Since 1987 Uddcomb Engineering has repaired pulps by their own developed overlay welding method even called Uddcomb method. Currently each welding machine is operated by two persons. To increase Uddcomb Engineering competitiveness the reduced number of operators is desired. An installation of a monitoring system which can aid humans in the welding quality control also helps to improve company’s position. A future goal would be to make this monitoring system automatic without a human operator in the loop. In this thesis, arc voltage, weld current and audio signals were collected and analyzed with aim on finding algorithms to monitor the quality of the welding process. The use of statistics tools is the basis for detecting variations in the voltage and current data, associated with welding process. It has been shown that voltage signal can be used as a part of the welding quality control. The audio signal from welding at low frequencies varies with the speed of the process. The signal can also be incorporated in the monitoring of the process. The use of filters, growing sums and statistics are key elements in the algorithms presented in this report.

Current manufacturing process controls are principally based only on statistical performance. The next evolution is to make physics based models combined with the state of the art sensors and actuators to control the manufacturing processes. In this paper, metal inert gas welding is used as an example of how the first steps in developing a reliable estimation technique to implement a physics based controller. The weld bead geometry will be the main focus because it is crucial to creating a quality weld. This paper uses an IR camera to generate and evaluate multiple weld bead width estimation techniques and characterizes their corresponding standard deviations. Also a Gaussian Mixture Model (GMM) is used to fit the temperature linescan data to fit an analytical function to the numerical data. The GMM is then used to estimate the weld bead width. Finally, the optimal linescan location is calculated to produce the best possible weld bead estimation. The result is that only one of the estimation techniques actually follows a step input and vi the optimal linescan location is 4 mm from the back of the arc. Furthermore, the GMM provides an excellent fit to the temperature linescan, but does not increase the accuracy of the estimate. / text

The purpose of this study was to investigate whether or not differing base metals and filler wires used during welding processes contributed to differing amounts of ultrafine particles (UFP) and nanoparticles being emitted during the welding procedure. The study was also conducted to determine UFP and nanoparticle exposure in the breathing zones of the welders as well as the breathing zones of pipefitters and fire watchers, who commonly sit 6ft behind the welding arc. In order to determine if UFP and NP exposures differed with base metal and filler wire, all welding processes utilized the same welding machine for metal inert gas (MIG), the same wire speed, and the same voltages during each welding process. The only variation in welding procedures were cover gases used, base metals, and filler wires. Measurements gathered during welding procedures were conducted in the breathing zone of the welder and pipefitters consisted of UFP measurements taken by two different condensation particle counters (CPC), which operated in synchrony at the start and cessation of the welding process. NP measurements were taken by a NanoScan Scanning Mobility Particle Sizer (SMPS) and were also placed in the breathing zone of the welder. Lastly, particle characterization measurements for transmission electron microscopy (TEM) and energy dispersive spectroscopy (EDS) were gathered using a filter attached to a high flow pump, which was placed in the breathing zone of the welder. According to the results, base metal and filler wire do emit differing amounts of NP and UFP during the welding processes. Carbon steel emits the highest amount of nanoparticles, while stainless steel emits the second highest amount, and inconel emits the least. The results also concluded that welders are exposed to a greater concentration of nanoparticles and UFPs than those experienced by pipefitters who stand 6ft from the welding arc.

