1fronius usa / mike ludwig / aws shipbuilding conference 2011 / xx.xx.201x using the time twin...
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1 Fronius USA / Mike Ludwig / AWS Shipbuilding Conference 2011 / xx.xx.201x
Using the Time Twin Process to Improve Quality and Reduce Costs in High Deposition
Welding of Thick Section Aluminium
Mike Ludwig
Market Segment Manager Shipbuilding & Power Generation
Fronius USA - Welding Division
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Outline
/ Introduction
/ Technical Requirements
/ Approach
/ Results
/ Conclusions
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Acknowledgements
/ Work done by Fronius International R&D Group
/ Contributors:
/ Christoph Kammerhuber, International Shipbuilding Segment Manager
/ Stephen Egerland, International Pipeline/Offshore Segment Manager
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Liquefied Natural Gas (LNG)
/ Increasing importance of Natural Gas in Energy Sector
/ Storage a/o transport over long distances
/ Significant volume reduction by liquefaction
/ Approximately 1/600 of the original volume at temperatures of approx. – 162°C
/ Different methods to transport LNG
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Liquefied Natural Gas Containment Vessels (LNG)
/ Excellent method for LNG long distance transport
/ Globally applicable
/ Economically reasonable due to increasing storage capacities
/ Great engineering expertise and capital equipment for vessel construction
Source: Hyundai Heavy Industries
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LNG Vessel Construction Principles
Sphere (Moss Type) Membrane
© TOSAKA
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LNG Carrier – Membrane Containment Type
/ Base Material: 64FeNi (Invar 36©)/ Filler Material: NiMo28Fe4Cr (~ S
Ni1069 acc. to DIN EN ISO 18274)/ Peculiarities:/ Welding Process: Plasma Arc
Welding (PAW) and Gas Tungsten Arc Welding (GTAW)
/ ‘Difficult‘ to weld (Highly skilled welders needed)
/ Heat Input to be monitored accurately
/ Leak detection difficult to perform
9 Fronius USA / Mike Ludwig / AWS Shipbuilding Conference 2011 / xx.xx.201x
SPB > Self-supporting Prismatic-shape IMO B
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SPB > Self-supporting Prismatic-shape IMO B
/ Intermediate principle between Membrane and Spherical Type
/ Aluminum Alloy Construction
/ Wall Thickness: 25 mm≦
/ Benefits:/ Good Hull Stability/ Low Centre of Gravity/ Low Boil-Off Rate/ Good Maintenance Conditions
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LNG Carrier – Spherical Containment Type
/ Spheres as LNG Containments
/ Construction is based on the Kvaerner-Moss Type Principle
/ Aluminum alloys are used as base materials
/ Four-Tank Design for Cargo Operation Improvement
/ Storage Capacity slightly below Membrane Containments
Source: KAWASAKI Heavy Industries
© TOSAKA
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LNG Sphere Containment Construction
/ Benefits:/ Manufacturing may occur separately to
hull-construction
/ Increased use of semi-automated welding processes
/ Higher production rates
/ Improved test and repair conditions Source: KAWASAKI Heavy Industries
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Outline
/ Introduction
/ Technical Requirements
/ Approach
/ Results
/ Conclusion
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It was required to...
/ Improve welding process conditions:/ Improve weld quality/ Increase process efficiency/ Reduce production costs
/ Investigate High Performance Time Twin MIG Welding to replace manual MIG Welding and make Time Twin suitable for out-of-position welding applications in LNG Sphere Containment Manufacturing
Source: KAWASAKI Heavy Industries
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Project Goals:
/ To investigate and evaluate the welding of thick section Aluminium using the MIG single wire & Twin Time (Tandem) welding process in common welding positions and under common welding process conditions
/ To develop and design a special Single & Tandem Torch for the welding in reduced weld preparation on thick section Aluminium
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Outline
/ Introduction
/ Technical Requirements
/ Approach
/ Results
/ Conclusion
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From where we got started...
