Embed Size (px)
Citation preview
High-speed, High-quality Welding of
Copper-nickel Pipe Joints
Nick Kapustka
Senior Engineer, Arc Welding
EWI
614.688.5175
EWI Project No. 56132GTH
Welding Technology Panel Meeting
September 19, 2017
Approved for Public Release: Distribution is Unlimited
Acknowledgments
This project was funded by the National Shipbuilding Research Program – Advanced Shipbuilding Enterprise.
Fronius USA and OTC-Daihen supported this project by providing equipment and technical assistance.
Airgas provided assistance during shipyard trials at Vigor Industrial.
2
Introduction
Virtually all ship designs utilize copper-nickel alloys:
─ Fire mains and other seawater/fresh water piping.
─ Tanks, penetrations, mask emitters, rope guards, deck drains.
Most pipe joints are welded with manual gas tungsten arc welding (GTAW) at an approximate travel speed of 4 ipm.
Gas metal arc welding (GMAW) can operate at travel speeds of 12 to 18 ipm and fewer passes are typically required compared to GTAW.
The goal of this project was to develop GMAW procedures to provide enhanced welding of copper-nickel systems resulting in higher speeds, higher quality welds, lower heat input, reduced distortion, and minimal rework.
3
Objectives
To provide the GMAW welding procedures needed for the range of applications selected by the project team.
To disseminate the project results to the U.S. shipbuilding community.
4
Project Team
EWI (prime):─ Nick Kapustka (PI), Harvey Castner (PM)
Nassco: ─ Mike Sullivan
Vigor:─ Ken Johnson
5
Approach
Task 1 – Project Initiation and Kickoff Meeting:
─ Identify candidate applications and acceptance criteria.
Task 2 – Procedure Development and Feasibility Demonstration:
─ Develop semi-automatic and/or mechanized GMAW procedures for each application.
─ Produce procedure qualification weldments for each application and evaluate in accordance with NAVSEA Tech Pub 248.
Task 3 – Identification of the Qualification Test Matrix:
─ Determine tests required for procedure qualification in accordance with NAVSEA Tech Pub 248 for each application.
Task 4 – Shipyard Process Demonstrations:
─ Arrange equipment and materials for shipyard demonstration.
─ Fabricate mock-ups for each application using the procedures developed in Task 2.
─ Subject mock-ups to tests identified by the project team.
Task 5 – Technology Transfer and Reporting
─ Briefings at NSRP meetings.
─ Final written report.
6
Application 1
Butt Joint with Backing
Butt joint, welded on permanent backing ring, V-groove, P-3:
─ Figure 35 in MIL-STD-22D.
─ 90/10 Cu-Ni pipe, 6.625-in. OD, 0.134-in. nominal wall thickness.
─ MIL-RN-67 wire, 0.035 or 0.045-in. Ø.
─ 5G position using semi-automatic welding is preferred (pipe fixed).
Welding procedures:
─ Pulsed GMAW (GMAW-P) mode.
─ Two layers required.
7
Application 2
Fillet-welded Coupling Joint
Fillet-welded slip on coupling, P-13: ─ Figure 45 in MIL-STD-22D.
─ 90/10 Cu-Ni pipe, 6.625-in. OD, 0.134-in. nominal wall thickness.
─ 90/10 Cu-Ni coupling ring.
─ MIL-RN-67 wire, 0.035 or 0.045-in. Ø.
─ 5F position using semi-automatic welding is preferred.
Welding procedures:─ GMAW-P mode.
─ Two layers required.
8
Accomplishments
Application Position Location System
Semi-
Automatic/
Mechanized
Accomplishments
Butt Joint with Backing 5G EWI Fronius TPS 5000 Semi-automatic Procedures identified that pass VT, but not RT (0729-1).
Butt Joint with Backing 1G-R EWI Fronius TPS 5000 MechanizedWeldment 0809-1: Meets procedure qualification requirements
of Tech Pub 248 everywhere except the start/stop.
Butt Joint with Backing 5G EWI Fronius TPS 5000 Mechanized
Weldment 1031-1: Meets the Class 1 procedure qualification
requirements of Tech Pub 248 for PT, RT, mechanical testing.
