Penetration ◽  
Pipe Model

Rolls-Royce plc is conducting work to investigate the feasibility of using Reduced Pressure Electron Beam Welding (RPEB) for thick section welded joints in power plant construction. As part of the work, simple specimens have been manufactured at TWI ltd in order to develop welding parameters and conditions and to examine the achievable weld quality. Previous work in this project has shown good correlations between measured and predicted stresses in RPEB welds in ferritic components [5,6]. This paper describes Finite Element (FE) modelling that was carried out to try to predict the residual stress field generated by the welding process in three of the specimens. The first specimen that was modelled was a full penetration butt weld in 80 mm thick Type 316L plate (W17). The other two models were of circumferential butt welds in 14 inch nominal diameter Type 304L pipe. The first pipe model (W20) was a single pass, 360° weld, while the second (W22) featured a slope-up and slope-down each lasting for 16° either side of a 360° full penetration weld, giving a total weld of 392°. The modelling was carried out in Abaqus [1] using a DFLUX user subroutine to model the welding heat input as a cylindrical heat source, due to the reduced pressure during specimen manufacture, only radiation heat losses were considered. The built-in Chaboche mixed hardening model was used for both materials during the structural analysis. The residual stresses predicted by the FE modelling have been compared with the results of Deep Hole Drilling (DHD) that was carried out on the equivalent specimens. Full details of the measurements are reported in [4].

Development of Electron Beam Welding Technology Using AA6061-T6 Aluminum Alloy for Nuclear Fuel Plate Assembly

2013 ◽  
Author(s):  
Soo-sung Kim ◽  
Don-bae Lee ◽  
Yoon-sang Lee ◽  
Jong-man Park
Keyword(s):  
Aluminum Alloy ◽  
Electron Beam ◽  
Nuclear Fuel ◽  
Cross Sections ◽  
Electron Beam Welding ◽  
Preliminary Investigation ◽  
Welding Process ◽  
Beam Current ◽  
Welding Parameters ◽  
Plate Assembly

This study was carried out to establish the electron beam welding process for a nuclear fuel plate assembly fabrication. A preliminary investigation for plate fuel fabrication was conducted with a consideration of weld performance using AA6061-T6 aluminum alloy made by the EBW (Electron Beam Welding) process. The optimum welding parameters for the fuel plate assembly were obtained in terms of the accelerating voltage, beam current and welding time. The welds made by the optimum parameters showed slightly lower tensile strengths than those of the un-welded specimens. The integrity of the welds by the EBW process was confirmed by the results of the tensile test, an examination of the macro-cross sections and the fracture surfaces of the welded specimens.

A Process Model for Electron Beam Welding with Variable Thickness

2013 ◽  
Vol 762 ◽  
pp. 538-543
Author(s):  
Jiang Lin Huang ◽  
Jean Christophe Gebelin ◽  
Richard Turner ◽  
Roger C. Reed
Keyword(s):  
Electron Beam ◽  
Variable Thickness ◽  
Process Model ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Eb Welding ◽  
Experimental Calibration ◽  
Beam Focusing

A process model for electron beam (EB) welding with a variable thickness weld joint has been developed. Based on theoretical aspects and experimental calibration of electron beam focusing, welding parameters including beam power, focus current, working distance and welding speed were formulated in the heat source model. The model has been applied for the simulation of assembly of components in a gas turbine engine compressor. A series of metallographic weld sections with different welding thickness were investigated to validate the predicted thermal results. The workpieces were scanned both prior to-and after welding, using automated optical metrology (GOM scanning) in order to measure the distortion induced in the welding process. The measured result was compared with predicted displacement. This work demonstrates the attempts to improve the EB welding process modelling by connecting the heat input directly from the actual welding parameters, which could potentially reduce (or even remove) the need for weld bead calibrations from experimental observation.

