Ingenieurwissenschaften und zugeordnete Tätigkeiten
Filtern
Erscheinungsjahr
- 2019 (17) (entfernen)
Dokumenttyp
Schlagworte
- Hybrid Laser Arc Welding (3)
- Bulging effect (2)
- High power laser beam welding (2)
- Hybrid laser-arc welding (2)
- Laser beam welding (2)
- Numerical simulation (2)
- Solidification cracking (2)
- Thermography (2)
- 3D Druck (1)
- 3D printing (1)
Organisationseinheit der BAM
Additive Fertigungsverfahren gewinnen aufgrund der schnellen, flexiblen und kosten-günstigen Fertigung von Bauteilen zunehmend an Bedeutung. Das Laserpulverauf-tragschweißen (LPA) wurde anfangs hauptsächlich als Beschichtungsverfahren ein-gesetzt. Diese Technologie bewerkstelligt aber auch das Reparieren von verschlisse-nen Bauteilen, sodass diese zeitsparend und ressourcenschonend erneuert werden können. Die hohe Aufbaurate, die flexible Pulverzusammensetzung sowie die hohe Endkonturnähe ermöglichen heutzutage die Entwicklung und additive Fertigung von neuen Materialien, wie zum Beispiel Nickel-Titan-Formgedächtnislegierungen.
The present work deals with the development of a strategy for the prevention of end crater defects in high-power laser welding of thick-walled circumferential welds. A series of experiments were performed to understand the influence of the welding Parameters on the formation of end crater defects such as pores, cracks, root excess weld metal and shrinkage cavities in the overlap area. An abrupt switch-off of the laser power while closing the circumferential weld leads to a formation of a hole which passes through the whole welded material thickness. A laser power ramp-down causes solidification cracks which are initiated on the transition from full-penetration mode to partial penetration. Defocusing the laser beam led to promising results in terms of avoiding end crater defects. Cracks and pores in the overlap area could be effectively avoided by using defocusing techniques.
A strategy for avoiding of end crater imperfections was tested on flat specimens of steel grade S355J2 with a wall thickness of between 8 mm and 10 mm and then transferred on the 10 mm thick pipe sections made of high-strength pipeline steel API5L-X100Q.
A novel approach for the reconstruction of an equivalent volumetric heat source from a known weld pool shape is proposed. It is based on previously obtained weld pool geometries from a steady-state thermo-fluid dynamics simulation. Hereby the weld pool dimensions are obtained under consideration of the most crucial physical phenomena, such as phase transformations, thermo-capillary convection, natural convection and temperature-dependent material properties. The algorithm provides a time and calibration efficient way for the reproduction of the weld pool shape by local Lamé curves. By adjusting their parameters, the identification of the finite elements located within the weld pool is enabled. The heat input due to the equivalent heat source is assured by replacing the detected nodes’ temperature by the melting temperature.
The model offers variable parameters making it flexible and adaptable for a wide range of workpiece thicknesses and materials and allows for the investigation of transient thermal effects, e.g. the cooling stage of the workpiece. The calculation times remain acceptably short especially when compared to a fully coupled process simulation. The computational results are in good agreement with performed complete-penetration laser beam welding experiments.
With global increases in clean energy demand, the natural gas is gaining in importance. Pipelines are the safest and most cost-effective way of transporting natural gas. Due to high transport volume and resulting high operation pressure, the demand for ultra-high strength steel grades such as X120 is very strong. As a result of the fact that these steels are produced by thermo-mechanical controlled processing, the welding process must be selected accordingly. Based on investigations, a high heat input such as by submerged arc welding process leads to softening in the weld metal and loss of strength whereas pure laser beam welding results in high cooling rates and deteriorate toughness of the weld metal. The objective of this research is to investigate the influence of heat input to mechanical properties of hybrid laser-arc welded pipeline steels of grade X120. Test specimens with a thickness of 20 mm could be welded without preheating in a single-pass with different welding velocities to observe the largest possible parameter window of the heat input. The achieved V-notch impact energy for hybrid laser-arc welded samples was 144±37 J at a testing temperature of -40 °C. With a tensile strength of 930±4 MPa the requirements of API 5L was achieved. To prevent gravity drop-outs at the slow welding speeds, an electromagnetic weld pool support system was used, which works contactless and is based on generating Lorentz forces. It was therefore possible to control the cooling rate in order to meet the requirements of the mechanical properties. By adapting the electromagnetic weld pool support to the laser and laser hybrid welding process, the application potential of these technologies for industrial implementation can be drastically increased.
