In the thesis are analysed influences of three shield gases, based on literary pursuit. Compared was influence of the gas consisting of pure Ar, mixture Ar with 3vol.% CO2 and the mixture Ar with 18vol.% CO2 on mechanical properties of conduction laser welded blunt welds made from structural steel DC01 and S235JR with thickness 3mm and 2mm. Compared were strength properties of the welds in tension, weld hardness and hardness of the heat affected area under the low stress. Further was observed and compared stream of the gases during welding process and its influences on the appearance of the trial welds. On the metallographical cuts of the welds were evaluated mistakes and dimensions of the welds.

O arame tubular AWS E71T-1 tem sido utilizado, na grande maioria das aplicaÃÃes, com CO2 e argÃnio. No entanto, para esta mistura de gÃs, as informaÃÃes nÃo foram levantadas, de forma suficiente, com relaÃÃo ao desempenho operacional do arame. Sabe-se que o tipo de gÃs afeta tambÃm a transferÃncia metÃlica, o comportamento do arco, a geometria do cordÃo de solda, a taxa de deposiÃÃo e a eficiÃncia de fusÃo do arame, dentre outras caracterÃsticas do processo de soldagem. O objetivo do trabalho consiste em realizar um levantamento das caracterÃsticas operacionais do arame tubular AWS E71T-1 empregando CO2 puro e uma mistura de CO2 + argÃnio na soldagem convencional em tensÃo constante e na soldagem com corrente pulsada. Neste sentido, foram realizadas soldas, com arame tubular AWS E71T-1 de 1,2 mm de diÃmetro, em simples deposiÃÃo, na posiÃÃo plana, em corpos de prova de aÃo ABNT 1020 com dimensÃes de 150x50x8 mm. Empregou-se uma fonte eletrÃnica de soldagem e um sistema automÃtico de posicionamento da pistola. A tensÃo de soldagem foi mantida em 23 V. A relaÃÃo entre a velocidade de alimentaÃÃo do arame e a velocidade de soldagem foi mantida entre 20 e 23, para garantir uma Ãrea adicionada aproximadamente constante de 18 mm2. analisaram-se os efeitos do tipo de gÃs de proteÃÃo (CO2 e Ar + CO2 ), da distÃncia bico de contato peÃa (20 e 25 mm), dos nÃveis de corrente (160, 180 e 200 A) e sua natureza (convencional e pulsada) sobre o comportamento do arco, sobre a geometria da solda e sobre as caracterÃsticas econÃmicas do arame (taxa de fusÃo, taxa de deposiÃÃo e eficiÃncia de deposiÃÃo). Os resultados indicam que o tipo de gÃs de proteÃÃo afeta mais significativamente a transferÃncia metÃlica e a geometria da solda, exercendo pequena influÃncia sobre as caracterÃsticas econÃmicas do arame. Constatou-se tambÃm que o efeito da intensidade de corrente sobre a operacionalidade do arame tubular AWS E71T-1 depende sensivelmente do tipo de corrente (convencional ou pulsada). / The flux cored wire AWS E71T-1 has been used in the vast majority of its applications with pure CO2 as a shielding gas. A recent study demonstrated that it is possible to improve the metallurgical characteristics of the weld metal of the flux cored wire by the application of a mixture of CO2 and argon. However, information for this gas mixture hasnât been raised sufficiently concerning the operational performance of the wire using this gas mixture. It is known that the gas type also affects the metal transfer, the behavior of arc welding, the weld bead geometry, the deposition rate and the deposition efficiency of the wire within other characteristics of the welding process. The aim of the study consists in the realization of a survey of the AWS E71T-1 flux cored wire operational characteristics (economic characteristics of the welding consumable, geometric weld characteristics, arc stability and metal transfer). Due to this, bead on plate welding was performed using the flux cored wire AWS E71T-1 with a diameter of 1,2 mm, in flat position on samples of ABNT 1020 steel with a size of 150x50x8 mm. An electronic welding source and a positioning system were used. It was sustained a welding tension of 23 V. The relationship between the wire feed speed and the travel speed was kept constant between 20 and 23 to guarantee a deposit area of approximately 18 mm2. The influence of shielding gas (CO2 and Ar and CO2 ), the contact tube-to-work (TTW) (20 and 25 mm), the welding current (160, 180 and 200 A) and its nature (conventional and pulsed) were analyzed regarding the behavior of arc welding, the weld geometry and the economic characteristics of cored wire (fusion rate, deposition rate and deposition efficiency). The results showed that the shielding gas type has more influence on metal transfer and welding geometry and little influence on economic characteristics of the cored wire. It was also shown that the effect of the current intensity on the operationally of the flux cored wire AWS E71T-1 depends perceptibly on the current type (conventional or pulsed).

