scholarly journals Optimization of Filler Metals Consumption in the Production of Welded Steel Structures

2016 ◽  
Vol 16 (1) ◽  
pp. 27-34
Author(s):  
K. Pańcikiewicz ◽  
L. Tuz ◽  
Z. Żurek ◽  
Ł. Rakoczy
Keyword(s):  
Filler Metal ◽  
Mobile Apps ◽  
Welding Process ◽  
Steel Structures ◽  
Correct Choice ◽  
Design Stage ◽  
Calculation Methods ◽  
Metal Consumption ◽  
Welded Steel ◽  
Filler Metals

Abstract The paper presents the some aspects of the optimization of filler metals consumption in the production of welded steel structures. Correct choice of beveling method can allow to decrease cost of production and increase quality. The review of calculation methods of filler metal consumption at the design stage was carried out. Moreover, the practical examples of amount of filler metals calculation were presented and analyzed. The article also contain examples of mobile apps which are makes it easy to see welding costs in just a few seconds. Apps as well as simple excel spreadsheets with correct mathematic equations allows to optimize welding process.

Fatigue Behaviour of Friction Stir Welded Steel Joints

2014 ◽  
Vol 891-892 ◽  
pp. 1488-1493 ◽  
Author(s):  
José Azevedo ◽  
Virgínia Infante ◽  
Luisa Quintino ◽  
Jorge dos Santos
Keyword(s):  
Base Material ◽  
Welding Process ◽  
Steel Structures ◽  
Fatigue Behaviour ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Welded Steel ◽  
Shipbuilding Industry ◽  
Friction Stir ◽  
Steel Joints

The development and application of friction stir welding (FSW) technology in steel structures in the shipbuilding industry provide an effective tool of achieving superior joint integrity especially where reliability and damage tolerance are of major concerns. Since the shipbuilding components are inevitably subjected to dynamic or cyclic stresses in services, the fatigue properties of the friction stir welded joints must be properly evaluated to ensure the safety and longevity. This research intends to fulfill a clear knowledge gap that exists nowadays and, as such, it is dedicated to the study of welded steel shipbuilding joints in GL-A36 steel, with 4 mm thick. The fatigue resistance of base material and four plates in as-welded condition (using several different parameters, tools and pre-welding conditions) were investigated. The joints culminate globally with defect-free welds, from which tensile, microhardness, and fatigue analyses were performed. The fatigue tests were carried out with a constant amplitude loading, a stress ratio of R=0.1 and frequency between 100 and 120 Hz. The experimental results show the quality of the welding process applied to steel GL-A36 which is reflected in the mechanical properties of joints tested.

The effect of filler metal and butter layer on microstructural and mechanical properties of pure Cu to AISI304 stainless steel dissimilar joint

2018 ◽  
Vol 233 (9) ◽  
pp. 1894-1905 ◽  
Author(s):  
M Rafiei ◽  
H Mostaan
Keyword(s):  
Stainless Steel ◽  
Electron Microscope ◽  
Scanning Electron Microscope ◽  
Heat Affected Zone ◽  
Filler Metal ◽  
Welding Process ◽  
Dissimilar Joint ◽  
Pure Cu ◽  
Filler Metals ◽  
Scanning Electron

In this research, dissimilar joint properties of pure Cu to AISI304 stainless steel using three different filler metals were studied. In this regard, the welding process was done with gas tungsten arc welding process using ER308L, ER309L, and ERNiCrMo3 filler metals and ERNi1 butter layer. The microstructural evaluations were carried out using optical microscope and scanning electron microscope. The mechanical tests were conducted by microhardness, tensile, bending and impact tests, and the fracture surfaces of impact and tensile tests were studied by scanning electron microscope. The results show that there is no crack or discontinuity in the welded samples. Energy-dispersive spectroscopy analysis revealed that the diffusion of Cu from base metal to butter layer has been occurred during welding. The microhardness profiles indicated the increase of hardness in heat-affected zone and butter layer. The welded sample with ERNiCrMo3 filler metal showed higher microhardness (200 HV) as compared with two other welded samples. The welded sample with ER309L filler metal had lower microhardness of about 150 HV. The tensile test revealed that the welded sample with ER309L filler metal showed maximum (193 MPa) and the welded sample with ER308L showed minimum (147 MPa) of ultimate tensile strength. In bending test of the welded samples with ER308L and ERNiCrMo3 filler metals, the crack and discontinuity were revealed in weld metal and heat-affected zone of Cu, respectively, while in the welded sample with ER309L filler metal no crack and discontinuity were seen. Also the welded sample with ER309L filler metal had highest impact energy of about 90 J as compared to other samples (81 and 88 J for the welded samples with ER308L and ERNiCrMo3 filler metals, respectively). The welded sample with ER309L filler metal showed more ductile fracture surface as compared with other samples.

