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Die hier vorgestellte Großanlage zur Prüfung und Simulation von Bauteil schweißungen (GAPSI 16) mit einer Maximalprüfkraft von ±16 MN erlaubt wirklichkeitsnahe Analysen des Bau teilverhaltens während des Schwei ßens. Ein fundamentaler Vorteil ge genüber konventionellen Universal prüfmaschinen ist, Momente während des Schweißens mittels acht unabhän giger Hydraulikzylinder in zwei Prüf tischen aufbringen bzw. registrieren zu können.
Derzeitige Forschungsvorhaben sind zum einen Spannungs- und Verformungsvorgängen während des Schweißens von Blechen und zum anderen Modellen gewidmet, womit Kenngrößen für Flammrichtarbeiten ermittelt werden können. Simulations versuche an Großproben tragen we sentlich zu höherer Aussagesicherheit bei, zumal konventionelle Prüfmetho den mit einfachen Kleinproben und auch Berechnungen nach der Finite Elemente-Methode (FEM) stets Rand bedingungen und zumeist größere Idealisierungen enthalten. Dagegen weist die Großprüfanlage GAPSI 16 mit angepaßten Probengeometrien und Spannkräften einen neuen Weg.
Up to the present, the thermomechanical loads during welding and subsequent cooling under design-specific shrinkage restraint resulting from the interaction between the materials and the structure have often not been taken into consideration approperiately for weldability assessment of components. As compared to previous investigations using small specimens this report presents component weld tests under varying intensities of restraint. Online records of the reaction forces and moments demonstrate in which way the intensity of restraint affects the reaction stresses and moments and their meaning for the evaluation of the load level in welded components.
Düring the past decades, weldability studies have predominantly been concentrated on the material and the welding process. In order to achieve a closer insight into the structural effects, component weldability tests have been performed by online monitoring of the reaction forces and moments. As a particular item, the effects of different strengths of the base and filier material on the reaction force and stress build up transverse to the welding direction have been studied at a specific structural restraint. As a most relevant result for practical welding it is demonstrated that the final reaction force and also the reaction stress level in the multilayer butt welds decreases with overmatch of the weld metal.
Is it reasonable to restrict ISO 3690 any longer to the determination of the weld metal hydrogen content of ferritic steel?
In what respect is the determination of the content of the diffusible and of the total hydrogen content, respectively, (still) merely a research task (supermartensite, duplex materials, austenite, magnesium, aluminium), or is there actually a demand in industry and is there already a first cause for monitoring in view of damage prevention, respectively?
Is there a need, arising from the development of materials and filler materials and from their intended applications, for more extensive standards dealing with hydrogen analyses for these materials?
Which parts of ISO 3690 could also be applied to any other metallic material/filler material, if necessary, and where would a complete alteration be required, respectively?
As an approach towards more rough industrial laser welding applications, the Nd:YAG laser welding process has been coupled to the plasma powder welding process for the first time. Process stabilities have been achieved by such hybrid welding which are even better than those known from previous coupling of the laser process with gas metal arc welding (GMAW), for instance.
The present contribution focuses on the technology and potentials of the novel laser hybrid welding technique and addresses the realisation and the perspectives for practical applications. The experimental results demonstrate that the new process coupling enables welding of austenitic stainless steels in the thickness range between 3 mm and 8 mm at various weld geometries and joint configurations and at welding speeds exceeding 2 m/min. In addition it has been proven that the laser plasma powder arc welding (LPPAW) technique can also be applied to out-of-position conditions. Continuous advancement of the welding equipment ensures a high gap bridging ability and levelling of misalignment due to higher powder feeding rates. The recent development of a new plasma powder torch even provides a higher efficiency of powder feeding and guarantees smoth weld surfaces. Up to the present, the investigations demonstrated that the novel laser plasma powder hybrid welding technique offers all perspectives for application in pipe fabrication, ship building and offshore as well as transportation industry.
