O objetivo deste trabalho é viabilizar o uso conjunto, em um mesmo sistema de tubulação, na indústria de óleo e gás, dos aços inoxidáveis superduplex UNS S32750 e UNS S32760. Atualmente as especificações de projeto limitam o uso de um ou outro para um dado sistema, implicando em menor flexibilidade de fornecimento e maiores custos. Adicionalmente será avaliado o processo de soldagem automatizado com arame tubular com matriz metálica (metal cored) e com proteção gasosa. Este processo de soldagem possui grande produtividade e rendimento. Foram estudadas a resistência à corrosão, a resistência mecânica e possíveis danos causados à microestrutura do metal de solda e das zonas afetadas pelo calor (ZAC) dos aços inoxidáveis superduplex UNS S32750 e UNS S32760. A junta foi realizada com chanfro em meio \"V\", com geometria de 300 mm por 200 mm por 6,35 mm e com os seguintes parâmetros de soldagem: tensão de 25 V, corrente de 150 A, velocidade de soldagem de 6,35 mm/s, velocidade de alimentação do arame de 135 mm/s e distância de trabalho de 20 mm. As juntas foram caracterizadas por microscopia óptica, eletrônica de varredura, ensaio de tração, ensaio de dobramento, ensaio Charpy V a - 46 °C e ensaio de corrosão segundo a norma ASTM G48. A base para os critérios de aprovação será o disposto normativo da Norsok Standard M-601, Welding and inspection of piping, na sua mais recente edição (2008). Os resultados mostraram que não existem diferenças significativas entre as soldagens similares e dissimilares com relação às propriedades testadas. / The objective of this work is to enable the use in the same piping system, used in the oil and gas industry, of UNS S32750 and UNS S32760 superduplex stainless steels. Currently, the design specifications limit the use of one or the other for a given system, resulting in less flexibility in supply and higher costs. Additionally, it will be evaluated automated welding process with metal cored using a shielding gas. This welding process has high productivity and efficiency. It was studied corrosion resistance, mechanical strength and possible damage to the weld metal microstructure and heat affected zones (HAZ) of stainless steels superduplex UNS S32750 and UNS S32760. The joint was welded using a half \"V\" bevel geometry, with 300 mm by 200 mm by 6.35 mm and the following welding parameters: voltage 25 V, current 150 A, welding speed of 6.35 mm/s, wire feed speed of 135 mm/s and 20 mm working distance. The joints were characterized by optical microscopy, scanning electron microscopy, tensile test, bending test, Charpy V test at - 46 °C and corrosion test according to ASTM G48. The basis for the criteria for approval is the normative provisions of Norsok Standard M-601, Welding and inspection of piping in its latest edition (2008). The results showed that there are no significant differences between similar and dissimilar welds with respect to the tested properties.

Aços inoxidáveis austeníticos são indicados para aplicações a baixas temperaturas por praticamente não apresentarem temperatura de transição dúctil/frágil. Quando estes aços são soldados há a formação de ferrita na zona fundida que, dependendo da morfologia e da quantidade, pode induzir uma temperatura de transição dúctil/frágil. Este trabalho busca estudar as propriedades mecânicas e microestruturais a baixas temperaturas (-100°C) na zona fundida do cordão de solda. Chapas de aço inoxidável AISI 304 com 25,4 mm de espessura foram soldadas pelo processo de soldagem a arco submerso, empregando-se um arame ER 308L, e dois tipos de fluxos distintos: um neutro e um auto-compensante em cromo. Os procedimentos de soldagem foram realizados utilizando-se corrente contínua em polaridade reversa e corrente alternada de onda quadrada. Esta apresentou melhores resultados de tenacidade que a soldagem em corrente contínua para os dois fluxos estudados. Os corpos de prova soldados com fluxo neutro apresentaram maior tenacidade que os soldados com fluxo autocompensante em cromo, comparando-se o mesmo tipo de corrente na soldagem. / Austenitic stainless steels are recommended for low temperature applications due to a very low ductile/brittle transition. When this stainless steel type is welded, there is formation of delta ferrite in the fusion zone which, depending on its morphology and distribution may increase ductile/brittle temperature transition to higher values compared with base metal. This work aims at studying the mechanical properties and microstructure at low temperatures (-100°C) on the weld bead fusion zone using AISI 304 plates 1 inch thick which were welded with submerged arc welding process using ER308L and two different fluxes types: a neutral and a chromium auto-compensating one. The welding procedures were made using reverse polarity continuous current and square wave alternate current. The latter presented better toughness results than the continuous current for both fluxes types. The neutral flux led to greater toughness than the chromium auto-compensating flux, comparing the same current type output.

