Made available in DSpace on 2014-06-11T19:27:11Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-11-04Bitstream added on 2014-06-13T19:55:28Z : No. of bitstreams: 1 barrosjunior_jfc_me_guara.pdf: 1817218 bytes, checksum: e69e6e1e02780c3a6051459aeafb5bfe (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Devido ao aumento da demanda no mercado de tubos de condução, houve a necessidade de um incremento na velocidade de soldagem na etapa interna, que possui uma defasagem em média de 10 pol./min em relação a etapa externa. Isto porque o processo trabalha com três arames na etapa interna pelo método de soldagem por arco submerso, enquanto o externo, com quatro arames. Como ação, a etapa interna foi aumentada para quatro arames a fim de equalizar a velocidade destas etapas. Porém, há a necessidade de se definir qual será a velocidade limite. Assim, neste estudo aplicado a tubos de condução, segundo a norma API 5L e grau X70, inicialmente, foi feita uma retirada de amostra de macrografia da solda para avaliar o alinhamento entre o cordão de solda interno e o externo e a sobreposição entre os cordões de solda. Posteriormente, foi realizada na porção da solda interna, os ensaios de dureza pelo método de Vickers e ensaio de impacto pelo método de Charpy, obtendo-se as curvas de transição. Com o auxilio do gráfico t 8/5 foram definidos os limites de velocidade de soldagem para aplicar na EPS (Especificação do Procedimento de Soldagem). Pode-se obter maior confiabilidade na decisão da variável velocidade de soldagem que irá contemplar na EPS e com menor quantidade de retirada de amostras, através dos limites e valores máximos e mínimos da dureza. Desta forma, a prática mostrou-se satisfatória e os resultados mostraram a faixa de velocidade para atender com segurança os limites de valores das propriedades mecânicas solicitados pela norma API 5L. / Due to increased in the demand for conduction pipes in the market, there has been a necessity to increase the welding speed in the internal phase, which has an average discrepancy of 10 inches / min when compared to the external phase. It happens because the process works with three wires in the internal step method following the submerged arc welding, while the external one uses four wires. As a consequence the internal step was increased to four wires in order to equalize the speed of these steps. There are need to define what the top speed limit is. Therefore this study is applied to conduction pipes, according to API 5L grade X70 and, at first, a sample was drawn from Macrographic solder to assess the alignment between the weld and the inside and the outside overlap between the weld. This was followed by the analyses of the inside portion of weld, the hardness test method for Vickers and impact test Charpy method, obtaining the curves of transition. With the help of graphic t 8 / 5 speed limits were set to apply to welding in WPS (Welding Procedure Specification). It is possible to achieve more reliability in the decision about variable welding speed that will include the WPS and the least amount of sampling through the limits and minimum and maximum hardness. Thus the practice was satisfactory and the results showed that the speed range meets the safety limits of values of the mechanical properties required by the standard API 5L.

