Weldability Studies on the Replacement Repair Welded Joints of a Damaged Steel Bridge

2008 ◽  
Vol 580-582 ◽  
pp. 655-658 ◽  
Author(s):  
Kyong Ho Chang ◽  
H.C. Park ◽  
Chin Hyung Lee ◽  
Gab Chul Jang ◽  
Sang Hyong Lee ◽  
...  
Keyword(s):  
Welded Joints ◽  
Welding Process ◽  
Hardness Test ◽  
Steel Plates ◽  
Composition Analysis ◽  
Steel Bridge ◽  
Repair Welding ◽  
Repair Method ◽  
Flux Cored Arc Welding ◽  
Safety And Reliability

In recent years, the replacement repair welding, through which damaged bridges are repaired by replacing of the damaged sections with new steel plates through cutting and welding under in-service conditions, has been highlighted for its brilliant features i.e. it can be achieved without incurring traffic dislocation. However, the validity of the repair method is not fully verified because of its lack of safety and reliability. Moreover, repair method by welding inevitably involves cutting and welding process, and the weldability of the replacement repair welded joints has not yet been clarified. In this paper, the weldability of the replacement-repair-welded joints was investigated in order to improve reliability in the repair welded joints of the aged steel bridge. A Steel plate was extracted from the steel bridge after the period of prolonged service, and was welded with a new plate, using replacement repair welding technique, in order to construct a specimen. Flux Cored Arc Welding (FCAW) process was used to fabricate the double "V" butt joints. Welded joints were characterized on the basis of chemical composition analysis, hardness test and micro-structural analysis.

Proactive In-Situ Welding Stress Control for Laser Repair Welding of Irradiated Austenitic Materials

2017 ◽  
Author(s):  
Jian Chen ◽  
Jonathan Tatman ◽  
Zongyao Chen ◽  
Zhili Feng ◽  
Greg Frederick
Keyword(s):  
Numerical Simulations ◽  
Technology Development ◽  
Welding Process ◽  
Steel Plates ◽  
Image Correlation ◽  
Process Conditions ◽  
Welding Stress ◽  
Repair Welding ◽  
Materials Used

Substantial research has been performed in recent years to determine the effects and feasibility of welding on highly irradiated austenitic materials. This research has been driven by the need to preemptively develop welding techniques capable of repairing highly irradiated light water reactor (LWR) components susceptible to detrimental corrosion and cracking. However, the materials used to fabricate internal LWR components become increasingly difficult to weld with in-service age due to irradiation-induced generation of helium in the material matrix over time. This paper introduces a patent-pending technology that proactively manages the stresses during laser repair welding of highly irradiated reactor internals to avoid the occurrence of intergranular helium-induced cracking. The technology development relied on numerical simulations that made it possible to refine and optimize the innovative welding concept and to identify specific process conditions achieving significant reduction of tensile stress (or even formation of compressive stress) near the weld pool in the heat-affected zone on cooling. The candidate welding process conditions identified by the numerical simulations were experimentally tested on stainless steel plates (Type 304L) with a laser welding system purposely designed and engineered to incorporate the proactive stress management concept. In-situ temperature and strain measurement technique based on digital image correlation were applied to validate the numerical simulations.

Application of Multiple Methods of NDT for the Evaluation of Welded Joints in a Steel Bridge ASTM-A-588

2019 ◽  
Vol 287 ◽  
pp. 8-12
Author(s):  
Héctor C. Terán ◽  
Oscar Arteaga ◽  
F.S. Alcocer ◽  
Richard R. Navas ◽  
Stalin P. Mena ◽  
...  
Keyword(s):  
Welded Joints ◽  
Arc Welding ◽  
Base Material ◽  
Steel Bridge ◽  
Shielded Metal Arc Welding ◽  
Destructive Testing ◽  
Final State ◽  
Metal Arc Welding ◽  
Flux Cored Arc Welding ◽  
Non Destructive

