Develop an Excel-Based Modeling Tool to Predict Weld and HAZ Cooling Rate and Hardness for Pipeline Welding

2015 ◽  
Author(s):  
Yu-Ping Yang ◽  
Zhenning Cao ◽  
Jerry Gould ◽  
Tom McGaughy ◽  
Jon Jennings
Keyword(s):  
Heat Source ◽  
Cooling Rate ◽  
Screening Tool ◽  
Plate Thickness ◽  
Welding Process ◽  
Thickness Effect ◽  
Welding Parameters ◽  
Microstructure Model ◽  
Pipeline Welding ◽  
Welding Procedure

A Microsoft Excel-based screening tool was developed to allow an engineer with weld process knowledge to predict cooling rate and hardness during welding procedure qualifications to screen a combination of materials and welding process parameters quickly to meet requirements of fabrication and design codes. The material properties for commonly used pipeline steels have been built into a database coupled with the screening tool. The Excel-based tool includes a physics-based laser and arc welding solution which was developed based on Rosenthal’s mathematical equations for a point heat source to predict thermal cycles by inputting welding parameters. A reflecting heat source scheme was adapted to model the boundary conditions and plate thickness effect on cooling rate. The Excel-based tool also includes a microstructure model which was developed based on the Ashby model. The microstructure model can be used to predict the distributions of individual phases such as ferrite, bainite, and martensite along with a hardness map across the weld and heat-affected-zone (HAZ) regions by integrating with the thermal model.

GTAW Procedure Expert System Based on Neural Network

2013 ◽  
Vol 455 ◽  
pp. 425-430 ◽  
Author(s):  
Xue Wu Wang ◽  
Shang Yong Yang
Keyword(s):  
Neural Network ◽  
Expert System ◽  
Expert Knowledge ◽  
Welding Process ◽  
Learning Ability ◽  
Welding Parameters ◽  
Neural Network Learning ◽  
The Neural Network ◽  
Function Design ◽  
Welding Procedure

Intelligent procedure expert system was developed to select appropriate GTAW procedure in this paper. First, the function design and implementation methods of the welding procedure expert system were introduced. The expert system can present the welding procedure card, multimedia display of welding process, and output function to makes the data sharing more convenient. Then, the database design of the welding procedure expert system based on C/S mode was presented where the expert knowledge was stored. At last, the neural network model was established to realize procedure selection based on the neural network learning ability and the welding case from the database. With the BPNN model, the welding parameters can be obtained based on the input welding conditions.

Development of an Effective ASME IX Welding Procedure Qualification Program for Pipeline Facility and Fabrication Welding

2016 ◽  
Author(s):  
Junfang Lu ◽  
Bob Huntley ◽  
Luke Ludwig
Keyword(s):  
Oil And Gas ◽  
Material Selection ◽  
Base Material ◽  
Welding Process ◽  
Notch Toughness ◽  
Essential Variable ◽  
Performance Qualification ◽  
Pipeline Welding ◽  
Welding Consumable ◽  
Welding Procedure

For cross country pipeline welding in Canada, welding procedures shall be qualified in accordance with the requirements of CSA Z662 Oil and Gas Pipeline Systems. For pipeline facility and fabrication welding on systems designed in accordance with CSA Z662 or ASME B31.4, welding procedures qualified in accordance with the requirements of ASME Boiler & Pressure Vessel Code Section IX are permitted and generally preferred. Welding procedures qualified in accordance with ASME IX provide advantages for pipeline facility and fabrication applications as a result of the flexibility achieved through the larger essential variable ranges. The resulting welding procedures have broader coverage on material thickness, diameter, joint configuration and welding positions. Similarly, ASME IX is more flexible on welder performance qualification requirements and accordingly a welder will have wider range of performance qualifications. When applied correctly, the use of ASME IX welding procedures often means significantly fewer welding procedures and welder performance qualifications are required for a given scope of work. Even though ASME IX qualified welding procedures have been widely used in pipeline facility and fabrication welding, it is not well understood on how to qualify the welding procedures in accordance with ASME IX and meet the additional requirements of the governing code or standard such as CSA Z662 in Canada. One significant consideration is that ASME IX refers to the construction code for the applicability of notch toughness requirements for welding procedure qualification, yet CSA Z662 and ASME B31.4 are both silent on notch toughness requirements for welding procedure qualification. This paper explains one preferred method to establish and develop an effective ASME IX welding procedure qualification program for pipeline facility and fabrication welding while ensuring suitability for use and appropriate notch toughness requirements. The paper discusses topics such as base material selection, welding process, welding consumable consideration and weld test acceptance criteria.