Made available in DSpace on 2014-06-11T19:27:10Z (GMT). No. of bitstreams: 0 Previous issue date: 2012-03-02Bitstream added on 2014-06-13T19:14:22Z : No. of bitstreams: 1 dian_gh_me_guara.pdf: 1321697 bytes, checksum: 8fb3e8a60fe110f8d10e0fd186569bbf (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / O processo de soldagem por resistência elétrica de alta frequência (High Frequecy Electric Resistance Welding, HF-ERW) apresenta três tipos de fenômenos de soldagem. Quando os fenômenos tipo 1 ou tipo 3 são os predominantes no processo de soldagem, a retenção de óxidos na junta soldada é facilitada e a melhor qualidade da junta soldada é obtida quando o fenômeno tipo 2 é o predominante. Dentre os parâmetros de soldagem, o aporte de calor e a velocidade têm grande influência na determinação de qual fenômeno é predominante no processo e, consequentemente, na taxa de descontinuidades obtida. A fim de se avaliar como o aporte de calor e a velocidade de soldagem influenciam na tenacidade da junta soldada pelo processo HF-ERW, é proposto a realização de combinações entre esses parâmetros durante a produção de tubos de 13 3/8” de diâmetro externo, 0,380” de espessura da parede, norma de fabricação API 5L, grau do aço X56. Para avaliar os resultados, um estudo comparativo do ensaio de impacto Charpy com entalhe na linha de solda foi realizado. Para caracterizar o metal base e a junta soldada, foram realizadas análises de composição química, microestrutura, resistência mecânica, dureza e energia absorvida em ensaio de impacto Charpy. Das análises de caracterização, foi possível evidenciar o cumprimento de requisitos da norma de fabricação API 5L X56 e analisar aspectos principais da junta soldada. Por meio dos resultados de impacto Charpy na linha de solda, foi possível se avaliar a influência do aporte de calor e da velocidade de soldagem, sendo constatado que o aumento da velocidade é benéfico para a tenacidade da junta soldada. Com as análises realizadas também foi possível correlacionar os resultados obtidos com os fenômenos de soldagem / At the high frequency electric resistance welding, HF-ERW, the three types of welding phenomenon define the way to obtain a welded joint without oxides after the squeeze out. When welding phenomenon type 1 or 3 are predominant at the welding process, the retention of oxides at the welded joint is facilitated and the best quality occurs when type 2 is obtained. Among the welding parameters, the heat-input and the welding speed have great influence in what type of welding phenomenon is obtained at the welding, and, therefore, at the discontinuity rate. With the objective of evaluate how the heat-input and the welding speed influence the HF-ERW process it is proposed to combine these parameters during the production of 13 3/8” outside diameter, 0,380” wall thickness, API 5L standard, X56 steel grade, pipes. In order to analyze the results, a comparative study of the Charpy V-notch test at the welding line was done. The characterization of the base metal and welding was performed through the analysis of the chemical composition, tensile properties, hardness test, Charpy test and microestrutural evaluation. With the characterization analysis it was possible to certificate the accordance of the pipe produced with the API 5L X56 requirements and analyze the main aspects of the welded joint. By means of the results of the Charpy impact test at the weld line, it was possible to analyze the influence of the heat-input and welding speed at the HF-ERW process, in which it was verified that the increase of the welding speed improve the weld joint toughness. Through the analysis, it was also possible to correlate the results with the welding phenomenon

Orientador: Ângelo Carporalli Filho / Banca: Marcelino Pereira do Nascimento / Banca: Vicente Afonso Ventrella / Resumo: O processo de soldagem por resistência elétrica de alta frequência (High Frequecy Electric Resistance Welding, HF-ERW) apresenta três tipos de fenômenos de soldagem. Quando os fenômenos tipo 1 ou tipo 3 são os predominantes no processo de soldagem, a retenção de óxidos na junta soldada é facilitada e a melhor qualidade da junta soldada é obtida quando o fenômeno tipo 2 é o predominante. Dentre os parâmetros de soldagem, o aporte de calor e a velocidade têm grande influência na determinação de qual fenômeno é predominante no processo e, consequentemente, na taxa de descontinuidades obtida. A fim de se avaliar como o aporte de calor e a velocidade de soldagem influenciam na tenacidade da junta soldada pelo processo HF-ERW, é proposto a realização de combinações entre esses parâmetros durante a produção de tubos de 13 3/8" de diâmetro externo, 0,380" de espessura da parede, norma de fabricação API 5L, grau do aço X56. Para avaliar os resultados, um estudo comparativo do ensaio de impacto Charpy com