The broad range applications of Ultra-Fine Grained metals is substantially limited by the lack of a welding method that allows them to be joined without losing the strong refinement of structure. From this point of view, the solid state welding processes are privileged. Friction welding tests were carried out on UFG 316L stainless steel. A joining process at high temperature activates the recrystallization, therefore the friction welding parameters were selected according to the criterion of the lowest degree of weakness due to recrystallization in the heat affected zone. In order to characterize the structure of basic material and selected areas of the obtained joint, were performed SEM, TEM and metallographic examinations in terms of hardness and range of softening of the material and tensile test. Despite the short time and relatively low welding temperature, results of the test by scanning electron microscopy and transmission electron microscopy confirmed the loss of the primary ultrafine structure in the Heat Affected Zone of welded joint.
The research deals with the examination of thermally hardened sheets of weldable S540Q steel of high strength, obtained by thermo mechanical treatment. Conventional rolling and controlled rolling with rapid cooling processes were compared. Example of technological process of high strength sheets production was presented. The basic mechanical properties of this steel were determined (static tensile tests results as well as technological bend tests results were given). Then the steel sheets were welded by a semi-automatic MAG method. The research on the quality of welded joints was performed and their suitability for further research was worked out. Mechanical properties of S540Q steel welded joints were elaborated. The mechanical properties of native material were compared to the properties of welded joints. Joints microstructure was examined in the joints axis, in heat-affected zone and in native material. Fatigue tests were conducted in the non-symmetric tension - compression cycle for the welded joints. The computational fatigue strength was determined and then compared to fatigue strength of the welded joints. The tests results were elaborated statistically by the analysis of linear regression. Wöhler charts were made after conducting fatigue tests. The analysis of increasing the fatigue strength of S540Q steel welded joints was also performed.
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W artykule opisano zasadę badań symulacyjnych spawalniczych cykli cieplnych oraz korzyści, jakie te badania dają. Przedstawiono metodykę badań, omówiono możliwości zastosowania badań symulacyjnych cykli cieplnych w różnych dziedzinach. Opisano symulator cykli cieplnych stosowany do badań symulacyjnych w procesach spawalniczych.
EN
The article describes the principle of simulation testing of the welding thermal cycles and benefits that result from application of this simulation. Methods of investigation were presented and potential applications of simulation testing of thermal cycles in different fields of research were outlined. A simulator of thermal cycles used for simulation testing of the welding processes was described.
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The thermal – mechanical interactions in welding process of the ferritic steels are described. The definition of numerical analysis of weldability and short discussion on this problem has been presented. Furthermore the actual development of correlations between: thermal field – microstructure and mechanical properties are characterised. It enables to establish the methodology for steels weldability investigation on basis of current calculation standards. Finally, some remarks about possibilities of application of the neural networks methods for estimation of weldability of ferritic steels are presented.
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Przedstawiono wyniki badań spawalności stali do pracy w podwyższonych temperaturach w gatunkach X20CrMoV12.1 praz P91 (wytop francuski). Badania, przeprowadzone na symulatorze cykli cieplno-odkształceniowych, obejmowały ocenę skłonności badanych stali do pękania kruchego, gorącego i wyżarzeniowego. Dodatkowo zamieszczono i porównano wyniki badań spawalności polskiego odpowiednika stali P91 - H9MAVNb.
EN
It has been presented results of investigation into weldability of X20CrMoV12.1 and P91 (French manufacture) steels designed for elevated temperatures. Investigations carried out with use of the thermal-strain cycles simulator included the evaluation of the susceptibility of the test steels to brittle, hot and annealing cracking. Additionaly, it has been inserted and compared weldability investigation results of the Polish equivalent of P91 steel, namely H9MAVNb.
A Si-Fe-Al ternary oxide-based micropowder coating was used to prevent the formation of a Zn coating on steel during the hot-dip Zn galvanizing process to reduce the welding fume and defects generated during the welding of Zn-galvanized steel. The composition ratio of the oxide powder was optimized and its microstructure and weldability were evaluated. The optimized oxide coating was stable in the hot-dip galvanizing bath at 470°C and effectively inhibited the formation of Zn coating. The Zn residue could be easily removed with simple mechanical impact. The proposed coating reduced Zn fume and prevented the residual Zn from melting in the weld bead during high-temperature welding, thus reducing the number of welding defects. The results indicated that this pretreatment can simplify the manufacturing process and shorten the process time cost-effectively.