scholarly journals Braze Welding TIG of Titanium and Aluminium Alloy Type Al – Mg

2016 ◽  
Vol 61 (1) ◽  
pp. 133-142 ◽  
Author(s):  
A. Winiowski ◽  
D. Majewski
Keyword(s):  
Aluminium Alloy ◽  
Filler Metal ◽  
Energy Dispersive Spectrometer ◽  
Welding Process ◽  
Tensile Tests ◽  
X Ray ◽  
Alloy Type ◽  
Filler Metals ◽  
Scanning Electron

The article presents the course and the results of technological tests related to TIG-based arc braze welding of titanium and AW-5754 (AlMg3) aluminium alloy. The tests involved the use of an aluminium filler metal (Al99.5) and two filler metals based on Al-Si alloys (AlSi5 and AlSi12). Braze welded joints underwent tensile tests, metallographic examinations using a light microscope as well as structural examinations involving the use of a scanning electron microscope and an X-ray energy dispersive spectrometer (EDS). The highest strength and quality of welds was obtained when the Al99.5 filler metal was used in a braze welding process. The tests enabled the development of the most convenient braze welding conditions and parameters.

The Effect of Filler ER4043 and ER5356 on Porosity Distribution of Welded AA6061 Aluminum Alloy

2010 ◽  
Vol 146-147 ◽  
pp. 987-990
Author(s):  
Che Lah Nur Azida ◽  
Muhammad Faizol Ahmad Ibrahim ◽  
Azman Jalar ◽  
J. Sharif ◽  
Norinsan Kamil Othman ◽  
...  
Keyword(s):  
Welded Joints ◽  
Filler Metal ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Butt Joint ◽  
Hardness Profile ◽  
Porosity Formation ◽  
Metal Arc Welding ◽  
Arc Welding Process ◽  
Filler Metals

The filler metal used during welding process is believed to play an important role on porosity formation in aluminium alloy welded. The present investigation is aimed to study the effect of different fillers ER4043 (Al-5%Si) and ER5356 (Al-5%Mg) on porosity formation of AA6061 alloy welded joints. Butt-joint welds were made on 6 mm thick plates using 21 – 22 V arc voltages by using Gas Metal Arc Welding process (GMAW). The hardness profile of each types of AA6061 welded joints for both fillers were characterized by the Vickers microhardness test. In order to study the formation and distribution of porosity, the images of analysis were obtained using the X- ray CT-Scan. It was observed that, more porosities were found in the alloy AA6061 using ER4043 compared to ER5356 filler metals with the percentage area value of porosity about 18.3 and 8.4%, respectively. The hardness profile of ER5356 and ER4043 welded materials exhibited the similar hardness pattern profile. It is proposed that Si and Mg contents in the filler metal could play significant role in the distribution of porosity. No significant effect was observed on the hardness profile for both filler metals of welded materials.

Reduction of Manufacturing Distortion in Arc Welded Ship Panels Using Thermal Tensioning

2008 ◽  
Vol 24 (04) ◽  
pp. 177-179
Author(s):  
Ruth Sanderson ◽  
Bill Lucas ◽  
Roy Pocock
Keyword(s):  
Arc Welding ◽  
Thermal Stresses ◽  
Welding Process ◽  
Steel Structures ◽  
Steel Plates ◽  
Welded Steel ◽  
Large Structures ◽  
Arc Welding Process ◽  
Thermal Tensioning ◽  
The Cost

Large sheet or thin plate steel structures invariably suffer from distortion especially when fabricated using an arc welding process. The cost of reworking in shipbuilding is high. Low-stress no-distortion (LSND) welding has been demonstrated to effectively prevent distortion. The technique has been show to work well by rapidly cooling the weld with atomized water or liquid CO2 immediately after solidification. However, this can be expensive and difficult to apply in the fabrication of large structures. In this work, only a thermal tensioning technique is presented. The technique controls distortion by applying thermal stresses in front of the weld pool to counteract the stresses induced in the structure by welding. A combination of finite element modeling and experimentation has been used to find a thermal tensioning arrangement that reduces distortion by 50% in 4 mm butt welded steel plates using arc welding.