This work is based on making a comparison of different inspection methods of non-destructive testing (NDT), to detect porosity, bite, undercut, splash, overlap, slag, concavity, lack of fusion and damage to base material, in welds of shielded metal arc welding (SMAW) and flux-cored arc welding (FCAW), made on a steel bridge ASTM-A-588. The main application of non-destructive tests is to evaluate the final state of a welded joint in critical points, in addition the fundamental objective is to ensure that the established acceptance and rejection criteria are met rigorously. For which non-destructive techniques are analyzed, such as the visual testing of welding on the beams of a bridge of length 35000 mm, subsequently, tests of inspection by liquid penetrant were used, based on the AWS D1.5 standard to confirm the failures in welded joints in ABA webs, an ultrasonic is also carried out using an SIUI CTS 602 equipment, finally to issue an acceptance and rejection criterion as determined by ASTM E165 and ASTM E2544-09.

The Effect of Welding Residual Stress Distribution in Thickness Direction With Thick Steel Plate to Identification of Fracture Toughness

2016 ◽  
Author(s):  
Gyubaek An ◽  
Wanchuck Woo ◽  
Jeongung Park
Keyword(s):  
Residual Stress ◽  
Crack Propagation ◽  
Steel Plate ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Steel Plates ◽  
Propagation Path ◽  
Crack Propagation Path ◽  
Flux Cored Arc Welding ◽  
Thick Steel

Along with the rapid increase in the size of welding structures, the steel plate used for structure has been increased in thickness. Especially, the growing capacity of large scale ships such as container ships has led to an increase in the thickness and the strength of steel plates for shipbuilding. The toughness and the resistance to brittle fractures of the steel plate tend to decrease for thick plates, which is a result of the so-called thickness effect. Steel plates with 80mm thickness were used and two welding processes, which are flux cored arc welding (FCAW) process and electron gas welding process (EGW), were used to produce full thickness weld joints. To evaluate of brittle crack propagation path, measurement of welding residual stress in both welded joint. In this study, it was aimed to investigate the effect of welding variables on the crack arrest toughness and crack propagation path of thick steel plate welds. Quantitative analysis by temperature gradient ESSO test was conducted to clarify the effect of welding variables for flux cored arc welding (FCAW) and electro gas welding (EGW) joint of thick steel plates with the thickness of 50 and 80mm. Also, welding residual stress was measured for evaluate of welding residual stress effect in both welding process in brittle crack propagation path using neutron science analysis.

Micromechanical Analysis of Constraint Effect on Fracture Initiation in Strength Mismatched Welded Joints

2007 ◽  
Vol 555 ◽  
pp. 571-576 ◽  
Author(s):  
M. Dobrojević ◽  
Marko Rakin ◽  
Nenad Gubeljak ◽  
Ivana Cvijović ◽  
Misa Zrilić ◽  
...  
Keyword(s):  
Crack Growth ◽  
Welded Joints ◽  
Volume Fraction ◽  
Hsla Steel ◽  
Micromechanical Model ◽  
Welding Process ◽  
Constraint Effect ◽  
Precracked Specimen ◽  
Flux Cored Arc Welding ◽  
Growth Initiation

In this paper the micromechanical approach to ductile fracture was applied in a study of constraint effect on crack growth initiation in mismatched welded joints. The single-edged notched bend specimens (precrack length a0/W=0.32) were experimentally and numerically analyzed. The coupled micromechanical model proposed by Gurson, Tvergaard and Needleman was used. Constraint effect was tested by varying widths of the welded joints (6, 12 and 18mm). Highstrength low-alloyed (HSLA) steel was used as the base metal in a quenched and tempered condition. The flux-cored arc-welding process in shielding gas was used. Two different fillers were selected to obtain over- and undermatched weld metal. The micromechanical parameters used in prediction of the crack growth initiation on precracked specimen were calibrated on a round smooth specimen. The difference in fracture behavior between over- and undermatched welded joints obtained in experimental results was followed by numerical computations of void volume fraction in front of the crack tip.

scholarly journals Failure Analysis of Weld Cracking in External Cold Water Pipeline of Condenser in Converter Station

