1 / 35

The Economics of Advanced Welding Techniques: Innovations and Applications in Nuclear Fabrication

This presentation explores the economic aspects of advanced welding techniques, particularly focusing on laser welding and friction stir welding. It highlights key processes, their applications in the nuclear industry, and associated cost benefits. The session discusses advancements in laser technology, including greater productivity and reduced distortion, while addressing the challenges of capital costs and joint preparation. Friction stir welding's contributions to various sectors, including shipbuilding and aerospace, are also examined, showcasing significant savings and efficiency improvements.

ordell
Télécharger la présentation

The Economics of Advanced Welding Techniques: Innovations and Applications in Nuclear Fabrication

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Economics of Advanced Welding Techniques March 28, 2013 Stephen Levesque Director, EWI Nuclear Fabrication Center Email: slevesque@ewi.org Office: 614-688-5183 Mobile: 614-284-5426

  2. Nuclear Fabrication Consortium • Some information in this presentation was based upon research funded by the US Department of Energy through the Nuclear Fabrication Consortium (operated by EWI) • The Nuclear Fabrication Consortium (NFC) was established to independently develop fabrication approaches and data that support the re-establishment of a vibrant US nuclear industry

  3. Overview • Laser Welding • Process description (Laser and Hybrid Laser Technologies) • Potential applications • Cost benefit • Friction Stir Welding • Process description • Potential applications • Cost benefit • Cladding Technologies • Comparison of various technologies • Tandem GMAW (bonus)

  4. Laser Welding

  5. Laser Background • Solid-state laser technology is rapidly advancing • Output powers are continuously increasing • Price per kilowatt is dropping (~$750K for 20-kW) • Improved portability and electrical efficiency • Improved beam quality – fiber deliverable • Two laser technologies primarily responsible • Fiber Laser (IPG Photonics) • Disk Laser (Trumpf) • ROI for laser processing is becoming more attractive • Cost/watt, cycle time, penetration, distortion

  6. Advantages and Challenges • The main advantages of laser processing include: • High productivity • Low heat input • Minimal distortion • Some challenges include: • Critical joint preparation due to limited gap bridging • Increased capital cost compared to traditional arc-welding equipment 0.005-in. gap 0.010-in. gap 0.015-in. gap

  7. Laser Beam Laser-Induced Vapor Plume Shielding gas Liquid Weld Pool Laser Keyhole or Vapor Cavity Solidified Weld Metal General Terminology • Autogenous Laser Welding

  8. GMAW Torch Laser Beam General Terminology • Hybrid Laser-Arc Welding (Hybrid Welding) • The combination of two welding processes in the same weld pool • Most often GMAW and Laser Welding

  9. “Arc-Leading” HLAW “Laser-Leading” HLAW Hybrid Terminology • The HLAW process can be used in two orientations:

  10. Laser Tube Sheet Welding • High-level cost model built by EWI • Assumes 1 min. of arc time for GTAW and 2 sec. of laser time per tube • Varied process efficiency to evaluate the ROI

  11. Laser Tube Sheet Welding

  12. Containment Welding • Hybrid Laser-GMAW welding vs.Tandem GMAW vs. Submerged Arc Welding

  13. Productivity • For one weldment X long Includes setup time and weld time

  14. Cost Comparison Includes setup time/weld time (@$75/hr) and filler metal cost • For one weldment X long

  15. Combined Comparison Data 200-in

  16. Other Benefits • Peak Temperature Models showing reduction in heat input SAW HLAW GMAW-T

  17. Distortion and Residual Stress SAW Tandem HLAW

  18. Friction Stir Welding

  19. Friction Stir Welding • Invented by TWI in 1991 • Wayne Thomas • Solid-state joining process • No bulk melting of the substrate • Capable of joining • Aluminum, Magnesium, Copper, Steel, Titanium, Nickel, many more • Non-consumable tool rotates and traverses along a joint • Combination of frictional heating and strain causes dynamic recrystallization • Adiabatic heating • Creates a very fine grain microstructure • Low distortion • Excellent weld properties

  20. Friction Stir Welding Variables • Essential FSW variables • Vertical (Forge) force, Fz • RPM,  • Travel (Traverse) speed, Vf • Process forces • Travel (Traverse) force, Fx • Cross (Transverse) force, Fy • Vertical (Forge) force, Fz Ref: Arbegast, William J., "Week 2 Friction Stir Joining: Process Optimization." (2003).

