Arcmatic Welding Systems (AWS)

1175 Nimitz Ave. Mare Island Vallejo, CA, 94592 Phone: 1-707-5523232 Phone : 1-707-643-5517 Fax : 1-707-643-2652 e-mail: sales@arcmatic.com WWW.Arcmatic.com

Proposed Method to Calculate Heat Input in Electroslag Welding

The purpose of this analysis is to modify the standard formula (formula 1 below) for calculating the Heat Input to allow us to rationally compare its effect on the HAZ across a range of plate thicknesses and different Vertical Rate of Rise (VRR). Please refer to the attached EXCEL spreadsheet. We calculated the Heat Input for a range of plate thickness and guide tube sizes using the actual welding parameters programmed in Arcmatics standard welding procedures that pass the D1.1 and D1.5 requirements. In other words the welding parameters used in this Table consistently produced good sound welds. Standard formula Looking the heat input on column A in the spreadsheet, calculated with the standard formula (1), it becomes apparent that the Heat Input (H-I) is approximately proportional to the plate thickness. For example the Heat Input for welding a 2 thick plate is twice that calculated for a 1 thick plate. Test and experience however indicates that the nugget depth, HAZ size and the mechanical properties in both cases are comparable. This leads to the conclusion that the gross heat input is a very poor indicator of weld quality. (1) Heat Input = AMPS x VOLTS x 60 [K Joules/In] 1000 x VRR Proposed formula (2) corrected for plate (weld) thickness To correct this problem we would like to introduce the concept of Specific Heat Input (Heat Input per unit of plate thickness). The rationalization of this concept is as follows. Referring again to the 1 & 2 thk plates if the heat generated at the weld (and flowing toward the plate, or weldment) per unit area of the heat path is the same in both cases the temperature gradient needed to drive the heat flow is the same, ergo the actual temperature throughout the heat path. Since (all other things being equal), the changes that occur in the HAZ are due to high temperature and the temperatures are similar, their effect on the HAZ is also similar See Figure #1 (2) Specific Heat Input = AMPS x VOLTS x 60 1000 x VRR x PLATE THK [K Joules/In In]

The results of the calculated Heat Input using formula (2) are shown in column B of the spreadsheet. The two referenced welds (2 & 1) were sound welds that pass the tests required by D1.1 and D1.5 We can see that the Heat Input calculated with formula (2) is more accurate in predicting the effect of the Heat Input on the HAZ characteristics and mechanical properties.

Figure #1
Analyzing the values shown in column B however we can see that the specific heat input for the thinner plates are higher than for the thicker plates suggesting a lager HAZ and nugget. Again experience and tests indicate otherwise. The explanation for this inconsistency is that both formulas (1) & (2) ignore the substantial heat removed by the water-cooled shoes.

Proposed formula (3) corrected for plate (weld) thickness and heat removal This formula can be described in simple terms as Specific Heat Input = Heat generated electrically Heat removed by the cooling shoes VRR x Plate Thickness (3) Specific Heat Input= (.05688 x AMPS x VOLTS Q) x 1.055 [K Joules/In In] VRR x Plate Thk

Where Q is the heat removed by the cooling shoes in BTU per min [BTU/min] To calculate Q use formula (4) (4) Q= W [GPM] x 8.9999x (T2-T1)

Where W is the water flow through the shoes, T1 cold-water temperature to the first shoes, T2 hot water temperature out of the last shoe. The temperatures are measured in Degree Fahrenheit. Suggestion: to measure W. Disconnect the water hose coming out of the last shoe and using a 5 gallons pail measure the time in minutes to fill it up. Repeat this measurement two or three times and average the time. (5) W=5 (gallons)/Time (min) [GPM]