Made available in DSpace on 2014-06-11T19:27:13Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-02-01Bitstream added on 2014-06-13T19:35:06Z : No. of bitstreams: 1 moreira_af_me_ilha.pdf: 2273819 bytes, checksum: 1e78bc9d82277d9e226607de07b8a4a9 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / O objetivo deste trabalho é verificar a influência da atmosfera protetora nas características geométricas do cordão de solda, na susceptibilidade a formação de porosidades e inclusões, na microestrutura, na dureza e nas taxas de deposição e diluição do metal de solda obtido através das soldagens GMAW e FCAW, com arame sólido AWS E70S-6 e tubular AWS E309LT-1, respectivamente, visando otimizar o processo de recuperação por soldagem de turbinas Francis de aço carbono danificadas por erosão cavitacional. Para tanto, foram feitas deposições “bead on plate” com arames de 1,2 mm de diâmetro sobre chapas de aço carbono ASTM A-36. Utilizou-se como gás de proteção: Argônio puro, CO2 puro, misturas binárias Argônio/CO2, Argônio/O2 e uma mistura ternária Argônio/CO2/O2. No caso da soldagem FCAW, a taxa de deposição parece não ter estrita relação com o tipo de gás empregado, parecendo ser mais dependente da corrente de soldagem. Já parâmetros como largura, altura, penetração, taxa de diluição, nível de porosidades/inclusões e fração de ferrita parecem sofrer influência direta da composição química do gás de proteção empregado. No caso da soldagem GMAW, a taxa de deposição, largura, altura, penetração, taxa de diluição e nível de porosidades/inclusões demonstraram estar diretamente relacionados ao tipo de gás de proteção empregado. Não foi observada uma significativa variação nos valores de dureza do metal de solda obtidos com o processo FCAW devido a mudança na composição química do gás de proteção. Já os picos de dureza encontrados na ZTA para esse processo podem ser decorrentes da formação de carbonetos de cromo. No caso da soldagem GMAW, o que se pode observar foi uma queda na dureza desde o metal de solda até o metal de base. Os elevados valores de dureza do metal de solda para esse tipo de soldagem... / The goal of this study is to verify the influence of shielding gas composition in the geometric aspects of weld metals like width, height and depth, besides dilution and deposition rates. Besides this analyses were made upon the volumetric fraction of porosities/inclusions and upon the ferrite fraction to the austenitic weld metal. Additionally was withdrawn microhardness Vickers profiles from weld metal up base metal. Weld metals have been made with “bead on plate” deposition of wires AWS E309LT-1 and AWS E70S-6, both with 1,2 mm diameter, upon carbon steel ASTM A-36 plates by FCAW and GMAW welding process, respectively. The shielding gases employed were: pure Argon, pure CO2, binary mixtures of Argon/CO2, Argon/O2 and shielding gas containing Argon/CO2/O2. Related to the FCAW process, the deposition rate didn’t show a direct relationship with the chemical composition of shielding gas, being more dependent of the welding current. Parameters like width, height, depth, dilution rate, porosity/inclusion levels and ferrite fraction showed to keep a direct relation to the chemical composition of the shielding gas. To the GMAW process, deposition rate, width, height, depth, dilution ratio and porosity/inclusion levels maintained a direct relation to the chemical composition of shielding gas. It wasn’t observed a significative variation upon microhardness values of the weld metals produced with FCAW process because of the change in the shielding gas employed. In the GMAW welding, it was observed an abatement on the microhardness profile from the weld metal upto the base metal because, of, probably, the quenching increase in this area by the dilution of a metal with a high quantity of Manganese manganese coming from wire composition.

