Hybrid Laser/Gas Metal Arc Welding of High Strength Steel Gas Transmission Pipelines

2008 ◽  
Author(s):  
Ian D. Harris ◽  
Mark I. Norfolk
Keyword(s):  
Fiber Laser ◽  
High Power ◽  
Arc Welding ◽  
Fiber Lasers ◽  
Band System ◽  
Gas Metal Arc Welding ◽  
High Strength ◽  
Travel Speed ◽  
Metal Arc Welding ◽  
Welding Processes

Despite significant investment, one-shot welding and power beam processes have not been very successful in achieving real benefits in pipeline construction. The most promising of the newer and more innovative welding processes is the hybrid Laser/arc welding process (HLAW), which can complete 5G welds, assure weld soundness, material properties, and an acceptable geometric profile. The combination of new lasers and pulsed gas metal arc welding (GMAW-P) power source technologies have led to important innovations in the HLAW process that have been shown to increase the travel speed for successful root pass welding. In particular, high power Yb fiber lasers with high efficiency (25% compared with 3% for a Nd:YAG laser) allow a 10kW laser to be built the size of a refrigerator. This allows for previously unheard of portability and power levels for use outside the laboratory and on the pipeline right-of-way. The objective was to develop and apply an innovative HLAW system for mechanized welding of high strength, high integrity, pipelines and develop 5G welding procedures for X80 and X100 pipe, including mechanical testing to API 1104. The main goal of a cost-matched JIP was to develop a prototype hybrid high power Yb fiber laser and GMAW head based on a commercially available bug and band system (Figure 1). Under the DOT project, the subject of this paper, innovative technologies for pipeline girth welding were developed. External hybrid root pass welding techniques were developed for variations of laser power (4–10 kW) and root face thickness (4–8 mm) as this has the greatest potential to meet existing pipeline integrity requirements and facilitate the use of new high power Yb fiber lasers for high speed HLAW of pipe root passes. Following the integration of the Yb fiber laser and GMAW head onto a commercially available bug and band system (CRC-Evans P450) the system was used to achieve full penetration welds with a 4 mm root at a travel speed of 2.3 m/min. The root welds were made in a “double down” configuration using laser powers up to 10kW and travel speeds up to 3 m/min. The final objective of the project is to demonstrate the hybrid LBW/GMAW system under field conditions.

Hybrid Welding of AA5754-H111 Alloy Using a Fiber Laser

2012 ◽  
Vol 628 ◽  
pp. 193-198 ◽  
Author(s):  
Giuseppe Casalino ◽  
Sabina Campanelli ◽  
Antonio D. Ludovico
Keyword(s):  
Fiber Laser ◽  
High Power ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Spot Size ◽  
Welding Parameters ◽  
Hybrid Welding ◽  
Gas Tungsten Arc ◽  
Metal Arc Welding ◽  
New Generation

The new generation of high power fiber lasers presents several benefits for industrial application. Nevertheless, due to the small spot size of the laser, the fiber laser has difficulties in some welding applications. These shortcomings can be overcome by laser-arc hybrid welding technique such as laser-gas metal arc welding or laser-gas tungsten arc welding. In this work, a high power fiber laser was coupled to an arc welder and the AA5754-H111 magnesium aluminum alloy was welded. The trials were carried out using laser leading configuration. A new generation of high power fiber laser was used. The experimental trials included process parameters such as laser power, welding speed and arc current. Microstructure, microhardness and weld appearance were analyzed. The experimental results showed that laser leading configuration produces full penetration for some welding parameters. The obtained results worth a larger investigation based on the experimental design technique.

scholarly journals Porosity Characteristics and Effect on Tensile Shear Strength of High-Strength Galvanized Steel Sheets after the Gas Metal Arc Welding Process

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 1077 ◽  
Author(s):  
Seungmin Shin ◽  
Sehun Rhee
Keyword(s):  
Shear Strength ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
High Strength ◽  
Galvanized Steel ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Tensile Test Specimen ◽  
Metal Arc Welding