Meets Class 2 & 3 requirements for VT due to a 0.05-in. long
area with undercut between 1/64 and 1/32 in.
Fillet-welded Coupling
Joint2F-R EWI Fronius TPS 5000 Mechanized
Weldment 0906-1: Meets procedure qualification requirements
of Tech Pub 248 everywhere except the start/stop.
Butt Joint with Backing 1G-R VigorOTC-Daihen Welbee
P400Semi-automatic
Weldment 0202-5: Meets procedure qualification requirements
of Tech Pub 248 at all locations.
Butt Joint with Backing 1G-R VigorOTC-Daihen Welbee
P500LMechanized
Weldment 0203-1: Meets NDE requirements of Tech Pub 248
at all locations, mechanical testing is in process.
0729-1, EWI, 5G, Semi-Auto
0809-1, EWI, 1G-R,
Mechanized
1031-1, EWI, 5G,
Mechanized0906-1, EWI, 2F-R,
Mechanized
0202-5, Vigor, 1G-R
Semi-Auto
0203-1, Vigor, 1G-R
Mechanized
9
Mechanized Trials at EWI
Evaluated mechanized welding in the 1G-R and 5G positions for the butt joint and the 2F-R position for the coupling joint.
Equipment:
─ ABB IRB 1600 robot
─ ABB 2-axis positioner (1G-R, 2F-R positions)
─ Jetline Engineering positioner (5G position, not-rotating)
─ Fronius TPS 5000 power supply
─ Fronius VR7000 wire feeder
─ Fronius Robacta Drive torch
10
5G
2F-R1G-R
0809-1 – 1G Butt Joint
Goal: ─ Produce a butt joint that meets the procedure
qualification requirements.
Approach:─ Mechanized welding in the 1G-R position.
─ Each pass is 360 degrees.
─ MIL-RN-67 wire.
─ GMAW-P.
─ Travel angle: 0 degree (neutral).
Evaluation:─ VT, PT, RT, two tensiles, four bends, macro.
11
Pass
Work
Angle
(deg)
Travel
Speed
(ipm)
Weave/
Stringer
WFS
(ipm)Wire Alignment
1 0 10.0 Weave 325 Center of groove
2 8 10.0 Stringer 250 Edge of the wire at the bevel wall
3 0 10.0 Stringer 250 – 270 Edge of wire at the bevel wall
0809-1 – Results
No dressing of the completed weldment prior to NDE.
Start/stop location was not included in NDE testing:
─ Procedures for start/stop location can be developed in the future.
VT:
─ Main weld region meets Class 1 requirements of MIL-STD-2035, provided that excess reinforcement is removed.
─ Reinforcement is about 3/32 in. (1/16 in. max for Class 1 welds).
PT and RT:
─ Main weld region meets the PT and RT requirements of MIL-STD-2035.
12
0809-1 – Results
All bend test specimens passed.
Both tensile test specimens met the requirements of NAVSEA Tech Pub 248:
─ Fracture faces of both specimens extended from the fusion line/near heat-affected zone (HAZ) into the HAZ/base metal.
─ Minimum ultimate tensile test strength specified by MIL-T-16420k is 38 ksi for 90/10 copper nickel.
─ Tensile test specimens had tensile strength of 38.4 and 42.6 ksi.
13
1031-1 – 5G Butt Joint
Pass
Work
Angle
(deg)
Travel
Speed
(ipm)
Wire AlignmentWFS
(ipm)
Stringer or
Weave
1 0 5.8 – 10.0 Center 200 – 325 Weave
2 8 8.0Edge of wire is aligned with the
toe of Pass 1200 Weave
3 0 6.3Wire is centered on the
exposed face of Pass 1200 Weave
Goal:─ Produce a butt joint that meets the procedure
qualification requirements.
Approach:─ Mechanized welding in the 5G position (pipe is fixed).
─ Each pass is 360 degrees.
─ MIL-RN-67 wire.
─ GMAW-P.
─ Travel angle: 0 degree (neutral).
Evaluation:─ VT, PT, RT, two tensiles, four bends, macro.
