Development of a Remote Welding Machine for a DUPIC Fuel Bundle Fabrication

2009 ◽  
Author(s):  
Soo-sung Kim ◽  
Geun-il Park ◽  
Jung-won Lee ◽  
Jin-hyun Koh
Keyword(s):  
Preliminary Investigation ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Resistance Welding ◽  
Welding Parameters ◽  
Current Electrode ◽  
Welding Machine ◽  
Hands On ◽  
Welding Processes ◽  
Remote Welding

A remote welding machine for a DUPIC (Direct Use of spent PWR fuel In CANDU reactors) bundle fabrication was designed to establish the optimum welding processes in a hot cell environment. An initial investigation for hands-on fabrication outside the hot cell was performed in the consideration of the constraints of welding machine in the hot cell conditions. Gas tungsten arc welding (GTAW), laser beam welding (LBW), friction welding (FW), and resistance welding (RW) process were assessed as candidates for this application. A preliminary welding investigation to improve the RW process was also performed. The RW process was determined to be the most suitable process in a hot cell environment for joining an endplate to an endcap. An advantage of RW would be a qualified process for overlapped plates welding for which there is extensive production experience were available. A preliminary investigation for a hands-on fuel fabrication outside the hot cell was conducted in the consideration of the constraints caused by a welding in a hot cell. The optimum resistance welding parameters for the endplate welding process were obtained in terms of the current, electrode pressure and welding cycle. This paper presents an outline of the developed RW machine for a DUPIC bundle fabrication and reviews the conceptual design of a remote RW welder by using a master-slave manipulator. The design of RW machine by using the 3D modeling method was also designed. Furthermore the integrity of the welds by the resistance welding was confirmed by the results of the torque test, an examination of the microstructure and the fracture surfaces of the welds.

Remote Resistance Welding of Zr-4 Endplate for DUPIC Fuel Fabrication

2008 ◽  
Vol 580-582 ◽  
pp. 397-400 ◽  
Author(s):  
Soo Sung Kim ◽  
Dae Seo Koo ◽  
Geun Il Park ◽  
Jin Hyun Koh
Keyword(s):  
Preliminary Investigation ◽  
Welding Process ◽  
Resistance Welding ◽  
Optimum Conditions ◽  
Candu Reactors ◽  
Welding Technology ◽  
Fuel Fabrication ◽  
Hands On ◽  
End Caps ◽  
Direct Use

The remote resistance welding technology in the hot cell environment for DUPIC (Direct Use of spent PWR fuel In CANDU reactors) fuel fabrication was established. To do this, a preliminary investigation for hands-on fuel fabrication outside the hot cell was conducted in the consideration of constraints caused by welding in the hot cell. Further welding experiments were carried out to improve the RW process. A remote resistance welding apparatus was developed. The characteristics of welds made by RW and LBW were compared in terms of the weld nugget penetrations and torque strength. It was found that resistance welding was a more suitable welding process for joining the endplate to the end caps in the hot cell. The optimum conditions for RW in the hot cell operation in a remote manner were also obtained.

scholarly journals Design and Fabrication of Remote Welding Equipment in a Hot-Cell

2013 ◽  
Vol 2013 ◽  
pp. 1-8 ◽  
Author(s):  
Soosung Kim ◽  
Kihwan Kim ◽  
Jungwon Lee ◽  
Jinhyun Koh
Keyword(s):  
Nuclear Fuel ◽  
Performance Test ◽  
Preliminary Investigation ◽  
Welding Process ◽  
Resistance Welding ◽  
Welding Equipment ◽  
End Plate ◽  
Fuel Fabrication ◽  
Fuel Bundle ◽  
Remote Welding

The remote welding equipment for nuclear fuel bundle fabrication in a hot-cell was designed and developed. To achieve this, a preliminary investigation of hands-on fuel fabrication outside a hot-cell was conducted with a consideration of the constraints caused by the welding in a hot-cell. Some basic experiments were also carried out to improve the end-plate welding process for nuclear fuel bundle fabrication. The resistance welding equipment using end-plate welding was also improved. It was found that the remote resistance welding was more suitable for joining an end-plate to end caps in a hot-cell. This paper presents an outline of the developed welding equipment for nuclear fuel bundle fabrication and reviews a conceptual design of remote welding equipment using a master-slave manipulator. Furthermore, the mechanical considerations and a mock-up simulation test were described. Finally, its performance test results were presented for a mock-up of the remote resistance welding equipment for nuclear fuel bundle fabrication.