2020 ◽  
Vol 165 ◽  
pp. 06031
Author(s):  
Jun Wang ◽  
Yaxia Qiao ◽  
Hao Zhang ◽  
Hongjian Lou
Keyword(s):  
Electron Microscopy ◽  
Scanning Electron Microscopy ◽  
Cold Water ◽  
Welding Process ◽  
Hardness Test ◽  
Control Measures ◽  
Composition Analysis ◽  
Chemical Composition Analysis ◽  
Water Pipeline ◽  
Scanning Electron

The cause of weld cracking in external cold water pipeline of condenser in a ±800kV converter station were analyzed by macro inspection, chemical composition analysis, hardness test, microstructure inspection, scanning electron microscopy and energy spectrum test methods.The results show that the main reason for the cracks is that the material and manufacturing process are not qualified, and the welding process is not good. Corresponding control measures are put forward to avoid similar failures from happening again.

Experimental Investigation on the Fatigue Strength of the Replacement Repair Welded Joints

2007 ◽  
Vol 345-346 ◽  
pp. 355-358
Author(s):  
Kyong Ho Chang ◽  
H.C. Park ◽  
Chin Hyung Lee ◽  
Gab Chul Jang ◽  
E.H. Choi
Keyword(s):  
Fatigue Strength ◽  
Welded Joints ◽  
Steel Plate ◽  
Fatigue Tests ◽  
Steel Plates ◽  
Steel Girder ◽  
Girder Bridges ◽  
Steel Girder Bridges ◽  
Flux Cored Arc Welding ◽  
Girder Bridge

In recent years, the replacement repair welding, which repairs damaged steel girder bridges by replacement of the damaged sections with new steel plates through cutting and welding under in-service conditions, is spotlighted for its brilliant features, i.e. it can be achieved without incurring traffic dislocation. However, the mechanical behavior of the welded joints under cyclic loads due to the traffic which passes along the girder bridges is not clarified. In this paper, the fatigue strength of the replacement repair welded joints was investigated in order to improve reliability in the repair welded joints. Steel plate was extracted from the old steel girder bridge; then was welded with new steel plate to construct specimen with the replacement repair welded joints. Flux Cored Arc Welding (FCAW) process was used to fabricate the double "V" butt joints. Fatigue tests were conducted using a servo hydraulic controlled 50tonf capacity UTM with a frequency of 5Hz under constant amplitude loading. The fatigue strength of the replacement repair welded joints was analyzed in detail.

Effect of Orbital Automatic Welding on the Weld Metal Mechanical Properties in API 5L X65 Natural Gas Transmission Pipe

2000 ◽  
Author(s):  
Jong-hyun Baek ◽  
Young-pyo Kim ◽  
Woo-sik Kim
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Welding Process ◽  
Charpy Impact ◽  
Hardness Test ◽  
Outer Diameter ◽  
Automatic Welding ◽  
Shielded Metal Arc Welding ◽  
Flux Cored Arc Welding ◽  
Filler Metals

API 5L X65 steel pipes with a 17.5mm wall thickness and 762mm in outer diameter were welded using an orbital automatic welding process. Flux Cored Arc Welding (FCAW) and Gas Tungsten Arc Welding (GTAW) consumables were utilized to evaluate automatic the welding process. Manual welds were deposited using GTAW with ER70S-G filler metal for the root pass and Shielded Metal Arc Welding (SMAW) with low hydrogen E9016-G electrode for the remaining passes. Charpy impact test, CTOD (Crack Tip Opening Test) test and micro-hardness test on the weld metal were carried out and the effects of weld metal composition and microstructure on the weld metal toughness were investigated. The filler metals that have superior fracture toughness were E80T1-K2 and E71T-1 of FCAW process and ER80S-G of GTAW process. The filler metals that have proper hardness were E80T1-K2 and E71T-1 of FCAW process.

scholarly journals Inspection and rehabilitation of old White Nile steel bridge substructure

2021 ◽  
Vol 9 (1) ◽  
pp. 57-64
Author(s):  
Eltayeb Elrayah Khalafalla ◽  
Ali Hussein Mohammed Ali
Keyword(s):  
Field Tests ◽  
Hardness Test ◽  
Life Time ◽  
Steel Plates ◽  
Bending Test ◽  
Steel Bridge ◽  
Concrete Core ◽  
Assessment Study ◽  
White Nile ◽  
Cathodic Protection System

