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In oil and gas industries, submerged arc welding is the only primarily used process to weld high thickness, large distance structural oil pipes. Welding process parameters play a significant role in determining the quality of a weld joint in submerged arc welding. In the present work, an attempt has been made to optimize the weld bead parameters: weld bead form factor, dilution, microhardness and diffusible hydrogen content for welding of structural pipe steel (API 5L X65 grade) by desirability function approach used by Derringer and Harrington. For design of experiments, response surface methodology had been used. Mathematical models for output responses had been developed in terms of welding parameters and checked for adequacy using t-test and analysis of variance (F-test). It was found that welding current was the most significant parameter controlling all the responses, and arc voltage had increasing effect on all the responses except microhardness. © IMechE 2013.

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Department of Mechanical Engineering

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Effect of welding parameters on bead profile, microhardness and H 2 content in submerged arc welding of high-strength low-alloy steel

Chemical and mechanical properties of the welded joint are greatly affected by flux composition. The resulting chemical compositions of C, Si, Mn, P and S in the weld metal have been studied using formulated fluxes. The constrained mixture design, extreme vertices design, has been used to formulate fluxes to study the effect of flux constituents. Regression models were developed for weld metal content in terms of individual flux constituents and their binary mixtures for submerged arc welding of high-strength low-alloy steel. From the results, it is found that CaF2 is the most significant flux constituent and Al2O3 is the second most significant constituent among individual mixtures. CaO-MgO and CaO-Al2O3 binary mixtures are the most effective to change weld metal content. Regression mathematical models have been checked for adequacy using t-test and analysis of variance (F-test). Flux mixtures' composition has been provided for optimum chemical composition of weld metal. © IMechE 2014.

Modeling flux chemistry for submerged arc weldments of high-strength low-alloy steel

Fluxes in submerged arc welding of high-strength low-alloy steels are not readily available, flux compositions are not clear and compositions are patented. This study aims at the design, development and optimization of flux for submerged arc welding of high-strength low-alloy steel. Extreme vertices design suggested by McLean and Anderson is used to formulate twenty-one fluxes to study the effect of flux constituents on tensile strength, percentage elongation, impact strength, diffusible hydrogen content and microstructure of the weld metal. Mathematical models for ultimate tensile strength, percentage elongation, impact strength and diffusible hydrogen content for welded specimens versus flux constituents have been developed. From the experiments, it is found that tensile strength and elongation are affected the most with Al 2O3 content, whereas CaO and CaF2 contents have significant effect on impact strength. Synergic binary effect of CaO·CaF2, CaO·MgO and Al2O 3·CaF2 mixtures is more than other binary mixtures on the mechanical properties. Developed regression models have been checked for adequacy using t-test for regression coefficients and analysis of variance (F-test) for whole regression equation. Finally, optimum flux composition giving optimum mechanical and microstructural characteristics is suggested. © 2013 IMechE.

Investigation on flux design for submerged arc welding of high-strength low-alloy steel

High carbon steels are more difficult to weld than low and medium carbon steels due to its high hardness because of the presence of the high carbon content in it which results in crack formation during the cold working. The present work aims at studying the mechanical behavior of high carbon steel welds with a variation of welding parameters and surface heat treatment processes and relating their effects on the mechanical properties of the material In this work, high carbon steel with 0.90 wt pet C is used as the specimen material. The specimens are prepared using different arc welding parameters followed by heat treatment in the furnace for 700°C, 800°C for 60 and 120 minutes. The mechanical properties of these specimens are measured and analyzed to estimate the effect of variation of process parameters.