Submitted by Fabio Sobreira Campos da Costa (fabio.sobreira@ufpe.br) on 2017-07-14T12:39:02Z No. of bitstreams: 2 license_rdf: 811 bytes, checksum: e39d27027a6cc9cb039ad269a5db8e34 (MD5) Daniel Wallerstein Figueirôa.pdf: 6874381 bytes, checksum: b0106c6e767c291f4fe73db9698c1a3f (MD5) / Made available in DSpace on 2017-07-14T12:39:02Z (GMT). No. of bitstreams: 2 license_rdf: 811 bytes, checksum: e39d27027a6cc9cb039ad269a5db8e34 (MD5) Daniel Wallerstein Figueirôa.pdf: 6874381 bytes, checksum: b0106c6e767c291f4fe73db9698c1a3f (MD5) Previous issue date: 2016-08-12 / CAPES / No presente trabalho, realizou-se um estudo da soldagem híbrida laser-GMAW aplicada a chapas espessas em aço estrutural. O objetivo do trabalho é avaliar a influência do gás de proteção e do tipo de arame na microestrutura final das juntas soldadas e, consequentemente, nas suas propriedades mecânicas. Para tal, realizaram-se ensaios de soldagem laser-GMAW em aço estrutural EN 10025-2 S355 J2 N, nas espessuras de 15 e 30 mm, com misturas argônio (Ar) + dióxido de carbono (CO2) nas proporções de 2%, 8% e 15% de CO2, bem como arames maciço AWS ER70S-6 e tubular AWS E71T-1M. As seções transversais das juntas soldadas revelaram a formação de duas regiões distintas, sejam a região de influência laserarco e a região de predomínio do laser, o que se deve à característica de menor penetração do arco elétrico em relação ao laser. Realizaram-se, em cada região, medições de características geométricas, análise microestrutural por técnicas de microscopia ótica e eletrônica de varredura e caracterização mecânica por ensaio de dureza por microindentação. As juntas soldadas também foram submetidas a ensaio de tração. A microestrutura diferiu significativamente entre as duas regiões: na área de influência laser-arco encontraram-se grãos maiores e predomínio de microestruturas ferríticas; a região de predominância do laser apresentou microestrutura mais acicular, com presença de bainita e martensita. Menores teores de CO2 resultaram em soldas com microestruturas mais aciculares, provenientes de maiores taxas de resfriamento. Comportamento similar foi verificado ao comparar soldas realizadas com arame maciço e tubular: o primeiro resultou em predominância de microestruturas aciculares, enquanto o segundo favoreceu a formação de microestruturas ferríticas, além de garantir maior penetração. A caracterização mecânica revelou resistência à tração superior da junta soldada em comparação ao metal base e maiores valores de dureza na região de predominância de laser em comparação à região laser-arco. / In this work, a study of the laser-GMAW hybrid welding applied to thick sheets was carried out. The objective is to evaluate the influence of welding gas and wire in the final microstructure of the welds, and therefore in the mechanical properties of the joints. To achieve this goal, laser-GMAW tests were carried out on structural steel EN 10025-2 S355 J2 N, on 15 and 30 mm thick sheets, with mixtures argon (Ar) + carbon dioxide (CO2) in the proportions of 2%, 8% and 15% CO2 as well as solid and flux-cored wires AWS ER70S-6 and AWS E71T-1M, respectively. The cross sections of welded joints showed the formation of two distinct regions, the laser-arc zone and the laser zone, which is due to the characteristic of lowest penetration of electric arc in comparison to the laser. In each region, measurements of geometric characteristics, microstructural analysis by optical and scanning electron microscopy and microhardness tests were carried out. The welded joints were also subjected to tensile tests. The microstructure differed significantly between the two regions: in laser-arc zone larger grains and predominant ferritic microstructures were found; laser region had more acicular microstructure with the presence of bainite and martensite. Lower CO2 levels resulted in welds with more acicular microstructure, because of higher cooling rates. Similar behavior was observed when comparing welds performed with solid and flux-cored wire: the first resulted in predominantly acicular microstructures, while the second favored the formation of ferritic microstructures and ensures greater penetration. Mechanical characterization showed superior tensile strength of the weld zone compared to the base metal and higher hardness values in the laser zone when compared to laser-arc region.