We can see the results of calculating the (Specific) Heat Input using formula (3) in column C in the spreadsheet. The cooling effect of the copper shoes are much more significant for the thinner plates lowering the calculated Heat Input. These values correlate very well with the actual etch tests in terms of nugget shape dimensions and extent of the HAZ and the mechanical properties. Several cooling rate tests performed by Arcmatic showed that the heat removed by the Arcmatic design water-cooled copper shoes varies from 20,000 to 24,000 BTU per HOUR or 370 BTU per MINUTE regardless of the plate thickness or weld parameters. This value of 370 (BTU/Min} was used to calculate the values in column C of the spread sheet. Since the rate of heat removal by the shoes is roughly constant, the rate of heat available to flow into the plate will be (proportionally) much lower for a thinner weldment - thus, the resultant temperature gradient will be steeper and the HAZ smaller (See fig #1 above). This is confirmed by actual test results indicating that the Heat Affected Zones are smaller for thinner plates.

CONCLUTIONS: (Please refer to the attached Spread Sheet) 1. In column A generated with (Formula #1) we can see that the Heat Input increases proportionally to the thickness of the plate. Consequently, these values are useless for rational interpretation if the thickness of the plate is changed. 2. In the next column, B the values are corrected by taking into consideration the thickness of the plate Formula # 2. We can see that the values are comparables for different plate thickness. However, as plate thickness increases, the Heat Input decrease. The formula shows that ignoring the cooling effect of the watercooled copper shoes distorts the results. The calculations show that thinner plate have larger Specific Heat Input thus should have larger Heat Affected Zone, while test results show that thinner plates actually have smaller HAZ. 3. Finally the next column C was generated using Formula # 3. It shows that, if we subtract the heat removed by the cooling shoes, the calculated results are consistent with the test results. In our opinion calculating the Specific Heat Input Values using Formula # 3 will allow a more accurate comparison of HEAT INPUTS across a range of thickness as well as Vertical Rate of Rise.

Furthermore looking at the values in column C we can see an increase in the Specific Heat Input for plate thickness 1 7/8 through 2 . This suggest that we may lower the voltage for this range of plate thickness and obtain a good weld with lower Heat Input. Please refer to the attached graph Comments re. VRR The Heat Input also decreases in direct proportion with the increase of VRR The upper limits of the VRR are set by many factors such as the possibility for cracks at the center of the welds (Form Factors), Flux inclusions in the weld, etc. However this parameter is outside the scope of this write-up. Please note that the attached table is an EXCEL spread sheet and its values can be changed to suit different conditions or actual test data. All of the values shown in yellow can be changed to fit your own analysis. The formulas are protected to prevent accidental changes, however there is no password. The entire worksheet can be unprotected. Highlights of the ARCMATIC designed Water Cooled Copper Shoes One of the unintended consequences of the water-cooled copper shoes is the chilling effect on the edge of the welding plates (wet lines). This effect requires higher Voltage to insure good wet lines. This in turns creates two related problems: a. Increases the Heat Input b. Creates a larger nugget with a larger HAZ at the center of the weld with all the associated problems. (See fig #2) To ameliorate this problem Arcmatic developed a water-cooled copper shoe with larger water channel and flow capacity. This larger flow capacity is responsible for removing more heat much faster from the weld area proper (center of the shoe). Each shoe also has a relief on either side of the shoe that reduces the amount of contact area against the parent material. This reduction in contact area decreases the chilling effect on the wet lines allowing for lower voltages to produce good tie-in along the wet lines. Lower weld voltages result in a more linear and uniform penetration pattern into the parent material, (flatter nugget and HAZ See figure #3). Lower Voltage also reduces the Heat Input with all the associated benefits. The statements above and Fig #2 & #3 are backed up by years of trying different shoe designs and configurations and innumerable weld tests and etchings.