Orientador: Vicente Afonso Ventrella / Banca: Juno Gallego / Banca: José Roberto Berretta / Resumo: O objetivo deste trabalho é verificar a influência da atmosfera protetora nas características geométricas do cordão de solda, na susceptibilidade a formação de porosidades e inclusões, na microestrutura, na dureza e nas taxas de deposição e diluição do metal de solda obtido através das soldagens GMAW e FCAW, com arame sólido AWS E70S-6 e tubular AWS E309LT-1, respectivamente, visando otimizar o processo de recuperação por soldagem de turbinas Francis de aço carbono danificadas por erosão cavitacional. Para tanto, foram feitas deposições "bead on plate" com arames de 1,2 mm de diâmetro sobre chapas de aço carbono ASTM A-36. Utilizou-se como gás de proteção: Argônio puro, CO2 puro, misturas binárias Argônio/CO2, Argônio/O2 e uma mistura ternária Argônio/CO2/O2. No caso da soldagem FCAW, a taxa de deposição parece não ter estrita relação com o tipo de gás empregado, parecendo ser mais dependente da corrente de soldagem. Já parâmetros como largura, altura, penetração, taxa de diluição, nível de porosidades/inclusões e fração de ferrita parecem sofrer influência direta da composição química do gás de proteção empregado. No caso da soldagem GMAW, a taxa de deposição, largura, altura, penetração, taxa de diluição e nível de porosidades/inclusões demonstraram estar diretamente relacionados ao tipo de gás de proteção empregado. Não foi observada uma significativa variação nos valores de dureza do metal de solda obtidos com o processo FCAW devido a mudança na composição química do gás de proteção. Já os picos de dureza encontrados na ZTA para esse processo podem ser decorrentes da formação de carbonetos de cromo. No caso da soldagem GMAW, o que se pode observar foi uma queda na dureza desde o metal de solda até o metal de base. Os elevados valores de dureza do metal de solda para esse tipo de soldagem... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The goal of this study is to verify the influence of shielding gas composition in the geometric aspects of weld metals like width, height and depth, besides dilution and deposition rates. Besides this analyses were made upon the volumetric fraction of porosities/inclusions and upon the ferrite fraction to the austenitic weld metal. Additionally was withdrawn microhardness Vickers profiles from weld metal up base metal. Weld metals have been made with "bead on plate" deposition of wires AWS E309LT-1 and AWS E70S-6, both with 1,2 mm diameter, upon carbon steel ASTM A-36 plates by FCAW and GMAW welding process, respectively. The shielding gases employed were: pure Argon, pure CO2, binary mixtures of Argon/CO2, Argon/O2 and shielding gas containing Argon/CO2/O2. Related to the FCAW process, the deposition rate didn't show a direct relationship with the chemical composition of shielding gas, being more dependent of the welding current. Parameters like width, height, depth, dilution rate, porosity/inclusion levels and ferrite fraction showed to keep a direct relation to the chemical composition of the shielding gas. To the GMAW process, deposition rate, width, height, depth, dilution ratio and porosity/inclusion levels maintained a direct relation to the chemical composition of shielding gas. It wasn't observed a significative variation upon microhardness values of the weld metals produced with FCAW process because of the change in the shielding gas employed. In the GMAW welding, it was observed an abatement on the microhardness profile from the weld metal upto the base metal because, of, probably, the quenching increase in this area by the dilution of a metal with a high quantity of Manganese manganese coming from wire composition. / Mestre

No description available.