Optimization of CA-TIG welding parameters to predict and maximize tensile properties of super alloy 718 sheets for gas turbine applications

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Tushar Sonar ◽  
Visvalingam Balasubramanian ◽  
Sudersanan Malarvizhi ◽  
Thiruvenkatam Venkateswaran ◽  
Dhenuvakonda Sivakumar
Keyword(s):  
Tensile Properties ◽  
Gas Turbine ◽  
Inconel 718 ◽  
Electron Beam Welding ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Tig Welding ◽  
Welding Parameters ◽  
Content Type ◽  
Welding Processes

Purpose The primary objective of this investigation is to optimize the constricted arc tungsten inert gas (CA-TIG) welding parameters specifically welding current (WC), arc constriction current (ACC), ACC frequency (ACCF) and CA traverse speed to maximize the tensile properties of thin Inconel 718 sheets (2 mm thick) using a statistical technique of response surface methodology and desirability function for gas turbine engine applications. Design/methodology/approach The four factor – five level central composite design (4 × 5 – CCD) matrix pertaining to the minimum number of experiments was chosen in this investigation for designing the experimental matrix. The techniques of numerical and graphical optimization were used to find the optimal conditions of CA-TIG welding parameters. Findings The thin sheets of Inconel 718 (2 mm thick) can be welded successfully using CA-TIG welding process without any defects. The joints welded using optimized conditions of CA-TIG welding parameters showed maximum of 99.20%, 94.45% and 73.5% of base metal tensile strength, yield strength and elongation. Originality/value The joints made using optimized CA-TIG welding parameters disclosed 99.20% joint efficiency which is comparatively 20%–30% superior than conventional TIG welding process and comparable to costly electron beam welding and laser beam welding processes. The parametric mathematical equations were designed to predict the tensile properties of Inconel 718 joints accurately with a confidence level of 95% and less than 4.5% error. The mathematical relationships were also developed to predict the tensile properties of joints from the grain size (secondary dendritic arm spacing-SDAS) of fusion zone microstructure.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

Demonstration of Intelligent Welding Machine for Polyethylene Pipe

2021 ◽  
Author(s):  
Guangte Xiang ◽  
Yurui Hu ◽  
Sheng Zeng ◽  
Jianfeng Shi ◽  
Jinyang Zheng
Keyword(s):  
Welding Process ◽  
Maximum Temperature ◽  
Welding Parameters ◽  
Welding Time ◽  
Constant Voltage ◽  
Welding Machine ◽  
Reinforced Composite ◽  
Composite Pipe ◽  
The Difference

Abstract Electrofusion (EF) welding is one of the most common connection methods for polyethylene (PE) pipe, as well as thermoplastic pipe and reinforced composite pipe. Conventional EF welding generally adopts constant-voltage welding mode. The welding machine outputs a constant welding voltage to heat the resistance wire within specific welding time. In our previous study, intelligent welding machine was designed to ensure the quality of the EF joint, based on the study of the temperature field in EF joint. In this paper, three experiments were used to show the difference between the intelligent welding machine and traditional welding machine. The intelligent welding machine can actively adjust the welding parameters to ensure the quality of EF joint even it was given the wrong welding voltage and welding time. Compared with the traditional welding machine, the intelligent welding machine can automatically control the maximum temperature and the depth of melting region in EF joint during the welding process, and this method applies for EF joints with various diameters or design welding parameters.

Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100

2013 ◽  
Vol 789 ◽  
pp. 356-359 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
A.A.D. Nugroho ◽  
D. Rahayu ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Tilt Angle ◽  
Welding Process ◽  
Tool Material ◽  
Tensile Load ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Welding Processes

Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters onmicro Friction Stir Lap Weldingto the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable oftooltilt angle(0, 1, 2 degree) and a variable ofFeed rate(50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used aResponse Surface Methods(RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.

scholarly journals Mechanical and Fatigue Strength Assessment of Friction Stir Welded Plates of Magnesium Alloy AZ31B

2018 ◽  
Vol 23 (1) ◽  
pp. 52-59
Author(s):  
Carlos Fernando Luna ◽  
Fernando Franco Arenas ◽  
Victor Ferrinho Pereira ◽  
Julián Arnaldo Ávila
Keyword(s):  
Fatigue Strength ◽  
Magnesium Alloy ◽  
Welding Process ◽  
Welding Parameters ◽  
Speed Ratio ◽  
Bead Width ◽  
Strength Assessment ◽  
Friction Stir ◽  
Magnesium Alloy Az31b ◽  
Welding Processes

Abstract Light-alloys play a significant role in saving weight in automotive and aerospace industries; however, a few joining methods guarantee mechanical and fatigue strengths for high performance application. Even conventional arc welding processes do not offer constant quality joints. Therefore, this study uses an alternative solid-state welding process, friction stir welding (FSW), to analyze post processing microstructures and assess mechanical and fatigue strength. Magnesium alloy AZ31B plates were welded using different welding parameters in a dedicated FSW machine. The effect of the spindle speed (ω) and welding speed (ν) on the microstructure, the tensile strength and fatigue were studied. The stirred zone (SZ) at the FS-welded joints presented a microstructure composed by homogeneous equiaxial grains, refined by dynamic recrystallization. A rise in grain size, weld bead width, tensile and fatigue strengths with the increase of speed ratio (ω/ν) were observed. Results of the fatigue and mechanical strength here presented outperformed results from welds made with conventional milling machines.

