Advanced Welding Processes: Technologies and Process Control

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Sliding particle stop Undeflected beam path High-energy density processes 163 Anode and operating parameters. These systems simplify parameter selection and may often be linked into integrated manufacturing cells. By using telecommunication data links, it is also possible to perform remote setting and diagnostics. Non-vacuum EBW Non-vacuum EBW (NVEB) has become more feasible as beam powers have increased. Production systems are in operation welding up to 6 mm thick aluminium and the development of systems for use in robotic installations is in progress. 8.4.7 Power sources for EBW Deflection coils Deflected beam path Drift channel 8.18 The Welding Institute (TWI) three-bend magnetic trap. The solid-state power source technology described in Chapter 3 may be applied to EBW power supplies to provide improved control and consistency. Inverter designs that offer high electrical efficiency are particularly suitable for these applications.
164 Advanced welding processes 8.4.8 Summary: EBW Electron beam welding has been used successfully for many years to produce high-quality deep-penetration welds with limited distortion. The advances which have been made in equipment design should enable the productivity of the process to be improved. Compared with arc welding systems, the capital cost of EBW equipment is high, but this must be evaluated against the potential improvements in quality and productivity. 8.5 Summary Three high-energy welding processes have been discussed in this chapter. Of these plasma keyhole welding is well established but probably under-utilized, electron beam techniques are highly developed and exploited in well-defined application areas, and laser welding is being applied in an increasing number of applications. The hybrid laser arc processes offer a combination of the benefits of laser and arc processes, which include increased travel speed and improved tolerance to joint fit-up. The features of the processes are summarized in Table 8.4. Table 8.4 Comparison of high-energy welding processes Feature Plasma keyhole Laser Electron beam Energy density 3 ¥ 10 10 3 ¥ 10 11 10 13 (W m –2 ) Thickness range (mm) Up to 12 Up to 20 Up to 200 Travel speed Higher than GTAW High Very high Materials All, but aluminium Most, but difficult Most, but not low weldable needs DCEP or on reflective vapour pressure, AC surface (e.g. Cu, e.g. Cd, Zn and Ag) coated metal System Simple; as for Highly Usually vacuum requirements automated automated system, x-ray GTAW plus screening screens and high safety interlocks level of automation Capital cost Slightly more than 10 to 50 times 10 to 50 times GTAW GTAW GTAW Running cost Low High Very high Cost of weld Depends on application
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Advanced welding processes i
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Advanced welding processes Technolo
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Contents Preface ix Acknowledgement
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Contents vii 10.4 Automated control
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Welding has traditionally been rega
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Acknowledgements I would like to ac
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1.1 Introduction Welding and joinin
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An introduction to welding processe
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Stage 1 Stage 2 An introduction to
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Slag deposit on weld surface An int
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∑ no heavy slag - reduced post-we
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Electro slag SAW multi wire SAW FCA
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Weld metal used (kg m -1 ) 40 35 30
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Advanced process development trends
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% consumed 70 60 50 40 30 20 10 Adv
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Advanced process development trends
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Mains input Power regulation Contro
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Welding power source technology 29
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Three-phase transformer Three-phase
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Mains input Welding power source te
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Off line storage Operator interface
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4.2.1 Improved toughness Filler mat
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Filler materials for arc welding 47
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Flat strip Solidified slag on weld
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Gases for advanced welding processe
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CVN impact energy (J) 200 150 100 5
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∑ argon plus 15-25% carbon dioxid
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25 23 21 19 17 15 13 11 9 7 20 18 1
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Ozone emission (ml min -1 ) 4 3 2 1
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Table 5.3 Continued Argon + 1 to 7%
