Beruflich Dokumente
Kultur Dokumente
Comparisons
Supervisor
Dr. Vishvesh J Badheka, IWE
Associate Professor, Mechanical Engineering Dept
School of Technology,
Pandit Deendayal Petroleum University.
Presented By
Pritesh J. Prajapati
Ro.No- 13RME011
PhD Student, PDPU
1
Content of Presentation
PhD journey
Introduction.
GMAW
FCAW
MCAW
Gap Analyses.
Research Plan
Proposed Objectives
Material Selection.
Experimental Procedure.
Acknowledgement.
PhD Journey
Enrolled in July 2013
SEM
WORK DONE
DURATION
REMARK
Sem -I
Course work
1).Fundamentals of Welding (ME-704)
2).Advanced welding processes (ME-701)
3).Research Methodology (PET-701)
July-Dec
2013
Good
Sem -II
Jan-June
2013
Good
Sem -III
Experiment-I
July-Dec
2014
Very good
Sem -IV
Experiment-II
Jan-June
2015
Introduction
GMAW is an electric arc welding process
Fig.1
FCAW, has a hollow wire with flux in the center, Just as the name states, a Flux
Core.
The main difference between MIG welding and FCAW is, FCAW gets its shielding
from the flux core, so use at weld outdoors. MIG welding is the way the electrode is
shielded from the air.
Fig.2
6
The internal components of a metal cored wire are composed chiefly of the alloys,
manganese, silicon, and in some cases, nickel. chromium and molybdenum as well as very
small amounts of arc stabilizers such as sodium and potassium, with the balance being iron
powder.
Gap Analyses
Existing literature available in the area of the GMAW and FCAW. Most of research
papers published are the comparison of the solid wire with flux cored wire.
Metal cored wires are the latest development in the area of advances consumables.
There is general comparison of characteristics of wires (solid, flux cored and metal
cored) are available but effect of different wire on mechanical and metallurgical is
not reported.
Conventionally root run are being filled with the GTAW process because it has
excellent weld metal properties and subsequently passes with GMAW or SAW
depending on the size of the job.
In addition to the above mentioned detail there is very little research has been
carried out in the area of application of hybrid welds using GMAW, FCAW &
MCAW process.
Mechanical and metallurgical properties of solid, flux cored wires ,metal cored
wires are also will be compared with hybrid welds.
8
Hybrid Welds
Hybrid welds in which root and filler pass filled with different process.
Research Plan
Parameters
II
III
ROOT SIDE
GMAW
FCAW
MCAW
GMAW
FCAW
MCAW
FCAW
GMAW
GMAW
MCAW
MCAW
FCAW
SAMPLE ID
ROOT RUN
FILLER RUN
GMAW
GMAW
GMAW
FCAW
GMAW
MCAW
FCAW
GMAW
FCAW
FCAW
FCAW
MCAW
MCAW
GMAW
MCAW
FCAW
MCAW
MCAW
11
Fig.3
Proposed Objectives
Experiments are made to in single V (60) groove joint design for 10mm thick
SA516 Gr70 carbon steel plate using Solid wire (ER70S6), flux cored wire (E71T1C), and Metal Cored wire (E70C-6M) of 1.2 mm in diameter.
Establishment of Welding Parameters for welding SA516 Gr70 Carbon steel plate
using GMAW ,FCAW and MCAW process.
13
Material Selection
SA516Gr70 carbon steel materials are widely used in heavy fabrication application
in which cost saving factor and high strength are most important.
SA516 Grade 70 offers greater tensile and yield strength when compared to ASTM
SA516 Grade 65 and can operate in even lower temperature service.
Table 1. Mechanical properties of consumables
Metal Cored
Wire
Base metal
Solid Wire
(ER70S-6)
(E71T-1C)
Yield Strength
427 MPa
605 MPa
448 MPa
446.9 MPa
Tensile Strength
529 MPa
579 MPa
549 MPa
590.60 MPa
Elongation
26%
31 %
31 %
(Temp. C)
35 J (
30C)
(-30 C)
(-18C)
Shielding Gas
---
100% CO2
75% Ar-25%
CO2
Mechanical Properties
(SA516Gr70)
(E70C-6M)
24.8 %
---
---
14
Table 2. Chemical composition of the filler wire and SA516 Gr70 carbon steel material.
