The Effects of Temper Bead Welding Technique on Weld Integrity for In-Service Welding of Carbon Steels

2012 ◽  
Author(s):  
K. Meszaros ◽  
C. Vrolyk ◽  
J. Pepin ◽  
M. Yarmuch ◽  
T. Mah-Paulson
Keyword(s):  
Heat Input ◽  
Weld Zone ◽  
Carbon Steels ◽  
Steel Plates ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Shielded Metal Arc Welding ◽  
Burn Through ◽  
Welding Technique ◽  
Repair Techniques

The maintenance of pipeline infrastructure is a significant integrity consideration for the pipeline industry. Employing traditional repair techniques, whereby to conduct repairs when the pipeline is shut-down and drained, can result in significant losses to revenue and production. There is industry demand for repair techniques that allow both scheduled and emergency ‘in-service’ weld repair techniques to be developed. As a result, in-service welding with the temper bead technique is becoming increasingly common for repair operations. During in-service welding, the two most prevalent metallurgical concerns are burn-through and hydrogen induced cracking (HIC). The risk of burn-through can be limited through appropriate welding parameter and heat input control during welding. The temper bead welding technique utilizes special bead placement to ensure appropriate heat flow throughout the weld zone to metallurgically improve resistance to HIC. In this study, a series of shielded metal arc welding (SMAW) coupons were produced on 0.250″ thick carbon steel plates subjected to water-cooling. Single and double-layer deposits were made. The second layer tempering bead heat input was purposely varied from plate to plate. The first layer of the welds were all performed using similar welding parameters, so the “tempering” effect from the second weld layer on the metallurgical properties of the resultant welds could be examined. To further expand the understanding of important procedural variables for in-service welding applications, this study investigates the effect of welder technique on the weldment properties achieved during temper bead welding.

Effect of Welding Heat Input on Grain Size and Microstructure of 316L Stainless Steel Welded Joint

2013 ◽  
Vol 331 ◽  
pp. 578-582 ◽  
Author(s):  
Li Chan Li ◽  
Meng Yu Chai ◽  
Yong Quan Li ◽  
Wen Jie Bai ◽  
Quan Duan
Keyword(s):  
Grain Size ◽  
Stainless Steel ◽  
Heat Input ◽  
316L Stainless Steel ◽  
Weld Zone ◽  
Welding Process ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding ◽  
Average Grain Size ◽  
Arc Welding Process

Influences of heat input on the microstructure and grain size of shielded metal arc welded 316L stainless steel joints were studied. Three heat input combinations were selected from the operating window of the shielded metal arc welding process and welded joints made using these combinations were subjected to microstructural evaluations so as to analyze the effect of thermal arc energy on the microstructure and grain size of these joints. The results of this investigation indicate that the microstructure of the weld zone and the fusion zone are austenite and a small amount of ferrite while the microstructure of the heat affected zone (HAZ) are austenite and a small amount of MC type carbides, and it can be seen that the amount of ferrite in the weld zone decreases with heat input. For the joints investigated in this study, the average grain size in the HAZ increases with heat input.

Feasibility study of welding dissimilar Advanced and Ultra High Strength Steels

2020 ◽  
Vol 59 (1) ◽  
pp. 54-66
Author(s):  
Francois Njock Bayock ◽  
Paul Kah ◽  
Antti Salminen ◽  
Mvola Belinga ◽  
Xiaochen Yang
Keyword(s):  
Heat Input ◽  
High Strength Steel ◽  
Gas Metal Arc Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Hardness Test ◽  
Welding Parameter ◽  
Welding Parameters

