high-performance gmaw
DESCRIPTION
High-Performance GMAW. Paul Blomquist Applied Thermal Sciences, Inc. NSRP Welding Technology Panel Project “High Performance GMAW”. Awarded late February, 2011 Project Team: Applied Thermal Sciences, Inc. Vigor (Todd-Pacific) Shipyards HII - Ingalls and HII - Newport News - PowerPoint PPT PresentationTRANSCRIPT
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
High-Performance GMAW
Paul BlomquistApplied Thermal Sciences, Inc.
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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NSRP Welding Technology Panel Project“High Performance GMAW”
Awarded late February, 2011
Project Team:Applied Thermal Sciences, Inc.Vigor (Todd-Pacific) ShipyardsHII - Ingalls and HII - Newport NewsConcurrent Technologies Corp.
Scheduled Completion: 2/28/2012
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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The Hymn of Breaking StrainRudyard Kipling - 1935
The careful text-books measure(Let all who build beware!)
The load, the shock, the pressure Material can bear.
So, when the buckled girderLets down the grinding
span, The blame of loss, or murder,
Is laid upon the man. Not on the Stuff - the Man!
"Galloping Gertie" Collapses November 7, 1940 http://www.wsdot.wa.gov/tnbhistory/Connections/connections3.htm
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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“Form Follows Failure”- Henry Petroski -1994
“Form Follows Function”- Louis Sullivan -1896
“The Tall Office Building Artistically Considered”
Two Short Statements about Progress
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Outline• Historical Perspective• About ATS• NSRP Panel Project Technical Approach
• Goals – consensus as to shipyard needs• Percentage of mechanized v. semi-auto• Migration from semi-auto to mechanized/auto
• “Benchmarking”• What does the market offer?• Many new items – how do they compare?• Interesting R&D, especially foreign
• Potential of modification to existing equipment• Challenges for implementation• Q&A
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Historical Perspective
Bare Rods & Covered ElectrodesSAW & GMAW Short-Arc & (Marginal) PulseFCAW –Widespread Cost ReductionsInverters & Better InvertersCombined & Hybrid ProcessesDifferentiation & More Improvement
Truly an exciting time in welding!
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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About ATS
• R&D & Limited Manufacturing• Conventional & Laser-Based Welding– 20,000 ft2 Manufacturing Facility– Two 10kW Lasers: Gantry & Robotic Integration– First in US to Qualify HLAW for Primary Hull Apps– Manufacturing Products for DDG-1000 (Outfitting)
• Internal Combustion Engine Development• Scram-jet, Rocket & Missile Development
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Advanced HLAW System Approach
Sensor Input Laser feedback GMAW feedback Joint Data Motion feedback On-the-fly inspection
Control Parameters Gap response Mismatch response
User Defined Process Limits Gap/Mismatch GMAW Voltage/Current Weld Speed Laser Power Post Weld Inspection
Basic HLAW Weld Parameters Laser GMAW Motion System Gas Flow
Adaptive Process Control and Weld Quality Assurance
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
ATS HLAW Processing Facilities
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20,000 Sq ft Production SpaceHLAW Gantry (2005) ESAB/ATS CNC Gantry
16ft (5m) x 50ft (15m) modular weld space IPG 10kW fiber laser
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
ATS HLAW Processing Facilities
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Robotic Workcell (2008) ABB IRB4400 (2m) Trumpf TruDisk 10003 (10kW)
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
HLAW Fillet-Reinforced Tee WeldingProject Application Material Development
Objective Status
ONR HSLA65
Structural Tee Beams HSLA65 Process/Product
Qualification
Qualification approvedCustomer has purchased machine
ONR HSLA80
Structural Tee Beams HSLA80 Process
Qualification Qualification approved
LASCOR Lap Welds AL2003 Duplex SS
High Productivity / Low Heat input
Qualified
NGRTC Lap Welds 90XF High Productivity Complete
PSI-FHwA
Orthotropic Bridge Decks
A572 Gr50
100% Penetration – single side
Test articles submitted for fatigue testing
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AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
US Shipbuilding - HSLA65/HSLA 80