The development of weldable steels was discussed together with the methods of obtaining them. The influence of these methods on steel properties was explained. Research was performed on quenched weldable S540Q steel of high strength. Basic mechanical properties of this steel were determined. The results of a static tensile test and technological bending test were given. Next, steel sheets were welded by semi-automatic MAG method. The welds quality was examined and their future suitability was stated. Mechanical properties of the joints welded of this steel were determined. Mechanical properties of native material and welded joints were compared. Joints microstructure was examined in the weld axis, in the heat influence zone and in the native material. Fatigue tests were conducted in the cycle of nonsymmetrical tension – compression of welded joints. The analytical fatigue strength was obtained and it was compared with fatigue strength of welded joints. Tests results were elaborated with the static analysis of linear regression. Wohler diagrams were made after conducting fatigue tests. Finally, weldable joints were melted by TIG method without adding filler metal. The angle and radius of welds nobs entrance into the native material was measured. The increase of fatigue strength is related to the decrease of geometric notch on the edges of weld nobs.
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Wet welding with the use of covered electrodes is one of the methods of underwater welding. This method is the oldest, the most economic and the most versatile. The main difficulties during underwater wet welding are: high cooling rates of the joint, the presence of hydrogen in the arc area and formation of hard martensitic structure in the weld. These phenomena are often accompanied by porosity of welds and large number of spatters, which are more advanced with the increase of water depth. In this paper result of non-destructive tests, hardness tests and metallographic observations of S500MC steel joints performed underwater are presented. The weldability of 500MC steel at water environment was determined.
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Przedstawiono wyniki badań stali 13HMF po 100 000 godzin eksploatacji. Omówiono wpływ cykli cieplnych spawania na własności strefy wpływu ciepła, skłonność stali do pękania wyżarzeniowego, skłonność do zmęczenia cieplnego i wytrzymałość na pełzanie. Przedstawiono warunki wykonania i własności złączy spawanych wykonanych z tej stali. Podano niektóre zalecenia technologiczne wykonywania złączy spawanych ze stali 13HMF po długotrwałej ekploatacji.
EN
It has been presented the results of 13HMF steel testing after 100 000 hr operation and discussed the influence of welding thermal cycles on HAZ properties, susceptibility of steel to annealing cracking and thermal fatigue, and creep strength. The conditions for manufacture of welded joints in this steel have been presented as well. It has been given some technological recommendations for making welded joints in 13HMF steel after prolonged operation.
The article presents the possibility of using twin-spot laser welding (i.e. laser welding with focusing a laser beam on two spots) for making overlap joints made of 0.8-1 mm thick HSLA and DP type high strength steel sheets. Joints were made using a Yb:YAG disc laser having a maximum power of 12 kW and a welding head by means of which it was possible to focus a laser beam on two spots, 0.6 mm and 1 mm away. The angle between focuses amounted to 0° or 90°, whereas the power distribution was 50%-50%. With settings as presented above it was possible to obtain high-quality overlap joints. The geometrical parameters of the joints were primarily affected by beams positions (in relation to each other) and, to a lesser degree, by the distance between the focuses. It was possible to obtain a 10% hardness reduction in the fusion zone of the DPHSLA steel joints if the angle between the beams amounted to 90°. The tests also involved microstructural examinations of individual zones of the joints.
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The algorithm for the weldability estimate was presented. In details were presented review of the mathematical relations that define the temperature – dependent space dimensioning in welds and influence of mechanical parameters. Later a brief outline of the metallurgical and micro-structural transformation was presented. Finally, the basic information on strains, stresses and normalised fracture mechanics parameters are characterised.
Weldable steels of high strength were discussed. The factors influencing the achievement of low grain structure that ensures high strength of these steels was explained. Traditional and modern methods of producing high strength steel were shown. The scheme of production line was shown, the line which is used to manufacture steel of high strength in thermomechanical way. The methods of achieving strength to fatigue used for welded joints were presented. The factors influencing the increase of strength to fatigue of welded joints were elaborated. The thermally hardened steel sheets of high strength weldable S640Q steel underwent research. Basic mechanical properties of this steel were indicated. The results of static tensile test and technological bend test were given. Then the sheets were welded by semiautomatic MAG method. The examinations of welds quality were conducted and their usefulness for further tests was stated. Mechanical properties of welded joints were determined. The mechanical properties of native material and welded joints were compared. The microstructure of welded joints in the weld axis, in heat influence zone as well as in native material was examined. Fatigue tests in a non-symmetrical cycle of lengthening – compressing for the welded joints were carried out. The computational strength to fatigue was determined and compared with fatigue strength of welded joints. Tests results were elaborated by the statistical analysis of linear regression. After conducting fatigue tests, the Wöhler diagrams were made. Afterwards, the joints welded with TIG method, were penetrated without adding filler metal. The results were presented for the fatigue tests as well as the Wohler graph for welded joints after penetration of the joints edges with TIG method without adding filler metal. The results were compared.
