Pulssimuodon vaikutus valokaaren käytettävyyteen pulssi-MIG/MAG-hitsauksessa

Käytettävyydeltään huippuluokkaa olevan pulssi-MIG/MAG-hitsausvalokaaren toteuttaminen vaatii runsaasti tietoa eri pulssiparametreista ja niiden vaikutuksista hitsaukseen. Näihin vaikutuksiin liittyvä tieteellinen tutkimus on ollut melko vähäistä. Erityisesti tieto pulssimuodon vaikutuksista hitsausääneen on perustunut lähinnä kokemuksen tuomaan tuntumaan. Tässä diplomityössä tutkittiin pulssimuodon vaikutusta valokaaren käytettävyyteen pulssi-MIG/MAG-hitsauksessa. Käytettävyys käsittää tässä tapauksessa hitsausäänen, hitsin geometrian ja hitsausominaisuudet. Tutkimuksen alussa perehdyttiin kirjallisuuteen ja tuoreimpiin tutkimuksiin, jonka jälkeen vertailtiin erilaisia pulssimuotoja keskenään hitsauskokeiden avulla. Hitsausääneen ja hitsin geometriaan liittyvät kokeet suoritettiin mekanisoidusti. Hitsausääneen liittyvät mittaukset suoritettiin luokan 1 äänitasomittarilla ja tuloksia analysoitiin tietokoneohjelmistolla. Hitsien geometrioiden vertailu suoritettiin makrohietutkimuksena. Hitsausominaisuuksia tutkittiin suurnopeuskameran ja oskilloskoopin, sekä lopulta käsinhitsauskokeiden avulla. Kaikissa koevaiheissa pulssimuodon tarkasteluun käytettiin oskilloskooppia. Lisäksi käytössä oli toinen oskilloskooppi, jolla tarkasteltiin hitsausvirran spektriä. Pulssimuodon muokkaamiseen käytettiin erillistä tietokoneohjelmaa. Työn kokeellinen osuus keskittyi pulssi-MAG-hitsaukseen. Pulssimuotoa muokkaamalla saatiin aikaan miellyttävämpi hitsausääni. Lisäksi havaittiin, että pulssimuotoa muokkaamalla hitsistä saadaan kapeampi, jolloin juuritunkeumaa saavutetaan enemmän. Käsinhitsauskokeet osoittivat muokatun pulssimuodon olevan myös hitsaajan näkökulmasta käytettävyydeltään paras pulssimuoto. Erityisesti valokaaren vakaus ja kohdistuvuus sekä suurien hitsausnopeuksien sietokyky olivat muokatun pulssimuodon etuja. Selviä haittavaikutuksia pulssimuodon muokkaamiselle ei löydetty.

The effect of focal point parameters in fiber laser welding of structural steel

In this thesis the effect of focal point parameters in fiber laser welding of structural steel is studied. The goal is to establish relations between laser power, focal point diameter and focal point position with the resulting quality, weld-bead geometry and hardness of the welds. In the laboratory experiments, AB AH36 shipbuilding steel was welded in an I-butt joint configuration using IPG YLS-10000 continuous wave fiber laser. The quality of the welds produced were evaluated based on standard SFS-EN ISO 13919-1. The weld-bead geometry was defined from the weld cross-sections and Vickers hardness test was used to measure hardness's from the middle of the cross-sections. It was shown that all the studied focal point parameters have an effect on the quality, weld-bead geometry and hardness of the welds produced.

