Orientador: Itamar Ferreira / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-14T09:06:17Z (GMT). No. of bitstreams: 1 Cazetta_JoseRoberto.pdf: 4497773 bytes, checksum: b712ca165319b331601bb3ff49914861 (MD5) Previous issue date: 2009 / Resumo: Ao longo da história dos elevadores as suas respectivas portas passaram por muitas fases de desenvolvimento, desde a sua não utilização até modelos que poderiam acarretar perigo ao usuário. Atualmente os modelos de painéis de portas são seguros, porém de maneira geral, ainda utilizam processos produtivos tradicionais para efetuar a união mecânica entre os componentes, fazendo uso da soldagem. Este trabalho tem por objetivo desenvolver um conjunto painel metálico aplicando os processos de colagem e rebitagem em concomitância na união dos seus componentes, e demonstrar também a sua viabilidade em ser uma alternativa ao conjunto painel soldado. Para isso foram manufaturados dois conjuntos de painéis e seus componentes tiveram as mesmas dimensões e geometrias, diferenciando somente no processo produtivo, pois um teve os seus componentes unidos por meio da soldagem MIG e no outro painel aplicou-se fita adesiva VHB e rebites de aço inoxidável na união de seus componentes. A legitimação da alternativa entre processos se fez por meio da análise comparativa dos dados obtidos em dois diferentes ensaios executados nos painéis, sendo um deles de flexão, ou seja, consiste em aplicar uma carga de 300N perpendicular à face frontal do painel e em seu ponto mais vulnerável. O outro ensaio foi submeter os painéis a esforços de torção, por meio da aplicação de uma carga de 500N durante cinco minutos. Os resultados dos ensaios demonstraram que o conjunto painel soldado tem a melhor rigidez comparativamente ao painel colado e rebitado, porém o painel colado e rebitado teve o melhor desempenho, em termo dos dois ensaios utilizados. / Abstract: Along the elevators' history its door has passed through many development phases since its no using of the doors by the ones which could cause injuries to the user. Nowadays the models of the doors panels are safe, however they still have used traditional productive processes (welding) to make the mechanical union among the components. The objective of this work is to develop a metallic panel applying the agglutinated and riveting processes in concomitance in the union of their components and also to demonstrate the viability as an alternative of the welded panel, so that two panels were manufactured and their components had the same dimensions and geometries, differing only on the productive process. One of them their components were jointed by welding MIG and the other one was applied VHB adhesive tape and stainless steel rivets for joining of their components. The legitimation of the alternative among processes was made by using the comparative analysis of the results obtained from two different tests executed on the panels. One of them consists to apply 300N perpendicular to the panel front face, in the more vulnerable point. It is the flexure test. The other test was to submit the panels to torsion efforts, by using the load application of 500N for five minutes. The results of the tests demonstrated that the welded panel has the best rigidity and the agglutinated and riveted panel had the best performance in terms of the used tests. / Universidade Estadual de Campi / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

Welding is a key process for heavy steel structures, but it is also a weak link in the structure since fatigue fractures in welds are a common cause of failure. This thesis proposes several changes in order to improve the fatigue properties in acost effective way, enabling reduced weight and reduced cost of welded structures. The main idea is to adapt the weld requirements and welding procedures to the load conditions of the weld. This approach ensures that the main focus in the welding process is the critical characteristics of the welds fatigue life properties. The fatigue life critical properties are most often related to the geometrical factors of the weld such as the radius at the weld toe or the penetration in the root. The thesis describes a holistic view of the subject and covers fatigue, weld quality, weld requirements and welding procedures. It becomes evident that the traditional way of working without a direct connection to fatigue is not the best. With an adaptation to the load conditions and fatigue, it is possible to enhance the fatigue life and reduce the welding cost. The main challenge is to connect the welding process, weld requirements and fatigue life properties. It is needed for an optimised welding process of heavy structures subjected to fatigue and toget a predictable fatigue life. Welds optimised for enhanced fatigue life properties are not necessary accepted according to the requirements in a current standard. Several welding procedures are proposed for improving the fatigue life properties of the weld, which indicate a high potential for enhanced fatigue lifeof fillet welds. The idea is to replace the "standard" fillet weld with three different weld types: (i) Welds with deep penetration, (ii) Welds with large weld toe radius and (iii) Welds produced with low cost. Together with customised requirements and reduced over-welding there is a vast potential for reduced weight, reduced cost and increased productivity.The main contribution of this thesis work is the cross-functional studies including design, analysis, production and quality control. This gives a framework for improvements supporting reduced cost and reduced weight of VIII welded structures without reducing the fatigue strength. Many shortcomings have been highlighted to change the welding from a state where welds are done in a way as they "always" have, by tradition, to a more contemporary situation where weld requirements and welding procedures are actively chosen to match the load conditions of the weld. This result in requirements and welding procedures which actually are connected to the fatigue properties as defined by the loading conditions, and where auditors with high probability can say that an accepted weld actually is better than a rejected weld.