Neste trabalho foram soldadas 4 amostras de rodas para veículos comerciais pelo processo de soldagem Tandem-MIG. Para cada amostra foram utilizados parâmetros de soldagem diferentes de modo a se obter formatos de cordão de solda distintos. O objetivo do trabalho foi avaliar a influência desses formatos de cordão de solda no desempenho em fadiga. Para os materiais utilizados, SAE1010AA e SAE1015A, foram realizados os seguintes ensaios: análise de composição química, análise micrográfica, levantamento das curvas tensão x deformação, medidas de microdureza Vickers e levantamento das curvas SN pelo método de flexão alternada (R=-1). Através da composição química constatou-se que ambos os aços são de baixo carbono e atendem o especificado pela norma SAEJ403. Através da análise micrográfica foi verificado que as fases presentes foram ferrita e perlita, e o tamanho médio de grão foi de 11,2 ?m para os dois materiais. O aço SAE1010AA apresentou limite de escoamento médio de 265,2 MPa, limite de resistência de 384,8 MPa e alongamento médio de 43,9%. Já o aço SAE1015AA apresentou limite de escoamento médio de 260,1 MPa, limite de resistência de 407,3 MPa e alongamento de 41,9%. Para os dois materiais, o limite de resistência à fadiga (2.10-6 ciclos) foi de 225 MPa. Foi realizada a caracterização das 4 amostras soldadas. Através das curvas SN observou-se que o limite de resistência à fadiga para as amostras soldadas apresentou redução para valores entre 180 e 160 MPa. Com os mapas de microdureza Vickers levantados foi possível perceber as diferenças de microdureza obtidas de acordo com os parâmetros de soldagem utilizados e consequentemente com as microestruturas formadas. Com as imagens obtidas na análise micrográfica observou-se a formação de microestruturas com formatos e tamanhos diversos tanto nas regiões da zona termicamente afetada das amostras como na região de solidificação do cordão de solda. Finalmente, com a realização da análise via MEV, constatou-se que todas as trincas por fadiga iniciaram na superfície dos corpos de prova. Foram observadas estrias de fadiga, com maior e menor intensidade de acordo com cada amostra, ao longo da região de fratura. Além disso, foi observada a geração de múltiplas trincas por fadiga em duas amostras. / In this study four samples of commercial vehicle wheels were welded using the Tandem-MIG process. For each sample different welding parameters were used to get different kinds of weld bead shape. The aim of this study was to evaluate the influence of these weld bead shapes in fatigue performance. For the SAE1010AA and SAE1015AA materials the following tests were performed: chemical composition analysis, microstructure characterization, SN curves by alternating bending method (R=-1). Through analyzing chemical composition, it was found that both materials are low carbon steel and they meet the SAE J403 standard. In microstructure characterization, ferrite and perlite microstructure were found, with an average grain size of 11,2 ?m for both steels. The SAE1010AA showed an average yield strength of 265,2 MPa, an average tensile strength of 384,8 MPa, and alongation of 43,9%. The SAE1015AA showed an average yield strength of 260,1 MPa, an average tensile strength of 407,3 MPa, and alongation of 41,9%. For both materials, the fatigue limit (2.10-6 ciclos) was 225 MPa. The characterization of the four samples was done. In SN curves the fatigue limit for welded samples showed a reduction to values of between 180 and 160 MPa. In the Vickers microhardness test, it was possible to notice the differences between the microhardness obtained in accordance with welding parameters used and, consequently, the microstructure formed. In microstructure analysis, different kinds and sizes of microstructure were observed to have formed in both the heat-affected zone and the welded zone. Finally, through MEV analysis, all fatigue cracks were seen to have begun on the surface of the samples. Fatigue estriaton, with major and minor intensity depending on the sample, was observed along the fracture region. Furthermore, the beginning of multiple fatigue cracks were seen in two samples.