Underwater Remote Welding Technology for Offshore Structures

The construction of offshore structures, equipment and devices requires a high level of mechanical reliability in terms of strength, toughness and ductility. One major site for mechanical failure, the weld joint region, needs particularly careful examination, and weld joint quality has become a major focus of research in recent times. Underwater welding carried out offshore faces specific challenges affecting the mechanical reliability of constructions completed underwater. The focus of this thesis is on improvement of weld quality of underwater welding using control theory. This research work identifies ways of optimizing the welding process parameters of flux cored arc welding (FCAW) during underwater welding so as to achieve desired weld bead geometry when welding in a water environment. The weld bead geometry has no known linear relationship with the welding process parameters, which makes it difficult to determine a satisfactory weld quality. However, good weld bead geometry is achievable by controlling the welding process parameters. The doctoral dissertation comprises two sections. The first part introduces the topic of the research, discusses the mechanisms of underwater welding and examines the effect of the water environment on the weld quality of wet welding. The second part comprises four research papers examining different aspects of underwater wet welding and its control and optimization. Issues considered include the effects of welding process parameters on weld bead geometry, optimization of FCAW process parameters, and design of a control system for the purpose of achieving a desired bead geometry that can ensure a high level of mechanical reliability in welded joints of offshore structures. Artificial neural network systems and a fuzzy logic controller, which are incorporated in the control system design, and a hybrid of fuzzy and PID controllers are the major control dynamics used. This study contributes to knowledge of possible solutions for achieving similar high weld quality in underwater wet welding as found with welding in air. The study shows that carefully selected steels with very low carbon equivalent and proper control of the welding process parameters are essential in achieving good weld quality. The study provides a platform for further research in underwater welding. It promotes increased awareness of the need to improve the quality of underwater welding for offshore industries and thus minimize the risk of structural defects resulting from poor weld quality.

Introducao ao estudo de fluxos para arco submerso

O maior objetivo deste trabalho foi estudar os efeitos da composição dos fluxos para arco submerso sobre algumas importantes características de um metal de solda ferrítico, como composição química, microestrutura, propriedades mecânicas e geometria do cordão. Para realizar tal pesquisa, vinte oito fluxos aglomerados foram elaborados de compostos de pureza comercial e utilizados em soldagens ao aorco submerso, mantendo constante todas as demais condições de soldagem. Houve uma notável influência da composição química e do índice de basicidade dos fluxos sobre os níveis de oxig~enio, silício e manganês do metal de solda. Um modelo termodinâmico, baseado no conceito de potencial de oxigênio, foi proposto para explicar as reações gás-meta-escória ocorrendo durante a soldagem. Este modelo mostrou-se usável para as reações entre silício, oxigênio e carbono, permitindo um melhor entendimento das mesmas. A composição química do metal de solda pôde ser relacionada a sua microestrutura, através de metalografia quantitativa. Foi observado que oxigênio, silício, manganês e titânio têm grande influência sobre ela. A fase mais tenaz encontrada foi a ferrita acicular. A respeito da geometria do cordão, a sílica mostrou o efeito mais forte, com os outros compostos influenciando somente o acabamento do cordão soldado.

Repair Welding Effects on the Bending Fatigue Strength of AISI 4130 Aeronautical Steel used in a Critical to the Flight-Safety Structure

The aim of this study was to analyze the effect of successive TIG (tungsten inert gas) welding repairs on the reverse bending fatigue strength of AISI 4130 steel, which is widely used in components critical to the flight-safety. In order to simulate the abrupt maneuvers, wind bursts, motor vibration and helixes efforts, which generate cyclic bending loadings at the welded joints of a specific aircraft component called motor cradle, experimental reverse bending fatigue tests were carried out on specimens made from hot-rolled steel plate, 1.10 mm (0.043 in) thick, by mean of a SCHENK PWS equipment, with load ratio R = -1, under constant amplitude, at 30 Hz frequency and room temperature. It was observed that the bending fatigue strength decreases after the TIG (Tungsten Inert Gas) welding process application on AISI 4130 steel, with subsequent decrease due to re-welding sequence as well. Microstructural analyses and microhardness measurements on the base material, heat-affected zone (HAZ) and weld metal, as well as the effects of the weld bead geometry on the obtained results, have complemented this study.

Caracterização microestrutural do metal de solda depositado por arco submerso em chapas de aço-carbono estrutural

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Influência da potência de laser Nd: YAG na soldagem do aço inoxidável duplex UNS S32205

Pós-graduação em Engenharia Mecânica - FEIS

Uso de agentes inteligentes no controle simultâneo da largura e do reforço dos cordões de solda no processo GMAW-S

Tese (mestrado)—Universidade de Brasília, Faculdade de Tecnologia, Departamento de Engenharia Mecânica, 2016.