Development of Welding Procedures for X90-Grade Seamless Pipes for Riser Applications

2012 ◽  
Author(s):  
Hiroyuki Nagayama ◽  
Masahiko Hamada ◽  
Mark F. Mruczek ◽  
Mark Vickers ◽  
Nobuyuki Hisamune ◽  
...  
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Mechanical Test ◽  
Welding Process ◽  
High Strength ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
Flux Cored Arc Welding ◽  
Welding Procedure ◽  
Submerged Arc

Ultra-high strength seamless pipes of X90 and X100 grades have been developed for deepwater or ultra-deepwater applications. Girth welding procedure specifications (WPSs) should be developed for the ultra-high strength pipes. However, there is little information for double jointing welding procedure by using submerged arc welding process for high strength line pipes. This paper describes mechanical test results of submerged arc welding (SAW) and gas shielded flux cored arc welding (GSFCAW) trials with various welding consumables procured from commercial markets. Welds were then made with typical welding parameters for riser productions using high strength X90 seamless pipes. The submerged arc weld metal strength could increase by increasing alloy elements in weld metal. The weld metal with CE (IIW) value of 0.74 mass% achieved fully overmatching for the X90 pipe. The weld metal yield strength (0.2% offset) was 694 MPa, and the ultimate tensile strength was 833 MPa. It was also confirmed that the reduction of boron in weld metal can improve low temperature toughness of high strength weld metal. Furthermore, it was confirmed that the HAZ has excellent mechanical properties and toughness for riser applications. In this study GSFCAW procedures were also developed. GSFCAW can be used for joining pipe and connector material for riser production welding. The weld metal with a CE (IIW) value of 0.54 mass% could meet the required strength level for X90-grade pipe as specified in ISO 3183. Cross weld tensile testing showed that fractures were achieved in the base metal. Good Charpy impact properties in weld metal and HAZ were also confirmed.

Weld Repair of Shell Plates During Seagoing Operations

2002 ◽  
Author(s):  
Per R. M. Lindstro¨m ◽  
Anders Ulfvarson
Keyword(s):  
Grain Size ◽  
Theoretical Model ◽  
Chemical Composition ◽  
Cooling Rate ◽  
Base Material ◽  
Forced Flow ◽  
Welding Parameters ◽  
Weld Repair ◽  
Welding Seam ◽  
Welding Procedure

An algorithm to estimate the cooling rate of welding seams on the shell plating of a ship, below the waterline, while it is on voyage has been derived. The demand for this technique has arisen from the wish of ship operators to make it possible for the safe repair of ship structures without taking them out of operation. [1] The strength of the shell plating after welding is determined by its metallurgic structure, which is dependent on the cooling rate, its chemical composition and the original grain size of the base material. [2] The cooling rate for this type of welding seam depends on the velocity of the water flow, the distance from the bow, the thickness of the plate, and the heat from the heat input of the welding. The algorithm makes it possible to calculate the cooling rate for a base material affected by a forced flow of fluid by means of Rosenthal’s equation and thus enabling suitable welding parameters to be determined. As the welding parameters can be chosen to fit the specific repair to be made, it is now possible to determine the suitability of a welding procedure in advance. The algorithm is applicable when determining welding parameters at Hot-Tapping operations as well, where the base material is affected by a forced flow of fluid. A number of experiments have been performed and the results support the theoretical model. The research project continues with the aim of finding an algorithm to include the enhanced cooling rate due to the layer of boiling fluid on the back of the base material. A method to improve the measurements of the most important parameter in the algorithm has been developed and makes it possible to build up a quantitative database of typical values for various configurations.

scholarly journals Fatigue Life Enhancement of Transverse and Longitudinal T-Joint on Offshore Steel Structure HSLAS460G2+M using Semi-automated GMAW and HFMI/PIT