14
1031-1 – Results
Start/stop location was included in NDE testing.
VT:
─ Meets VT requirements for Class 2 & 3 welds
▪ Would meet Class 1 requirements, but there is undercut at 220 degrees that is about 0.05-in. long that is at the 1/64-in. max depth limit for Class 1 welds.
─ Reinforcement is 0.060 to 0.082 in. (max reinforcement for Class 1 welds is 0.062 in.).
PT and RT:
─ Meets PT and RT requirements for Class 1 welds the full length (including start/stop area).
15
1031-1 – Completed Weldment
Photos of the completed weldment are shown.
16
1031-1 – Mechanical Testing
Results
All bend test specimens passed.
Both tensile specimens met the requirements of NAVSEA Tech Pub 248:
─ Both specimens failed in the HAZ or the base metal.
─ Minimum tensile strength specified by MIL-T-16420k is 38 ksi for 90/10 copper nickel.
─ Tensile test specimens had tensile strength of 43.6 ksi and 44.2 ksi.
17
0906-1 – 2F Coupling Joint
Goal:
─ Produce a fillet-welded coupling joint that meets the procedure qualification requirements.
Approach:
─ Mechanized welding in the 2F position (pipe rolled).
─ Each pass is 360 degrees.
─ MIL-RN-67 wire.
─ GMAW-P.
─ Travel angle: 0 degree (neutral).
─ Stringer technique for all passes.
Evaluation:
─ VT and PT.
─ Four macro specimens removed 90 degrees apart.
18
Pass
Work
Angle
(deg)
Travel
Speed
(ipm)
Weave/
Stringer
WFS
(ipm)Wire Alignment
1 35 17.5 Stringer 350 1 Ø from joint
2 26 12.0 Stringer 300 1 Ø from toe of Pass 2
3 15 12.0 Stringer 300 Center between bevel wall and toe
of Pass 2
0906-1 – Results
No dressing of the completed weldment prior to NDE.
Start/stop location was not included in NDE testing:
─ Procedures for start/stop location can be developed in the future.
VT and PT:
─ Main weld region meets the VT and PT requirements of MIL-STD-2035.
─ Distance from the coupling wall to the horizontal toe is about 0.35 in. (requirement is 0.26 in.).
19
0906-1 – Met Sections
Metallographic sections:
─ Removed 45 degrees (M1), 135 degrees (M2), 225 degrees (M3), and 315 degrees (M4) from the start.
All four metallographic sections meet the requirements of Tech Pub 248:
─ Horizontal size and leg = 0.34 in.
▪ Required size is 1.75 T = 0.26 in.
─ Vertical size and leg = T = 0.146 in.
▪ Required size = T = 0.146 in.
20
Trials at Vigor
Evaluated semi-automatic and mechanized welding of butt joints in the 1G-R position.
Semi-automatic welding equipment:─ OTC Manual Welbee WB-P400 power supply
─ OTC CM-743 wire feeder
─ OTC BT3510-45UT torch, 4.5 m/15 ft
─ Jetline Engineering positioner
Mechanized welding equipment:─ OTC FD-V6L robot
─ OTC A2PF tilt and rotate positioner
─ OTC Welbee WB-P500L power supply
─ OTC AF-4012 wire feeder
─ OTC RTW5000H torch
21
0202-5 – 1G-R Semi-Auto Butt Joint
Goal:─ Produce a butt joint in the 1G-R position that
meets the procedure qualification requirements.
Approach:─ Semi-automatic welding in the 1G position (pipe
rolled).
─ Each pass is 360 degrees.
─ MIL-RN-67 wire.
─ Wave Pulse synergic line that was custom built by OTC for this project.
─ Travel angle: 0 degree.
─ Torch is aligned at 1:00 with a slight downhill progression.
Evaluation:─ VT, PT, RT, two tensiles, four bends, macro.
Pass
Travel
Angle
(deg)
Work
Angle
(deg)
Travel
Speed
(ipm)
Weave/
Stringer
Set WFS
(ipm)
Wave Pulse
Frequency
(Hz)
1 0 0 9.9 Weave 325 32
2 0 0 7.8 Weave 325 32
Roll
22
0202-5 – Results
Vigor performed VT, PT, and RT on the entire weldment.