entalhe na linha de solda foi realizado. Para caracterizar o metal base e a junta soldada, foram realizadas análises de composição química, microestrutura, resistência mecânica, dureza e energia absorvida em ensaio de impacto Charpy. Das análises de caracterização, foi possível evidenciar o cumprimento de requisitos da norma de fabricação API 5L X56 e analisar aspectos principais da junta soldada. Por meio dos resultados de impacto Charpy na linha de solda, foi possível se avaliar a influência do aporte de calor e da velocidade de soldagem, sendo constatado que o aumento da velocidade é benéfico para a tenacidade da junta soldada. Com as análises realizadas também foi possível correlacionar os resultados obtidos com os fenômenos de soldagem / Abstract: At the high frequency electric resistance welding, HF-ERW, the three types of welding phenomenon define the way to obtain a welded joint without oxides after the squeeze out. When welding phenomenon type 1 or 3 are predominant at the welding process, the retention of oxides at the welded joint is facilitated and the best quality occurs when type 2 is obtained. Among the welding parameters, the heat-input and the welding speed have great influence in what type of welding phenomenon is obtained at the welding, and, therefore, at the discontinuity rate. With the objective of evaluate how the heat-input and the welding speed influence the HF-ERW process it is proposed to combine these parameters during the production of 13 3/8" outside diameter, 0,380" wall thickness, API 5L standard, X56 steel grade, pipes. In order to analyze the results, a comparative study of the Charpy V-notch test at the welding line was done. The characterization of the base metal and welding was performed through the analysis of the chemical composition, tensile properties, hardness test, Charpy test and microestrutural evaluation. With the characterization analysis it was possible to certificate the accordance of the pipe produced with the API 5L X56 requirements and analyze the main aspects of the welded joint. By means of the results of the Charpy impact test at the weld line, it was possible to analyze the influence of the heat-input and welding speed at the HF-ERW process, in which it was verified that the increase of the welding speed improve the weld joint toughness. Through the analysis, it was also possible to correlate the results with the welding phenomenon / Mestre

Orientador: Tomaz Manabu Hashimoto / Banca: Marcelo dos Santos Pereira / Banca: Rosinei Batista Ribeiro / Resumo: Devido ao aumento da demanda no mercado de tubos de condução, houve a necessidade de um incremento na velocidade de soldagem na etapa interna, que possui uma defasagem em média de 10 pol./min em relação a etapa externa. Isto porque o processo trabalha com três arames na etapa interna pelo método de soldagem por arco submerso, enquanto o externo, com quatro arames. Como ação, a etapa interna foi aumentada para quatro arames a fim de equalizar a velocidade destas etapas. Porém, há a necessidade de se definir qual será a velocidade limite. Assim, neste estudo aplicado a tubos de condução, segundo a norma API 5L e grau X70, inicialmente, foi feita uma retirada de amostra de macrografia da solda para avaliar o alinhamento entre o cordão de solda interno e o externo e a sobreposição entre os cordões de solda. Posteriormente, foi realizada na porção da solda interna, os ensaios de dureza pelo método de Vickers e ensaio de impacto pelo método de Charpy, obtendo-se as curvas de transição. Com o auxilio do gráfico t 8/5 foram definidos os limites de velocidade de soldagem para aplicar na EPS (Especificação do Procedimento de Soldagem). Pode-se obter maior confiabilidade na decisão da variável velocidade de soldagem que irá contemplar na EPS e com menor quantidade de retirada de amostras, através dos limites e valores máximos e mínimos da dureza. Desta forma, a prática mostrou-se satisfatória e os resultados mostraram a faixa de velocidade para atender com segurança os limites de valores das propriedades mecânicas solicitados pela norma API 5L. / Abstract: Due to increased in the demand for conduction pipes in the market, there has been a necessity to increase the welding speed in the internal phase, which has an average discrepancy of 10 inches / min when compared to the external phase. It happens because the process works with three wires in the internal step method following the submerged arc welding, while the external one uses four wires. As a consequence the internal step was increased to four wires in order to equalize the speed of these steps. There are need to define what the top speed limit is. Therefore this study is applied to conduction pipes, according to API 5L grade X70 and, at first, a sample was drawn from Macrographic solder to assess the alignment between the weld and the inside and the outside overlap between the weld. This was followed by the analyses of the inside portion of weld, the hardness test method for Vickers and impact test Charpy method, obtaining the curves of transition. With the help of graphic t 8 / 5 speed limits were set to apply to welding in WPS (Welding Procedure Specification). It is possible to achieve more reliability in the decision about variable welding speed that will include the WPS and the least amount of sampling through the limits and minimum and maximum hardness. Thus the practice was satisfactory and the results showed that the speed range meets the safety limits of values of the mechanical properties required by the standard API 5L. / Mestre