The effects of real time control of welding parameters on weld quality in plasma arc keyhole welding

Joints intended for welding frequently show variations in geometry and position, for which it is unfortunately not possible to apply a single set of operating parameters to ensure constant quality. The cause of this difficulty lies in a number of factors, including inaccurate joint preparation and joint fit up, tack welds, as well as thermal distortion of the workpiece. In plasma arc keyhole welding of butt joints, deviations in the gap width may cause weld defects such as an incomplete weld bead, excessive penetration and burn through. Manual adjustment of welding parameters to compensate for variations in the gap width is very difficult, and unsatisfactory weld quality is often obtained. In this study a control system for plasma arc keyhole welding has been developed and used to study the effects of the real time control of welding parameters on gap tolerance during welding of austenitic stainless steel AISI 304L. The welding tests demonstrated the beneficial effect of real time control on weld quality. Compared with welding using constant parameters, the maximum tolerable gap width with an acceptable weld quality was 47% higher when using the real time controlled parameters for a plate thickness of 5 mm. In addition, burn through occurred with significantly larger gap widths when parameters were controlled in real time. Increased gap tolerance enables joints to be prepared and fit up less accurately, saving time and preparation costs for welding. In addition to the control system, a novel technique for back face monitoring is described in this study. The test results showed that the technique could be successfully applied for penetration monitoring when welding non magnetic materials. The results also imply that it is possible to measure the dimensions of the plasma efflux or weld root, and use this information in a feedback control system and, thus, maintain the required weld quality.

Comparison between DC(+) and Square Wave AC SAW Current Outputs to Weld AISI 304 for Low-Temperature Applications

Welded equipment for cryogenic applications is utilized in chemical, petrochemical, and metallurgical industries. One material suitable for cryogenic application is austenitic stainless steel, which usually doesn`t present ductile/brittle transition temperature, except in the weld metal, where the presence of ferrite and micro inclusions can promote a brittle failure, either by ferrite cleavage or dimple nucleation and growth, respectively. A 25-mm- (1-in.-) thick AISI 304 stainless steel base metal was welded with the SAW process using a 308L solid wire and two kinds of fluxes and constant voltage power sources with two types of electrical outputs: direct current electrode positive and balanced square wave alternating current. The welded joints were analyzed by chemical composition, microstructure characterization, room temperature mechanical properties, and CVN impact test at -100 degrees C (-73 degrees F). Results showed that an increase of chromium and nickel content was observed in all weld beads compared to base metal. The chromium and nickel equivalents ratio for the weld beads were always higher for welding with square wave AC for the two types of fluxes than for direct current. The modification in the Cr(eq)/Ni(eq) ratio changes the delta ferrite morphology and, consequently, modifies the weld bead toughness at lower temperatures. The oxygen content can also affect the toughness in the weld bead. The highest absorbed energy in a CVN impact test was obtained for the welding condition with square wave AC electrical output and neutral flux, followed by DC(+) electrical output and neutral flux, and square wave AC electrical output and alloyed flux.

Welding current effect on diffusible hydrogen content in flux cored arc weld metal

The application of flux cored arc welding (FCAW) has increased in manufacturing and fabrication. Even though FCAW is well known for its good capability in producing quality welds, few reports have been published on the cause of the relatively high diffusible hydrogen content in the weld metal and its relation with the ingredients used in the wire production and with the welding parameters (mainly welding current). This paper describes experiments where data obtained from weld metal diffusible hydrogen analysis, metal droplet collection, and high-speed recording of metal droplet transfer were used to evaluate the effect of welding current on diffusible hydrogen content in the weld metal. The results from gas chromatography analysis showed that weld metal hydrogen content indeed increased with welding current. A polynomial regressional analysis concluded that hydrogen increase with current was better described by a linear function with proportional constant of approximately 0.7 or 70%. Different from the GMA welding transfer behavior, statistical analysis showed only a small increase in metal droplet size with increasing current. The metal transfer mode remained in the globular range for currents between 100 and 150 A. The most surprising findings were with the high-speed cinematography recording. Observing the high speed movies, it was possible to see that at low current, "unmelted" flux sporadically touched the weld pool but at higher current, the flux remained touching the weld pool during the whole time of droplet formation and transfer. It is believed that since the flux has ingredients that contain hydrogen, hydrogen passes through the arc undisturbed, going to the weld bead intact and increasing the hydrogen content in the weld metal. Another important observation is regarding to droplet size. Droplet size increased with increasing current because forces from decomposed gases from the flux could sustain the droplets, retarding their transfer and allowing them to grow.

