1-2_advanced Welding Technology & Allied Processes_additional Lecture_student

8/19/2019 1-2_advanced Welding Technology & Allied Processes_additional Lecture_student

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Laser Hybrid Welding


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• 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.

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Magnetically Impelled Arc Butt (MIAB) Welding


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Results of OD 89 mm

and WT=10 mm

Internal Flash= 1 mm


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• 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


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API 5L X70, OD = 168 mm and WT = 7 mm

MIAB Welding of Pipe: Specimen Property and Parameter


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Weld Metal(Fine Grain)

P a r e n t M

e t a l

MIAB Welding of Pipe: Macrograph


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300 HV

250 HV

200 HV

150 HV

100 HV

MIAB Welding of Pipe: Mechanical Properties


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10 mm

16 mm

Magnetically Impelled

Arc Butt Welding

Flash Butt Welding (FBW)

MIAB Welding: HAZ Comparison


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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


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Boiler PipePipe with Union

Al + Al and Al + Cu Non-circular

Current Applications of MIAB Welding (cont’d)


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Fracture Test

Rupture Test

TulipTest

Bend Test

Mechanical Tests of MIAB- Welded Components


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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


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Some Examples of Fatigue Failure of WeldedStructure


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Fatigue Failure on Edges


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Causes of Weld Fatigue Failures


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Effect of Material Grade


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Selection of stress cases in accordanceto commission XIII


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Relation between accuracy and complexity using variousassessment methods


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When to manage structural life?


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Tensile Residual Stress Weld Geometry

Compressive Residual Stress Improved Weld Geometry

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Main Causes of Life Reduction/Extension


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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


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Examples of Existing HFMI Applications


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Investigation of Residual Stress

Examples of Existing HFMI Research


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Examples of Existing HFMI Research


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1-2_advanced Welding Technology & Allied Processes_additional Lecture_student

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