Investigation of Electron Beam Welding Characteristics Using AA6061-T6 for Nuclear Plate-Type Fuel Assembly

2014 ◽  
Author(s):  
Soo-sung Kim ◽  
Yong-jin Jeong ◽  
Jong-man Park ◽  
Yoon-sang Lee
Keyword(s):  
Electron Beam ◽  
Fuel Assembly ◽  
Cross Sections ◽  
Electron Beam Welding ◽  
Preliminary Investigation ◽  
Welding Process ◽  
Beam Current ◽  
Welding Parameters ◽  
Type Fuel ◽  
Plate Type

This study was carried out to establish an electron beam welding process for nuclear plate-type fuel assembly fabrication. A preliminary investigation for plate fuel fabrication was conducted with a consideration of the weld performance using AA6061-T6 aluminum alloy made through the EBW (Electron Beam Welding) process. The optimum welding parameters for the plate-type fuel assembly were obtained in terms of the accelerating voltage, beam current and welding time. The welds made by the optimum parameters showed slightly lower tensile strengths than those of the un-welded specimens. The integrity of the welds by the EBW process was confirmed by the results of the tensile test, an examination of the macro-cross sections and the fracture surfaces of the welded specimens.

GRADIENT BOOSTING METHOD APPLICATION TO SUPPORT PROCESS DECISIONS IN THE ELECTRON-BEAM WELDING PROCESS

2020 ◽  
Vol 21 (2) ◽  
pp. 206-214
Author(s):  
V. S. Tynchenko ◽  
◽  
I. A. Golovenok ◽  
V. E. Petrenko ◽  
A. V. Milov ◽  
...  
Keyword(s):  
Electron Beam ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Gradient Boosting ◽  
Boosting Method

Effect of the Heat Input in the Transformation of Retained Austenite in Advanced Steels of Transformation Induced Plasticity (TRIP) Welded with Gas Metal Arc Welding

2013 ◽  
Vol 339 ◽  
pp. 700-705 ◽  
Author(s):  
Victor Lopez ◽  
Arturo Reyes ◽  
Patricia Zambrano
Keyword(s):  
Heat Input ◽  
Arc Welding ◽  
Retained Austenite ◽  
Volume Fraction ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Residual Austenite ◽  
Welding Parameters ◽  
Transformation Induced Plasticity ◽  
Metal Arc Welding

The effect of heat input on the transformation of retained austenite steels transformation induced plasticity (TRIP) was investigated in the heat affected zone (HAZ) of the Gas Metal Arc Welding GMAW process. The determination of retained austenite of the HAZ is important in optimizing the welding parameters when welding TRIP steels, because this will greatly influence the mechanical properties of the welding joint due to the transformation of residual austenite into martensite due to work hardening. Coupons were welded with high and low heat input for investigating the austenite transformation of the base metal due to heat applied by the welding process and was evaluated by optical microscopy and the method of X-Ray Diffraction (XRD). Data analyzed shows that the volume fraction of retained austenite in the HAZ increases with the heat input applied by the welding process, being greater as the heat input increase and decrease the cooling rate, this due to variation in the travel speed of the weld path.

Study on Electron Beam Welding of AZ61 Magnesium Alloy

2010 ◽  
Vol 34-35 ◽  
pp. 1516-1520
Author(s):  
Hong Ye ◽  
Han Li Yang ◽  
Zhong Lin Yan
Keyword(s):  
Electron Beam ◽  
Magnesium Alloys ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Processing Parameters ◽  
Beam Current ◽  
Fine Grained ◽  
Section Shape

Electron beam welding process of AZ61 with 10mm thickness magnesium alloys was investigated. The influence of processing parameters including focusing current, welding beam current and welding speed was researched. The results show that an ideal weld bead can be formed by choosing processing parameters properly. Focusing current is main parameter that determines cross section shape. The beam current and welding speed are main parameters that determine the weld width and dimensions. The test results for typical welds indicate that the microhardness of the weld zone is better than that of the base meta1. A fine-grained weld region has been observed and no obvious heat-affected zone is found. The fusion zone mainly consists of small α-Mg phase and β-Mg17A112. The small grains and β phases in the joint are believed to play an important role in the increase of the strength of weld for AZ61 magnesium alloys.

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