  21. Friction Stir Welding Main Spindle Fixturing Local Clamp FSW Tool

  22. FSW Economics • FSW of Aluminum • 15% reduction in man-hour per ton rate in aluminum panel fabrication – Hydro Aluminum • Total fabrication savings of 10% in shipbuilding - Fjellstrand • 60% cost savings on Delta II and IV rockets – Boeing • 400% improvement in cycle time for fabricating 25mm thick plates – General Dynamics Land Systems • FSW of Steel Pipeline • Estimated cost savings • Onshore construction, 7% • Offshore construction (J-Lay), 25% • Kallee, S. W. (2010). Industrial Applications of Friction Stir Welding. In D. Lohwasser, & Z. Chen, Friction Stir Welding From Basics to • Applications (pp. 118-163). Boca Raton: CRC Press. • Kumar, A., Fairchild, D. P., Macia, M., Anderson, T. D., Jin, H. W., Ayer, R., . . . Mueller, R. R. (2011). Evaluation of Economic • Incentives and Weld Properties for Welding Steel Pipelines Using Friction Stir Welding.Proceedings of the Twenty-first (2011) • INternational Offshore and Polar Engineering Conference (pp. 460-467). Maui: ISOPE.

  23. FSW of Steel Cost Model • Assumptions • Plain carbon steel • Simple butt joint configuration • Use of EWI DuraStir™ tools • Machine and fixturing purpose built for assumed application • Range of thicknesses • 3, 6, 9, 12, 16, 19 mm • Broken down in terms of cost/meter based upon weld length achievable each month

  24. FSW Cost Summary

  25. Cladding

  26. Introduction • Many process options exist for weld cladding and hardfacing • A number of factors should be considered when selecting a process: • Desired deposition rate • Required dilution level • Welding position • Component size/geometry • Method of application • Manual/semi-automatic • Mechanized • Automated • Welder/operator skill • Alloy/material to be deposited • Equipment cost

  27. Available Processes for Surfacing Include • Thermal spray • Resistance cladding • Laser cladding • Gas tungsten arc welding (GTAW) • Plasma arc welding (PAW) • Gas metal arc welding (GMAW) • Submerged arc welding (SAW) • Single and multi-wire SAW • Submerged arc strip cladding • Electroslag strip cladding • Explosion welding

  28. Resistance Cladding • Uses Simple off the shelf sheet material and may use interlayers to make a fusion type weld between CRA and Pipe • Can make the clad weld in one pass • Uses sheet metal consumables which are much lower cost than wire consumables • Post weld surface finish should meet customer requirements • No dilution of base metal into CRA surface

  29. Resistance Cladding

  30. Current Cladding Techiques • Explosive Welding $$$$ • Requires post cladding longitudinal seam weld which impacts fatigue • Roll Bonding • Requires post clad longitudinal seam weld • GMAW / GTAW / SAW welding • Processing time intensive with inspectability issues • Liner Expansion (lowest cost) • Risk of liner buckling is concerning to customers during installation or dynamic lines

  31. Resistance Cladding • Cost comparison

  32. Tandem GMAW Bonus Material

  33. Deposition rate (lbs/hr) Why Use Tandem GMAW? • Improve Productivity and Quality • Increased deposition rates • Faster travel speeds • Maintain or improve overall weld quality, gap filling capability Image courtesy of Lincoln Electric

  34. Example • 5.25-in.-thick test joint • 0.5-in.wide groove • 2° included angle • Travel speed: 15 ipm • Heat input: 46 kJ/in. • Single bead per layer • 27 passes required to fill 4.5 in. • Fill height per pass ≈ 0.17 in. • Clean UT results

More Related