-
September 13, 2011
David WorkmanSenior Engineer, Resistance and Solid-State
WeldingEmail: [email protected]: 614.688.5244Resistance Seam
Cladding
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Resistance Seam Cladding for Linepipe BackgroundCRA pipe 316 SS
or High-Ni alloys CRA is becoming criticalGas applications with CO2
and Cl ionsFluid applications with H2SAbrasion resistanceVery
expensive as a solid pipeClad CRA pipeReduced cost per foot of
piping system Steel substrate with 2- to 3-mm clad layerCRA
cladding methods are:Roll bondingMetallurigical bonded50% of
marketMechanical bondPlastic deformation of CRA30% of marketOther
clad processes: explosion and arc cladding
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Why Resistance Seam Clad?Shorter turn time (reduced WIP)Faster
production rateSimple parts configurationFlexibility to alter pipe
or CRA on the flyLower cost $/per foot less than other
metallurgical cladding processes (estimated $1150/foot at 150-mm
diameter)Comparatively low capital investmentAbility to use DOM
pipe
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Flat Plate Trials EWI Project No. 51549GTOTrials between flat
steel plate and 1- to 3-mm CRA cladsThermal analyses associated
with the process evaluatedClads showed up to 100% bondingSurfaces
were flat to within 100 mImproved thermal profiles seen with
thinner clad layersShear test failed in base metalProof of concept
established
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Weld Quality when Applying CRAs to Steel Pipe with
RSeWCFull-face bonding observed during testingShear tests failed
consistently in the cladAdaptation to pipes showed better than 90%
bondingNo dilution seen on the sectioned pipe samplesTracking and
surface quality being addressed by improved tooling
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Metallographic SectionsNarrow fusion zone apparent between CRA
and PipeFree of voidsFusion zones overlap to create continuous
welded interface
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Process Adaptations to Round Pipe EWI Project No.
52864IRDAdaptation of deep reach seam welding system200-kVA
transformerDedicated tooling for pipe positioningFlood cooling
integral to the processSteel pipe ~10-mm wall 350-mm
diameterInconel 625 liner rolled from sheet stock ~2-mm
thickProcess adapted to the deep reach welding frameLower speeds
and currents
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Functionality of the Welding SystemWater cooling to protect
wheelsProcess adaptations for specific welding systemIndustrial
level cleaning of pipe for joiningDemonstrated overlays to create
continuous attachmentsMinimal residual heat from the processMinimal
disruption to clad surfaceWheel designs to minimize disruption of
external pipe surface
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How is it Applied to Line Pipes?DOM pipes can be used or welded
pipesInternal pig is used to transfer force and current through the
pipe section without compromising pipe wallNormal high current
Resistance seam welder is used to drive the system Systems can be
ganged to run multiple heads simultaneously40-foot section very
easily managed in production set-up
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Why Does it Work?The welding process is laid out to confine
fusion zone to the CRA Pipe ID interfaceProprietary surface
preparation techniquesResistance seam welding is an established
process for joining similar material thickness partsSolidification
of fusion zone occurs under welding force applied by wheels to
create sound microstructureProcess is self regulatingWelding force
maintains fit-up between CRA and Pipe ID
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Modeling of Thermal Profile in Joint
Chart1
1110.601906638851.5708655752481.0258660343
1172.1503576384961.0933757124663.5661447882
1221.49740742041049.0346474354810.143350071
1261.02838766721119.6455752275927.842712982
1292.65414208791176.33934151761022.3535709929
1317.90339254851221.85640267691098.2443784489
1337.9966342431258.39695686461159.1835359592
1353.90513184161287.72729693951208.1167130987
1366.3978683641311.26518930831247.4092358251
1376.07871618681330.14840574591278.960421317