Figure #2
Written by Charles A. Bck PE Arcmatic Welding Systems

Figure # 3

DATE PREPARED REVISED

1/3/2005 ----

ARCMATIC WELDING SYSTEMS

FORMULAS TO CALCULATE HEAT INPUT
VRR= VERTICAL RATE OF RISE (INCH PER MIN)

Weld Thick

Std Guide Tube

Weld Speed VRR

WELD PARAMETERS

Heat Input Net Proposed Net Std Kilo- Proposed KiloKilo Joules/In Joules/InxIn Joules/InxIn 358 478 280 386 442 268 428 428 272 460 409 267 515 412 281 551 401 278 599 400 284 659 406 296 723 413 308 768 410 309 816 408 311 867 408 313 906 403 310 948 399 309 998 399 310 1,075 409 321 1,152 419 332 1,248 434 347 1,339 446 360 1,460 467 381 1,570 483 396 1,659 492 404 1,758 502 413 1,896 523 433 2,019 538 446 2,157 557 462 2,346 587 489 2,524 612 511 Gross Metric Std KiloJoules/Cm 141 152 169 181 203 217 236 259 285 302 321 341 357 373 393 423 454 491 527 575 618 653 692 746 795 849 924 994

Note 1 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 1 7/8 2 2 1/8 2 1/4 2 3/8 2 1/2 2 5/8 2 3/4 2 7/8 3 3 1/8 3 1/4 3 3/8 3 1/2 3 5/8 3 3/4 3 7/8 4 4 1/8

Width 5/8 5/8 5/8 5/8 1 1 1 1 1 1/2 1 1/2 1 1/2 1 1/2 2 2 2 2 2 1/2 2 1/2 2 1/2 2 1/2 3 3 3 3 3 1/2 3 1/2 3 1/2 3 1/2

(in IPM) 2.625 2.563 2.500 2.438 2.375 2.313 2.250 2.188 2.125 2.063 2.000 1.938 1.875 1.813 1.750 1.688 1.625 1.563 1.500 1.438 1.375 1.313 1.250 1.188 1.125 1.063 1.000 0.938

VOLTS 33 33 34 34 34 34 31 31 32 32 32 32 32 32 32 32.5 32.5 32.5 32.5 33 33 33 33 33.5 33.5 33.5 34 34

AMP. 475 500 525 550 600 625 725 775 800 825 850 875 885 895 910 930 960 1,000 1,030 1,060 1,090 1,100 1,110 1,120 1,130 1,140 1,150 1,160

HEAT INPUT
3,000 2,500 K-JULES/IN IN 2,000 1,500 1,000 500 0
4 2 4 4 2 4 4 2 3/ 4 1 2 3 4 3/ 3 1/ 1/ 3/ 1/ 1/ 3/ 1/ 1 1 1 2 2 2 3 3 1/ 4

WELD THICKNESS Std Kilo-Joules/In Proposed Net Kilo Joules/InxIn Proposed Kilo-Joules/InxIn

STD HEAT INPUT FORMULA #1 AMPxVOLTSx60 1000*VRR K-JOULE IN

22200

PROPOSED GROSS HEAT INPUT FORMULA Gross Joules per Inch of Vertical Rise & Inch of Plate Thk AMPxVOLTSx60 KJOULE IN x IN 100 x VRR x Weld Thk

#2

PROPOSED NET HEAT INPUT FORMULA Net Joules per Inch of Vertical Rise & Inch of Plate Thk (5.688 x Volts x Amps- Heat Removed By Cooper Shoes)x1.055 100 x VRR x Weld Thk

KJOULE IN x IN

#3

#4 HEAT REMOVED BY COOLING COOPER SHOES COOLING WATER FLOW (GPM) x 8.337 (LBS/GAL) x (WATER TEMP OUT-WATER TEMP. IN) HEAT REMOVAL TESTS VALUE= 370 BTU/MIN ARCMATIC RUN TEST INDICATES THE HEAT REMOVAL RATE BY THE COOLING SHOES IS ABOUT 22,000 BTU PER HOUR OR 370 BTU PER MIN. REGARDLESS OF PLATE THICKNESS OR WELDING PARAMETERS.