Nickel alloys, despite their good strength properties at high temperature, are characterized by limited weldability due to their susceptibility to hot cracking. So far, theories describing the causes of hot cracking have focused on the presence of impurities in the form of sulphur and phosphorus. These elements form low-melting eutectic mixtures that cause discontinuities, most frequently along solid solution grain boundaries, under the influence of welding deformations. Progress in metallurgy has effectively reduced the presence of sulphur and phosphorus compounds in the material, however, the phenomenon of hot cracking continues to be the main problem during the welding of nickel-based alloys. It was determined that nickel-based alloys, including Inconel 617, show a tendency towards hot cracking within the high-temperature brittleness range (HTBR). There is no information on any structural changes occurring in the HTBR. Moreover, the literature indicates no correlations between material-related factors connected with structural changes and the amount of energy delivered into the material during welding.This article presents identification of correlations between these factors contributes to the exploration of the mechanism of hot cracking in solid-solution strengthened alloys with an addition of cobalt (e.g. Inconel 617). The article was ended with development of hot cracking model for Ni-Cr-Mo-Co alloys.
Spawanie traktowane jest aktualnie jako proces specjalny, którego rezultaty nie mogą być w pełni ocenione, zbadane i sklasyfikowane, co ostatecznie stwarza pewien stopień ryzyka i niepewności pracy konstrukcji spawanych. Proces spawania związany jest bezpośrednio z lokalną zmianą energii wewnętrznej łączonych materiałów a jego realizacja w sposób naturalny prowadzi do lokalnej zmiany stanu materiału wyrażającego się w przemianach struktury i właściwości mechanicznych, z czym związany jest stopień uwrażliwienia materiału spawanego i ocena spawalności. Jest to relacja bardzo złożona, o sprzężeniu zwrotnym, co w sensie fizycznym prowadzi do ustalenia związku pomiędzy modułami: polem termicznym – ewolucją mikrostruktury – polem mechanicznym, o wzajemnym oddziaływaniu o charakterze synergicznym. Ocena stopnia uwrażliwienia różnych gatunków stali powinna więc polegać na analizie wymiarowej określonych wyżej modułów, przy ścisłym zapisie fizykalnym zachodzących w nich procesów. Istota problemu oceny spawalności polega więc na ocenie skutków powtórnej ingerencji metalurgicznej w stali w obszarze spoiny, ponownej krystalizacji oraz przemianach strukturalnych, najczęściej o charakterze zupełnie odmiennym, którą posiadała stal przed procesem spawania. Podobne uwagi można odnieść do obszaru bezpośrednio przylegającego do spoiny (SP) – strefy wpływu ciepła (SWC), gdzie zachodzą przemiany struktury w stanie stałym. Lokalne oddziaływanie termiczne w procesie spawania w wyniku oddziaływania więzów mechanicznych jest również źródłem naprężeń własnych i deformacji, tworząc nowy stan mechaniczny powstającego złącza spawanego.
EN
Currently the welding as a technological process is concerned with special processes, the results of which cannot be checked in a complete degree by subsequent control, test of production what finally causes uncertainty of work of welded constructions. The process of welding is related to the local change of the internal energy of welded system and that leads to the local change of state of material expressing by change of microstructure and mechanical properties. This phenomena decide on the assessment of susceptibility of materials under defined welding condition and estimate of the weldability. It is compound relation and the mechanical behaviour of welded joints is sensitive to the close coupling between modules: heat transfer, microstructure evolution an mechanical fields. Welding process in physical meaning it is jointed with three laws govern mass and heat flow the laws of conservation of: mass, momentum and energy. The knowledge of the run of thermo-dynamical process under welding indicates on the possibility of active modelling and control of welding process with use intensive and extensive parameters. As the weld metal cools in the temperature range 2300 to 1800°K, the dissolved oxygen and deoxidising elements in liquid steel react to form complex oxide inclusions of 0,1 to 1 μm size range. In the temperature range 1800 to 1600°K, solidification of liquid to δ ferrite starts und envelops these oxide inclusions. After δ ferrite transforms to austenite in the temperature range 1100 to 500°K, the austenite transforms to different ferrite morphologies such as ferrite: allotriomorphic, Widmanstättena, and acicular. The macro-mechanical heterogeneity of welded structures is one of their primary features. The heterogeneous nature of the weld joints is characterised by macroscopic dissimilarity in mechanical properties. Numerical weldability analysis is a new powerful research and development tool which is useful for metallurgistics technologist and design engineers. Saying strictly the numerical analysis of weldability comprises thermodynamic, thermomechanical and microstructural modelling of the welding process. The result of this analysis is material susceptibility (SU). The fracture resistance of welded joints is mainly characterised by normalised parameters: SU1 = KIth / KIC for cold cracking or in the exploitation condition by SU2 =δ / δ c or J / Jc, SU1 ≠ SU2 . From above-mentioned equations result that does not exist one global parameter which defines the step of susceptibility SU of base materials has been also executed with use of SINTAP program.
