The present work researches influence of energy focusing effect to the fusion zone defects in the electron beam welding, which include fusion zone shape, welding depth, welding width, rippling and spiking. And to verify the model of welding defects base on theory and experiment. A spike is a sudden increase in penetration beyond what might be called the average penetration line. Many spikes have voids and cold shuts in their lower portions, because molten metal does not fill in completely, producing a condition similar to a cold shut in a casting. Ripples on a workpiece surface are generally associated with segregation, porosity and other microstructure defects. These become the objectives in this project.

A computer controlled weld quality assurance system has been developed to detect weld defects ultrasonically whilst welding is in progress. This system, including a flash analogue to digital converter and built-in memories to store sampled data, a peak characters extractor and a welding process controller, enabled welding processes to be controlled automatically and welding defects to be detected concurrently with welding. In this way, the weld quality could be satisfactorily assured if no defect was detected and the welding cost was minimised either through avoiding similar defects to occur or by stopping the welding process if repair was necessary. This work demonstrated that the high temperature field around the weld pool was the major source of difficulties and unreliabilities in defect detection during welding and, had to be taken into account in welding control by ultrasonic means. The high temperatures not only influence ultrasonic characteristic parameters which are the defect judgement and assessment criterion, but also introduce noise into signals. The signal averaging technique and statistical analysis based on B-scan data have proved their feasibility to increase 'signal to noise ratio' effectively and to judge or assess weld defects. The hardware and the software for the system is explained in this work. By using this system, real-time 'A-scan' signals on screen display, and, A-scan, B-scan or three dimensional results can be printed on paper, or stored on disks, and, as a result, weld quality could be fully computerized.

Continuous welding is one of the prominent techniques used in producing seamless piping used in many applications such as the mining and the oil and gas industries. Weld defects cause significant loss of time and money in the piping production industry. Therefore, there is a need for effective online weld defects detection systems. A laser-based weld defects detection (LBWDD) system has been developed by the industrial partner. However, the current LBWDD system can only detect some geometrically based weld defects, but not material inhomogeneity such as voids, impurities, inclusions, etc. The main objective of this study is to assess the predictability of a thermal imaging-based weld defects detection system (TIBWDD) using an IR camera that can be integrated with the current LBWDD system. The aim of the integrated detection system is to be able to detect a wider range of weld defects. A test rig has been designed and used to carry out a set of emissivity (ε) calculation experiments considering three different materials – Aluminum 5154 (Al), Stainless Steel 304L (SS), and Low Carbon Steel A131 (LCS) with two surface finishes 0.25 μm (FM) and 2.5 μm (RM), which are relevant to pipe welding operations. Al showed least change in ε varying from 0.162 to 0.172 for FM samples and from 0.225 to 0.250 for RM samples from 50°C to 550°C. LCS showed highest change in ε varying from 0.257 – 0.918 for FM samples and from 0.292 to 0.948 for RM samples. SS showed a consistent increase in ε for both FM and RM samples. Experimental and numerical analysis have been carried out mimicking two sets of possible weld defects investigating defect size, Dh, and distance between effect and sample surface, δ. Results showed that the δ based defects that are located within 3 mm can be detected by the IR camera. Defects with Dh = 1. 5 mm can be detected by the IR camera with and without glass wool. Laser welding simulations using 2D and 3D Gaussian heat source models have been carried out to assess the predictability of a set of possible weld defects. The heat source models have been validated using experimental data. Three sets of defects were considered representing material-based inhomogeneity, step and inclined misalignment defects. For material-based inhomogeneity in thin plates all defects located at 1.25 mm from the surface are found detectable as ΔT (temperature difference obtained on surface) > ΔTmin (detectability limit of TIBWDD system). For inhomogeneity defects in thick plates, except defects of 2.5 mm in square size all other defects were found detectable as ΔT > ΔTmin. All step misalignment defects were detected for thin and thick plates. In the case of inclined misalignment defects, for thin plates, the misalignment error in the thin plate had to be at least 0.275 mm to be detected. In the case of thick plates, the misalignment error had be at least 0.375 mm to be detected. Overall, results of the present study confirm that thermal imaging can be successfully used in detecting material-based and geometry-based weld defects. / Thesis / Master of Applied Science (MASc)