Rainbow Test of Laser Reconditioned Frame 6 Buckets

2003 ◽  
Author(s):  
M. C. van Beek ◽  
M. G. H. M. Hendriks ◽  
D. C. M. Wilms
Keyword(s):  
Laser Welding ◽  
Gas Turbines ◽  
Filler Metal ◽  
Welding Process ◽  
Maintenance Cost ◽  
Factors Affecting ◽  
The Difference ◽  
Lower Temperature ◽  
Filler Metals ◽  
Laser Welding Process

The procurement and reconditioning of turbine buckets and vanes drive the maintenance cost for gas turbines. The use of advanced repair methods like laser welding can help to reduce these costs. The main advantage of the laser welding process is that high-grade filler metals can be used with the possibility to extend current repair-limits. Before the laser welding process can be applied for industrial repairs the method has to be extensively tested for attained mechanical properties and for the performance during exposure in an actual turbine. This paper discusses the first rainbow test as performed on a frame 6 gas turbine of the Bergum power plant in the Netherlands. For a set of first stage buckets with 12139 operating hours (OH) 6 buckets were reconditioned using conventional TIG repair and 6 buckets using the laser-powder welding process. In both cases In 625 was used as the filler metal. The remaining buckets were not reconditioned. Monitoring of the performance of the reconditioned buckets is done using pyrometry and by boroscopic inspections. The reconditioned buckets are about 17°C cooler than the others. Moreover, it is found that the buckets repaired using laser welding have lower tip temperatures compared to the buckets reconditioned using conventional TIG welding. The overall lower temperature is partly caused by the difference in colour between the reconditioned and non-reconditioned buckets, which affects the emissivity. This difference was found still present during a boroscopic inspection 1776 OH after the overhaul. The other possible factors affecting the temperature difference are identified but are not yet fully understood.

scholarly journals Failure Analysis of Premature Corrosion of HF Seam-Welded Steel Pipe in Central Heating System

2021 ◽  
Author(s):  
Dorota Tyrala ◽  
Bogdan Pawlowski
Keyword(s):  
High Frequency ◽  
Energy Dispersive Spectrometry ◽  
Weld Line ◽  
Welding Process ◽  
Heating System ◽  
Bond Line ◽  
Steel Pipe ◽  
Huge Number ◽  
Welded Steel ◽  
Central Heating

AbstractPremature corrosion in the form of longitudinal cracking in a high-frequency (HF) induction seam-welded steel pipe occurred after just 24 months in service. The failed pipe was investigated to reveal the main cause of its failure, and the results of microstructural examinations (light optical microscopy, scanning electron microscopy with energy-dispersive spectrometry) suggest that the failure resulted from an HF induction welding process defect—a so-called cast weld, that is, a huge number of iron oxides in the weld line caused by insufficient ejection of the molten metal from the bond line.

scholarly journals Process Stability, Microstructure and Mechanical Properties of Underwater Submerged-Arc Welded Steel

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1249
Author(s):  
Maofu Zhang ◽  
Yanfei Han ◽  
Chuanbao Jia ◽  
Shengfa Dong ◽  
Sergii Maksimov ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Epoxy Resin ◽  
Water Glass ◽  
Welding Process ◽  
Process Stability ◽  
Surrounding Water ◽  
Welded Steel ◽  
Underwater Wet Welding ◽  
Marine Engineering ◽  
High Level

In underwater wet welding, the unstable welding process caused by the generation and rupture of bubbles and the chilling effect of water on the welding area result in low quality of welded joints, which makes it difficult to meet the practical application of marine engineering. To improve the process stability and joining quality, a mixture of welding flux with a water glass or epoxy resin was placed on the welding zone before underwater welding. In this paper, welds’ appearance, geometry statistics of welds’ formation, welding process stability, slag structure, microstructure, pores and mechanical properties were investigated. It was found that with the addition of water glass in the mixture, the penetration of weld was effectively increased, and the frequency of arc extinction was reduced. Though the porosity rose to a relatively high level, the joints’ comprehensive mechanical properties were not significantly improved. Notably, the applied epoxy resin completely isolated the surrounding water from the welding area, which greatly improved process stability. Furthermore, it benefited from the microstructure filled with massive acicular ferrite, the average elongation and room temperature impact toughness increased by 178.4%, and 69.1% compared with underwater wet welding, respectively, and the bending angle of the joint reaches to 180°.

scholarly journals Study of Laser Welding of HCT600X Dual Phase Steels

2014 ◽  
Vol 22 (1) ◽  
pp. 93-98
Author(s):  
Pavol Švec ◽  
Viliam Hrnčiar ◽  
Alexander Schrek
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welding Speed ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Dual Phase ◽  
Welded Steel ◽  
Steel Sheets

AbstractThe effects of beam power and welding speed on microstructure, microhardnes and tensile strength of HCT600X laser welded steel sheets were evaluated. The welding parameters influenced both the width and the microstructure of the fusion zone and heat affected zone. The welding process has no effect on tensile strength of joints which achieved the strength of base metal and all joints fractured in the base metal.

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