Submerged arc welding (SAW) is often the method of choice in pressure vessel fabrication. This process features high production rates, welding energy and/or welding speed and requires minimal operator skill. The selection of appropriate parameters in SAW is essential, not only to optimize the welding process in order to maintain the highest level of productivity, but also to obtain the most desirable mechanical properties of the weld.<p> The focus of this study was to investigate the effect of welding speed on the properties of SA516 Grade 70. Plates of SA516 Gr. 70 steel 17 mm x 915 mm x 122 mm were submerged arc welded with a welding current of 700 A and welding speeds of 15.3, 12.3 and 9.3 mm/s. Following the welding; strength, microstructure, hardness and impact toughness of the specimens were examined. Charpy impact testing was performed according to ASTM E 23 on specimens notched in the weld metal (WM) and in the heat-affected zone (HAZ), to measure the impact toughness. Fractography was performed on broken specimens using optical and scanning electron microscopy in order to correlate the mechanisms of fracture with the impact toughness values.<p> The highest hardness values were in the coarse-grained HAZ followed by the WM with the lowest hardness in the parent metal (PM). The HAZ had higher impact toughness than the WM and PM for all welding speeds. The slowest welding speed (9.3 mm/s) obtained complete penetration and therefore produced the most visually sound weld. The fastest welding speed (15.3 mm/s) had the narrowest HAZ and showed good ductile-to-brittle transition behaviour for both the WM and HAZ specimens, but produced incomplete penetration defects. Welding speed had little affect on the notch toughness of the HAZ with only a 9 J rise in upper shelf energy and an 8 °C drop in the impact transition temperature (ITT) with increased welding speed from 9.3 to 15.3 mm/s. However, for the WM, there was a 63 J drop in the upper shelf energy but also a 41 °C improvement of the ITT between the 9.3 and 15.3 mm/s welding speeds.

Submerged arc welding (SAW) is often the method of choice in pressure vessel fabrication. This process features high production rates, welding energy and/or welding speed and requires minimal operator skill. The selection of appropriate parameters in SAW is essential, not only to optimize the welding process in order to maintain the highest level of productivity, but also to obtain the most desirable mechanical properties of the weld.<p> The focus of this study was to investigate the effect of welding speed on the properties of SA516 Grade 70. Plates of SA516 Gr. 70 steel 17 mm x 915 mm x 122 mm were submerged arc welded with a welding current of 700 A and welding speeds of 15.3, 12.3 and 9.3 mm/s. Following the welding; strength, microstructure, hardness and impact toughness of the specimens were examined. Charpy impact testing was performed according to ASTM E 23 on specimens notched in the weld metal (WM) and in the heat-affected zone (HAZ), to measure the impact toughness. Fractography was performed on broken specimens using optical and scanning electron microscopy in order to correlate the mechanisms of fracture with the impact toughness values.<p> The highest hardness values were in the coarse-grained HAZ followed by the WM with the lowest hardness in the parent metal (PM). The HAZ had higher impact toughness than the WM and PM for all welding speeds. The slowest welding speed (9.3 mm/s) obtained complete penetration and therefore produced the most visually sound weld. The fastest welding speed (15.3 mm/s) had the narrowest HAZ and showed good ductile-to-brittle transition behaviour for both the WM and HAZ specimens, but produced incomplete penetration defects. Welding speed had little affect on the notch toughness of the HAZ with only a 9 J rise in upper shelf energy and an 8 °C drop in the impact transition temperature (ITT) with increased welding speed from 9.3 to 15.3 mm/s. However, for the WM, there was a 63 J drop in the upper shelf energy but also a 41 °C improvement of the ITT between the 9.3 and 15.3 mm/s welding speeds.