In the welding of more sensitive metals such as stainless steel, titanium and some specific nickel alloys, the presence and application of a protective gas is essential. Without the use of a nonreactive shielding gas, defects occur in or adjacent to the weld joint, which vary from light discoloration of the weld bead to the direct onset and propagation of cracks. The supply of shielding gas is usually via the welding tool. Unfortunately, when it comes to welding pipes, the problem arises when the root bead comes into contact with the oxygen present within the pipe. Since the shielding gas supplied from the welding tool has no possibility of penetrating into the pipe and protecting the melt from the oxygen, the result consequence will be defects in the weld bead. To prevent this from happening, the pipes are sealed before welding and the oxygen in the pipe is purged and replaced with protective gas. Due to the fact that pipe welding operations concern a vast spectrum of pipe dimensions, complications arise for the welding operator as the solutions available have a low degree of adaptability. Thus, the purpose of this project is to investigate the possibility of designing and developing a new method of supplying root gas protection that can be adapted to several pipe diameters. Field studies at welding companies resulted in the clarification of which diameter spans the root gas protection solution should comply with, the pipe diameter span to cater for was identified as 25-100 mm in diameter. Requests were also made regarding the robustness of the product, with expressed desire for the product to withstand the strenuous working environment often encountered during welding operations. Solution proposals were produced which later developed into six separate concepts. From these six concepts, one was selected as the foremost solution and further developed for construction. The concept was sketched out and reproduced using CAD and a model was made using 3D printers. The model showed a need for modifications as it was not of a sufficiently adaptable nature. A modified model was thus developed and manufactured using a 3D printer, this modified model showed better results of adaptation to different pipe diameters. Furthermore, a flow analysis of the gas as it enters via the root gas plug and into the pipe was conducted, to verify total distribution of the gas within the pipe. The material with which to construct the concept with will be silicone infused with additives to make it more heat resistant and more resistant to wear. However, the exact mixture of silicone and additives in question was not available for this project but is something that is intended for future work. The concept meets the specified requirements of being applicable to multiple pipe diameters, more specifically so meeting the wishes of those active within the industry, covering a pipe span of 25- 100 mm. / Vid svetsning av mer känsliga metaller såsom rostfritt stål, titan och vissa specifika nickellegeringar är närvaron och tillämpningen av en skyddsgas väsentligt. Utan nyttjandet av en icke reaktiv skyddsgas uppkommer defekter i eller intill svetsfogen, vilka varierar från lätta missfärgningar av svetssträngen till den direkta uppkomsten och propageringen av sprickor. Tillförseln av skyddsgas sker vanligtvis via svetsverktyget. När det kommer till svetsning av rör uppstår dessvärre problemet att rotsträngen kommer i kontakt med syret som finns på insidan av röret. Eftersom att den skyddsgas som tillförs från svetsverktyget inte har någon möjlighet att tränga sig in i röret och skydda smältan från syret kommer det resultera i en svetssträng med defekter. För att förhindra detta från att ske tätas rören innan svetsning och syret i röret ersätts med skyddsgas. Eftersom att de rör som skall sammanfogas förekommer i flera dimensioner uppstår komplikationer för svetsoperatören ty de lösningar som finns tillgängliga har låg anpassningsgrad. Därmed är syftet med detta projekt att undersöka möjligheten att designa och utveckla ett nytt rotgasskydd som kan anpassas till flera diametrar. Fältstudier hos svetsföretag resulterade i ett tydligt spann för vilka diametrar som bör tillgodoses med sagda rotgasskydd, detta spann av rördiametrar var 25-100 mm. Det uppgavs även önskemål om säkerställning av att produkterna är robusta nog att klara den påfrestande arbetsmiljö som ofta förekommer vid svetsning. Lösningsförslag lades fram vilket senare utvecklades till sex separata koncept. Från dessa sex koncept utsågs en som den främsta lösningen och togs vidare till konstruktion. Konceptet skissades upp i CAD och en modell gjordes i 3D-skrivare. Modellen visade upp behov på modifieringar då den inte var av tillräckligt anpassningsbar karaktär. En modifierad modell togs därmed fram och tillverkades i en 3D-skrivare, denna modifierade modell visade bättre prov på anpassning till olika  rördiametrar. Vidare gjordes en flödesanalys av gasen då den färdas in via rotgaspluggen, vilket visade att gasen fyller röret som önskat. Materialet som konceptet kommer tillverkas i är silikon med tillförda additiv för att göra det mer värmebeständigt och mer resistent mot slitage. Den exakta blandningen av silikon och additiv i fråga var dock inte tillgängliga till detta projekt utan är något som får gå till vidare arbete. Konceptet uppfyller kraven på anpassning till flera rördiametrar och möter mer specifikt även önskemålet från branschaktiva med dess spann på 25-100 mm.