Contents
Solid Wire
(ER70S-6)
Flux cored
wire
Base metal
(E70C-6M)
(SA516Gr70)
(E71T-1C)
0.07
0.03
0.048
0.186
Si
0.86
0.56
0.582
0.322
Mn
1.44
1.29
1.375
1.112
0.014
0.011
0.014
0.014
0.008
0.005
0.012
0.009
Cr
0.025
0.04
0.023
0.030
Ni
0.014
0.02
0.014
0.026
Mo
0.002
0.01
0.001
0.019
0.002
0.02
0.004
0.001
Nb
N/A
N/A
0.002
Nil
Cu
0.15
0.01
0.015
0.033
15
Experiment Procedure.
16
Ar/CO2
Gas Mixer
Power Source Equipment
Standard
Gas
Cylinders
Fume
Extractor
SPM
Head
Welding
Torch
Fig.4 Above setup available at PDPU( Research work carried out under sponsored project of
Department of Science and Technology (DST), New Delhi)
Experimental Condition
Base metal
: SA516Grade70
Size
: 30010010 mm
Joint Design : V- groove (60 angle, Root Gap= 04 mm)
Wire Type : 1.2 mm Solid (ER70S6), Flux cored (E71T-1C/M), MetalCored(E70C-6M)
Welding Variable:
a)
Normal Fe mode
b)
Welding Current -200 A
c)
Welding Voltage 28 V
d)
Travel Speed 200mm/min
e)
Nozzle to Plate Distance -15 mm
f)
Electrode Extension -8 to 10 mm
g)
Shielding Gas -90%Ar + 10% CO2
18
Fig.5 Joint Design
FF
FS
FM
Carbon steel plate SA516Gr70 welded using FF shows that both root pass and filler
pass filled with flux cored wire.
FS indicate Hybrid welds in which root pass filled with flux cored wire and filler
pass with solid wire.
FM indicate Hybrid shows that root pass filled with flux cored wire and filler pass
with metal cored wired.
19
ID
Current in Amp
Welding
speed in
mm/min
Voltage in Volt
Set
1 (*)
2 (*)
Actual
Avg.(*)
Set
1 (*)
2 (*)
Actual
Avg.(*)
Set
Cal.
Cal.1 (*)
Cal.2 (*)
Actual
Avg.(*)
FF
200
273
282
277.5
28
27.9
28
27.95
200
1.68
2.28
2.36
2.32
FS
200
234
272
253.0
28
27.9
28.1
28.00
200
1.68
1.95
2.29
2.12
FM
200
228
271
249.5
28
27.9
28
27.95
200
1.68
1.90
2.27
2.09
1: First Trial
2: Second Trial
.
ctual (*): Values recorded by online data monitoring system (During Welding).
KJ/mm
Where,
V- Voltage,
I- Current,
S- Welding Speed
-Welding Efficiency 0.9
20
Angular Distortion
Dial Indicator
Filler run
Temp.
2.68
420
394
2.66
367
411
389Co
1.72
287
358
322.5 Co
Vertical
Horizontal
Displacemen Displacement
t Z in mm
X in mm
Welding
process
FF
4.66
100
FS
4.98
100
FM
3.94
100
407.0 Co
Contact type
thermocouple
(K-Type- Nibase
,chromel & alumel)
5
% Angu Dist
Avg. Peck
Temperature
4
3
2
1
0
FF
FS
Consumables
FM
Macro preparation
The test specimen were cut from the welded plate after removing run on and run
off.
