scholarly journals Hybrid Laser-Arc Welding of Thick-Walled, Closed, Circumferential Pipe Welds

2022 ◽  
Vol 101 (1) ◽  
pp. 15-26
Author(s):  
ÖMER ÜSTÜNDAĞ ◽  
◽  
SERGEJ GOOK ◽  
ANDREY GUMENYUK ◽  
MICHAEL RETHMEIER ◽  
...  
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Control Strategies ◽  
Welding Process ◽  
Beam Diameter ◽  
Circumferential Welds ◽  
Hybrid Laser Arc Welding ◽  
Solidification Cracks ◽  
High Level ◽  
Overlap Area

The application of hybrid laser-arc welding (HLAW) for joining closed circumferential welds is a challenge due to the high risk of forming a defective overlap area with a shrinkage void or solidification cracks in the material thickness. A series of HLAW experiments were performed to understand the development of a faulty overlap area when closing the circumferential weld. Welding trials on flat specimens and pipe segments were supported by numerical analyses in which the thermomechanical behavior of the welds in the overlap area was investigated. Different process control strategies were tested, including variations in defocusing levels and the overlap length. The newly developed HLAW head, including laser optics with a motor-driven collimation system, made it possible to defocus the laser beam during welding without disturbing the stability of the welding process. High-level defocusing of the laser beam of more than 40 mm relative to the specimen surface with a resulting beam diameter of > 2.9 mm, and in combination with a short overlap length of 15 mm, was promising with respect to the formation of a desired cup-shaped weld profile that is resistant to solidification cracks.

scholarly journals Hybrid laser-arc welding of laser- and plasma-cut 20-mm-thick structural steels

2022 ◽  
Author(s):  
Ömer Üstündağ ◽  
Nasim Bakir ◽  
Sergej Gook ◽  
Andrey Gumenyuk ◽  
Michael Rethmeier
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Laser Beam Welding ◽  
Digital Camera ◽  
Welding Process ◽  
Beam Power ◽  
Beam Diameter ◽  
Hybrid Laser Arc Welding ◽  
Single Pass ◽  
New Findings

AbstractIt is already known that the laser beam welding (LBW) or hybrid laser-arc welding (HLAW) processes are sensitive to manufacturing tolerances such as gaps and misalignment of the edges, especially at welding of thick-walled steels due to its narrow beam diameter. Therefore, the joining parts preferably have to be milled. The study deals with the influence of the edge quality, the gap and the misalignment of edges on the weld seam quality of hybrid laser-arc welded 20-mm-thick structural steel plates which were prepared by laser and plasma cutting. Single-pass welds were conducted in butt joint configuration. An AC magnet was used as a contactless backing. It was positioned under the workpiece during the welding process to prevent sagging. The profile of the edges and the gap between the workpieces were measured before welding by a profile scanner or a digital camera, respectively. With a laser beam power of just 13.7 kW, the single-pass welds could be performed. A gap bridgeability up to 1 mm at laser-cut and 2 mm at plasma-cut samples could be reached respectively. Furthermore, a misalignment of the edges up to 2 mm could be welded in a single pass. The new findings may eliminate the need for cost and time-consuming preparation of the edges.

Low Heat Input Welding for Thin Steel Fabrication

2006 ◽  
Vol 22 (02) ◽  
pp. 105-109
Author(s):  
S.M. Kelly ◽  
R.P. Martukanitz ◽  
P. Michaleris ◽  
M. Bugarewicz ◽  
T. D. Huang ◽  
...  
Keyword(s):  
Laser Beam ◽  
Heat Input ◽  
Arc Welding ◽  
Process Development ◽  
High Heat ◽  
Hybrid Laser Arc Welding ◽  
Thin Steel ◽  
High Heat Input ◽  
Time Distortion ◽  
Buckling Distortion

As thinner members are used in marine construction, the use of conventional joining techniques results in significant angular and buckling distortion due to the inherent high heat input with these processes. Several low heat input alternatives, including laser beam, gas metal arc, and hybrid laser arc welding, are explored. The paper focuses on process development, real time distortion measurements, and implementation of these processes.

Strategies for Controlling Welding Fumes at the Source - A Review

2014 ◽  
Vol 592-594 ◽  
pp. 2539-2545 ◽  
Author(s):  
Sreejith Mohan ◽  
S.P. Sivapirakasham ◽  
P. Bineesh ◽  
K. K. Satpathy
Keyword(s):  
Arc Welding ◽  
Control Strategies ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Detailed Knowledge ◽  
Welding Fumes ◽  
Shielded Metal Arc Welding ◽  
Factors Affecting ◽  
Metal Arc Welding ◽  
New Research

Exposure to welding fumes and its related hazards has always been a matter of serious concern. The mass and composition of fumes from welding depends on several factors. A detailed knowledge of these factors is necessary for understanding the mechanism of fume formation and developing suitable control strategies. This paper gives a literature overview on the various factors affecting welding fumes and strategies for controlling it. The paper focus on types of welding process like Manual Metal Arc Welding (MMAW) or Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Flux Core Arc Welding (FCAW), Gas and Tungsten Arc Welding (GTAW). The research in the area of controlling fumes at the source has grown rapidly recently. Still, effective methods have hardly been explored. Improving arc stability by addition of materials with low ionization potential to the welding electrode lead to promising new research directions.

