Update on FHWA Welding and Fabrication Related Research
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TURNER-FAIRBANK HIGHWAY RESEARCH CENTER Office of Infrastructure RD&T Update on FHWA Welding and Fabrication Related Research Justin Ocel, PhD, PE Structural Steel Research Program Manager FHWA Turner-Fairbank Highway Research Center McLean, VA 22101 1
Transcript of Update on FHWA Welding and Fabrication Related Research
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Update on FHWA Welding
and Fabrication Related
Research
Justin Ocel, PhD, PEStructural Steel Research Program Manager
FHWA Turner-Fairbank Highway Research Center
McLean, VA 22101
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TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Electroslag Welding (ESW)
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A very efficient welding
process with potential
reduced fabrication
cost.
– Application limited by
AASHTO/AWS D1.5
– Three full-scale
beams with
HPS/HPS and
HPS/50W flange butt
welds
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SFOBB ESW Weld
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SAW
ESW
2947 kips
(78 ksi)
SFOBB ESW Weld
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SFOBB ESW Weld
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“Development of Innovative Welding
for High Performance Bridge Steel”
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• Small Business Innovative Research (SBIR)
grant
• Metric to develop process(s) demonstrated
faster than SAW for a hypothetical 3” x 30”
CJP butt weld
• Two vendors had Phase 2 contracts
– Hybrid Laser Arc Welding (HLAW)
– Resistance welding with a Homopolar Generator
(HPG)
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Homopolar Generator
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** Images copyrighted KAI, LLC. **
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Homopolar Generator
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** Image copyrighted KAI, LLC. **
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Homopolar Generator
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** Image copyrighted KAI, LLC. **
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Plasma Cut Holes
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Tested the fatigue and static resistance of plasma cut
holes. Likely to recommend to AASHTO:
1. Prohibit conventional process, require “high-definition”
plasma to attain necessary hole quality.
2. Prohibit use on primary and FCM’s.
3. Require reduction factor, Rp= 0.90 in design.
4. Open holes would be Category E’ for fatigue design.
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• Can we build a steel tubular bridge?– Not covered in AASHTO/AWS D1.5
– AWS D1 TG7 working to marry AWS D1.1 tubular provisions into D1.5.
• Toughness of tubes– Co-Op Agreement with
Lehigh looking at fracture toughness of tube corners.
– TFHRC looking at degradation of CVN toughness as function of bend radius.
www.cidect.com
Fracture Resistance of Cold Bent Steel
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TFM/FMC Workshop
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• TFHRC NDE Lab hosted a 2-day workshop
on Total Focus Method/Full Matrix Capture
(May 31-June1)
• A new version of UT examination
• About 45 participants
• Tried to identify next steps towards adoption
into bridge inspection (both fabrication and in-
service)
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Questions
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