metallurgical characteristics of double-sided arc welding
TRANSCRIPT
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Y.M. Zhang, A.T. Male, M. Jiang, S.ZhangUniversity of Kentucky
Lexington, Kentucky
P.XuLink-Belt Construction Equipment Company
Lexington, Kentucky
Metallurgical Characteristics of Double-Sided Arc Welding in High Strength Structural Steels
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Process Principle
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Process Characteristics
z Direction of Current Flowz Presence of Arc through-the-thickness of the Keyhole è continuous arc compensation through the thickness
z Deep Narrow Penetration Capability z Symmetric Heat Input and Minimized Distortion
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Energy Compensation Through Thickness
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Energy Distribution: Regular Plasma Arc
Plasma arc Plasma arc Efflux plasma
without keyhole with keyhole
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Arc Concentration in DSAW
without keyhole with keyhole
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Practical System
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Double-sided Arc Weld: Flat Positionwithout filler metal
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Double-sided Arc Weld: Horizontal Positionwithout filler metal
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Double-sided Arc Weld: Vertical-Down Positionwith filler metal
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Test Materials: Low Alloy High Strength Steels
ASTM A514 and SSAB Domex 100XF:•Widely used in Structural and Pressure Vessel Applications•Low Alloy High Strength (690 MPa (100 ksi) minimum yield strength) •Good Ductility, Toughness Formability and Weldability
ASTM A514: by US Steel, quenched and tempered (Q&T) steelDomex 100XF: by SSAB, thermo-mechanically control-processed (TMCP)
microalloyed steel, extremely fine grain structure of amixture of quasi-polygonal ferrite and granular bainite
Thickness: 10mm-thick (3/8”)
Steel Yield StrengthMPa (ksi)
Tensile StrengthMPa (ksi)
Total Elongation%
Reduction of Area%
ASTM A514 725 (105.0) 787 (114.0) 26.3 47.3
Domex100XF 760 (110.1) 826 (119.7) 26.0 -
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Welding Parameters
DSAW Parameters
“Bead-on-plate” weldDomex100XF
Butt joint, square groove weld
ASTM A514 Domex100XF
Plasma current 150 A 200 A 180 A
Double-sided arc current 100 A 110 A 110 A
Welding speed 90 mm/min 120 mm/min 140 mm/min
Plasma gas flow rate 6.0 cfh 4.5 cfh 5.0 cfh
Plasma shielding gas flow rate 35 cfh 35 cfh 35 cfh
Plasma orifice diameter 2 mm 2 mm 2 mm
Double-sided arc shielding gas flow rate 55 cfh 55 cfh 55 cfh
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Weld Cross-Sections
Bead-on-Plate, Domex 100XF. 2% Nital etch.
Butt Joint, Domex 100XF. 2% Nital etch.
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Weld Metal Structures
Weld metal microstructure of butt joint, square groove, double-sided arc weld in 10mm A514 plate.2% Nital etch.
Weld metal microstructure of butt joint, square groove, double-sided arc weld in 10mm Domex 100XF plate.2% Nital etch.
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Weld Metal Structures: GMAW
Weld metal microstructure of GMAW process in 10mm A514 plate. 2% Nitaletch.
Weld metal microstructure of GMAW process in 10mm Domex 100XF plate. 2% Nital etch.
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Comparison of Weld Metal and Unaffected Base Metal
Weld metal microstructure of DSAW in10mm A514 plate. 2% Nital etch.
Microstructure of unaffected base plate of10mm A514 plate. 2% Nital etch.
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Microhardness Traverse in DSAW Joint on A512
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Microhardness Traverse in DSAW Joint on on Domex 100XF
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Microhardness Traverse in GMAW Butt Joints
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Charpy V-notch Specimen
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Test WeldmentsTest Temperature
oC (o F)
CVN Impact Toughness of ½-size
SpecimenJoules (ft-lbs)
Equivalent Toughness of Full-
size Specimen*Joules (ft-lbs)
10mm A514Butt Joint
Square Groove
24 (75)19.0 (14.0) 28.0 (20.5)
19.0 (14.0) 28.0 (20.5)
19.0 (14.0) 28.0 (20.5)
-29 (-20)8.0 (6.0) 12.0 (8.8)
8.0 (6.0) 12.0 (8.8)
8.0 (6.0) 12.0 (8.8)
10mm Domex100XFButt Joint
SquareGroove
24 (75)41.0 (30.0) 60.0 (44.0)
110.5 (81.5) 161.0 (119.5)
104.5 (77.0) 153.0 (113.0)
-29 (-20)4.0 (3.0) 6.0 (4.5)
6.0 (4.5) 9.0 (5.5)
5.5 (4.0) 8.0 (6.0)
Charpy V-notch Impact Toughness Test Results
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Conclusions
z Symmetrical Weldz Deep Narrow Penetrationz Fine Equiaxed Grainsz Hardness: acceptablez Toughness: filler metal use
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Acknowledgement
z NSF Grant # 9812981z National Shipbuilding Research Programz Center for Robotics and Manufacturing Systems