<p>Solid state Friction stir welding (FSW) is of major interest in the welding of aluminium since it improves the joint properties. Many applications where Al-alloys are used are subject to varying load conditions, making fatigue failure a critical issue. In the scope of this thesis, the fatigue performance of friction stir welded AlMgSi-alloy 6082 has been investigated. Static and dynamic properties of different joint configurations and welds produced with varying process parameters have been determined. Microstructures of fractured surfaces have been studied to evaluate the effect of weld discontinuities on fatigue. The mechanical strength of the friction stir welds was set in relation to that of conventional fusion welds, and that of other FS welded Al-alloys.</p><p>The friction stir process produced aluminium butt welds with high and consistent fatigue strengths, which exceeded the strengths of similar fusion welded samples. A smooth weld geometry showed to be of great importance for the fatigue performance, favouring the friction stir welds. Welding speed in a tested range of 0.35-1.4 m/min had only a modest influence on the properties of the friction stir welds; properties were not deteriorating at the highest speed. The softening of the alloy around the weldline was modelled. A fair description of the hardness profiles across the weld was obtained. At a low and high welding speed a full and partial softening respectively was predicted, indicating that full softening is not required to obtain a flawless weld.</p><p>In case of friction stir overlap welds, tool design is even more important than in butt welding to secure weld quality. A broad tool shoulder with a concave pin end gave the best performance. In particular, the minimal influence on the sheet interface when welding with such a tool was beneficial for the fatigue strength. The stress distribution in overlap and T-type test specimens has been modelled. The stress intensity factors were determined. The corresponding crack propagation rates were in fair accordance with the experimental results. It was found that a simplified approach, developed to estimate ∆K for overlap spot welds, could be used also for friction stir overlap joints.</p>

Solid state Friction stir welding (FSW) is of major interest in the welding of aluminium since it improves the joint properties. Many applications where Al-alloys are used are subject to varying load conditions, making fatigue failure a critical issue. In the scope of this thesis, the fatigue performance of friction stir welded AlMgSi-alloy 6082 has been investigated. Static and dynamic properties of different joint configurations and welds produced with varying process parameters have been determined. Microstructures of fractured surfaces have been studied to evaluate the effect of weld discontinuities on fatigue. The mechanical strength of the friction stir welds was set in relation to that of conventional fusion welds, and that of other FS welded Al-alloys. The friction stir process produced aluminium butt welds with high and consistent fatigue strengths, which exceeded the strengths of similar fusion welded samples. A smooth weld geometry showed to be of great importance for the fatigue performance, favouring the friction stir welds. Welding speed in a tested range of 0.35-1.4 m/min had only a modest influence on the properties of the friction stir welds; properties were not deteriorating at the highest speed. The softening of the alloy around the weldline was modelled. A fair description of the hardness profiles across the weld was obtained. At a low and high welding speed a full and partial softening respectively was predicted, indicating that full softening is not required to obtain a flawless weld. In case of friction stir overlap welds, tool design is even more important than in butt welding to secure weld quality. A broad tool shoulder with a concave pin end gave the best performance. In particular, the minimal influence on the sheet interface when welding with such a tool was beneficial for the fatigue strength. The stress distribution in overlap and T-type test specimens has been modelled. The stress intensity factors were determined. The corresponding crack propagation rates were in fair accordance with the experimental results. It was found that a simplified approach, developed to estimate ∆K for overlap spot welds, could be used also for friction stir overlap joints. / QC 20101008