FF
FS
Fig.9
FM
23
Position
FF
3 X 15
A/B
FS
3 X 15
A/B
FM
3 X 15
A/B
Observation
Miner defect are
reported and
accepted within
standard
FF
FS
FM
24
25
Destructive Testing
Table 6. Tensile Test Specimens
Sample Id
Remarks
FF
FS
FM
26
Set of
Experiments
Yield
Strength
(MPa)
Avg. Yield
Strength
(MPa)
387
FF
359
385
568
Broken from
parent
559
Broken from
parent
562
379
382
Broken from
parent
619
375
3
565
517
388
FM
Observation
519
382
2
Avg. Tensile
Strength
(MPa)
611
330
FS
Tensile
Strength
(MPa)
555
Average yield strength and tensile strength values are higher for FS hybrid weld.
27
TS in MPa
YS in MPa
600
420
400
380
360
340
320
300
580
560
540
520
500
FF
FS
Consumables
FM
FF
FS
FM
Consumables
28
FS
Set of
specimen
%
Elongation
25
21
08
22
20
FM
% Elongation
26
30
25
20
15
10
5
0
Avg. %
Elongation
23
15
23
FS
FM
Consumables
29
568.00
FM
558.20
Joint Efficiency in %
96
96
95
Joint Efficiency
100
95
90
85
80
FF
FS
FM
Consumables
FF
FS
FM
Face bend
Root Bend
Set. 1
Set. 2
Remarks
Pass
Pass
Pass
31
Impact Test in J
Welding
process
set of specimen
set of specimen
II
II
Avg.
Weld
FF
46
44
38
43
32
FS
44
50
52
49
26
FM
20
24
18
21
24
60
55
50
45
40
35
30
25
20
15
10
WELD
HAZ
FF Consumables
FS
FM
Avg.
HAZ
III
38
36
35
22
22
24
28
22
25
Equipment
Load
Dwell Time
Objective
: ESEWAY-4000.Modal-4302
: 10 Kg & 300grm
: 15 Sec.
: 20 X
FF
FS
FM
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
HV 10
280
265
250
235
220
205
190
175
160
145
130
115
100
Dist. from Center of weld to both side
Root side
Filler side
270
255
240
FF
HV 10
225
FS
210
195
FM
180
165
150
-5
-4
-3
-2
-1
34
FF
FS
FM
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
HV 0.3
400
385
370
355
340
325
310
295
280
265
250
235
220
205
190
175
160
145
130
115
100
Dist. from Center of weld to both side
HV 0.3
Root side
-5
-4
-3
-2
-1
Filler side
FF
FS
FM
35
Content
in %
Filler
FS
Wire
Welded
Sample
Carbon
0.07
0.112
Manganese
1.44
1.510
Silicon
0.86
= increased and
0.618
FM
Filler Wire
Welded
Sample
Filler Wire
Welded
Sample
0.03
0.092
0.048
0.108
1.29
1.415
1.375
1.309
0.56
0.674
0.582
0.391
From above table , C-Mn-Si for FS welds metal is higher compared to filler metal.
In second cases, C-Mn % for FF welds metal is higher compared to filler metal, while Si is
low record. C for FM weld higher while Mn-Si is lower compared to filler metal.
36
From table 10, in some cause % for Manganese and % of silicon in weld metal is
reduced as compared to filler wire because of all this element react with oxygen
strongly during welding.
The loss of manganese and silicon may be caused by oxidation reactions in the
weld pool: [20]
Carbon, decreases. the ductility, formability, weldability and increases the strength
and hardenability.
Manganese slightly increases the strength of ferrite, and also increases the hardness
penetration of steel in the quench by decreasing the critical quenching speed. This
also makes the steel more stable in the quench
Silicon is used as a deoxidizer in the manufacture of steel.
It slightly increases the strength of ferrite, and when used in conjunction with other
alloys can help increase the toughness and hardness penetration of steel.
37
(c) Microstructure of
Top run
Normal
weld
Hybrid
weld
(d) Microstructure of
Middle run
(g) Microstructure of
PM &HAZ Right
(interface)
38
(c) Microstructure of
Top run
Hybrid
weld
(d) Microstructure of
Middle run
(c) Microstructure of
Top run
Hybrid
weld
(d) Microstructure of
Middle run
(g) Microstructure of
Root run
(f) Microstructure of
Middle run (50 X)
(h) Microstructure of
PM &HAZ
Right (interface)
The properties of the steel depends upon the microstructure. Decreasing the size of the
grains and decreasing the amount of pearlite improve the strength, ductility and
toughness of the steel
Microstructure investigation reflects the extremely fine grain structure of weld and as
well HAZ of FS weld.