In this study, lap joint experiments were conducted using galvanized high-strength steel, SGAFH 590 FB 2.3 mmt, which was applied to automotive chassis components in the gas metal arc welding (GMAW) process. Zinc residues were confirmed using a semi-quantitative energy dispersive X-ray spectroscopy (EDS) analysis of the porosity in the weld. In addition, a tensile shear test was performed to evaluate the weldability. Furthermore, the effect of porosity defects, such as blowholes and pits generated in the weld, on the tensile shear strength was experimentally verified by comparing the porosity at the weld section of the tensile test specimen with that measured through radiographic testing.

A study on sustainability assessment of welding processes

2019 ◽  
Vol 234 (3) ◽  
pp. 501-512 ◽  
Author(s):  
Jaber Jamal ◽  
Basil Darras ◽  
Hossam Kishawy
Keyword(s):  
Arc Welding ◽  
Social Impact ◽  
Sustainability Assessment ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Metal Arc Welding ◽  
Sustainability Assessments ◽  
Welding Processes

The concept of “sustainability” has recently risen to take the old concept of going “green” further. This article presents general methodologies for sustainability assessments. These were then adapted to measure and assess the sustainability of welding processes through building a complete framework, to determine the best welding process for a particular application. To apply this methodology, data about the welding processes would be collected and segregated into four categories: environmental impact, economic impact, social impact, and physical performance. The performance of each category would then be aggregated into a single sustainability score. To demonstrate the capability of this methodology, case studies of three different welding processes were performed. Friction stir welding obtained the highest overall sustainability score compared to gas tungsten arc welding and gas metal arc welding.

Tandem laser-gas metal arc welding joining of 20 mm thick super duplex stainless steel: An experimental and numerical study

2020 ◽  
Vol 234 (5) ◽  
pp. 697-710
Author(s):  
A Mathieu ◽  
I Tkachenko ◽  
JM Jouvard ◽  
I Tomashchuk
Keyword(s):  
Numerical Simulation ◽  
Heat Source ◽  
Laser Beam ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Image Correlation ◽  
Angular Distortion ◽  
Metal Arc Welding ◽  
Welded Structure ◽  
Welding Processes

The present work covers the topic of strains and stresses prediction in case of welded steel structures. Steel sheets of 20 mm thickness made in UR™2507Cu are welded using a laser and gas metal arc welding processes combination. The focused laser beam leads the arc in a Y-shape chamfer geometry. Both sources are 20 mm apart from each other in order to avoid any synergic effect with each other. In order to predict residual strain, a 3D unsteady numerical simulation has been developed in COMSOL finite element software. A volume heat source has been identified based on the temperature measurements made by 10 K-type thermocouples, implanted inside the workpiece. The 50 mm deep holes are drilled in the workpiece using dye-sinking Electrical Discharge Machining (EDM) machine. Before the implantation in the hole, each thermocouple is surrounded by Inconel sheathing. Hot junctions of the thermocouples are positioned in a way to feel two advancing molten pools. The equivalent heat source is composed of three sources. First one is a Goldak source that represents the molten pool induced by gas metal arc welding. The second one is a cylinder with an elliptic cross-section that represents the focused laser beam penetrating into the workpiece. The third one is a surface Gaussian source that represents energy radiated by arc and blocked by workpiece surface. Concerning mechanical simulation, an elasto-plastic behavior with isotropic hardening is implemented. A weak coupling is established between equations governing heat transfer and mechanics thanks to the temperature dependent coefficient of linear expansion. This numerical simulation made with some simplifying assumptions predicts an angular distortion and a longitudinal shrinkage of the welded structure. The numerical results are consistent with the displacements measured by digital image correlation method.

Advanced gas metal arc welding processes

2012 ◽  
Vol 67 (1-4) ◽  
pp. 655-674 ◽  
Author(s):  
P. Kah ◽  
R. Suoranta ◽  
J. Martikainen
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Metal Arc Welding ◽  
Welding Processes
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