/ Traditional manual MIG Welding/ Usual wire diameters (1.6 mm)/ Highly Skilled Welders
/ Push-Pull Torches required/ CV Spray Arc / Quality limitations
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Equipment for single wire MIG welding trials
TPS 7200/9000 Welding System
Robacta Drive Torch
RCU 5000i
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Semi-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,0mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x 250 x 30mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 40/45 cm/min/ Welding Position: 1 F / Two layers
/ second layer > two weld beads
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Semi-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,0mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x 250 x 30mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 40/40 cm/min/ Welding Position: 1 F / Two layers
/ second layer > oscillated
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Semi-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,0mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x 250 x 30mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 22,5 cm/min/ Welding Position: 2 F / One layer
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Semi-Automated Single Wire MIG-Welding
/ New developed torch parts (gas nozzle, contact tip, wear parts)
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2.0 mm
/ Base Material: AA 5356 (EN AW AlMg5)/ Dimensions: 500 x 250 x 35 mm
/ (no preheating permitted)/ Shielding Gas: Ar70/He30/ Welding Position: 2G / Welding Speed: 60 cm/min/ Especially developed Welding
Characteristic
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Fully-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 1,6mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x 250 x 15mm
/ (no preheating permitted)
/ Shielding Gas: 100% Ar./ Welding Speed: 25cm/min/ Welding Position: 2 F / One layer > oscillated
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Fully-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 1,6mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x250 x 15mm
/ (no preheating permitted)
/ Shielding Gas: 100% Ar./ Welding Speed: 22,5 cm/min/ Welding Position: 3 F Vertical up/ One layer > oscillated
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Fully-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,4mm/ Base Material: AA 5083 (AlMg4,5Mn)/ Dimension: 500 x 150 x 25mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 60/40 cm/min/ Welding Position: 1 F / four layers > 8 weld beads
26 Fronius USA / Mike Ludwig / AWS Shipbuilding Conference 2011 / xx.xx.201x
Fully-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,4mm/ Base Material: AA 5083 (AlMg4,5Mn)/ Dimension: 500 x 150 x 25mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 38 cm/min/ Welding Position: 1 G / Two layers > oscillated
/ one layer from each side
27 Fronius USA / Mike Ludwig / AWS Shipbuilding Conference 2011 / xx.xx.201x
Fully-Automatic single wire MIG welding
/ Filler Wire: AA 5183 (AlMg4,5Mn) 2,4mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 500 x 150 x 15mm
/ (no preheating permitted)
/ Shielding Gas: Ar70/He30/ Welding Speed: 60/40 cm/min/ Welding Position: 1 G / Two layers
/ second layer > oscillated
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Metallographic Results of Single Wire MIG Welding Trials
Position 2G Position 3G
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Single Wire MIG Welding Procedure: 3G-Position
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2006 – The very first humble steps in Single-Wire MIG Welding / Manual welding torch on ‘quasi-similar‘ joint
geometry/ Wire diameter: AA 5183 ( 1.6 mm)/ Base material: AA 6061 (AlMgSi) / Thickness: 15 mm
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... and the results
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Next Step – Fundamental Investigations on Manual MIG
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The Tool and the Outcome
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Outline
/ Introduction
/ Technical Requirements
/ Approach
/ Twin Welding
/ Conclusion
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Time Twin – Tandem High Performance MIG Welding
LHSBLHSB
*LHSB = Local High Speed Bus
/ Fully Synchronised welding system.
/ 2 digital power sources/ 2 wire feeders/ 2 separate electrode potentials/ 1 high duty cycle welding torch / All linked by a high speed bus
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Equipment
Oscillation Unit
Tripod Unit
Time Twin Welding System
Time Twin Torch
RCU 5000i
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Time Twin High Performance Tandem Welding System
/ Commercially available Tandem Welding System
/ Especially shaped gas nozzle / Varying arc-gaps during the weld trial
series/ Column and Boom System for
mechanized torch motion/ Implementation of weaving motion / Trials started under using regular welding
characteristic
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Specific LNG Containment Narrow Gap Weld Sequence
/ Specifically developed for LNG sphere containment heavy wall applications
/ Considerable reduction of weld metal deposition rate
/ Considerable reduction of operation time
/ Limited suitability for semi-automated welding processes
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Modified Narrow Gap Design
Diagram with permission of Norrish, J. – ‘Advanced Welding Processes‘, © IOP Publishing 1992
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Tandem Welding – Electromagnetic Interferences
Source: UEYAMA, T., ‘Occurrence of Arc Interference andInterruption in Tandem Pulsed GMA Welding‘ IIW Doc. No. XII-1883-06
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Electromagnetic Interference – A Closer View...
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Improved Tandem MIG Welding Characteristic
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Advanced State of Research and Development
/ Specifically modified narrow gap gas nozzle, contact tips and wear parts
/ Excellent narrow gap root access/ Adjusted tip or arc gap assures high
process stability/ Stable and sound weld pool
controllability/ Appropriate nozzle cooling yields good
resistance against thermal impact
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New Developed Narrow Gap Tandem Torch
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Time Twin Welding in 3G Position
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Reducing the number of layers...
/ Total number of weld layers was required to be reduced from 8 (workshop-condition) down to 6
/ 7 front side + 2 rear side layers were achieved at the trials beginning using Time Twin High Performance welding in 3G-position
/ Continuous reduction of layer number could be obtained by improving welding conditions and -sequence
7 front side layer trial
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Final Weld Joint Configuration …
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Final Weld Sequence …
60
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Variables
/ Filler Wire: AA 5356 (AlMg5) 1,6mm/ Base Material: AA 5356 (AlMg5)/ Dimension: 1000 x 350 x 60mm / Preheating > 60°, interpass temperature 60°/ Shielding Gas: Ar70/He30/ Welding Speed: Target 7.5 ipm/ Welding Position: 3 G / six layers > oscillated
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…Pictorial Results
Metallographic Result
Front View Cap Layer1
2
3
4
5
6
Back face
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Weld Deposition Rates – 3G-Position Narrow Gap Time Twin Aluminum Welding
Number of Layer/ Weld
Deposition Rate lb/h
Leading ElectrodeWire Feed Speed
m/min
Trailing ElectrodeWire Feed Speed
in/min
Welding Speedin/min
1 / ~ 14.0 433 334 8.6
2 / ~ 10.4 334 236 7.1
3 / ~ 10.8 334 256 7.9
4 / ~ 6.5 197 157 7.1
5 / ~ 10.0 315 236 7.1
6 / ~ 8.6 275 197 7.1
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Conclusion
/ LNG aluminum alloy sphere manufacturing requires highest weld quality levels
/ Continuous increase in production rates requires a rise in welding process efficiency
/ Out-of-position single wire MIG GMAW has reached physical limits
/ Time Twin Tandem Welding was shifted towards being usable for out-of-position welding
/ Project requirements to improve quality and efficiency could be met entirely
/ Tailor-made welding power supply welding characteristics were used to cover the complete process range
/ Sophisticated welding torch engineering resolved joint design restrictions
/ Time Twin Process with narrow groove torch equipment proved excellent suitability for similar aluminum welding applications