It has two major constituents, which are ferrite and pearlite.
Its major components include allotriomorphic ferrite, Widmansttten (called side plate
ferrite) ferrite, and acicular ferrite.
The dark regions are the microstructure is the pearlite. it is made up from a fine
mixture of ferrite and iron carbide.
The light coloured region is the ferrite. boundary ferrite is called allotriomorphic
ferrite.
41
FF sample
FS sample
Figure13. Fracture morphology (SEM image) of tensile specimen fractured at room temperature, (a) FF sample,
(b) FS sample. (C) FM sample. The inclusion is indicated by the arrow. The EDAX spectra of the inclusions are
shown in Fig
42
FM sample
Small spots within the ferrite grains. These inclusions are silicon oxides and manganese
oxides, and sulphides etc.
The difference in composition of the inclusions is due to the different sources of the
inclusions.
In MAG, the Impurities mainly arose from the shielding gas. In FCAW, the impurities
mainly arose from the ux and shielding gas. [18]
43
Scanning Electron
Microscope - PDPU
Image Analyser
ERDA, Baroda
Model: Olympus
44
CONCLUSIONS
The angular distortion is higher with flux cored wire compare to hybrid weld.
Pick temperature reported with flux cored wire is higher compare to hybrid weld
which shown that high hear input with welding with flux cored wire.
Yield strength and tensile strength values are higher for with FS hybrid weld.
Percent elongation is higher for flux cored wire as compare to hybrid welds
During tensile test all specimens failed from parent material; means welded joints
are stronger then parent metal.
Samples welded with different consumables shows good integrity of welded
joints during bend test.
Excellent impact toughness of the weld metal reported for the FS hybrid welds
compared to other cases.
Higher macro and micro hardness value reported for flux cored welds compare to
others hybrid welds.
Weld metal microstructure confirm the presence of allotriomorphic ferrite,
Widmansttten ferrite, and acicular ferrite in the weld metal.
45
While comparing the mechanical properties of the FF welds with FS and FM. It was
found that FS weld is better compared to others in terms of YS, TS JE and weld
impact. This may be due to the externally fine microstructure (ferrite,
Widmansttten ferrite, and acicular ferrite) developed.
Additionally, it is future conform through the weld metal chemical analysis as
shown in table 9.it was found that C-Mn-S for FS weld metal is higher compared to
filler metal.
46
Paper submitted
1.International Journal of Pressure Vessels and Piping (ELSEVIER).
Impact Factor: 1.532,Date-26/12/2014, DC ON 12/12/2014
Title: The effect of welding consumables on the Mechanical and Metallurgical
properties of carbon Steel Material.
Current Status: Paper under review.
2. Journal of Pressure Vessel Technology ,ASME
submitted on Date-13/04/2015
Reviewer 1:
Originality
Acceptable
Significance
Acceptable
Scientific relevance
Acceptable
Completeness
Acceptable
Acceptable
Organization
Marginal
Clarity of Writing
Marginal
Marginal
Yes
No
No
Yes
Yes
Yes
Recommendation
48
Reviewer 2:
Originality
Acceptable
Significance
Acceptable
Scientific relevance
Acceptable
Completeness
Marginal
Marginal
Organization
Clarity of Writing
Clarity of Tables, Graphs, and Illustrations
Acceptable
Poor
Marginal
In your opinion, is the technical treatment plausible and free of technical errors?
Yes
Yes
No
Yes
Yes
No
Recommendation
This paper is Not Acceptable (Revision and resubmitted required) . The quality of the
paper is Average.
49
(Delivered on 10/10/2013)
(Delivered on 27/01/ 2014)
(Delivered 15th May 2014)
(Delivered 29th Des 2014)
(will be deliver before 11nd June2015)
References
1.
2.
3.
4.