The increasing application of supermartensitic steels for welded pipelines is an economical alternative to the hitherto used higher-alloyed materials in the North Sea oil and gas indus-try. Failure in such constructions must at any rate be excluded for economical and ecologi-cal reasons. The application of these steels for the transport of corrosive mixtures may, however, involve hydrogen pickup with subsequent hydrogen-assisted stress corrosion cracking. It is therefore necessary not only to assure the weldability, but particularly to have best possible knowledge of the service behaviour and of the failure risk. In order to ensure the transferability of test results to real joined components, innovative test methods are in-creasingly required to be incorporated into a closed test sequence. It will be demonstrated how it is possible to gain significant advantages from the direct comparison between ex-perimentally determined results from component weld tests on the one hand and material-specific data from small-scale tests on the other hand and numerical simulations. These data that have now been made available are of major importance for industrial applications and are considered to provide a sound basis for realistic lifetime assessments.
In the last decade, high-strength fine grained steels and welding consumables have gained a strong raise of application ranging from mobile cranes to bridge constructions. However, the cracking susceptibility of these steels increases significantly in correspondence with the achieved improvements in yield strength and the loss in plastic deformation reserves.
In order to determine this behavior a series of different standardized cold cracking tests has been developed. One remaining major problem of these tests is the uncertainty about the quantitative intensity of the restraint conditions as well as the corresponding welding residual stresses.
Consequently, the comparison of different tests and welding conditions as well as the transferability of the results onto real parts is difficult at best. The main topic of this paper is the analysis of the restraint conditions and their link with the welding induced residual stresses. The importance of the given standardized selfrestrained tests and first results about the transferability of
results onto real parts are discussed. The influence of the test specimen geometry on the restraint conditions of the test is investigated for a selected test with numerical Simulation using commercial FEA software. Additionally, the residual stresses caused by the welding process are measured and linked with the restraint conditions which are defined mainly by the geometry parameters.
Finally the transferability of the selected cold cracking test results is validated experimentally. The test results of a multilayer weld on high-strength fine grained steel of real size weldments are investigated. For these experiments a 16 MN large scale testing facility is used which is capable of applying the high reaction forces and clamping conditions found at large scale demonstrator parts.
The results show the importance of the quantitative knowledge of the restraint conditions and the welding residual stresses on the cold cracking resistance.
The purpose of the present study is to show the feasibility of examining hydrogen desorption in technical iron samples using neutron radiography at the ANTARES facility of the FRM II research reactor, Technische Universität München. It has been shown that this method is appropriate for in situ determination of hydrogen Desorption for concentrations as low as 20 ppmH. Experiments were carried out in the temperature range from room temperature up to 260 °C. Measurement was based on direct comparison between electrochemically hydrogen-loaded iron samples and hydrogen-free reference samples at the same temperature.
This enables the determination of hydrogen concentration as a function of time and temperature. Ex situ carrier gas hot extraction experiments using the same temperature–time profiles as the neutron radiography experiments have been used to calibrate the greyscale values of the radiographs to defined hydrogen concentrations. It can be stated that hydrogen desorption correlates with sample temperature.
Solid-state phase transformations and the evolution of thermal and elastic strains in novel low temperature transformation (LTT) weld filler materials in the near surface region are monitored in real time by means of an innovative experimental set-up at the PDIFF (powder diffraction) beamline at the synchrotron light source ANKA (Angströmquelle Karlsruhe) at the KIT (Karlsruhe Institute for Technology). The key components of the diffraction set-up are two fast microstrip line detectors, which enables the strain evolution to be followed as a function of time and temperature for a 0.5?s counting time. During controlled heating and cooling cycles, as well as during near welding cycles, the martensite–austenite–martensite phase transitions are analysed. The transformation kinetics are monitored during resistance heating of small chips of the pure LTT alloys and during gas tungsten arc welding of simplified LTT welds using a specially designed welding rig for in-situ studies on the diffraction instruments. Under the mechanically unconstrained condition allowing free thermal expansion and shrinkage, the LTT alloys are found to exhibit decreasing transformation temperatures Ac and MS and increasing phase fraction of retained austenite for increasing Ni content. The strain evolution during welding reveals increased compressive stresses upon welding, which is attributed to the martensite formation upon cooling, which counteracts the thermal contraction strains. Comparison of the transformation temperatures reveals higher values than in the pure LTT alloys, but no variation between the different alloys. On the one hand, this is attributed to preferred grain orientation affecting the diffraction measurements and the determination of the transformation temperatures. On the other hand, it is possible that with the different chemical compositions of the LTT alloys and the mechanical constraints during welding, the evolution of the residual strain and stress may vary and result in counteracting affects with respect to lowered martensite start temperatures.