This thesis analyzes the influence of process gases on the formation and the characteristics of process byproducts that emerge during additive manufacturing of an aluminum alloy belonging to the 2000 series.  In order to address the influence, four pure gases, argon, nitrogen, helium, and carbon dioxide, were used as a shielding gas on the same parameter sets.  The interaction of the laser beam with the powder bed under each shielding condition was recorded by a camera.  The humidity, particle size distribution, and chemistry of the spatters produced after each job was analyzed.  The chemistry of small cylinders printed, was determined.  The density of the produced cubic samples was determined following the Archimedes principle, as well as through the analysis of the  cross-section.   Lastly,  the  embedded  and  polished  samples  were  etched,  and  the penetration depth of the laser was determined.  Under argon and nitrogen shielding, the process looked the same and the produced spatters show similar results.  Under helium shielding, less incandescent spatters were seen, and the particle size distribution is smaller than under argon or nitrogen. Carbon dioxide resulted in the highest number of incandescent particles and a change of the color of the rays from red to yellow.  The chemical analysis shows that a slight increase of nitrogen in the spatters and the bulk material can be seen under nitrogen shielding.  Oxygen and hydrogen content was sim- ilar under argon, nitrogen, and helium shielding.  Carbon dioxide shielding resulted in the highest oxygen content in the spatter and the bulk material. The density is highest under helium shielding, and lowest under carbon dioxide shielding.  Under argon and nitrogen shielding, the density was similar.  The study concluded that the choice of a process gas is not an arbitrary one but should be selected with care. / Denna avhandling analyserar processgasernas påverkan på bildandet och egenskaperna hos process biprodukter som uppstår vid additiv tillverkning av en aluminiumlegering som tillhör 2000-serien. För att hantera inflytandet användes fyra rena gaser, argon, kväve,  helium  och  koldioxid  som  skyddsgas  på  samma  parameteruppsättningar. Interaktionen mellan  laserstrålen och  pulverbädden under  varje skärmningsförhållande registrerades  av  en  kamera.  Fuktigheten, partikelstorleksfördelningen  och  kemin  hos stänkarna som producerades efter varje jobb analyserades. Kemien hos de små cylindrarna  som  trycktes  bestämdes. Densiteten  hos  de  producerade  kubikproven  bestämdes enligt Archimedes princip, liksom genom analys av tvärsnittet. Slutligen etsades de inbäddade och polerade proverna och laserns penetrationsdjup bestämdes. Under argon- och kväveavskärmning såg processen likadan ut och de producerade stänkarna visar liknande resultat. Under heliumskärmning sågs mindre glödande stänk och partikelstorleksfördelningen är mindre än under argon eller kväve. Koldioxid resulterade i det högsta antalet glödande partiklar och en förändring av strålarnas färg från rött till gult. Den kemiska analysen visar att en liten ökning av kväve i stänkarna och bulkmaterialet kan ses under kväveavskärmning. Syre- och väteinnehållet var liknande under argon-,  kväve-  och  heliumskärmning. Koldioxidavskärmning  resulterade  i  det  högsta syreinnehållet i stänk och bulkmaterial. Densiteten är högst under heliumskärmning och lägst under koldioxidskärmning. Under argon- och kväveavskärmning var densiteten densamma. Studien drog slutsatsen att valet av en processgas inte är godtyckligt utan bör väljas med omsorg.