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W artykule przedstawiono rozwój odpornych na korozję stali dupleks, mikrostrukturę, właściwości, zastosowania oraz metalurgiczne podstawy spawalności odpornej na korozję austenityczno-ferrytycznej stali dupleks na tle innych chromowo-niklowych stali nierdzewnych. W oparciu o analizę spawalności stali dupleks i badania eksperymentalne autora sformułowano podstawowe zasady spawania wielkogabarytowych konstrukcji z tej stali.
EN
The paper presents the development of corrosion-resistant duplex steels, their microstructure, properties and applications, as well as the metallurgical basis of weldability of corrosion-resistant austenitic-ferritic duplex steel as compared to other chromium-nickel stainless steels. Based on the analysis of duplex steel and the author’s research, basic principles of welding large structures made of this steel have been formulated.
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Purpose: Among many disciplines within engineering, welding is probably one of the most inexact – rather more of an art than a science. As weldment is meant the complete joint comprising the weld metal, heat affected zones (HAZ) and the adjacent parent metal and should have the same properties as the parent metal. This paper aims provides a basic understanding of the metallurgical principles involved in how aluminium alloys achieve their strength and how welding can affect these properties. The most important and applied welding processes to Al alloys are here shortly introduced, as well as the preparation of parent metals prior to welding and good welding practice to avoid and/or keep under control defects and failures. Some case studies with possible failures will be introduced together with actions and suggestions to solve the observed problems. Design/methodology/approach: Two sheets of the EN AW 5454 (AlMg3Mn) alloy were weld with resistance welding process and after a mechanical processing of lamination was observed the presence of the defect. The microstructure of the defect as well as the welded part were evaluated with stereomicroscope (LEICA MS5), optical microscope (LEICA MEF4M), and with SEM analysis (LEO 1540 VP equipped with an energy dispersive X-ray spectroscope Oxford Link Pentafet). Findings: The well welded part was analysed with optical microscopy and electronic microscopy resulting with the attended mechanical properties. Micro-hardness indentations on the joint demonstrated the good mechanical properties of the joint while with the microscopic observations were identified the orientation and presence of precipitates typical of this alloy. In the defect, microscopically observations showed the presence of oxide inclusions. Research limitations/implications: There are a number of problems associated with the welding of aluminium and its alloys that make it difficult to achieve this ideal. The features and defects that may contribute to the loss of properties comprise the following: gas porosity, oxide inclusions and oxide filming, solidification (hot) cracking or hot tearing, reduced strength in the weld and HAZ, lack of fusion, reduced corrosion resistance and reduced electrical resistance. Originality/value: This case study illustrated clearly the importance of the cleaning on the surfaces to obtain a well welded joint ensuring the desired mechanical properties.
The process of welding has dynamic character and is related with the local change of the internal energy E of welded system and can be defined by general dependence between intensive .j and extensive .j parameters. The knowledge of the run of thermo-dynamical process under welding indicates on the possibility of active modelling of weldability and the control of welding process: .j = .E/..j. Hence, these process can be enhanced by mathematical modelling and numerical analysis of weldability models of, i.e. welding processes of material behaviour in welding and the strength of welded structures. The main attention is focused on the assessment of susceptibility of materials under defined welding conditions using fracture mechanics parameters. The analysis is based on the normalised parameters such as: ./.c, KIth/KIC, as a measure of the susceptibility of materials in welding process. The deformation process and fracture parameters calibrations are influenced by constraint; hence the importance of determining the deformation behaviour and fracture parameters as a function of constraint. Furthermore, there established analytically the condition of welding process in mismatched weld joints for strength equal to base metal. Finally, same analytical examples which present new capabilities of weldability estimates and mechanical properties of mismatched weld joints are presented.