The substructure of The Old White Nile Bridge consists of steel tubular piers (steel casings filled with concrete) supported by caissons drilled into the sandstone. This steel bridge which had been completed in 1928, was investigated and assessed for integrity and safety. The inspection and investigation of the piers covered visual inspection, field tests and laboratory tests. Steel plates tests included microstructure analysis for steel, tension test, bending test and hardness test to determine the chemical and mechanical properties, whereas concrete core tests were conducted for determining cubes crushing strength of concrete. The inspection tests and assessment study revealed that most of piers steel casing suffered from high corrosion problems. Thus, due to corrosion the thickness of the casing plate, which was originally 5 mm for fixed piers and 7mm for swing span pier, was reduced severely to about 1.5 mm or even in some cases to about only 0.4 mm (in the swing span piers). In some cases holes appeared in the casing plates indicating that the steel was corroded totally and all the thickness was lost. Then, the Foundation caissons which were permanently under water or fully buried in the ground were found sound and suffer no problem of corrosion. No sign of differential settlement was observed. The materil tests performed showed that the steel exceeded its expected life time and have lost their weld-ability. Moreover, cathodic protection system which had originally provided previously to protect against corrosion found damaged and not functioning. Therefore, this paper presents the results of inspection and rehabilitation of the bridge substructure.  

scholarly journals Validación de la soldabilidad mediante alambre tubular con núcleo de fundente “FCAW” para aceros navales deteriorados (FLUX CORED ARC WELDING)

2010 ◽  
Vol 3 (6) ◽  
pp. 41
Author(s):  
Alfonso Patarroyo ◽  
Elvis Solano ◽  
Fabio Cueca ◽  
Fernando Rojas ◽  
Alfredo Morales
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Steel Plates ◽  
Full Penetration ◽  
Flux Cored Arc Welding ◽  
Liquid Condition ◽  
Electric Arc Welding ◽  
Arc Welding Process ◽  
Metallurgical Reactions ◽  
High Degree

Repairs and changes of steel plates in the structure of the vessels where it is possible to find steels with a high degree of deterioration need reliable welded joints in naval steel of the type ASTM A–131 Gr. A new to old. Due to the fact that the variables associated to the weldability of the materials to be repaired are not known, it is necessary to make a study on the weldability of steel ASTM A131 Gr A, in full penetration seams or junctures, under the various parameters involved in the welding process, to determine the influence of the corroding residues that affect the application of welding compounds through the analysis of the metallurgical reactions of liquid condition in order to select the contributing materials with the alloy elements that are able to prevent these phenomena and to recommend the best practices for the electric arc welding process with tubular electrode with FCAW flux core.

scholarly journals Comparative investigation of friction stir welding and fusion welding of 6061 T6 – 5083 O aluminum alloy based on mechanical properties and microstructure

2014 ◽  
Vol 62 (4) ◽  
pp. 791-795 ◽  
Author(s):  
S. Jannet ◽  
P.K. Mathews ◽  
R. Raja
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welded Joints ◽  
Welding Process ◽  
Hardness Test ◽  
Comparative Investigation ◽  
Fusion Welding ◽  
Friction Stir ◽  
Advantages And Disadvantages ◽  
Fusion Welded Joints

Abstract This paper compares, the mechanical properties of welded joints 6061 T6 and 5083 O aluminium alloys obtained using friction stir welding (FSW) at four rotation speeds namely 450,560,710 and 900 rpm and that by conventional fusion welding. FSW welds were carried out on a milling machine. The performance of FSW and Fusion welded joints were identified using tensile test, hardness test and microstructure. The properties of FSW and fusion welded processes were also compared with each other to understand the advantages and disadvantages of these processes for welding applications for Al alloys. It was seen that the tensile strength obtained with FSW was higher as compared to conventional fusion welding process. The width of the heat affected zone of FSW was narrower than Fusion welded joints. The results showed that FSW improved the mechanical properties of welded joints.

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