1-2_advanced welding technology & allied processes_additional lecture_student
TRANSCRIPT
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
1/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
2/42
Laser Hybrid Welding
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
3/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
4/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
5/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
6/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
7/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
8/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
9/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
10/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
11/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
12/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
13/42
• Initially investigated by E.O. Paton Electric Welding Institute during the 1950's
and 1960's and further developed by Kuka Welding System named asMAGNETARC.
• It can be classified under Flash Butt Welding.
• It is a unique process utilizing relatively simple equipment.
• It relies on very complex interactions between arc, applied & induced magneticfield and upsetting force.
13
Magnetically Impelled Arc Butt (MIAB) Welding
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
14/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
15/42
15
Results of OD 89 mm
and WT=10 mm
Internal Flash= 1 mm
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
16/42
16
• Welding time reduction up to 90%• No edge preparation• No filler material• Less metal loss• Can weld dissimilar parts•
No spatter inside• Less distortion• Uniform welding (arc spinning speed up to 240 m/s)• Low maintenance of welding system• Low energy consumption• No rotation of components• Can weld pipe-to-pipe, pipe-to-plate & non-circular parts• Automatic mass production line is possible• No Hydrogen permeation from filler material or environment
Benefits of MIAB Welding
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
17/42
17
API 5L X70, OD = 168 mm and WT = 7 mm
MIAB Welding of Pipe: Specimen Property and Parameter
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
18/42
18
Weld Metal(Fine Grain)
P a r e n t M
e t a l
MIAB Welding of Pipe: Macrograph
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
19/42
19
300 HV
250 HV
200 HV
150 HV
100 HV
MIAB Welding of Pipe: Mechanical Properties
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
20/42
20
10 mm
16 mm
Magnetically Impelled
Arc Butt Welding
Flash Butt Welding (FBW)
MIAB Welding: HAZ Comparison
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
21/42
21
Pneumatic Spring (OD 19 x1.7 mm)
Shock Absorber(OD 53 x 1.8 mm)
Hydraulic Pipes
Hydraulic Cylinder
OD 120 x 7.5 mm
Current Applications of MIAB Welding
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
22/42
22
Boiler PipePipe with Union
Al + Al and Al + Cu Non-circular
Current Applications of MIAB Welding (cont’d)
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
23/42
23
Fracture Test
Rupture Test
TulipTest
Bend Test
Mechanical Tests of MIAB- Welded Components
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
24/42
Welding is today the most common joining method for metallic structures. Almost
60%-70% are used in industrial application and large structure. Typical examples
are steel bridges, ship structures and large offshore structures etc.
A fact, that welded joints are particularly vulnerable to fatigue damage whensubjected to repetitive loading.
Fatigue cracks may initiate and grow in the vicinity of the welds during service life
even if the dynamic stresses are modest and well below the yield limit.
What are the main factors on fatigue of welded structure?
STRUCTURAL LIFE EXTENSION
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
25/42
Some Examples of Fatigue Failure of WeldedStructure
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
26/42
Fatigue Failure on Edges
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
27/42
Causes of Weld Fatigue Failures
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
28/42
Effect of Material Grade
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
29/42
Selection of stress cases in accordanceto commission XIII
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
30/42
Relation between accuracy and complexity using variousassessment methods
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
31/42
When to manage structural life?
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
32/42
Tensile Residual Stress Weld Geometry
Compressive Residual Stress Improved Weld Geometry
32
Main Causes of Life Reduction/Extension
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
33/42
It is well-known that conventional hammer peening will induce compressive stresses in
the surface which are positive for the fatigue life...…but because of the fact that it isn't really reproducible it was never really
accepted.…but because of the fact that it isn't really reproducible it was never really
accepted.
Higher Frequency Mechanical Impact (HFMI)
Dr. Efim Statnikov developed a solution which achieve a maximum effect through the perfectcombination of speed and power of impact. And it is very reproducible because hedisconnected the impact from the operator with a separate spring system inside thehandtool. This technology is called Ultrasonic Impact Treatment (UIT).
Dr. Efim Statnikov developed a solution which achieve a maximum effect through the perfectcombination of speed and power of impact. And it is very reproducible because hedisconnected the impact from the operator with a separate spring system inside thehandtool. This technology is called Ultrasonic Impact Treatment (UIT).
1972
Pneumatic Impact Treatment (PIT)Pneumatic Impact Treatment (PIT)
2008
History of HFMI
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
34/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
35/42
Examples of Existing HFMI Applications
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
36/42
Investigation of Residual Stress
Examples of Existing HFMI Research
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
37/42
Examples of Existing HFMI Research
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
38/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
39/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
40/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
41/42
-
8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student
42/42