Cold Lap 2g405n
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Fundamental understanding of the formation of cold laps with welding parameters and heat transfer in Tandem-arc MIG/MAG welding Peigang Li Ph.D student Per Nylén Supervisor
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2
Tandem-arc MIG/MAG welding
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3
α
α
Base Metal
Base Metal
Welding Direction Base Metal
www.hv.se
4
www.hv.se
5
Quality of weld
www.hv.se
6
Quality of welds Chemical Composition: P, S, Mn, Si, Al……; Mechanical Property: Tensile, Bend, Fatigue…; Discontinuties: • • • • •
Porosity; Lack of fusion; Lack of penetration; Crack; STD Undercut;
• Cold lap; life
181- 0004
Fatigue
undercut
• Geometry;
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7
Cold laps
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8
Definition of Cold laps Small lack of fusion at weld toe. (KOST/LOST) • Small (typically < 0,5 mm), • Difficult to be detected by common NDT methods. • Initiate fatigue failure and thus decrease severely the fatigue life of welds. • Recent study classify it into: Spatter cold lap, overlap.
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9
Hypothesis of formation of cold laps Wire Shield Gas Arc
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Melted metal (hot)
Welding process
Heat Transfer
• Volatge; • Current (Wire feed speed); •Welding speed; •Angle factor; Etc.
• Temperature; • Interface substance;
Melted metal (cold)
10
Experiment Welding Direction TC2 150mm
30mm 30mm TC1
12mm
TC3
Thermal couple
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11
Welding Parameters Run Ord.
Welding Master Ratio Speed Voltage of (mm/s) (V) voltage
Slave voltage (V)
Wire feed speed* (m/min)
1
14
29.65
1
29.65
11.5
2
14
29.65
1
29.65
11.5
3
14
29.65
1
29.65
11.5
4
11
28.3
0.8
22.64
9
5
17
31
1.2
37.2
14
6
17
28.3
0.8
22.64
14
7
17
31
0.8
24.8
9
8
11
31
0.8
24.8
14
9
17
28.3
1.2
33.96
9
10
11
31
1.2
37.2
9
11
11
28.3
1.2
33.96
14
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level Parameters -
+
Ratio of voltage (%)
0,8
1,2
Welding Speed (mm/s)
11
17
Master Voltage (V)
28,3
31
Wire Feed Speed (m/min)
9
14
12
Collected Data
Welding Voltage (V), Welding Current (I), Thermal Couple 1, 2, 3 (TC1, TC2, TC3),
High speed Camera Video, Infrared Camera
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13
I,V,TC1,TC2,TC3
www.hv.se
14
www.hv.se
15
IR Camera • Line scanning at the Thermal couple
(TC) position. • Peak Temperature in weld pool. • Peak Temperature in of TC.
www.hv.se
16
Synchronization Synchronization is important to link the measurements with the other detector of the welding process, e.g. High Speed Video(Locating the high speed video).
www.hv.se
17
Next Step Detecting of cold laps;
MT? RT? Destructive Test??......
Statistical analysis of the collected data and response; Metallography sample; EDS (chemical composition test).
Future Works Qualitative study about the empirical relationship between
welding parameters and cold laps; Quantitative study for cold laps and parameters; Controlling parameters.
www.hv.se
18
Tack 谢谢
www.hv.se
19
Fundamental understanding of the formation of cold laps with welding parameters and heat transfer in Tandem-arc MIG/MAG welding Peigang Li Ph.D student Per Nylén Supervisor
www.hv.se
2
Tandem-arc MIG/MAG welding
www.hv.se
3
α
α
Base Metal
Base Metal
Welding Direction Base Metal
www.hv.se
4
www.hv.se
5
Quality of weld
www.hv.se
6
Quality of welds Chemical Composition: P, S, Mn, Si, Al……; Mechanical Property: Tensile, Bend, Fatigue…; Discontinuties: • • • • •
Porosity; Lack of fusion; Lack of penetration; Crack; STD Undercut;
• Cold lap; life
181- 0004
Fatigue
undercut
• Geometry;
www.hv.se
7
Cold laps
www.hv.se
8
Definition of Cold laps Small lack of fusion at weld toe. (KOST/LOST) • Small (typically < 0,5 mm), • Difficult to be detected by common NDT methods. • Initiate fatigue failure and thus decrease severely the fatigue life of welds. • Recent study classify it into: Spatter cold lap, overlap.
www.hv.se
9
Hypothesis of formation of cold laps Wire Shield Gas Arc
www.hv.se
Melted metal (hot)
Welding process
Heat Transfer
• Volatge; • Current (Wire feed speed); •Welding speed; •Angle factor; Etc.
• Temperature; • Interface substance;
Melted metal (cold)
10
Experiment Welding Direction TC2 150mm
30mm 30mm TC1
12mm
TC3
Thermal couple
www.hv.se
11
Welding Parameters Run Ord.
Welding Master Ratio Speed Voltage of (mm/s) (V) voltage
Slave voltage (V)
Wire feed speed* (m/min)
1
14
29.65
1
29.65
11.5
2
14
29.65
1
29.65
11.5
3
14
29.65
1
29.65
11.5
4
11
28.3
0.8
22.64
9
5
17
31
1.2
37.2
14
6
17
28.3
0.8
22.64
14
7
17
31
0.8
24.8
9
8
11
31
0.8
24.8
14
9
17
28.3
1.2
33.96
9
10
11
31
1.2
37.2
9
11
11
28.3
1.2
33.96
14
www.hv.se
level Parameters -
+
Ratio of voltage (%)
0,8
1,2
Welding Speed (mm/s)
11
17
Master Voltage (V)
28,3
31
Wire Feed Speed (m/min)
9
14
12
Collected Data
Welding Voltage (V), Welding Current (I), Thermal Couple 1, 2, 3 (TC1, TC2, TC3),
High speed Camera Video, Infrared Camera
www.hv.se
13
I,V,TC1,TC2,TC3
www.hv.se
14
www.hv.se
15
IR Camera • Line scanning at the Thermal couple
(TC) position. • Peak Temperature in weld pool. • Peak Temperature in of TC.
www.hv.se
16
Synchronization Synchronization is important to link the measurements with the other detector of the welding process, e.g. High Speed Video(Locating the high speed video).
www.hv.se
17
Next Step Detecting of cold laps;
MT? RT? Destructive Test??......
Statistical analysis of the collected data and response; Metallography sample; EDS (chemical composition test).
Future Works Qualitative study about the empirical relationship between
welding parameters and cold laps; Quantitative study for cold laps and parameters; Controlling parameters.
www.hv.se
18
Tack 谢谢
www.hv.se
19
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