The traditional method of teaching welding has remained unchanged for decades. In this model, an instructor gives demonstrations to a class of students and then helps them individually as they practice the techniques of welding. This traditional instructional method has been effective but is time consuming. Due to a significant increase in the demand for skilled welders within the United States, efforts have been made to develop more efficient methods of providing welding instruction. Various electronic welding guidance systems and virtual welding systems have recently been developed. In this study, the researcher addressed two questions 1) Does the use of an electronic welding guidance system improve the pass rate that entry-level high school students receive on basic gas metal arc weld tests? 2) Will entry-level high school students who learn gas metal arc welding with a guided welding training system learn how to weld faster and/or more proficiently than those taught using the traditional training method? A study was performed in an entry-level high school welding class to determine the effectiveness of a guided welding instruction system in comparison to the traditional method of teaching welding. The results of the study indicated that the traditional method of teaching welding and the use of a guided welding system yielded similar results, both in quality and efficiency, in student ability to produce basic GMAW welds.

Weld joint penetration determination is the key factor in welding process control area. Not only has it directly affected the weld joint mechanical properties, like fatigue for example. It also requires much of human intelligence, which either complex modeling or rich of welding experience. Therefore, weld penetration status identification has become the obstacle for intelligent welding system. In this dissertation, an innovative method has been proposed to detect the weld joint penetration status using machine-learning algorithms. A GTAW welding system is firstly built. Project a dot-structured laser pattern onto the weld pool surface during welding process, the reflected laser pattern is captured which contains all the information about the penetration status. An experienced welder is able to determine weld penetration status just based on the reflected laser pattern. However, it is difficult to characterize the images to extract key information that used to determine penetration status. To overcome the challenges in finding right features and accurately processing images to extract key features using conventional machine vision algorithms, we propose using convolutional neural network (CNN) to automatically extract key features and determine penetration status. Data-label pairs are needed to train a CNN. Therefore, an image acquiring system is designed to collect reflected laser pattern and the image of work-piece backside. Data augmentation is performed to enlarge the training data size, which resulting in 270,000 training data, 45,000 validation data and 45,000 test data. A six-layer convolutional neural network (CNN) has been designed and trained using a revised mini-batch gradient descent optimizer. Final test accuracy is 90.7% and using a voting mechanism based on three consequent images further improve the prediction accuracy.

Welding is a common industrial practice that has the potential to emit air pollutants. Emission factors are useful indicators to help in the understanding of the extent of pollution from a process and managing them to reduce or minimize health impacts. The objective of this thesis is to determine emission factors applicable to the gas metal arc welding (GMAW), under varying current and voltage conditions. The most used base metals and an electrode for the shipbuilding industry were considered. A weld fume chamber was used to achieve the project goals along with standard sampling and analytical procedures. Three test runs were performed for each sampling scenario to ensure repeatability. The EPA EF average for MS experiments with the ER70S-6 electrode is 5.2 g/kg, and for SS experiments with the ER316L-Si electrode is 3.2 g/kg, while the average results for this study were 6.81 g/kg and 3.28 g/kg respectively.