Relacao entre o angulo da ponta do eletrodo e a geometria do cordao de solda no processo de soldagem tig

No processo de soldagem TIG (Tungstênio Inerte Gás), um dos fatores que influenciam o formato do cordão de solda é o ângulo da extremidade do eletrodo. Para estudar o comportamento do arco elétrico em função da geometria de ponta do eletrodo e suas conseqüências nos cordões de solda, efetuaram-se soldagens sobre corpos de prova sem deposição de material (bead-on-plate) através de parâmetros controlados e a mecanização do processo. Parâmetros tais como vazão do gás, velocidade de avanço da tocha e comprimento do arco foram testados para verificar a atuação em conjunto com o ângulo do eletrodo. Pela análise metalográfica (macrografia) estudaram-se os perfis dos cordões de solda, verificando-se que o ângulo exerce uma influência significativa na característica do arco tensão-corrente, na largura e profundidade de penetração da solda. Para maiores ângulos de extremidade do eletrodo obteve-se aumento na penetração, diminuição da tensão e largura do cordão de solda para uma mesma intensidade de corrente.

Effects of several TIG weld repairs on the axial fatigue strength of AISI 4130 aeronautical steel-welded joints

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Fatigue strength of tungsten inert gas-repaired weld joints in airplane critical structures

In this work the effect of Gas Tungsten Arc Welding (GTAW) repairs on the axial fatigue strength of an AISI 4130 steel welded joint used in airframe critical to the flight-safety was investigated. Fatigue tests were performed at room temperature on 0.89 mm thick hot-rolled plates with constant amplitude and load ratio of R = 0.1, at 20 Hz frequency. Monotonic tensile tests, optical metallography and microhardness, residual stress and weld geometric factors measurements were also performed. The fatigue strength decreased with the number of GTAW repairs, and was related to microstructural and microhardness changes, as well as residual stress field and weld profile geometry factors, which gave origin to high stress concentration at the weld toe. (C) 2011 Elsevier B.V. All rights reserved.

Efeitos da soldagem por laser de fibra de Yb na microestrutura do compósito A356/SiCp

Materiais compósitos são projetados e fabricados para várias aplicações de alto desempenho, incluindo componentes para os segmentos automobilístico, aeroespacial, aeronáutico, naval, de defesa, de óleo e gás, energia eólica e até equipamentos esportivos. Porém, a união por soldagem de Compósitos de Matriz Metálica de Alumínio (Al-CMM) ainda é um grande obstáculo para a maior disseminação desta classe de materiais estruturais. As mudanças microestruturais decorrentes do ciclo de soldagem e/ou do tratamento térmico afetam sensivelmente as propriedades mecânicas e físico-químicas finais da junta e do metal base nas proximidades de mesma, daí a importância de se estudar a evolução microestrutural que prospera nestas etapas. O presente trabalho caracterizou a microestrutura do compósito liga-A356/SiCp soldado por laser de fibra de Itérbio, empregando-se nessa tarefa técnicas de microscopia óptica, radiografia e microscopia eletrônica de varredura, assim como difração de raios-X e de elétrons retroespalhados, ensaio instrumentado de dureza e microtomografia computadorizada. O foco das análises realizadas restringiu-se à geometria dos cordões de solda, à expulsão de SiC particulado da zona soldada, à volatilização de elementos químicos da poça de soldagem, à formação de precipitados fragilizantes de Al4SiC4 em formato de agulhas no cordão de solda e à determinação das regiões com concentração de poros, todos estes fenômenos tendo efeitos nocivos, em maior ou menor extensão, no desempenho global da junta do Al-CMM soldada a laser, notadamente em suas propriedades mecânicas e eletroquímicas.