AbstractThis study concerns the weldability of dissimilar Ultra high-strength steel (UHSS) and advanced high-strength steel (AHSS), which is used in the modern machine industry. The materials offered superior strength as well as relatively low weight, which reduces microstructure contamination during a live cycle. The choice of the welding process base of the base material (BM) and welding parameters is essential to improve the weld joint quality. S700MC/S960QC was welded using a gas metal arc welding (GMAW) process and overmatched filler wire, which was performed using three heat input (7, 10, and 15 kJ/cm). The weld samples were characterized by a Vickers-hardness test, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The test reveals a decrease of softening areas in the HAZ and the formation of the stable formation of Bainite-Ferrite for S700MC and Bainite-martensite for S960QC when the heat input of 10 kJ/cm is used. It is recommended to use the GMAW process and Laser welding (Laser beam-MIG), with an optimal welding parameter, which will be achieved a high quality of manufacturing products.

scholarly journals The effect of laser welding power on the properties of the joint made of 1.4462 duplex stainless steel

2018 ◽  
Vol 10 (1) ◽  
pp. 168781401775194 ◽  
Author(s):  
Robert Sołtysiak ◽  
Tomasz Giętka ◽  
Agnieszka Sołtysiak
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Laser Power ◽  
Gas Flow ◽  
Weld Zone ◽  
Steel Plates ◽  
Joint Surface ◽  
Welding Parameters ◽  
Butt Welding ◽  
Protective Gas

The butt welding of 1.4462 (2205) duplex stainless steel plates with thickness of 4 mm under various welding parameters was achieved by Nd:YAG laser type without the use of the filler material. Welding parameters such as welding power (kW) and the focus distance from the joint surface (mm) were changed. The Ar 5.0 protective gas flow and welding speed were the same for all the tests and were 20 L/min and 0.5 m/min, respectively. The weld shape, weld macrostructure, microstructure, strength and hardness, and the content of the ferrite in the weld zone, heat-affected zone, and base metal were emphatically investigated. The test results showed that increase in laser power increases the weld zone area. For the weld samples, a better ferrite/austenite ratio was obtained by focusing the laser beam on the sheet surface. Furthermore, the largest elongation from strength test has been observed for the weld samples made with laser power of 2.0 kW.

Multi Response Optimization of Spot Welding Process Parameters by Taguchi Method

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
S.P. Sundar Singh Sivam ◽  
A. Thirugnanam ◽  
K. Saravanan ◽  
D. Kumaran ◽  
M. Suresh
Keyword(s):  
Electrical Resistance ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Class Ii ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Steel Sheets

Electrode deterioration by deformation and chemical reaction during resistance spot welding of steel sheets confirming to AISI1020 is an issue for class II electrode. In view of this, the present study carried out the impacts of squeeze, weld, current and pressure on the nugget diameter, height, force and waviness of welding joint in electrical resistance spot welding of 0.8mm and 1.5 mm thickness of steel sheets with class II electrode to achieve the benefits of cost saving and quality products. A timer and current controlled electrical resistance spot welding machine having 120 kVA capacities were used. During welding process, current periods of 5, 10, 15, 20 and 25 were selected and it was adjusted by increasing from 8 to 10 kA. The optimum welding parameter for multi objectives was obtained using multi signal to noise ratio and the significant level of the welding parameters was further analysed by analysis of variance for all responses. Based on the confirmation test results, it is found out that the developed model can be effectively used to predict the size of weld zone which can improve the welding quality and performance in GRA. The details of welded joint generated by class II electrode were measured and results were analysed in detail.

scholarly journals Investigation on the effect of mechanical vibration in mild steel weld pool

2019 ◽  
Vol 6 ◽  
pp. 21 ◽  
Author(s):  
Pravin Kumar Singh
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Impact Strength ◽  
Mild Steel ◽  
Mechanical Vibration ◽  
Weld Zone ◽  
Welding Process ◽  
Steel Plates ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding

This study presents a new concept of a vibratory welding setup which can transfer the mechanical vibrations in the weld zone during Shielded Metal Arc welding (SMAW) process and can also produce the resonance frequency of 300 Hz. In the present investigation mild steel plates of 6 mm thickness has been butt welded using both conventional and vibratory welding conditions. Microstructure and the mechanical properties of the butt welded joints were evaluated, and the results were compared. Further, in order to optimize the process parameters of vibratory welding technique Taguchi and analysis of variance (ANOVA) technique have been adopted. The responses considered for analysis are hardness, ultimate tensile strength (UTS) and impact strength. The result of the study indicates that by applying the vibratory treatment during welding process the mechanical properties such as hardness, tensile strength and impact strength have been enhanced. Lastly, the obtained results are correlated from the results in the past researches.

scholarly journals Influence of Heat Inputs on Weld Profiles and Mechanical Properties of Carbon and Stainless Steel

2021 ◽  
Vol 18 (2) ◽  
pp. 135-143
Author(s):  
L.O. Osoba ◽  
W.A. Ayoola ◽  
Q.A. Adegbuji ◽  
O.A. Ajibade
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Stainless Steel ◽  
Carbon Steel ◽  
Ultimate Tensile Strength ◽  
Heat Input ◽  
Steel Plates ◽  
Shielded Metal Arc Welding ◽  
Full Penetration ◽  
Metal Arc Welding

This study examines the effect of heat input on the weld bead profile, microstructure and mechanical properties of single V- joint welded carbon and stainless-steel plates. The as-received sample steel plates were sectioned into eight pieces; dimension 75 X 30 X 10 mm  thicknesses. Shielded metal arc welding (SMAW) of heat inputs 1250 and 2030 J/mm was used to produce full penetration bead on the plates. Although visual inspection indicated that some of the welds were macro defect free, austenitic stainless steel exhibited more weld distortions than the carbon steel and this was partially attributed to its lower carbon content and the width to depth aspect ratio of the weld profile aside the magnitude of the induced stress. For the carbon steel, as the heat input increased, the hardness value of both the heat affected zone and fusion zone increased. In contrast, for stainless steel, the hardness values were reasonably comparable within same weld region (HAZ or FZ) irrespective of heat input. Furthermore, the ultimate tensile strength of the stainless steel decreased as heat input increased while the ductility increased with an increase in heat input, in contrast to carbon steel, where both ductility and ultimate tensile strength generally decreased.

Study on improvement of tensile strength in lap-welding of pure titanium using disk laser

2019 ◽  
Vol 33 (14n15) ◽  
pp. 1940039
Author(s):  
Ji Sung Kim ◽  
Jong-Do Kim
Keyword(s):  
Penetration Depth ◽  
Heat Input ◽  
Weld Zone ◽  
Pure Titanium ◽  
Welding Parameters ◽  
Maximum Output ◽  
Titanium Plate ◽  
Bead Width ◽  
Disk Laser ◽  
Lap Welding

Laser welding has the benefit of hardly causing welding deformation as it requires less heat input than existing welding methods. The heat input is determined by the laser output and welding speed, and the penetration depth, bead width, joining length, and bead shape are varied depending on these two welding parameters. In this study, bead and lap welding were performed on a thin pure titanium plate with a thickness of 0.5 mm using a disk laser with a maximum output of 3.3 kW. Weldability was evaluated by observing the penetration depth, bead width, joining length, and bead shape for different laser outputs and welding speeds. Results show that a weld zone with excellent joining length can be obtained for an output of 1.1 kW and speed of 2.5 m/min, as well as for an output of 1.3 kW and speed of 3.5 m/min in lap welding. Tensile-shear test was conducted with the specimens under these two conditions to investigate their mechanical characteristics.