Conselho Nacional de Desenvolvimento CientÃfico e TecnolÃgico / O objetivo principal desse trabalho foi avaliar o efeito do procedimento de soldagem empregado, com foco na energia de soldagem, no tipo de chanfro empregado e na tÃcnica de soldagem utilizada, sobre o nÃvel e a distribuiÃÃo das tensÃes residuais resultantes em junta submetida à soldagem multipasse. Foi avaliado tambÃm o efeito da corrente e da velocidade de soldagem de forma isolada sobre estas tensÃes, bem como a correlaÃÃo desses resultados com a microestrutura e dureza encontrada. As tensÃes residuais foram medidas utilizando a tÃcnica de difraÃÃo de raios-x, atravÃs de um minidifratÃmetro para mediÃÃo em campo. As anÃlises metalogrÃficas foram realizadas na seÃÃo transversal da junta, atravÃs de microscopia Ãtica e microscopia eletrÃnica de varredura. Foram levantados os perfis de microdureza na seÃÃo transversal da junta. Os resultados mostraram que as tensÃes residuais originadas da soldagem multipasse na superfÃcie das amostras analisadas sÃo compressivas no metal de solda e trativas da ZAC. As tensÃes residuais encontradas na raiz das amostras analisadas se mostraram trativas tanto no metal de solda quanto na ZAC. A energia de soldagem apresentou uma relaÃÃo nÃo linear com as tensÃes residuais encontradas, sendo encontrado que o parÃmetro que apresentou maior influÃncia foi a velocidade de soldagem, o que representa um problema, pois geralmente tal parÃmetro à o menos controlado nas soldagens manuais. As amostras chanfradas em meio-v foram as que apresentaram os menores nÃveis de tensÃes residuais, devido a alÃvios de tensÃo gerados por deformaÃÃes plÃsticas geradas durante a soldagem, fato que nÃo ocorre nas amostras chanfradas em X. A tÃcnica da dupla camada mostrou-se uma ferramenta bastante Ãtil à soldagem do aÃo ASTM A516 Gr70, pois alÃm de promover o refinamento e revenimento da ZAC-GG das amostras soldadas, acrescentou tensÃes residuais compressivas ao longo de toda a superfÃcie analisada das amostras. As microestruturas e durezas encontradas nas juntas foram bem similares para todas as amostras, sendo a ferrita acicular encontrada no metal de solda uma das provÃveis causas da caracterÃstica compressiva das tensÃes residuais encontradas / The main aim of this work was to evaluate the employed welding procedure effect on the level and profile of the final residual stresses on a multipass joint, with emphasis in the welding energy, chamfer and used welding technique. It was also evaluated the effect of the welding current and speed on these stresses, as well as it was correlated the results with microstructure and microhardness. The residual stress measurement was accomplished through X-ray diffraction, using a minidiffractometer for measurement in field. Metallographic analysis was accomplished in the transverse section of the welded joint, using optic microscopy and scanning electron microscopy. It were determined the microhardness profiles in the traverse section of the welded joint. The results showed that the multipass welding residual stresses on the surface of the analyzed samples are compressive in the weld metal and tensile in the HAZ. In the weld root, the welding residual stresses are tensile as in the weld metal as in the HAZ. The welding energy showed a non-linear relationship with the founded residual stresses and it was observed that the most influential parameter was the welding speed, what can be a trouble, since this parameter is the less controlled in manual weldings. The semi-v chamfered samples were the ones that present the fewer levels of residual stresses, due to the stress relief created by plastic deformations during the welding, what do not occur in the X chamfered samples. The double layer technique showed that it can be used in the welding of ASTM A516 Gr70 steel, because, besides promote a refinement and a drawing back of the CG-HAZ, it increased compressive residual stress in the whole surface of the analyzed samples. The founded microstructures and microhardness were similar for all samples and it has believed that the acicular ferrite founded in the weld metal was one of the the main causes for the compressive characteristics of the welding residual stresses in the joints