Conselho Nacional de Desenvolvimento Científico e Tecnológico / The process of welding with solid wire (GMAW) and cored wire (FCAW) processes that compete in quality, productivity and operational, need reliable information of its main features and applications for a given welding condition. Thus, the goal is to compare the capability of each process in the horizontal welding carbon steel ABNT 1020, varying the type of shielding gas on the same level of welding current and voltage to maintain a constant deposition rate per unit length. For this study we used the wire E71T-1 and ER 70S-6 under the shielding 100% CO2 gas and Ar +25% CO2 in two bands of four current and voltage ranges. We evaluated the stability of metal transfer mode and short-circuit capacity through income and presence of deposit discontinuity. In general, the process using a tubular wire had a higher deposition rate compared to solid wire, but with lower performance deposit. It was noted that, the same current range and with increasing voltage range, there was a change in transfer characteristics for both processes. With regard to straining of the weld beads, the solid wire bends showed better with lower voltage ranges. Cored wire for the values of runoff was similar, with a condition better than solid wire for higher values of welding voltage (region of predominance of metal transfer carried by the flow without short circuit). The shielding gas 100% CO2, for both processes, which was provided better performance and higher deposit with transfer voltage ranges with a predominance of short-circuit. / Os processos de soldagem com arame maciço (GMAW) e arame tubular (FCAW), processos que competem entre si em termos de qualidade, produtividade e operacionalidade, necessitam de informações seguras de suas principais características e aplicações para uma determinada condição de soldagem. Desta forma, o objetivo deste trabalho é comparar a potencialidade de cada processo na soldagem horizontal de aço carbono ABNT 1020, variando o tipo de gás de proteção sob um mesmo nível de corrente e tensão de soldagem, mantendo constante a taxa de deposição por unidade de comprimento. Para a realização deste estudo foram utilizados os arames E71T-1 e ER 70S-6 sob as proteções gasosas 100%CO2 e Ar+25%CO2 em duas faixas de corrente e quatro faixas de tensão. As características avaliadas foram a regularidade de transferência metálica no modo curto-circuito e a capacidade produtiva através do rendimento de depósito e presença descontinuidades. De maneira geral, o processo utilizando arame tubular apresentou maior taxa de deposição em relação ao arame maciço, porém com menor rendimento de depósito. Também se observou que, na mesma faixa de corrente e com a elevação da faixa de tensão, houve uma mudança nas características de transferências para os dois processos. Em relação ao escorrimento dos cordões de solda, o arame maciço apresentou melhores cordões com menores faixas de tensão. Para o arame tubular os valores dos escorrimentos foram próximos, tendo uma condição melhor que o arame maciço para maiores valores de tensão de soldagem (região de predominância de transferência metálica conduzida pelo fluxo sem curto-circuito). O gás de proteção 100%CO2, para ambos os processos, foi o que proporcionou melhor rendimento de depósito e maiores faixas de tensão com transferência com predominância de curto-circuito. / Mestre em Engenharia Mecânica

The diploma thesis deals with problems of laser welding in shielding gases. On the basis of theoretical knowledge in this thesis, was made welding an experiment of 10 samples of steel X5CrNi18-10 in two different shielding gases. Flow of shielding gases has been shown by schlieren method. On the samples of welding joints have been made mechanical tests (tensile test and hardness test). Welded joints were metallography evaluated and structure of them was confirmed by measurements on ferrite meter.

No description available.