2019 ◽  
Vol 269 ◽  
pp. 06001 ◽  
Author(s):  
Dahia Andud ◽  
Muhd Faiz Mat ◽  
Yupiter HP Manurung ◽  
Salina Saidin ◽  
Noridzwan Nordin ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Oil And Gas ◽  
Welding Process ◽  
Steel Structure ◽  
Raw Material ◽  
Welding Parameters ◽  
Weld Toe ◽  
Life Enhancement ◽  
Welding Procedure ◽  
Fatigue Life Enhancement

This research deals with a method and procedure for enhancing the structural life of the commonly used steel structure in oil and gas industries HSLA S460G2+M with a thickness of 10 mm. The type of joint and welding process is T-joint with transverse and longitudinal attachment welded using semi-automated GMAW. Filler wire ER80S-Ni1 and mixed shielding gas (80% Ar / 20% CO2) is used as material consumables. At first, the best suitable welding parameters are comprehensively investigated, prepared, tested and qualified according to welding procedure specification (WPS) qualification requirements. Further, the weld toe is treated by using HFMI/PIT with a frequency of 90Hz, 2 mm pin radius and air pressure of 6 bars. In accordance with the recommendation of the International Welding Institute (IIW), fatigue test is conducted using constant amplitude loading with the stress ratio of 0.1 and loading stresses from 55% to 75% of the yield strength of the material. Finally, the results of the fatigue experimental are compared with the fatigue recommendation of as-welded and HFMI/PIT of IIW as well as the untreated raw material. As a conclusion, it is observed that the fatigue life is increased up to 300% compared to IIW and 70% to as-welded. It is also obvious that treated transverse T-joint shows significant improvement than the longitudinal attachment.

Laser Beam Welding With Simultaneous Gaussian Laser Preheating

1993 ◽  
Vol 115 (1) ◽  
pp. 34-41 ◽  
Author(s):  
Y.-N. Liu ◽  
E. Kannatey-Asibu
Keyword(s):  
Heat Source ◽  
Laser Beam ◽  
Cooling Rate ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Input Power ◽  
Relative Power ◽  
Gaussian Source ◽  
Distribution Parameters ◽  
Dual Laser

An analytical solution of the dual, laser beam welding process is presented. It is based on a Gaussian distributed leading heat source for preheating, followed by a line source for the actual welding process. The effect of beam distribution parameters as well as interbeam spacing and relative power intensities on the resulting temperature distribution and cooling rate are presented. For a preheating Gaussian source of power 1550 W, the depth of region above 500°C is 2.25 mm, and that above 250°C is 3.5 mm. The cooling rate at the weld centerline without preheating for a temperature of 650° C, input power 1800 W, and welding velocity 20 mm/s is found to be 1004°C/s. Under the same conditions, the cooling rate with a 1550 W preheating Gaussian distributed heat source (beam distribution parameter 1 mm, and interbeam spacing 10 mm) is reduced to 570°C/s.

scholarly journals Temperature distribution of T- joint friction stir welding

2018 ◽  
Vol 7 (4) ◽  
pp. 2332
Author(s):  
Sadiq Aziz Hussein ◽  
Shaymaa Abdul Khader Al-Jumaili ◽  
Raed A. Mahmood
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Model ◽  
Thickness Effect ◽  
Joint Friction ◽  
Friction Stir ◽  
Welding Method ◽  
Structural Configurations

Friction stir welding is a reliable welding method; it can be employed to join different structural configurations. Joint types such as lap, butt and T have been successfully produced by this welding method. In this study, a trial has been made to numerically simulate the heat generation and temperature distribution during the welding process of a T-joint. The workpieces materials were hardened 5052 and tempered 7075 Al Alloys, each material was investigated separately. Different rotational and welding speeds were used, besides, the pin length was also varied to accommodate the investigation of the top plate thickness effect. A visco-plastic finite element model was adopted to investigate the effect of parameters ranges on the temperature distribution. The results showed that the temperature distribution of T-joint depends mainly on the material to be welded and rotational speed. Besides, increasing the pin length from 7 to 10 mm could significantly increase the resulted temperature by approximately 14%. Therefore, the thickness of the upper plates of the T-joint plays a significant role on the resulted process temperature.  