O presente trabalho tem como objetivo caracterizar e correlacionar formas de onda de sinais de emissÃo acÃstica, utilizando mÃtodos de anÃlise espectral e fractal, em corpos de prova previamente soldados com seus respectivos defeitos, avaliando assim a integridade estrutural do material aÃo carbono ASTM 516 Grau 60, utilizado em vasos de pressÃo, tubulaÃÃes, esferas de armazenamento, etc. Os sinais de emissÃo acÃstica foram gerados submetendo os corpos de prova a ensaios de traÃÃo. Para anÃlise dos sinais no domÃnio dos tempos, foram utilizados o mÃtodo de contagem de caixas, que fornece a dimensÃo fractal, e o de intervalo re-escalado de Hurst, e no domÃnio das freqÃÃncias o mÃtodo espectral de Fourier. AtravÃs das relaÃÃes previstas pelas leis de escala, concluiu-se que os expoentes calculados pelos mÃtodos espectral de Fourier e reescalado de Hurst, correlacionam-se entre si, bem como com a dimensÃo fractal obtida pelo mÃtodo de contagem de caixas. Mostrou-se tambÃm a existÃncia de duas regiÃes de escala distintas que caracterizam a mudanÃa do regime elÃstico para o regime plÃstico quando as amostras foram submetidas ao carregamento de traÃÃo. Verificou-se ainda que este comporta-mento foi caracterÃstico tanto para os materiais soldados como para o metal de base. / The present work aims to characterize and correlate waveforms of acoustic emission signals, using methods of spectral analysis and fractal in specimens previously soldiers with their defects, thus evaluating the structural integrity of the material carbon steel ASTM 516 Grade 60 used in pressure vessels, piping, storage spheres, etc.. The acoustic emission signals were generated by subjecting the specimens to tensile tests. For analysis of the signals in the time domain, we used the method of box counting, which provides the fractal dimension, and re-scaled range of Hurst, and in the frequency domain the Fourier spectral method. Through the relations laid down by law scale, it was concluded that the exponents calculated by Fourier transform and spectral methods reescalado Hurst, are correlated with each other as well as the fractal dimension obtained from a box counting. It was also shown existence of two regions of different scale characterizing the change of the elastic to the plastic regime when the samples were subjected to traction. It was further found that this behavior is characteristic for both the welded material as for the parent metal.

AgÃncia Nacional do PetrÃleo / O presente trabalho tem como objetivo caracterizar diferentes defeitos de soldagem ( falta de fusÃo, falta de penetraÃÃo e porosidade) inseridos em corpos de prova durante o processo de soldagem, atravÃs da anÃlise fractal di sinais ultra-sÃnicos obtidos pela tÃcnica TOFD. Para eliminar os ruÃdos, os sinais foram tratados usando dois mÃtodos de filtragem, passa banda e Savitzky-Golay. Na anÃlise fractal dos sinais foram utilizados trÃs mÃtodos: anÃlise de Hurst, anÃlise de flutuaÃÃo sem tendÃncias e anÃlise de cobertura mÃnima. Nos trÃs mÃtodos foram considerados sinais filtrados isoladamente, bem como sinais filtrados concatenados. Os parÃmetros caracterÃsticos das regiÃes de escala, para cada tipo de anÃlise, foram calculados atravÃs de regressÃes lineares, sendo tambÃm determinado o desvio padrÃo de cada sinal. A caracterizaÃÃo de todos os defeitos foi determinada atravÃs dos parÃmetros obtidos para os sinais filtrados pelo mÃtodo Savitzky-Golay e para os sinais concatenados filtrados pelo mÃtodo passa banda. Foi tambÃm mostrado que, no contexto dessa anÃlise fractal, a melhor discriminaÃÃo foi obtida utilizando o mÃtodo de Savitzky-Golay. / The present work aims to characterize different welding defects (lack of fusion, lack of penetration and porosity) inserted into the specimens during the welding process by analyzing fractal di ultrasonic signals obtained by the TOFD technique. To eliminate the noise, the signals were processed using two methods of filtering, band pass and Savitzky-Golay. In fractal analysis of signals using three methods: analysis of Hurst analysis, trends and fluctuation analysis without minimum coverage. In the three methods were individually filtered signals and filtered signals concatenated. The characteristic parameters of the regions of scale, for each type of analysis were calculated by linear regression, and is also given the standard deviation of each signal. The characterization of all defects was determined by the parameters obtained for the signals filtered by the method Savitzky-Golay and concatenated signals filtered by bandpass method. It was also shown that in the context of this fractal analysis, the best discrimination was achieved using the method Savitzky-Golay.