Vermeidung von Schweißimperfektionen im Überlappbereich bei laserstrahlhybridgeschweißten Rundnähten
(2019)
Die Laserstrahl-Hybrid-Schweißtechnologie erweist sich in der schweißtechnischen Fertigung immer mehr als innovative Alternative gegenüber anderen Schweißverfahren. Obwohl das Laserstrahl-Hybridschweißverfahren viele wirtschaftliche Vorteile gegenüber herkömmlichen Schweißverfahren aufweist, wie z.B. große Einschweißtiefe und dadurch eine reduzierte Anzahl von Schweißlagen, geringe thermische Belastung des Grundwerkstoffes aufgrund reduziertem Wärmeeintrag, konnte das Schweißverfahren überwiegend für das Schweißen von Längsnähten demonstriert werden. Eine Vielzahl von Schweißaufgaben, z.B. beim Schweißen von Segmenten von Windkraftanlagen oder dem Orbitalschweißen beim Verlegen von Großrohrleitungen sieht vor, dass die zu schweißenden Bauteile mit einer Rundnaht zusammengefügt werden. Die schweißtechnische Herausforderung ist hier, dass beim Schließen einer Rundnaht mit der Entstehung eines fehlerbehafteten Überlappbereiches zu rechnen ist. Ein zentrales Problem im Überlappbereich einer laserstrahl- sowie laserhybridgeschweißten Rundnaht ist die Bildung von Imperfektionen wie Poren, Rissen sowie die Bildung eines Endkraters, welcher als geometrische Kerbe wirkt. Bisher liegen keine universellen Lösungen zur fehlerfreien Ausführung von geschlossenen Rundnähten beim Laserstrahl-Hybridschweißen vor. Diese Studie befasst sich mit der Entwicklung eines Verfahrens, mit dem die Entstehung von o.g. Schweißimperfektionen vermieden wird. Die Strategie der Prozessführung beim Schließen der Rundnaht sieht hervor, dass ein fehlerfreier Überlappbereich durch die Kontrolle der Erstarrungsbedingungen am Schweißnahtende erreicht werden kann. Die kontrollierte Wärmeführung wird durch eine Anpassung der Parameter von beiden beteiligten Schweißprozessen, dem Laserstrahl- sowie MSG-Schweißprozess realisiert.
Im Rahmen dieser Arbeit wurde eine Serie von Schweißversuchen an 9,5 mm dicken Rohabschnitten aus hochfestem Pipelinestahl X100Q mit Variation der Prozessparameter wie der Laserleistung, der Defokussierung des Laserstrahls sowie der Endkraterfüllzeit im Überlappbereich der Rundnaht durchgeführt. Nachfolgend werden die erzielten Ergebnisse dargestellt und diskutiert.
In this paper shortwave infrared (SWIR) thermographic measurements of the manufacturing of thin single-line walls via laser metal deposition (LMD) are presented. As the thermographic camera is mounted fixed to the welding arm, an acceleration sensor was used to assist in reconstructing the spatial position from the predefined welding path. Hereby we could obtain data sets containing the size of the molten pool and the oxide covered areas as functions of the position in the workpiece. Furthermore, the influence of the acquisition wavelength onto the thermograms was investigated in a spectral range from 1250 nm to 1550 nm. All wavelengths turned out to be usable for the in-situ process monitoring of the LMD process. The longer wavelengths are shown to be beneficial for the lower temperature range, while shorter wavelengths show more details within the molten pool.