The Effects on Process Performance of Reducing the Pressure From 36 to 1Bar in Hyperbaric MIG Welding

2009 ◽  
Author(s):  
Hans Fostervoll ◽  
Neil Woodward ◽  
Odd M. Akselsen
Keyword(s):  
Water Depth ◽  
Deep Water ◽  
Sea Water ◽  
Ambient Pressure ◽  
Welding Process ◽  
Welding Parameters ◽  
Shallow Waters ◽  
Mig Welding ◽  
Water Conditions ◽  
Welding Procedure

Technology for remotely controlled (diverless) repair welding of subsea pipelines from 170 to 1000m water depth is being developed by StatoilHydro. The repair technology is based on a sleeve concept combined with MIG welding and the development is currently nearing completion. Technology for diver-assisted remotely controlled welding down to about 200m has been used in the North Sea for about twenty years. In order to reduce the use of divers, the deep water diverless technology is also being considered for use in shallow waters. The present work has been performed to investigate whether the deepwater welding procedure may also be used in shallow waters, and which modifications for the lower pressure conditions need to be made. Test welding has been performed in the pressure range from 36 to 1bar corresponding to 350 to 0m sea water depth to study the effect of ambient pressure upon the welding process behaviour and weld bead appearance and geometry. For the 12 o’clock welding position tested, welding parameters developed for deep water conditions also worked well for shallow water conditions down to about 2bar. It was also evident that the electrode polarity, which is negative for the deep water procedure, had to be changed to electrode positive for the lowest pressures, which coincides with conventional 1-atm MIG welding. Mechanical property testing and microstructure examinations revealed satisfactory results using the modified welding procedure.

Design of a Control System for Welding Robot with Tracking Simulation

2008 ◽  
Vol 580-582 ◽  
pp. 251-258
Author(s):  
Jin Seok Oh ◽  
Jong Do Kim ◽  
Jun Ho Kwak ◽  
Ji Young Lee
Keyword(s):  
Control System ◽  
Welding Process ◽  
Simulation Method ◽  
Seam Tracking ◽  
High Rate ◽  
Welding Parameters ◽  
Welding Robot ◽  
Robot System ◽  
Closed Area ◽  
Welding Procedure

Welding tasks in shipbuilding create great problems for a manual welder since welding takes place in closed area with associated work environmental problems. This paper addresses the problems involved in the welding robot with control algorithm and system. The control system may similarly be modified as a tracking simulation test. The performance of the control system is assessed through the use of field data. The aim of this paper is to determine feasible parameters for a welding procedure with simulation for seam tracking of welding robot system. The main advantage of tracking simulation is its flexibility in that as the welding parameters are modified at a sufficiently high rate. Tracking simulation showed that the development of robot control algorithms should be performed by simulation, since it saves time, expenses and efforts. This paper will contribute to an increased use of automated welding technology with tracking simulation methods. Also, this paper’s results can be used for the optimization of welding process using simulation method with LabVIEW.

scholarly journals Providing resistance to sulfide stress corrosion cracking of pipelines welded joints by selection of welding parameters

2019 ◽  
Vol 121 ◽  
pp. 04005
Author(s):  
Artem Khudyakov ◽  
Pavel Danilkin
Keyword(s):  
Cooling Rate ◽  
Welded Joints ◽  
Welding Process ◽  
Coarse Grained ◽  
Welding Parameters ◽  
Cooling Rates ◽  
Stress Cracking ◽  
Girth Welding ◽  
Sulfide Stress ◽  
Longitudinal Welds

Sulfide stress cracking (SSC) is one of the most dangerous types of pipelines destruction. Thermal impact of the welding process drives to heterogeneity of the microstructure and properties of the metal, which can lead to cracking of pipeline welded joints. Resistance to SSC of welded joints is determined by the thermal cycle of welding and cooling rate in the temperature range of austenite transformation. Due to performed studies based on simulation of welding heating the recommended range of cooling rates of 10–30 ° C/s was established, in which the resistance to SSC of welded joints is ensured. To calculate the cooling rates in coarse grained heat affected zone (CGHAZ) finite-element models of heat distribution were developed for longitudinal multi-electrode submerged arc welding (SAW) and multi-pass girth welding of pipes. Using the developed welding models, it was found that in order to achieve the cooling rate in CGHAZ it is necessary to reduce heat input up to 15-30% during multi-electrode SAW process of longitudinal welds of pipes . For multi-pass girth welding it is necessary to preheat the edges to be welded up to 100-300 °C depending on type of welding (GMAW or SMAW) and pipe wall thickness.

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