For the last decades usage of aluminium alloys have been increasing tremendously. They have been used in aerospace industry widely and now aluminium alloys are becoming more and more popular in automotive and defense industries. Consequently / successful welding of aluminium alloys gains importance. In this study a research is carried out on eldability of plates having different thicknesses of composition 5754 aluminium and 6063 aluminium in T-fillet geometry using Gas-metal Arc Welding technique. It was aimed to have a successful joint without using pre-weld and post-weld heat treatments. During tests welding current and voltage were the varying parameters as welding speed was held constant. Macro-examinations were performed to see the penetration of the weld metal. It was seen that the type of filler wire greatly effects weld penetration. Hardness tests, tensile tests were done to compare the mechanical properties of the welded joints with different filler wires. Despite having better penetration in 4043 filler wire used weld joints, 5356 filler wire used weld joints had higher tensile strength and ductility. In the second part of the study, a dynamic loading machine was designed and manufactured to see the behavior of the fillet welds under dynamic loading. The amount of stress and strain given to the specimen on this machine was adjustable but can&rsquo / t be measured. The tests that were made with this machine aimed only to compare the number of cycles of specimens before fracture. For dynamic loading tests two groups of specimens were prepared with filler wire 4043 / each group having been welded with different heat inputs. It was aimed to see the effect of welding heat input on service lifes but no significant difference between cycle numbers of specimen groups having been welded with different heat inputs was observed. Microstructure examinations of these specimens revealed that coarsening the grains, grain boundaries, particles in PMZ and HAZ regions between Al 6063 base metal and weld zone made these areas more susceptible and favorable for crack propogation than Al 6063 base metal.

In the present study, the applicability of the hybrid plasma arc welding, in which a keyhole is responsible of deep penetration and a filler wire electrode supplies a high deposition rate, was examined. The microstructural evolutions in grade 2205 duplex stainless steel plates joined by keyhole and melt-in techniques were investigated. The specimens obtained from welded plates having thickness of 8 mm were examined via optical and scanning electron microscopy. Metallographic investigations were supported by X-ray diffraction and energy dispersed spectra analyses by characterizing the phases formed after welding. Impact toughness properties, hardness profiles, and crack propagation behavior of welding zones were quantitatively and qualitatively compared for mechanical characterization. Fracture characteristics were determined via scanning electron microscopy examinations. It was observed that single-pass HPA weldment seemed to be free of secondary austenite precipitation in acicular form, which is inevitable in multi-pass conventional arc welding methods. Besides &delta / -ferrite was successfully kept under 70%, which is presented as a limit to not to deteriorate the mechanical properties of DSS. High linear welding speed and high power density supplied by HPAW presented narrower weld metal and heat affected zone with not only lower hardness but also higher impact toughness energies. Synergic effect of the keyhole formed by a plasma arc and the metal transfer supplied by gas metal arc gave reasonable dilution in the weld metal. Furthermore, fatigue crack growth tests revealed that crack propagation rates in HPAW joints were comparable to GMAW joints.

Thesis (Ph. D.)--Ohio State University, 2009. / Title from first page of PDF file. Includes bibliographical references (p. 229-238).

Submerged Arc Welding (SAW) for fillet joints is one of the major applications in the shipbuilding industry. Due to the requirement for the weld size, a sufficient amount of metal must be deposited. In conventional SAW process, the heat input is proportional to the amount of metal melted and is thus determined by the required weld size. To meet this requirement, an excessive amount of heat is applied causing large distortions on the welded structures whose follow-up straightening is highly costly. In order to reduce the needed heat input, Double-Electrode (DE) technology has been practiced creating the Double-Electrode SAW (DE-SAW) method for fillet joints. The reduction in the heat input, however, also reduces the penetration capability of the process, and the ability to produce required weld beads has to be compromised. To eliminate the unwanted side effect after using DE-SAW, a root opening between the panel and the tee has been proposed in this dissertation to form a modified fillet joint design. Experimental results verified that the use of root opening improves the ability of DE-SAW to produce the required weld beads at reduced heat input and penetration capability. Unfortunately, the use of root opening decreases the stability of the process significantly. To control the heat input at a minimally necessary level that guarantees the weld size and meanwhile the process stability, a feedback is needed to control the currents at their desired levels. To this end, the fillet DE-SAW process is modeled and a multivariable predictive control algorithm is developed based on the process model. Major parameters including the root opening size, travel speed and heat input level have been selected/optimized/minimized to produce required fillet weld beads with a minimized heat input based on qualitative and quantitative analyses. At the end of this dissertation, a series of experiments validated the feasibility and repeatability of the predictive control based DE-SAW process for fillet joints with root opening.