Heat Treatment and Surface Engineering - Proceedings of Heat Treatment and Surface Engineering, HTSE 2013

Mechanical behavior of high carbon steel with varying welding and heat treatment parameters

The application of high strength low alloy (HSLA) steels has been limited by unavailability of suitable joining and filler metals in submerged arc welding (SAW) processes. The present work aims at the design and development of flux for Submerged Arc Welding of HSLA steel. In the work L8 array of Taguchi Design is used to formulate eight types of fluxes to vary basicity index (BI) from 1.26 to 2.81 and to study the effect of flux constituents and basicity index on tensile strength, microhardness and microstructure of the weld metal. Empirical models for ultimate tensile strength and microhardness at the centre of weld versus flux constituents and basicity index have been developed. From the experiments it is found that ultimate tensile strength increase with increase of basicity index with minimum at 1.26 increases upto 2.33 and then further decreases whereas opposite in case of microhardness which is highest at 1.26 and minimum at 1.9. Increase of CaO in the flux increases ultimate tensile strength but microhardness remains unaffected whereas increase of SiO2 decreases ultimate tensile strength but microhardness remains constant. Microhardness decreases critically with increase of CaF2. © (2013) Trans Tech Publications, Switzerland.

Materials Science Forum

Effect of flux constituents and basicity index on mechanical properties and microstructural evolution of submerged arc welded high strength low alloy steel

Safe operation of nuclear power plants is one of the major concerns and relies primarily on the integrity of the reactor pressure vessel. Neutron exposure induces temperature dependent embrittlement and can lead to loss of fracture toughness of reactor pressure vessel steel. Conventional fracture mechanics suffers from a serious limitation of non-transferability of fracture data from specimen level to component level as fracture resistance data obtained is largely geometry dependant. This difficulty is largely overcome by Gurson-Tvegaard-Needleman (GTN) model which models the drop in load carrying capacity of a material with the increase in plastic strain, considering nucleation, growth and coalescence of micro-voids in the material. However, determination of the model-parameters with experiments is extremely difficult and doubtful. Hence, a parametric study was undertaken to find out the effects of different parameters on material behaviour of reactor pressure vessel steel and to asses the parameter for best practical result with least metallographic study using a hybrid approach. The model parameters were finally verified by predicting ductile fracture in compact tension and three point bend specimen made from reactor pressure vessel steel. © 2011 Elsevier Ltd.

Materials and Design

Micromechanical modelling of reactor pressure vessel steel

Bimetallic welds made between ferritic steels and austenitic stainless steels are conventionally fabricated using arc welding procedures such as Tungsten Inert Gas, Metal Inert Gas, Shielded Metal Arc Welding and Submerged Arc Welding. However friction welding provides a new and unique solid state approach for joining many similar and dissimilar materials, which may not be possible to join by other welding techniques available without adding any external filler metal. This approach is mostly used in joining of dissimilar materials. The reason for increased utility being the absence of any external filler material which may otherwise add to the heterogeneity of the weld structure. In this paper, the fabrication and effect of friction welding parameters on mechanical-micro structural changes of bimetallic weld joints has been discussed. An attempt has also been made to relate the effect of friction welding parameters on the peak temperature values taken near faying surface and micro hardness changes measured in various zones of weld. © (2012) Trans Tech Publications, Switzerland.

Advanced Materials Research

Optimization of process parameters for friction welding of bimetallic welds

Bimetallic welds (BMWs) have been a necessity within the steam generators of nuclear power plants, where the heavy section low alloy steel components are usually connected to stainless steel primary piping systems. These welds represent zones with metallurgical discontinuities, which tend to localize the strains and cause failures. The other critical issues which must be taken care of while welding of bimetallic joints include solidification cracking, thermal fatigue and residual stresses in welds. The occurrence and severity of all these problems associated with bimetallic welds depend upon the type of welding process used along with the other variables like welding consumables, heat input etc. In shielded metal arc welding (SMAW), welding electrode consumables/coatings play an important role in deciding the weld metal quality. The development of welding electrode coatings is quite difficult due to very rapid complex reactions taking place during welding and the involvement of many controlled process variables. The present paper is an effort to highlight the general issues and challenges for the systematic and scientific development of welding electrode coatings for bimetallic welds. The experimental procedure contains three sets of coated electrodes having varying ferro-alloys, silica and carbon content. In the first set of electrodes, non-ferrous elements are also introduced into the weld metal through flux addition. Further, the welded joints are subjected to various tests and then evaluated to ascertain their mechanical as well as metallurgical behaviour.