Correlation between Welding Parameter and Bead Geometry of Flux Cored Arc Welding (FCAW) in Horizontal Position (2F)

2014 ◽  
Vol 564 ◽  
pp. 549-554
Author(s):  
Nik Mohd Baihaki Abd Rahman ◽  
Abdul Ghalib Tham ◽  
Sunhaji Kiyai Abas ◽  
Razali Hassan ◽  
Yupiter H.P. Manurung ◽  
...  
Keyword(s):  
Heat Input ◽  
Arc Welding ◽  
Weld Bead ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Automatic Welding ◽  
Trend Line ◽  
Flux Cored Arc Welding ◽  
Good Prediction Accuracy

A robotic system can convert the semi-automatic Flux Cored Arc Welding (FCAW) to an automatic welding system. The critical requirement in automated welding process is that the optimal welding parameter has to be set before welding start. These input welding parameters cannot be easily guessed unless one has the knowledge. Only very specific range of heat input that produces quality weld deposition. The correlation between the heat input and fillet weld bead can be displayed in a unique trend-line graph. Mathematical formulas that match the trend-line profile can be used to create a prediction calculator that displays the digital values of weld bead geometry when welded at a specific range of heat input. Small Mean Absolute Deviation between predicted and measured geometry means good prediction accuracy. With this correlation chart, the welding parameter for quality weld bead can be selected and the geometry of FCAW weld deposition in 2F position can be predicted accurately without trial and error.

Modified GTAW Orbital Tube-to-Tubesheet Welding Technique, and the Effect of a Copper Weld Retainer During Welding of Alloy 825

2017 ◽  
Author(s):  
Angel Krustev ◽  
Boian Alexandrov ◽  
Jerry Kovacich
Keyword(s):  
Heat Input ◽  
High Heat ◽  
Carbon Steels ◽  
Bead Geometry ◽  
Filler Wire ◽  
Weld Bead Geometry ◽  
Gas Tungsten Arc ◽  
Orbital Welding ◽  
High Heat Input ◽  
Welding Technique

Tube-to-tubesheet welds are an essential part of the design of heat exchangers used in power generation, petro-chemical, chemical processing, pharmaceutical, and food processing industries. The tube-to-tubesheet welds are typically produced using gas tungsten arc welding (GTAW) with or without the addition of filler wire, and involve carbon steels and various creep and corrosion resistant alloys. The weld heat input in tube-to-tubesheet welds is an essential parameter that controls the productivity and weld quality, in terms of weld bead geometry and heat affected zone microstructure and properties. A modified GTAW tube-to-tubesheet orbital welding head that utilizes a copper weld retainer is described in this paper. The copper weld retainer provides a heat sink during welding, and supports the molten weld metal. This permits the use of a relatively high heat input, required for a single pass welding with filler wire addition. Furthermore, the copper retainer limits the amount of weld overlap into the tube bore. The application of the modified orbital welding technique, which helped for resolving a suspected liquation cracking problem in Alloy 825 tube to 316L stainless steel tubesheet welds, is presented.

Effects of bottom plate in friction stir welding of AA6061-T6

2020 ◽  
Vol 118 (1) ◽  
pp. 108
Author(s):  
M.A. Vinayagamoorthi ◽  
M. Prince ◽  
S. Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Axial Load ◽  
Weld Zone ◽  
Welding Process ◽  
Bottom Plate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Friction Stir ◽  
Weld Joints ◽  
Fine Grain

The effects of 40 mm width bottom plates on the microstructural modifications and the mechanical properties of a 6 mm thick FSW AA6061-T6 joint have been investigated. The bottom plates are placed partially at the weld zone to absorb and dissipate heat during the welding process. An axial load of 5 to 7 kN, a rotational speed of 500 rpm, and a welding speed of 50 mm/min are employed as welding parameters. The size of the nugget zone (NZ) and heat-affected zone (HAZ) in the weld joints obtained from AISI 1040 steel bottom plate is more significant than that of weld joints obtained using copper bottom plate due to lower thermal conductivity of steel. Also, the weld joints obtained using copper bottom plate have fine grain microstructure due to the dynamic recrystallization. The friction stir welded joints obtained with copper bottom plate have exhibited higher ductility of 8.9% and higher tensile strength of 172 MPa as compared to the joints obtained using a steel bottom plate.

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