5.
American Welding Society - Welding Hand book, Welding Processes, Eighth Edition - Vol.II, pp 110, pp 157-190.
American Society of Metals Handbook, Vol. 6 Welding, Brazing and Soldering, Published in 1993, pp 582-583.
www.esabna.com, "Advantages and Disadvantages of metal cored wire".
Nasir Ahmed, "New development in advance welding", Pub. Wood Head publishing limited Cambridge, England; pp 23.
Stanley E. Ferree, Michael S, Sierdzinski, "Stainless steel metal cored wires for welding automotive exhaust systems" ESAB
Welding and Cutting Products, Hanover (PA) USA. Svetsaren nr i , 2000, pp 15-18.
6. Kevin A. Lyttle, Praxair, Inc Senior Development Associate; "Metal Cored Wire: Where Do They Fit In Your Future?" Reprinted
from Welding Journal, Oct. 1996, pp 35-38.
7. www.esabmanualcom, "Flux Core arc Welding, ESAB".
8. David Widgery; Tubular wire welding, Jaico Publishing House.
9. Washington alloy co. www.weldingwire.com.
10. Avesatar welding www.avestarwelding.com.
11. BOC, IPRM 2006: Section 4: Welding processes.
12. BOC, AU: IPRM 2007: Section 8: Consumables.
13. M. Suban, J. Tusek, "Dependance of melting rate in MIG/MAG welding on the type of shielding gas used", Journal of Materials
Processing Technology 119 (2001), pp 185-192.
14. American Society of Metals Handbook, Vol. 6 Welding, Brazing and Soldering, Published in 1993, pp 163-174.
15. Tom Myers,"Choosing a shielding Gas for FCAW", A senior application engineer, The Lincoln Electric Co; Cleveland, Ohio.
16. John Norrish, -Advanced welding processes technologies and process control", Pub. Wood.
17. Head publishing limited Cambridge", England pp 108.
18. V. V. Vaidya, "Theory and practice of shielding gas mixtures for semiautomatic welds", Director, welding Technology and Business
Development, Air Liquide Canada Inc., Canada.
19. M Menzel, "The influence of individual components of an industrial gas mixture on the welding process and the properties of
welded joints". Linde Gas Poland; Welding International 2003 17 (4) 262-264.
20. .S. Mukhopadhyay and T.K.Pal.; "Effect of shielding gas mixture on gas metal arc welding of HSLA steel using solid and flux-cored
wires". Welding Technology Centre, Metallurgical Engineering Department, Jadavpur University, Kolkata.
21. AMOS DAVIS, business development manager, "Optimizing Metal Cored Performance" Hobart Brothers Company, Feb 1, 2009;
12:00 PM.
22. W. F. Garth Stapon, "Using Flux cored and Metal Cored Wire". Praxair. Inc. Marketing Manager Metal Fabrication; Reprinted from
Practical Welding Today Jan/Feb 2000.
23. V. Vel Murugan and V. Gunaraj, "Effect of process parameters on Angular Distortion of gas metal arc welded structural steel plates",
Welding Journal, November 2005.
51
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
52
53
Manganese (Mn):
Increases the strength, shock resistance, toughness, hardenability, weldebility, hot
formability, no change in ductility.
In addition Mn is a strong austenite former by reducing the eutectoid temperature
below to room temperature.
Manganese slightly increases the strength of ferrite, and also increases the hardness
penetration of steel in the quench by decreasing the critical quenching speed. This also
makes the steel more stable in the quench.
Sulfur (S):
The excess sulfur reduces the ability for hot (900C) deformation of steel forming the
brittle FeS phase at the grain boundaries (hot brittleness).
The solubility of S is higher than C therefore it restricts the formation of pearlite in the
zones with higher S contents, leading a banded structure of pearlite and ferrite.
(Macroscopy experiment: flow lines). This causes severe anisotropy in the mechanical
prop of steel therefore S content is limited 0.035%.
However, 0.3% S may be added to free cutting steels to increase the chip formation
thus the machinability
55
Silicone (Si):
Silicon is used as a deoxidizer in the manufacture of steel.