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Thickness 0.188, 0.250 ,0.313, 0.375
Travel Speed 70-115 ipm
Laser Power 5.5-6.5 kW
Objective: •Develop HLAW process for structural shapes •Qualify to NAVSEA & ABS NVR•First US Qualification of HLAW process
for Primary Hull Structure
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Orthotropic Bridge Decks
Thickness 0.313 (8mm) A572
Travel Speed 50 ipm
Laser Power 8.5kW
Special Full Pen – single side
Objective: Demonstrate process feasibility Fabricate specimens for fatigue testing
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
Metallic Sandwich Panel Design / Welding
Project Application Material Development Objective
Status
ONR LASCOR Duplex Stainless
Process FeasibilityProduct Testing
Feasibility confirmedTesting completed
DDG1000 Duplex Stainless
Lightweight structure In Production
NGRTC Crash protection
90XF Panel fabrication Completed
Commercial Trailer Deck ATI2003 Lightweight/Modular Prototype deliveredCommercial Mezzanine
FloorsCS High Productivity Feasibility confirmed
Awaiting Application
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AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
Sub-Scale/Full Scale Testing
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AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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NSRP Panel Project Technical Approach
• HLAW Performance: Breakthrough• Recent progress with HLAW has shown ~10X improvement
• Capital Cost: “Break-bank” • Hybrid systems can cost ~20X – and restructuring may be needed
• Lower-Cost Hybrid Processes – HPAW; Zhang; etc.• Recent Progress with GMAW power supplies and process
development shows major improvements• Find a “sweet spot” of increased performance at acceptable
cost• Determine path to implementation• For existing equipment, determine why implementation has
not occurred
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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The Promise of Higher Penetration
Double Fillet Weld Hi-Penetration Weld0.375-in fillet Full penetration with
0.125-in fillet reinforcement
0.578 lb/ft 0.144 lb/ft≈34,700 lb/ship ≈8600 lb/ship
Convert the double fillet weld to a fillet-reinforced tee weld
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Lower-Cost Hybrid Processes
http://cgi.ebay.com/PHILLIPS-PLASMA-MIG-WELDING-POWER-SUPPLY-/350329713149?pt=LH_DefaultDomain_0&hash=item51914731fd
http://www.nsrp.org/Ship_Production_Panels/Welding_Technology/downloads/080508_Modified_GMAW_System.pdf
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Recent Progress with GMAW
• New Equipment• All the makers have something new or recent• Many on display here• Some soon to be released• Is there a reason not to buy inverters?
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Interesting Variants – Single GMAW Source
I2R Heating (long stick-out)• Long history with SAW• Short life for GMAW?– 25% increase in WFS at same heat input– 2X Tip life (yes, doubled) – but – 10X Tip Cost!
http://www.migfast.com/downloads/MIGfast_AWJ_article.pdf
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Interesting Variants – Single GMAW Source“HI-Pen”• Zdeněk Hudec, Technical University of Liberic, CZ• Modify GMAW inverter parameters• Investigating “short-spray” region ~6V below standard spray• Substantially higher penetration/speed• Potential for application to existing equipment
Spray Short-spray
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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HI-Pen -Results
• Substantial increase in penetration
• Reduce weld volume• Reduced filler metal usage• Potentially reduced fume
levels• Higher dilution with base
metal• Potentially higher weld speed
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Challenges•Are we happy with what we’re seeing coming to market at this time? If not:•What do we need?• Better penetration? – good for fillets?• Does this imply volumetric NDT?
•Lower heat input means lower distortion• Always true? HAZ issues?• Higher dep rate at lower heat input – good for semi-auto?• Higher penetration - good for semi-auto?
•What is needed to assure shipyard implementation?• Training• Maintenance and parts support• Other obstacles to implementation
AWS Conference on Welding in Shipbuilding – Seattle, WA – May 11, 2011
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Applied Thermal Sciences, Inc.Sanford, Maine
Questions?