Currently the welding as a technological process is concerned with special processes, the results of which cannot be checked in a complete degree by subsequent control, test of production what finally causes uncertainty of work of welded constructions. The process of welding is related to the local change of the internal energy of welded system and that leads to the local change of state of material expressing by change of microstructure and mechanical properties. This phenomena decide on the assessment of susceptibility of materials under defined welding condition and estimate of the weldability. It is compound relation and the mechanical behaviour of welded joints is sensitive to the close coupling between modules: heat transfer, microstructure evolution an mechanical fields. Welding process in physical meaning it is jointed with three laws govern mass and heat flow the laws of conservation of: mass, momentum and energy. The knowledge of the run of thermo-dynamical process under welding indicates on the possibility of active modelling and control of welding process with use intensive and extensive parameters. As the weld metal cools in the temperature range 2300 to 1800°K, the dissolved oxygen and deoxidising elements in liquid steel react to form complex oxide inclusions of 0.1 to 1 žm size range. In the temperature range 1800 to 1600°K, solidification of liquid to . ferrite starts und envelops these oxide inclusions. After . ferrite transforms to austenite in the temperature range 1100 to 500°K, the austenite transforms to different ferrite morphologies such as ferrite: allotriomorphic, Widmanstättena, and acicular. The macro-mechanical heterogeneity of welded structures is one of their primary features. The heterogeneous nature of the weld joints is characterised by macroscopic dissimilarity in mechanical properties. Numerical weldability analysis is a new powerful research and development tool which is useful for metallurgistics technologist and design engineers. Saying strictly the numerical analysis of weldability comprises thermodynamic, thermomechanical and microstructural modelling of the welding process. The result of this analysis is material susceptibility (SU). The fracture resistance of welded joints is mainly characterised by normalised parameters: SU1 = KIth / KIC for cold cracking or in the exploitation condition by SU2 = ./.C or J/JC, SU1 . SU2. From above-mentioned equations result that does not exist one global parameter which defines the step of susceptibility SU of base materials has been also executed with use of SINTAP program.
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Przedstawiono sposób wytwarzania i własności stali obrabianych termomechanicznie. Przeprowadzono badania własności spoin oraz SWC stali S700MC o grubości 10 mm spawanej metodą GMA drutem litym Mn4Ni1,5CrMo o średnicy 1,0 mm. Przeprowadzona analiza składu chemicznego materiału rodzimego, stopiwa i spoiny wykazała wyraźne różnice w równoważniku węgla, co może wpływać na własności wytrzymałościowe i plastyczne złączy spawanych. Badania metalograficzne, rentgenowska analiza składu chemicznego oraz rentgenowska analiza fazowa wykazały niejednorodność strukturalną i chemiczną złączy spawanych ze stali S700 MC.
EN
It has been presented the manner of fabrication and properties of thermomechanical steels. It was carried out testing of weld metal and HAZ properties in 10 mm thick S7000MC steel, GMA welded with Mn4Ni 1,5CrMo solid wire, 1,0 mm in diameter. The analysis of the parent material, deposited metal and weld metal has shown clear differences in carbon equivalent what can affect mechanical and plastic properties of welded joints. Metallographic examination, X-ray chemical composition analysis and X-ray phase analysis have revealed structural and chemical heterogeneity of S700MC steel welded joints.
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Na podstawie źródeł i własnych doświadczeń dokonano analizy mikrostruktury, właściwości, zastosowań i materiałowo-technologicznych problemów spawania stali dupleks. Przedstawiono obszar zastosowań spawania, szczególnie konstrukcji wysokogabarytowych, na przykładzie spawania FCAW stali dupleks typu UNS S31803 w budowie statków do transportu chemikaliów. Analizowano wpływ wybranych aspektów technologii spawania, w tym energii liniowej i temperatury międzyściegowej, materiałów dodatkowych na przemiany mikrostruktury i właściwości złączy spawanych.
EN
Microstructure, properties, applications and material and technological problems of duplex steel welding were analysed basing on the sources and on our own experience. The area of welding applications was presented, in case of high-dimensioned constructions in particular, illustrated by FCAW welding of duplex steel type UNS S31803 for building of ships for transportation of chemicals. The influence of selected aspects of welding technology, including linear energy and inter-welding sequence temperature, auxiliary materials used for the change of microstructure and properties of welded joints, was analysed.
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