It slightly increases the strength of ferrite, and when used in conjunction with other
alloys can help increase the toughness and hardness penetration of steel.
It increases strength, decreases the weldability, magnetic losses, oxide formation
affinity, no change in ductility.
In addition Si has higher affinity to O than carbon therefore used as deoxizing agent
(semi-killed steels).
It is also austenite former agent leading the nucleation of austenite grain in many
size yielding finer grain size.
Copper (Cu):
Copper The addition of copper in amounts of 0.2 to 0.5 percent primarily improves
steels resistance to atmospheric corrosion. It should be noted that with respect to
knife steels, copper has a detrimental effect to surface quality and to hot-working
behavior due to migration into the grain boundaries of the steel.
Copper (Cu): restricted to max. 0.35%. Up to 0.2 % provides some resistance
against to atmospheric corrosion. Not desired in spring steels.
56
Chromium (Cr):
As the Cr content increases, strength, hardenability, corrosion resistance, high
temperature strength, decreases the oxide formation tendency. (forms a very
coherent oxide layer on the surface preventing further oxidation-- in stainless
steels).
It is also strong carbide former as an essential factor behaving as a strong second
phase particle, therefore, obstructs the dislocation motion particularly at elevated
temperatures. Also nitride former and used in nitriding steels.
Chromium As with manganese, chromium has a tendency to increase hardness
penetration. This element has many interesting effects on steel.
Phosphorus
It increases strength and hardness and decreases ductility and notch impact
toughness of steel.
The adverse effects on ductility and toughness are greater in quenched and
tempered higher-carbon steels.
Nickel
Nickel is a ferrite strengthener. Nickel does not form carbides in steel. It remains
in solution in ferrite, strengthening and toughening the ferrite phase. Nickel
increases the harden ability and impact strength of steels.
57
Ferrite
Pearlite and
Carbide
Pearlite
Steel
Cast iron
61
The solid solution formed when carbon atoms are absorbed into the face-centred cubic
structure of iron is called Austenite and the extremely low level of solid solution formed
when carbon dissolves in body-centred cubic iron is called Ferrite.
For many practical purposes we can regard ferrite as having the same properties as pure
iron.
the symbol ('gamma') is used to denote both the face-centred cubic form of iron and the
solid solution austenite, whilst the symbol ('alpha') is used to denote both the
body-centred cubic form of iron existing below 910C and the solid-solution ferrite
62
Definition of structures
Ferrite is known as solid solution.
It is an interstitial solid solution of a small amount of carbon dissolved
in (BCC) iron.
stable form of iron below 912 deg.C
The maximum solubility is 0.025 % C at 723C and it dissolves only
0.008 % C at room temperature.
It is the softest structure that appears on the diagram.
Definition of structures
Pearlite is the eutectoid mixture containing 0.80
% C and is formed at 723C on very slow cooling.
It is a very fine platelike or lamellar mixture of
ferrite and cementite.
The white ferritic background or matrix contains
thin plates of cementite (dark).
64
Crystal structure
Characteristics
Ferrite
BCC
Austenite
FCC
Cementite
Hard &brittle
Hypo-eutectoid steels: Steels having less than 0.8% carbon are called hypoeutectoid steels (hypo means "less than").
Hyper-eutectoid steels (hyper means "greater than") are those that contain more
than the eutectoid amount of Carbon.
67
The effect of heat input on cooling rate is similar to that of the preheat
temperature.
As either the heat input or the preheat temperature increases, the rate of cooling
decreases for a given base metal thickness.
These two variables interact with others such as material thickness, specific
heat, density, and thermal conductivity to influence the cooling rate.
The following proportionality function shows this relationship between preheat
temperature, heat input and cooling rate:
68
The cooling rate is a primary factor that determines the final metallurgical structure of the
weld and heat affected zone (HAZ), and is especially important with heat-treated steels.
When welding quenched and tempered steels, for example, slow cooling rates (resulting
from high heat inputs) can soften the material adjacent to the weld, reducing the loadcarrying capacity of the connection.
69