VT, PT, and RT:
─ Entire weldment meets the Class 1 requirements.
─ Reinforcement is just below 1/16 in.
23
0202-5 – Completed Weldment
Photos of the completed weldment are shown:─ Reinforcement is just below 1/16 in.
24
0202-5 – Results
All bend test specimens passed.
Both tensile test specimens met the requirements of NAVSEA Tech Pub 248:
─ Fracture faces are in the HAZ or the base metal.
─ Minimum ultimate tensile strength specified by MIL-T-16420k is 38 ksi for 90/10 copper nickel.
─ Tensile test specimens had tensile strength of 45.2 and 46.2 ksi.
25
0203-1 – 1G-R Mechanized Butt Joint
Goal:
─ Produce a butt joint in the 1G-R position that meets the procedure qualification requirements.
Approach:
─ Mechanized welding in the 1G position (pipe rolled).
─ Each pass is 360 degrees.
─ MIL-RN-67 wire.
─ Wave pulse synergic line (existing line from OTC).
─ Travel angle: 0 degree.
Evaluation:
─ VT, PT, RT, two tensiles, four bends, macro.
Pass
Travel
Angle
(deg)
Work
Angle
(deg)
Travel
Speed
(ipm)
Weave/
Stringer
Set
WFS
(ipm)
Wave Pulse
Frequency
(Hz)
Wave Pulse
Amplitude
(%)
1 0 0 7.9 Weave 320 32.0 50
2 0 0 7.9 Weave 320 32.0 50
26
0203-1 – Results
Vigor performed VT, PT, and RT on the entire weldment.
VT, PT, and RT:
─ Entire weldment meets the Class 1 requirements.
─ Reinforcement is just below 1/16 in.
Mechanical testing is in progress.
27
Summary – GMAW of Cu-Ni Pipe
(1 of 2)
28
The feasibility of producing welds that meet the procedure qualification requirements was demonstrated at EWI for the following conditions:
─ Butt joint with backing, 1G-R, mechanized.
─ Butt joint with backing, 5G, mechanized.
─ Fillet-welded coupling joint, 2F-R, mechanized.
Procedures were developed at Vigor for producing a semi-automatic 1G-R butt joint that met the procedure qualification requirements:
─ Approval of PQR data by NAVSEA will result in Vigor having a qualified, implementable welding procedure for this condition.
Procedures were developed at Vigor for producing a mechanized 1G-R butt joint that met the NDE requirements:
─ Mechanical testing is in progress
─ Acceptable mechanical test results and approval of the PQR data by NAVSEA will result in Vigor having a qualified, implementable welding procedure for this condition.
Semi-automatic procedures for the 5G butt joint were not completely developed:
─ Best procedures enabled welds that passed VT, but not RT.
Future work:
─ Determine semi-automatic procedures for producing butt joints in the 5G position and fillet-welded coupling joints in the 5F position that meet the procedure qualification requirements.
Summary – GMAW of Cu-Ni Pipe
(2 of 2)
29
EWI is the leading engineering and technology organization in North America dedicated
to developing, testing, and implementing advanced manufacturing technologies for
industry. Since 1984, EWI has offered applied research, manufacturing support, and
strategic services to leaders in the aerospace, automotive, consumer electronic,
medical, energy, government and defense, and heavy manufacturing sectors. By
matching our expertise to the needs of forward-thinking manufacturers, our technology
team serves as a valuable extension of our clients’ innovation and R&D teams to
provide premium, game-changing solutions that deliver a competitive advantage in the
global marketplace.
Columbus, Ohio
EWI (Headquarters)
1250 Arthur E. Adams Drive
Columbus, OH 43221
614.688.5000
Buffalo, New York
Buffalo Manufacturing Works
847 Main Street
Buffalo, NY 14203
716.710.5500
Loveland, Colorado
Rocky Mountain Center for Innovation & Technology
815 14th Street SW
Loveland, CO 80537
970.635.5105
EWI FACILITIES AND LABS