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.

Low Heat Input Welding for Thin Steel Fabrication

2005 ◽  
Author(s):  
S. M. Kelly ◽  
R. P. Martukanitz ◽  
P. Michaleris ◽  
M. Bugarewicz ◽  
T. D. Huang ◽  
...  
Keyword(s):  
Laser Beam ◽  
Heat Input ◽  
Arc Welding ◽  
Process Development ◽  
High Heat ◽  
Hybrid Laser Arc Welding ◽  
Thin Steel ◽  
High Heat Input ◽  
Time Distortion ◽  
Buckling Distortion

As thinner members are used in marine construction, the use of conventional joining techniques result in significant angular and buckling distortion due to the inherent high heat input with these processes. Several low heat input alternatives, including laser beam, gas metal arc, and hybrid laser-arc welding are explored. The paper focuses on process development, real time distortion measurements and implementation of these processes.

Influence of welding gases and filler metals on hybrid laser-GMAW and Laser-FCAW welds

2020 ◽  
pp. 095440622095705
Author(s):  
D Wallerstein ◽  
E Vaamonde ◽  
A Prada ◽  
EA Torres ◽  
SL Urtiga Filho ◽  
...  
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Laser Power ◽  
Laser Beam Welding ◽  
Cost Savings ◽  
The Other ◽  
Hybrid Laser Arc Welding ◽  
Steel Joints ◽  
Cored Wires ◽  
Filler Metals

Hybrid Laser-Arc Welding (HLAW) is a relatively new joining technique that combines advantages from both laser beam welding and arc welding. The interaction between laser beam and arc welding provides advantageous synergic effects, especially for thick joints. On the other hand, this interaction brings extra complexity to HLAW, limiting its acceptance in industry. Therefore, it is still necessary to elucidate some features of HLAW, such as the influence of parameters and consumables on the characteristics of the resulting joints. In the present study, the effects of welding gases (Ar + CO2 in different proportions) and filler metals (solid and flux-cored wires) on thick S355 structural steel joints are assessed. The best welds in terms of geometric characteristics, microstructures, and mechanical behavior were fabricated with high CO2 content welding gases and flux-cored welding wires. The use of flux-cored wires promoted higher penetration, lower hardness, and formation of acicular ferrite, avoiding the formation of martensite encountered in joints welded with solid wires. Moreover, the application of flux-cored wires could lead to cost savings in future applications, by reducing the laser power required to produce sound joints.

Hybrid laser/arc welding process for controlling bead profile

2007 ◽  
Vol 12 (8) ◽  
pp. 677-688 ◽  
Author(s):  
M.H. Cho ◽  
D. Farson ◽  
Y.C. Lim ◽  
H.W. Choi
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Hybrid Laser Arc Welding ◽  
Arc Welding Process ◽  
Bead Profile

scholarly journals Study on temperature- microstructure- stress fields of thick-walled plate welded by hybrid laser arc welding

2021 ◽  
Vol 2083 (2) ◽  
pp. 022075
Author(s):  
Hongjie Zhang ◽  
Tao Han ◽  
Yong Wang ◽  
Bangyu Wang ◽  
Guangxue Chen
Keyword(s):  
Arc Welding ◽  
Laser Energy ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Stress Fields ◽  
Deep Penetration ◽  
Bead Width ◽  
Hybrid Laser Arc Welding ◽  
Weld Profile ◽  
Welding Procedure

Abstract The 25mm DH36 steel was welded by hybrid laser arc welding (HLAW), and a sequence coupled thermal-metallurgical-mechanical (TMM) model was developed based on SYSWELD. The temperature-microstructure-stress fields are predicted by simulation verified by experiment. The ratio between the arc and laser energy showed a significant effect on weld profile. The laser provided the main power and ensured deep penetration, and the arc power showed a dominant effect on the bead width of the hybrid weld during HLAW. For the hybrid welding of a thick-walled plate, the microstructure and thermal cycles varied along with the thickness. The weld profile and microstructure were experimentally characterized. The 3-pass welding procedure produced larger welding residual stress than the 9-pass welding procedure, and the process stability is poorer than the 3-pass welding process. Overall, numerical results matched well with experimental results.

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