Results of experimental investigations of the relationship between laser-hybrid welding process parameters, type of the filler metal and the mechanical properties of the welds made from 9% nickel cryogenic steel X8Ni9 are discussed. The results contribute to the development and conversion in the industrial practice a new laser beam-based welding technology for the automated manufacturing of LNG tanks. The remarkable heterogeneity in the chemical composition of the weld metal as well as an insufficient impact toughness could be indicated by using austenitic filler wire. The most promising results were achieved by applying 11%Ni filler wire, which is similar to the base material. A correlation between impact toughness and wire feeding speed could be shown. The highest impact toughness was 134 J at -196°C. The laser-hybrid welds passed the tensile test. The failure stress of 720 MPa with a fracture location in the base metal was achieved for all samples tested.
Single-pass Hybrid Laser Arc Welding of Thick Materials Using Electromagnetic Weld Pool Support
(2019)
Hybrid laser-arc welding process allows single-pass welding of thick materials, provides good quality formation of joints with minimal thermal deformations and a high productivity in comparison with arc-based welding processes. Nevertheless, thick-walled steels with a thickness of 20 mm or more are still multi-pass welded using arc welding processes, due to increased process instability by increasing laser power. One limitation factor is the inadmissible formation of gravity drop-outs at the root. To prevent this, an innovative concept of electromagnetic weld pool support is used in this study. With help of such system a stable welding process can be established for 25 mm thick steel plates and beyond. Sound welds could be obtained which are tolerant to gaps and misalignment of the welded parts. The adaptation of this system to laser and hybrid laser-arc welding process can dramatically increase the potential field of application of these technologies for real industrial implementation.
The presented study deals with the performing and mechanical testing of single pass hybrid laser-arc welds (HLAW) on 25 mm thick plates made of steel grade S355J2. One of the challenges have to be solved at full penetration HLAW of thick plates is the drop formation occurring due to the disbalances of the forces acting in the keyhole and on the melt pool surface. Such irregularities mostly limit the use of high-power laser beam welding or HLAW of thick-walled constructions. To overcome this problem, an innovative concept of melt pool support based on generating Lorentz forces in the weld pool is used in this work. This method allows to perform high quality welds without sagging even for welding of 25 mm thick plates in flat position at a welding speed of 0.9 m min-1. For the obtain of full penetrated welds a laser beam power of 19 kW was needed. A high V-impact energy of up to 160 J could be achieved at the test temperature of 0 °C. Even at the most critical part in the weld root an impact energy of 60 J in average could be reached. The tensile strength of the weld reaches that of the base material. An introduce of the HLAW process with electromagnetic support of the melt pool in the industrial practice is an efficient alternative to the time- and cost-intensive arc-based multi-layer welding techniques which are established nowadays for joining of thick-walled constructions.
The advantage of selective laser melting (SLM) is its high accuracy and geometrical flexibility.
Because the maximum size of the components is limited by the process chamber, possibilities must be found to combine several parts manufactured by SLM. An application where this is necessary, is, for example, the components of gas turbines, such as burners or oil return pipes, and inserts, which can be joined by circumferential welds. However, only a few investigations to date have been carried out for the welding of components produced by SLM. The object of this paper is, therefore, to investigate the feasibility of laser beam welding for joining SLM tube connections made of nickel-based alloys.
For this purpose, SLM-manufactured Inconel 625 and Inconel 718 tubes were welded with a Yb:YAG disk laser and subsequently examined for residual stresses and defects. The results showed that the welds had no significant influence on the residual stresses. A good weld quality could be achieved in the seam circumference. However, pores and pore nests were found in the final overlap area, which meant that no continuous good welding quality could be accomplished. Pore formation was presumably caused by capillary instabilities when the laser power was ramped out.