Effect of electrode coatings on diffusible hydrogen content, hardness and microstructures of the ferritic heat affected zones in bimetallic welds

This work studied the ball indentation test at room temperature to characterize the local tensile properties of bi-metallic weld joints. The weld specimens used were fabricated by joining between SA 508 Gr. 3 ferritic steel and Type 304LN stainless steel with Alloy 82 buttering on the ferritic steel side and Alloy 82/182 weld metal. The test results showed that yield stress (YS) of weld metal was slightly higher than that of Type 304 and smaller than that of SA508 Gr.3, and ultimate tensile stress (UTS) of weld metal was similar as those of Type 304 and SA508 Gr.3 base metals. Also, the values of YS and UTS of buttering layer (Alloy 82) were nearly same as those of weld metal. Heat-affected-zones (HAZs) showed higher YS and UTS values compared to their base metals. © (2012) Trans Tech Publications, Switzerland.

Application of ball indentation technique for mechanical properties estimation of Bi-metallic weld

The application of High Strength Low Alloy (HSLA) steels has expanded to almost all fields viz. automobile industry, ship building, line pipe, pressure vessels, building construction, bridges, storage tanks. HSLA steels were developed primarily for the automotive industry to replace low-carbon steels in order to improve the strength-to-weight ratio and meet the need for higherstrength materials. Due to higher-strength and added excellent toughness and formability, demand for HSLA steel is increasing globally. With the increase of demand; other issues like the selection of filler grade and selection of suitable welding process for the joining of these steels have become very significant. This paper discusses the various issues regarding selection of suitable grade and selection of suitable welding process for joining of HSLA steels and issues concerning the structural integrity of HSLA steel welds.

Issues in welding of HSLA steels

Non-transferability of fracture data from specimen level to component level is a serious limitation of conventional fracture mechanics, as fracture resistance data obtained is largely geometry dependant. The difficulty is largely overcome by GTN model which models the drop in load carrying capacity of a material with the increase in plastic strain, considering nucleation, growth and coalescence of micro-voids in the material. However, determination of the modelparameters with experiments is extremely difficult and doubtful. Hence, a parameter-study has been done to find out the effects of different parameters on material behaviour to asses the parameter for best practical result with least metallographic study. The parameters were finally verified by predicting ductile fracture in a real life piping component. © 2010 Springer Science+Business Media B.V.

International Journal of Fracture

Micromechanical modelling of weldments using GTN model

Bimetallic welds (BMWs) play a critical and indispensable role in the primary heat transport piping system of nuclear reactors. The primary heat transport system itself is the critical part of a nuclear reactor. Any failure of this system can lead to very grave consequences, not only speaking of huge monetary losses resulting from non-utilization of the reactor setup, but also immensely valuable and irreparable loss of human life. This paper describes the experimental efforts towards estimation of Gurson material parameters of base metal and weld metal regions of a BMW so as to use the micromechanical modelling approach for addressing the structural integrity issues in BMWs. © IMechE 2008.

Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science

Estimation of Gurson material parameters in bimetallic weldments for the nuclear reactor heat transport piping system

The bimetallic welds (BMWs) play a critical and indispensable role in the primary heat transport piping system of nuclear reactors. The primary heat transport system in itself is the critical part of a nuclear reactor. Any failure of this system can lead to grave consequences, not only speaking of huge monetary losses resulting from non-utilization of the reactor setup, but also immensely valuable and irreparable loss of human life. The present paper is an effort towards identifying and understanding the problems affecting the BMWs and is as well an attempt to highlight the current issues in the structural integrity assessment of structures having these welds. The basic aim of this work is to provide a clear understanding of the current structural safety issues and their importance in underpinning the use of BMWs in modern nuclear reactors. © IMechE 2006.