Neste trabalho foram soldadas 4 amostras de rodas para veículos comerciais pelo processo de soldagem Tandem-MIG. Para cada amostra foram utilizados parâmetros de soldagem diferentes de modo a se obter formatos de cordão de solda distintos. O objetivo do trabalho foi avaliar a influência desses formatos de cordão de solda no desempenho em fadiga. Para os materiais utilizados, SAE1010AA e SAE1015A, foram realizados os seguintes ensaios: análise de composição química, análise micrográfica, levantamento das curvas tensão x deformação, medidas de microdureza Vickers e levantamento das curvas SN pelo método de flexão alternada (R=-1). Através da composição química constatou-se que ambos os aços são de baixo carbono e atendem o especificado pela norma SAEJ403. Através da análise micrográfica foi verificado que as fases presentes foram ferrita e perlita, e o tamanho médio de grão foi de 11,2 ?m para os dois materiais. O aço SAE1010AA apresentou limite de escoamento médio de 265,2 MPa, limite de resistência de 384,8 MPa e alongamento médio de 43,9%. Já o aço SAE1015AA apresentou limite de escoamento médio de 260,1 MPa, limite de resistência de 407,3 MPa e alongamento de 41,9%. Para os dois materiais, o limite de resistência à fadiga (2.10-6 ciclos) foi de 225 MPa. Foi realizada a caracterização das 4 amostras soldadas. Através das curvas SN observou-se que o limite de resistência à fadiga para as amostras soldadas apresentou redução para valores entre 180 e 160 MPa. Com os mapas de microdureza Vickers levantados foi possível perceber as diferenças de microdureza obtidas de acordo com os parâmetros de soldagem utilizados e consequentemente com as microestruturas formadas. Com as imagens obtidas na análise micrográfica observou-se a formação de microestruturas com formatos e tamanhos diversos tanto nas regiões da zona termicamente afetada das amostras como na região de solidificação do cordão de solda. Finalmente, com a realização da análise via MEV, constatou-se que todas as trincas por fadiga iniciaram na superfície dos corpos de prova. Foram observadas estrias de fadiga, com maior e menor intensidade de acordo com cada amostra, ao longo da região de fratura. Além disso, foi observada a geração de múltiplas trincas por fadiga em duas amostras. / In this study four samples of commercial vehicle wheels were welded using the Tandem-MIG process. For each sample different welding parameters were used to get different kinds of weld bead shape. The aim of this study was to evaluate the influence of these weld bead shapes in fatigue performance. For the SAE1010AA and SAE1015AA materials the following tests were performed: chemical composition analysis, microstructure characterization, SN curves by alternating bending method (R=-1). Through analyzing chemical composition, it was found that both materials are low carbon steel and they meet the SAE J403 standard. In microstructure characterization, ferrite and perlite microstructure were found, with an average grain size of 11,2 ?m for both steels. The SAE1010AA showed an average yield strength of 265,2 MPa, an average tensile strength of 384,8 MPa, and alongation of 43,9%. The SAE1015AA showed an average yield strength of 260,1 MPa, an average tensile strength of 407,3 MPa, and alongation of 41,9%. For both materials, the fatigue limit (2.10-6 ciclos) was 225 MPa. The characterization of the four samples was done. In SN curves the fatigue limit for welded samples showed a reduction to values of between 180 and 160 MPa. In the Vickers microhardness test, it was possible to notice the differences between the microhardness obtained in accordance with welding parameters used and, consequently, the microstructure formed. In microstructure analysis, different kinds and sizes of microstructure were observed to have formed in both the heat-affected zone and the welded zone. Finally, through MEV analysis, all fatigue cracks were seen to have begun on the surface of the samples. Fatigue estriaton, with major and minor intensity depending on the sample, was observed along the fracture region. Furthermore, the beginning of multiple fatigue cracks were seen in two samples.