Evaluation of High Penetration Hybrid Laser-GMAW Welding Process Productivity Applied in the Joining of Thick Plates and Pipelines

2022 ◽  
Author(s):  
Rafael Gomes Nunes Silva ◽  
Max Baranenko Rodrigues ◽  
Milton Pereira ◽  
Koen Faes
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Manufacturing Industry ◽  
Operating Time ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Major Influence ◽  
Thick Plates ◽  
High Penetration ◽  
Welding Processes

Abstract Welding processes are present in all sectors of the industry, highlighting the manufacturing industry of thick plates and pipelines. In these applications, welding processes have a major influence on costs, schedules, risk analysis and project feasibility. Conventional arc welding processes, such as the gas metal arc welding (GMAW) process, have limitations when applied to high thickness joints due to their maximum achievable penetration depth. On the other hand, the laser beam welding (LBW) welding process, despite reaching high penetration depths, has several limitations mainly regarding the geometric tolerance of the joint. In this regard, the hybrid laser-arc welding (HLAW) process emerges as a promising bonding process, combining the advantages of the GMAW and LBW processes into a single melting pool. Despite the many operational and metallurgical advantages, the HLAW process presents a high complexity due to the high number of parameters involved and the interaction between the laser beam and the electric arc. The present work discusses the challenges involved in the parametrization of the HLAW process applied to the joining of thick plates and pipes, and empirically evaluated a comparison between the HLAW and GMAW processes, showing a reduction of operating time of approximately 40 times, and a reduction of consumption of shielding gas and filler material of approximately 20 times, evidencing the technical and financial contribution of the hybrid process.

Cooling Curve Based Estimation of Mechanical Properties in High Strength Steel Welds

2016 ◽  
Vol 879 ◽  
pp. 1760-1765 ◽  
Author(s):  
Rahul Sharma ◽  
Uwe Reisgen
Keyword(s):  
Mechanical Properties ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Structural Steels ◽  
Cooling Time ◽  
Cooling Curve ◽  
Welding Parameters ◽  
Steel Welds ◽  
Welding Processes

The application of high strength steels in welded structures relies on easy to use quality assurance concepts for the welding process. For ferritic steels, one of the most common methods for estimating the mechanical properties of welded joints is the cooling time concept t8/5. Even without experimental determination, the calculation of cooling time with previously introduced formulas based on the welding parameters leads to good results. Because high strength structural steels and weld metals with a yield strength of 960 MPa contain higher quantities of alloying elements, the transformation start temperature Ar3 is found to be outside of the range of 800 °C to 500 °C. This leads to inadequate estimation results, as the thermal arrest caused by the microstructural transformation in this case is not considered. In this work the usage of the well-proven cooling time concept t8/5 is analyzed using high strength fine grained structural steels and suitable welding filler wires during gas metal arc and submerged arc welding processes. The results are discussed taking into account the microstructure and the transformation behavior. Based on the experimental work, an improved concept is presented.

Residual Stresses Evaluation on Radial Friction Welded Joints

2005 ◽  
Author(s):  
Rosa Irene Terra Pinto ◽  
Telmo Roberto Strohaecker
Keyword(s):  
Residual Stresses ◽  
Friction Welding ◽  
Deformation Gradient ◽  
Welding Process ◽  
Hole Drilling ◽  
Welding Parameters ◽  
Hole Drilling Method ◽  
Joint Quality ◽  
Welding Processes

The Radial Friction Welding (RFW) is a solid-state welding process in which two long elements of several metallic alloys can be joined, without the occurrence of common problems to the conventional welding processes that include fusion. During friction welding the temperature evolution is directly related with the deformation gradient, and these fields govern the joint properties. In this work, the finite element method was used to solve the full coupled termomechanical problem in order to determine the deformation and the stress fields and the variation of the temperature during RFW process. The simulation of the RFW process permitted to establish the influence of the welding parameters, like rotation and approximation speed, on the joint quality. Furthermore, the knowledge of the temperature gradient and cooling rates allowed the prediction of the resulting microestruture and determination of the level of residual stresses of the joint. To verify the analytical results the determination of the residual stresses was accomplished by the hole drilling method in several points along the perimeter of two welded workpieces.

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