Abstract This thesis studies controlling factors that govern transverse hydrogen cracking in high-strength multipass weld metal (WM). The experiments were concerned with heavy-restraint Y- and U-Groove multipass cracking tests of shielded-metal arc (SMAW) and submerged-arc (SAW) weld metals. Results of tensile tests, hardness surveys, weld residual stress measurements and microstructural investigations are discussed. The analytical phase comprised numerical calculations for analysing the interactions between crack-controlling factors. The objectives were: (i) the assessment of WM hydrogen cracking risk by defining the Crack-No Crack boundary conditions in terms of 'safe line' description giving the desired lower-bound estimates, and (ii) to derive predictive equations capable of giving reliable estimates of the required preheat/interpass temperature T0/Ti for the avoidance of cracking. Hydrogen cracking occurred predominantly in high strength weld metals of Rp0.2 ≈ 580-900 MPa. At intermediate strengths of Rp0.2 ≈ 500-550 MPa, cracking took place in the cases where the holding time from welding to NDT inspection was prolonged to 7 days. Low strength WMs of Rp0.2 ≤ 480 MPa did not exhibit cracking under any conditions examined. Cracking occurrence was, above all, governed by WM tensile strength, weld diffusible hydrogen and weld residual stresses amounting to the yield strength. The appearance of cracking vanished when transferring from 40 to 6 mm thick welds. The implications of the holding time were more significant than anticipated previously. A period of 16 hrs in accordance with SFS-EN 1011 appeared much too short for thick multipass welds. Interpass time and heat input showed no measurable effect on cracking sensitivity, hence being of secondary importance. Equations were derived to assess the weld critical hydrogen content Hcr corresponding to the Crack-No Crack conditions as a function of either weld metal Pcm, yield strength Rp0.2 or weld metal maximum hardness HV5(max). For the calculation of safe T0/Ti estimates, a formula incorporating: (i) WM strength as a linear function of either weld carbon equivalent CET or weld HV5(max), (ii) weld build-up thickness aw in the form of tanh expression and (iii) weld diffusible hydrogen HD in terms of a combined [ln / power law] expression was found descriptive.

The repair welding of main steam pipelines, which involves the welding of new material onto service-exposed material, are investigated. This paper investigates the literature and experimental work surrounding this subject. The introduction provides a background to the applicable welding technology. In section two the heat-affected zone is discussed with emphasis on the residual stresses that develop in this zone. The mechanical properties of the heat-affected zone are also investigated. This includes the tensile, toughness and hardness properties as well as inspecting the relevant microstructures. The effect of post weld heat treatment on these properties is also investigated. Section three investigates the phenomenon of creep. Not only is this important due to the high temperatures at which these pipelines operate, but creep is also associated with some failures of these weld during post weld heat treatment. The creep properties of the heat-affected zone are investigated in detail with the use of weld simulation. Sections four and five detail reasons for weld failure after welding due to hydrogen and reheat cracking. Hydrogen cracking is investigated with the use of slow strain rate tensile tests during cathodical charging the specimen with hydrogen. The phenomenon of reheat cracking is investigated with the use of high temperature tensile tests as well as a novel approach in which the stress relief of a welded joint is simulated while measuring crack growth and stress relieved. / Dissertation (MEng)--University of Pretoria, 2014. / gm2014 / Materials Science and Metallurgical Engineering / Unrestricted

No description available.

A pipe consisting of Inconel 600 welded to grade 106-B Carbon-Steel using Inconel 182 weld filler is used to transport heavy water in nuclear reactors. A confidential report concluded that cracking is one of the problems these pipes are currently facing. Before cracking can be fully understood the mechanical properties of the weld must be determined. This thesis analyzed the pipe at various length-scales using optical microscopy, micro-hardness testing, small and large scale tensile testing and digital image correlation (DIC). This thesis successfully achieved it goals of determining the mechanical properties and creating a model of the Inconel dissimilar metal weld. It partially met the goal of observing fracture mechanisms as it was able to observe fracture in tensile samples but was not able to successfully track crack growth.

Automated narrow-gap girth-butt welds are replacing conventional welding methods to join sections of austenitic stainless steel pipe in the primary circuit of Pressurised Water Reactors, to reduce manufacturing costs and improve quality. To ensure the safe operation of these systems, reliable structural integrity assessments have to be undertaken, requiring the mechanical properties of welded joints to be characterised alongside the weld residual stress magnitude and distribution.This research project characterised, for the first time, the weld residual stress field and the tensile and ductile fracture toughness properties of a 33 mm thick narrow-gap 304L stainless steel pipe weld. The residual stress was characterised using two complementary approaches: deep hole drilling and neutron diffraction. A novel neutron diffraction scanning technique was developed to characterise the residual stress field, without cutting an access window into the component, leaving the original weld residual stress field undisturbed. A modified deep hole drilling technique was developed to characterise the residual stress retained in fracture mechanics specimens extracted from the pipe weld in two orientations. The modified technique was shown to measure the original weld residual stress field more accurately than through conventional deep hole drilling. Residual stresses, exceeding 50% of the weld material proof strength, were retained in axially-orientated fracture mechanics specimens.Tensile tests showed that the weld was approximately 60% overmatched. It was demonstrated that neither retained residual stress, nor specimen orientation, had a discernible effect on the measured fracture toughness of the weld material. In less ductile materials, however, the level of retained residual stress may unduly influence the measurement of fracture toughness. At initiation, the fracture toughness properties of both the parent and weld materials were far in excess of the measuring capacity of the largest fracture mechanics specimens that could be machined from the weld.The influence of residual stress and fracture toughness on the performance of narrow-gap welded pipework was investigated. Full elastic-plastic finite element analyses were used to model the pipe weld, containing a postulated defect under combined primary and secondary loading. The results, applied within the framework of an R6 structural integrity assessment, compared different plasticity interaction parameters on the prediction of failure load; the conventional ρ-parameter approach was compared with the recently developed, more advanced, g-parameter. It was shown that the g-parameter significantly reduced the conservatism of the ρ-parameter approach. However, for this pipe weld, plastic collapse was predicted to precede failure by ductile initiation, suggesting that a plastic collapse solution may be an appropriate failure criterion to use in structural integrity assessments of similar component and defect combinations.