This research is aimed at understanding the effect of thermal cycles on the metallurgical and microstructural characteristics of the heat affected zone of a multi-pass pipeline weld. Continuous Cooling Transformation (CCT) diagrams of the pipeline steel grades studied (X65, X70 and X100) were generated using a thermo mechanical simulator (Gleeble 3500) and 10 mm diameter by 100 mm length samples. The volume change during phase transformation was studied by a dilatometer, this is to understand the thermodynamics and kinetics of phase formation when subjected to such varying cooling rates. Samples were heated rapidly at a rate of 400°C/s and the cooling rates were varied between t8/5 of 5.34°C/s to 1000°C/s. The transformation lines were identified using the dilatometric data, metallographic analysis and the micro hardness of the heat treated samples. Two welding processes, submerged arc welding (SAW) and tandem Metal Inert Gas (MIG) Welding, with vastly different heat inputs were studied. An API-5L grades X65, X70 and X100 pipeline steels with a narrow groove bevel were experimented with both welding processes. The welding thermal cycles during multi-pass welding were recorded using thermocouples. The microstructural characteristics and metallurgical phase formation was studied and correlated with the fracture toughness behaviour as determined through the Crack Tip Opening Displacement (CTOD) tests on the welded specimens. It was observed that SAW process is more susceptible to generate undesirable martensite-austenite (M-A) phase which induce formation of localised brittle zones (LBZ) which can adversely affect the CTOD performance. Superimposition of the multiple thermal cycles, measured in-situ from the different welding processes on the derived CCTs, helped in understanding the mechanism of formation of localised brittle zones. Charpy impact samples were machined from the two X65 and X70 grades, for use in thermal simulation experiments using thermo mechanical simulator (Gleeble). The real thermal cycles recorded from the HAZ of the SAW were used for the thermal simulations, in terms of heating and cooling rates. This is to reproduce the microstructures of the welds HAZ in bulk on a charpy impact sample which was used for impact toughness testing, hardness and metallurgical characterisation. The three materials used were showing different response in terms of the applied thermal cycles and the corresponding toughness behaviours. The X65 (a) i.e. the seamless pipe was showing a complete loss of toughness when subjected to the single, double and triple thermal cycles, while the X65 (b), which is a TMCP material was showing excellent toughness in most cases when subjected to the same thermal cycles at different test temperatures. The X70 TMCP as well was showing a loss of toughness as compared to the X65 (b). From the continuous cooling transformation diagrams and the thermally simulated samples results it could be established that different materials subjected to similar thermal cycle can produce different metallurgical phases depending on the composition, processing route and the starting microstructure.

Nesse trabalho foram realizados experimentos para determinar as tensões residuais introduzidas no Aço A36, que é uma liga de baixo carbono e que é muito utilizado em vários setores da produção industrial, quando esta é submetida à soldagem do tipo MIG (Metal Gas Inert). A escolha desse tipo de soldagem foi para manter constantes os parâmetros que pudessem influenciar nos resultados. Nessa análise foi verificada a distribuição das tensões residuais na zona termicamente afetada, a distribuição da tensão em relação a profundidade. Para isso usamos uma remoção eletrolítica e um corte transversal pelo processo de eletroerosão. Nesse trabalho foi usado o método do sen2, devido a sua facilidade para a análise dos dados do Programa PSD. O resultado das mediadas realizadas na região do cordão de solda, zona termicamente afetada (ZTA) e metal base próxima da ZTA, mostrou uma variação da distribuição da tensão em relação à profundidade do material e na distância do ponto de soldagem. No ponto de soldagem um aumento da tensão em relação à profundidade do material. Os fatores que influenciaram na introdução dessas tensões no processo de soldagem, foram causados pelo gradiente de temperatura, pelo resfriamento heterogêneo do material e também pelo resfriamento rápido da superfície / In this work experiments were conducted to determine the residual stresses introduced in the A36 steel, which is an alloy of low carbon, which is widely used in various sectors of industrial production, when it is subjected to welding-type MIG (Metal Inert Gas). The choice of this type of welding was to keep constant the parameters that could influence the results. In this analysis we detected the distribution of residual stresses in the heat affected zone, the stress distribution over the depth. For this we use an electrolytic removal and a cross section through the process of spark erosion. In this study we used the method of sen2, due to its ease to the analysis of data from the PSD. The result showed a variation of stress distribution for the depth of the material and the distance from the point of welding. The welding point ran a rise in tension over the depth of the material. Factors influencing the introduction of these stresses in the welding process were caused by the temperature gradient by cooling the heterogeneous material and also by the rapid cooling of the surface

Neste trabalho foram realizados experimentos de soldagem circunferencial em tubos de aço inoxidável super duplex UNS S32750, com diâmetros de 19,05 mm e 48,20 mm. Foram executadas soldas utilizando-se diversos parâmetros de soldagem num equipamento MIG com controle CMT&reg Cold Metal Transfer. Os cordões de solda foram avaliados por inspeção visual e dimensional, além dos ensaios de tração e microdureza Vickers, bem como a análise microestrutural em conjunto com análise de precipitação de fases, a qual foi realizada em acordo com a prática A da norma ASTM A923, e ensaio de corrosão conforme a prática A da norma ASTM G48 em conjunto com a norma ASTM A923. Os resultados indicaram que a soldagem do tubo com diâmetro de 19,05 mm apresentou cordão de solda com dimensões inaceitáveis conforme norma, tendo sido esta condição atribuída a utilização de um elevado diâmetro do arame para as condições (parâmetros) usadas de soldagem. A soldagem do tubo com diâmetro de 48,20 mm apresentou falta de penetração nas condições empregadas, quando soldado pelo processo CMT&reg convencional. No caso da utilização do CMT&reg combinado com arco pulsado, em condições que geraram maior aporte de calor durante a soldagem, assim obteve-se penetração total da junta e acabamento superficial adequado. Os resultados indicaram que a soldagem utilizando o processo CMT&reg combinado com arco pulsado, nas condições (parâmetros) empregados geraram bom acabamento superficial, aliado propriedades mecânicas compatíveis, atendendo exigências de normas, bem como uma microestrutura balanceada e alta resistência à corrosão. / This study carried out circumferential welding experiments in UNS S32750 Super Duplex Stainless Steel tubes using diameters of 19,05 mm and 48,20 mm. Welds were performed using various welding parameters on a MIG machine with Cold Metal Transfer&reg CMT control. The weld joints were evaluated by visual and dimensional inspection in addition to the Vickers microhardness and traction tests, as well as the microstructural analysis in conjunction with phase precipitation analysis, which was performed according to practice A of ASTM A923, and corrosion test in accordance with practice A of ASTM G48 in conjunction with ASTM A923. The results indicated that welds performed in pipes with a diameter of 19.05 mm showed a weld joint with unacceptable dimensions according to the standard, this condition being attributed the use of a high wire diameter for the welding conditions used. Welding performed for pipes with a diameter of 48.20 mm showed a lack of penetration under the conditions employed when welded by the conventional CMT&reg process. In the case of the use of CMT&reg combined with pulsed arc, under conditions that generated greater heat input during welding, this resulted in total penetration of the joint and adequate surface finish. The results indicated that welding using the CMT&reg process combined with pulsed arc, under the conditions (parameters) employed generated good surface finish, combined mechanical properties, meeting standards requirements, as well as a balanced microstructure and high resistance to corrosion.

The first part briefly defines the theory of the creation of educational materiál. The following chapters describe the history of the fusion welding, the aluminum and its alloys, definitions of basic electrical and welding terminology. Briefly is described health and safety during welding work and fire protection. The following sections describe in detail the hand welding of aluminum and its alloys, method 131 (MIG), welding machines, equipment, protective gases, gas cylinders, pressure reducing valves. Another part is focused on the defects generated during welding of aluminum and its detection and iterpretation. The final part discusses the requirements for qualification of welders.