Creep degradation of steam carrying vessels in the power generation industry is a concern that needs to be constantly monitored. The Weldcore® process has been earmarked as a potential method of creep sampling which will allow for thick-walled sections to be analysed. A component of the process involves plugging the resultant hole after removing a creep sample using a novel welding technique called friction hydro pillar processing. At the commencement of this study, insufficient data was available to warrant safe industrial application of the process. This research was conducted to evaluate the performance of 10CrMo910 friction hydro pillar process welds. The effects of downward force, stud taper angle, hole taper angle and hole base diameter on process response, defect population, static properties and dynamic performance were evaluated. The variation of downward force showed that higher forces produce significantly smaller defects and higher fatigue life. The occurrence of defects was linked to process parameters and geometry thereby identifying the correct parameters for safe use in the power generation industry. Flash formation was identified as an early indicator of weld defects and can assist with quality control in industrial applications. Methods of standardising the plunge depth and forge force were developed to identify the correct magnitudes for different geometries, without the need for testing. Defects were shown to populate specific regions of the weld and produce variations in fatigue life. Crack initiation sites were detected which will aid in identifying areas of focus in further research and development. Temperature measurements were linked to the occurrence of defects and crack initiation sites and have been identified as a method of identifying defective welds. The effects of process parameters and stud and hole taper angles on energy inputs and near interface temperatures were statistically evaluated. Downward force was shown to have the largest effect on energy input rates, total energy input and temperatures at the 11.5mm and 20.5mm positions. Smaller hole and stud taper angles produced lower energy inputs and were identified as more energy efficient than the larger taper angles. A regression model was also developed to predict the fatigue life of welds and can assist with critical process related decision making. A range of hole base diameters were identified which produced welds with low defect populations and fatigue performance similar to that of the parent plate. Larger hole base diameters were shown to produce significant defects along the hole bottom fillet, in the weld nugget and along the bond line. Temperature measurements of the larger diameter welds showed a delay in response and are attributed to a delayed contact of plasticised stud material with the sidewall. Welds with hole base diameters larger than 11mm produced unrepeatable and defective welds, and also required higher energy inputs making smaller diameters more desirable. Analysis of all welds in this study revealed that clearance and interfacial pressures characterise the quality of friction hydro pillar process welds, therefore models were developed to aid in critical decision making with respect to downward force and geometry. This study has successfully evaluated the effects of process parameters and geometry on the properties of friction hydro pillar process welds and thereby has increased understanding of the process.
| Identifer | oai:union.ndltd.org:netd.ac.za/oai:union.ndltd.org:nmmu/vital:9636 |
| Creators | Bulbring, Daniel Louis Hans |
| Publisher | Nelson Mandela Metropolitan University, Faculty of Engineering, the Built Environment and Information Technology |
| Source Sets | South African National ETD Portal |
| Language | English |
| Detected Language | English |
| Type | Thesis, Doctoral, PhD |
| Format | xxi, 294 leaves, pdf |
| Rights | Nelson Mandela Metropolitan University |
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