Foram estudadas as propriedades de fadiga em dois grupos de soldas de alta resistência e baixa liga com diferentes composições microestruturais. As soldas do grupo A apresentaram microestruturas compostas de ferrita acicular, ferrita alotriomórfica e ferrita de Widmanstätten, com limite de escoamento de aproximadamente 460 MPa, enquanto que as soldas do grupo B apresentaram microestruturas compostas de martensita de baixo carbono, bainita e ferrita acicular, com limite de escoamento de aproximadamente 850 MPa. A partir do ensaio de trincas longas, foi obtida a taxa de crescimento por ciclos de carregamento, da/dN, de da/dN=1,18·10-12·DeltaK2,91 e da/dN=1,34·10-11·DeltaK2,64, respectivamente para as soldas dos grupos A e B. Como pode ser observado a partir destas equações, a taxa de crescimento foi mais alta para o grupo B. Da análise do fechamento da trinca pode ser concluído que o principal fator determinante de uma menor taxa de propagação para as soldas do grupo A foi a plasticidade desenvolvida pela estrutura. Dos ensaios de trincas curtas foi observado que no caso das soldas do grupo A, uma vez nucleada a trinca, esta se propagava até o colapso do corpo de prova. Para as soldas do grupo B foi observado que não bastava a existência de uma trinca para que esta se propagasse até a fratura total do corpo de prova e que o fator controlador foi a granulomentria associada a uma determinada composição microestrutural. / The fatigue properties of two groups of high strength low alloy steel weld metals with different microstructural composition were studied. Weld metals from group A presented microstructures composed of acicular ferrite, Widmanstätten ferrite and allotriomorphic ferrite, with yield strength of 460 MPa. Weld metals from group B exhibited a microstructural composition of low carbon martensite, bainite and acicular ferrite, with a yield strength of 850 MPa. The fatigue crack growth per cycle of loading, da/dN, for weld metals from groups A and B is obtained from the relationships, da/dN=1,18·10-12·DeltaK2,91 and da/dN=1,34·10-11·DeltaK2,64, respectively. As can be seen from these equations, the crack growth rate was higher for group B. From the crack growth closure analysis, it may be concluded that the lower crack growth rate obtained for weld metals from group A was mainly due to the higher crack tip plasticity developed in this type of microstructure. From the short crack fatigue tests, it was observed for weld metals from group A, that once a crack was nucleated, it propagated until the testpiece plastic collapsed. For weld metals from group B, it was observed that the existence of a crack was not sufficient to cause the complete testpiece failure, and the association of the grain size with the local microstructure was the main factor controlling the failure process.

The thesis is focused on microstructural stability of heterogeneous weld joint of ODS steel and tungsten. The theoretical part summarizes the basic information about the structure and properties of ODS steels and describes the methods of joining these steels with tungsten. In the experimental part, materials MA956 and WL10 were welded by using electron beam. The individual samples differ by preheating temperature or use filler material. After annealing at 800 °C/1h and 1000 °C/5h, a change of the weld metal microstructure was evaluated by using scanning electron microscope. The chemical composition was measured by energy dispersive spectroscopy. It has been found that during annealing, massive precipitation of particles occures in the whole volume of the weld metal. These particles were identified as Laves phase.

This thesis submitted deals with the project of the change of the production of the semi-finished product of the console which is produced by casting from the cast iron ČSN 42 2420. The component forms the frame of the deburring machine with two electric motors with the gearbox. For the suggested production the method MAG of technology welding was chosen. Because of the given technology the new construction of the component was chosen. The welded product consists of eight parts burnt from heavy-walled sheet metals. The suggested material of the construction is steel S235JR and for welding the filler rod Weld G3Si1, diameter 1 mm is chosen. For the determination of the optimal parameters of welding the testing through the slap next to the skin weld (size a5) was made. Simultaneously with the testing the fracture areas and the weld root were examined. The suggested parameters of welding were used during the preparation of WPS. For the assembling of the component the operating schedule of welding is planned.