Le matériau principal de cette étude est l’acier inoxydable austénitique 316L(N) (X2CrNiMo17-12-2 à teneur en azote contrôlée) envisagé dans la conception de la cuve et des structures du circuit primaire des futurs réacteurs de quatrième génération refroidis au sodium. Pour assembler des composants de forte épaisseur, il faut réaliser des soudages multipasses avec métal d'apport. Lors du soudage, il a parfois été constaté des défauts de fissuration à chaud de solidification au refroidissement dans la zone pâteuse, près du bain de fusion. Ces fissures sont des décohésions du matériau apparaissant à haut température le long des joints de grains lorsque la déformation dépasse un seuil critique. Il est donc nécessaire de prévenir ce risque en utilisant un critère de fissuration à chaud. L'approche utilisée dans cette étude est double : développer un essai de fissuration à chaud à chargement extérieur, puis simuler numériquement ces expériences pour déterminer un seuil critique en déformation en utilisant un critère proposé par Kerrouault. Une version améliorée d’un essai de fissuration à chaud (Controlled Restraint Weldability (CRW) test) a été proposé dans cette étude afin d'analyser la susceptibilité à la fissuration de solidification du matériau 316L(N) et d’un métal d'apport de nuance Thermanit 19-15H. L'objectif de ce test est, en fonction de l'intensité du chargement extérieur, d'amorcer une fissure dans un régime thermique établi, puis d’arrêter la propagation de cette fissure si les conditions thermomécaniques locales sont remplies. Le modèle de comportement du matériau choisi est une loi élasto-visco-plastique à écrouissage mixte. Des essais thermomécaniques sur un simulateur Gleeble ont été réalisés à haute température afin d'identifier et d’améliorer la loi de comportement du matériau 316L(N). Le grossissement des grains dans la zone affectée thermiquement a été modélisé et intégré dans ce modèle. Les intervalles de fusion et de solidification du matériau 316L(N) ont été déterminés par des essais ATD (Analyse Thermique Différentielle). Des analyses des microstructures de solidification ont été également menées afin de mieux comprendre le phénomène de fissuration à chaud. Certains essais CRW ont ensuite été modélisés et simulés par éléments finis en utilisant les logiciels Cast3M et Abaqus afin valider le critère de fissuration à chaud et de déterminer un seuil critique de fissuration pour l'acier 316L(N). / The austenitic stainless steel AISI 316L(N) (X2CrNiMo17-12-2) with controlled nitrogen content is widely used for manufacture of vessel and primary circuit structures of the 4th Generation sodium- cooled fast reactors. Multi-pass welds with an appropriate filler metal is used to assemble thick components. Solidification cracks may occur in the mushy zone near the melting weld poor during solidification when a liquid film is distributed along grains boundaries and interdendritic regions and the shrinkage strains across the boundaries cannot be accommodated. It is therefore necessary to prevent this defect using a hot cracking criterion. The approach used in this study is to initiate experimentally a hot crack by a weldability test, and then to simulate these tests to identify a critical strain using a hot crack criterion for the prediction of solidification cracking. Therefore, a hot cracking test (Controlled Restraint Weldability (CRW) test) is proposed in the present study to analyze the susceptibility to hot cracking for base metal 316L(N) and its filler metal 19-15H Thermanit grade. This test is designed to initiate a hot crack in thermal steady state, and then to stop the crack once the local thermomechanical conditions are met. The initiation and stop of the crack depend on external mechanical preload. The material constitutive equations chosen for the material is a visco-plastic model with isotropic and kinematic hardening. The Gleeble thermomechanical tests have been performed at high temperature in order to identify material parameters. The increase of the grain size in the thermally affected zone was modeled and integrated into constitutive equations. The temperature range of melting and solidification of 316L(N) were determine by using the Differential Thermal Analysis (DTA). The analysis of the solidification microstructures were also carried out in order to better understand the phenomenon of hot cracking. Some CRW tests were then simulated by finite element method using the Cast3M and Abaqus software in order to valid the hot cracking criterion and to determine a thermomechanical criterion of hot cracking for 316L(N).