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Advanced gas tungsten arc welding 7
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Power source Advanced gas tungsten
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Number of arc starts 35 30 25 20 15
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Water cooling 6.7 Dual-shielded GTA
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∑ low current: 0.1-15 A; ∑ inte
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Surface tension Surface tension Adv
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7.2.1 Globular drop transfer Metal
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Gas metal arc welding 103 projected
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Droplet forming 7.6 Drop spray tran
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Number of counts 100 80 60 40 20 0
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Metal cored Rutile Basic Self-shiel
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F d Fem F v F st F g 7.13 Balance o
Page 126 and 127: Gas metal arc welding 113 is the cu
Page 128 and 129: Stick out Dip transfer Pulse/spray
Page 130 and 131: Gas metal arc welding 117 V = M + A
Page 132 and 133: Voltage (V) 50 40 30 20 10 Gas meta
Page 134 and 135: Pulse current t p 7.23 Pulsed trans
Page 136 and 137: Gas metal arc welding 123 The mean
Page 138 and 139: Wire feed rate (m min -1 ) 11 10.5
Page 140 and 141: Gas metal arc welding 127 Improveme
Page 142 and 143: Gas metal arc welding 129 and a num
Page 144 and 145: Current (A) 500 400 300 200 100 0 G
Page 146 and 147: Pulse amplitude (A) 500 400 300 200
Page 148 and 149: Gas metal arc welding 135 otherwise
Page 150 and 151: High-energy density processes 137
Page 152 and 153: High-energy density processes 139 P
Page 154 and 155: Arc voltage 30 25 20 15 10 High-ene
Page 156 and 157: High-energy density processes 143 N
Page 158 and 159: Reflecting mirror Laser cavity Powe
Page 160 and 161: High-energy density processes 147 H
Page 162 and 163: Laser beam Gas lens Plasma control
Page 164 and 165: High-energy density processes 151 P
Page 166 and 167: High-energy density processes 153 M
Page 168 and 169: High-energy density processes 155 a
Page 170 and 171: High-energy density processes 157 l
Page 172 and 173: High-energy density processes 159 p
Page 174 and 175: 8.4.5 Practical considerations High
Page 178 and 179: 9.1 Introduction 9 Narrow-gap weldi
Page 180 and 181: 6-16 mm Parallel-sided with backing
Page 182 and 183: Water cooling Main Shielding-gas po
Page 184 and 185: Narrow-gap welding techniques 171 T
Page 186 and 187: 9.7 ‘Twist arc’ narrow-gap GMAW
Page 188 and 189: GMAW torch The NOW process GMAW tor
Page 190 and 191: Narrow-gap welding techniques 177 T
Page 192 and 193: 10.1 Introduction 10 Monitoring and
Page 194 and 195: Monitoring and control of welding p
Page 196 and 197: PROJECT: WELDING CODE : WELDING PRO
Page 198 and 199: TYPE TOUGHNESS TEST TYPE No. TEMP R
Page 204 and 205: Data RAM ADC I/O device Monitoring
Page 208 and 209: Current I(A) 150 140 130 120 110 Mo
Page 210 and 211: Table 10.5 Stability criteria Monit
Page 224 and 225: CCD camera Travel direction Torch M
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Monitoring and control of welding p
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Welding automation and robotics 219
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Table 11.1 Robot applications Weldi
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∑ evaluate alternatives; ∑ eval
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Option Manual metal arc Gas metal a
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Appendices Appendices 247
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Arc Metal arc Manual metal arc Resi
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Tensile strength Appendices 251 Des
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Appendices 253 Exx16 Basic low-hydr
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GMAW stainless steel c Wire feed sp
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Appendix 4 American, Australian and
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Appendices 259 Carbon Manganese ste
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Consumable type Features Applicatio
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Appendix 7 Plasma keyhole welding o
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References [1] British Standards In
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References 267 [40] Anon, 1989 ‘S
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References 269 [88] Boughton P and
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References 271 Century Conference (
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References 273 [178] Benn B, 1988
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References 275 [224] Philpott M L,
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References 277 [269] UK Patent 8411
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Activated TIG (A-TIG) 91, 97 adapti
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digital measuring systems 189-90 di
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high-frequency high-voltage arc ini
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current measurement 194-6 determina
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carbon dioxide 63-4, 64-6 chlorine
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