The diploma thesis deals with the problematics of weld defects of cranes localisation and check. The aim is to analyse non-destructive methods, monitor the occurence of defects and their form and also to suggest the procedure of correction. The work is divided into a theoretical and practical part. In the theoretical part, there is an analysis of individual methods of non-destructive testing that are used for weld check on a particular girder. There is also an analysis of welding technologies used when making a crane girder. The practical part deals with evaluation of weld defects using two methods of non-destructive testing. Furthermore, statistics of defects is realised. In conclusion, the statistics outcome is resumed and evaluated.

This doctoral thesis is concerned with fatigue life of welded structures. Several topics related to fatigue of welded structures are treated such as; weld defects and their influence on fatigue performance of welded structures, fatigue life prediction using LEFM (Linear Elastic Fracture Mechanics), fatigue testing, welding simulation, residual stress prediction and measurement and their influence on fatigue life. The work that is reported in this doctoral thesis is part results of the Nordic R&D project QFAB (Quality and Cost of Fabricated Advanced Welded Structures) and the Swedish R&D project LOST (Light Optimized Welded Structures). One of the main objectives is to compare different welding processes for the fatigue performance, weld quality and gain understanding of the weld defects, their appearance in different welding processes and their effect on fatigue life. Another main objective is to study welding residual stresses and their effect on fatigue. The design rules are in some cases conservative and especially on the weld root sides the knowledge about the residual stress field may improve the life prediction. The aim is to develop simplified procedures for analysis of residual stresses, their relaxation and influence on fatigue life. Fatigue testing of Hybrid Nd: YAG laser/MAG and MAG welded (tandem arc solid wire, flux cored wire, tandem flux cored wire) non-load carrying cruciform joints was carried out. Four batches were produced, tested and the results were compared. The local weld geometry of the cruciform welded joints was measured and analyzed. Residual stress measurement was carried out close to the toe region using X-ray diffraction. Weld defects, in most cases cold laps, in the cracked specimens were measured. Further fatigue testing, weld defect assessment and residual stress and local weld geometry measurements were carried out on joints welded with flux cored and metal cored arc wires. Two-and three dimensional LEFM crack growth analysis were carried out in order to predict the influence of weld defects, local weld geometry and residual stresses. Residual stresses in multi-pass welded tube-to-plates were studied for two different tubular joint configurations; a three-pass single-U weld groove for maximum weld penetration and a two-pass fillet (no groove) welded tube-to-plates for minimum weld penetration. Torsion fatigue tests were performed in order to study crack propagation from the weld root. Mode III propagation from the lower and upper weld toe on the same tubular joints was also studied. Some tubes were stress relieved (PWHT) and some were fatigue tested with internal static pressure. A three dimensional finite element welding simulation of the multi-pass welded tubular joint was carried out. The calculated temperatures in the transient thermal analysis were compared with measured temperatures. The FE predicted residual stresses in the as-welded conditions were verified with hole drilling strain gage measurements. The residual stresses were used as internal stresses in the finite element model for the torsion fatigue simulation in order to study the cycle by cycle relaxation of the residual stresses in constant amplitude torsion loading. A two dimensional finite element welding simulation procedure was developed in order to predict welding residual stress. The predicted residual stresses were used together with a developed 2D LEFM subroutine to predict the fatigue life, crack path and the effect of residual stresses on weld root defects. The developed simulation subroutines were validated with results found in the literature. Residual stresses measurement, two-and three dimensional welding simulations were carried out in fillet welded joints in order to study the three dimensional effects of the welding process, boundary conditions and modelling technique on the formation of residual stresses. / QC 20100706