1383.41562695311345.28972086921304.2953869365
1388.76325136231357.42103372451324.6387711666
1392.38008223171367.12874623551340.973930037
1394.44094949151374.88210862721354.0904704677
1395.04547109221381.0559019871364.622418193
1394.22286832561385.94855438621373.0788652194
1391.93337831911389.79656626091379.8685782534
1388.06633198361392.78594234041385.319757617
1382.43480450441395.06118272171389.6959017544
1374.76657979181396.73226769711393.2085441878
1364.69099213351397.87997396881396.0274785997
1398.55977922261398.2889662982
1398.80454380241400.1023228004
1398.62609910841401.555201912
1398.01581950271402.7178327266
1396.94420536421403.6464143509
1395.3594571391404.3858324505
1393.18497146061404.9718289273
1390.31563830481405.4327296078
1386.61276019511405.7908134528
1381.89734786041406.0633894757
1375.94146827331406.263633423
1368.45722685181406.4012246624
1359.08285124531406.4828140624
1347.36520402741406.5123454814
1332.73787899381406.4912464056
1314.49382228831406.4184969505
1406.2905805618
1406.1013140325
1405.8415486203
1405.4987278164
1405.0562803904
1404.4928193725
1403.7811082528
1402.8867444256
1401.7664962414
1400.3662132797
1398.6182088333
1396.4379880762
1393.7201637628
1390.3333620324
1386.1138720755
1380.8577327004
1374.3108732819
1366.1568325269
1356.0014614062
1343.3538708272
1327.6027030968
1307.9865801873
1283.5573003382
1253.1340039951
1-mm, 16.7-kA
1.8-mm, 16.7-kA
3-mm, 16.6-kA
Fractional Distance Through the CRA
Temperature (C)
Rosenthal
Z (mm)Current =4900A
x0.20.5125clad =0.00000113Ohm-m
-22509.69423058862423.3940793582162.45145003681530.13862274497.9982511741tclad
=3mm
-1.83001.25455501362878.63749215762519.94918172521713.4043328445530.9186291704rcontact
=5mm
-1.63632.11153887623452.24582433162948.61528477311914.5282112009564.6932188467k
=51.9W/m-C
-1.44461.75222489994187.34866862373463.20340865152132.5530157633599.1317486032V
=0.00508m/s
-1.25587.49674998945147.79162154884079.11692735422365.0367064416634.0172120501
=0.0000135693m2/s
-17179.34772673816429.26129752224808.65131751692607.5999301083669.1088949886Cp
=486J/kg-C
-0.89560.34193979078172.91442490875652.43165846472853.5942119415704.1467219206density
=7870kg/m3
-0.613414.634044704410564.915201076583.3904441013094.0882675626738.8568382333
-0.420389.750639311513735.26658446717524.8354512763318.388309289772.9582344712
-0.234514.636368781117280.82217993238339.12847166553515.2084476339806.1701135223
051464.988941860719461.82202227118861.47881332623674.3592236082838.2196145506
0.237198.132769929318624.39780487148987.49170526083788.51421617868.8494526651
0.423683.593072555815954.11686410778740.42767459663854.4541208073897.8250205769
0.616793.156815189913225.72625682548241.44048469623873.3452812847924.9405318906
0.812898.665420668211026.76968486747626.17333510623850.0251578862950.0238621499
110439.36731035739348.67940288416992.17801974343791.6666673605972.939853491
1.28756.37417573988067.29589902766392.53599969893706.3370714267993.5919770478
1.47535.81650260867072.35400098855849.28612870063601.84237017711011.9223773037
1.66611.5285976726284.11923738015367.36112593113485.01357513961027.9104386954
1.85887.93997795835647.38660498194943.70246093163361.40160217661041.5701049127
25306.39032211455123.92096720044572.19501350433235.25976999081052.9462387299
2.24828.95731309414686.8499534364246.05111638753109.68620709311062.1103336005
2.44430.06928776994316.92437905413958.84530322012986.82985670041069.1558811354
2.64091.87088391444000.08184694283704.89025541982868.10146276541074.1936676466
2.83801.5241414813725.85366992543479.31159464042754.36057768761077.3472263568
33549.56570838163486.30885427093277.99662281162646.06846249751078.7486177299
3.23328.86854235233275.34184235823097.49917714552543.40685619551078.5346556077
4.8989794856
Rosenthal
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Z = 0
Z = 0.5
Z = 1.0
Z = 1.5
Z = 2
Distance along centerline (mm)
Temp (deg C)
1D analysis
x(mm) (C)d/dx (C/mm)I1Current =16600A
0851.572439.58090393I2clad =0.00000113Ohm-m
0.05961.091958.8817367996I3tclad =1.8mm
0.11049.031572.8707565185I4rcontact =3.2mm
0.151119.651262.8890113285I5k =11.1W/m-C
0.21176.341013.952641379I6V =0.3m/s3452.8
0.251221.86814.0285907336I7 =0.0000030992m2/s
0.31258.40653.4529549783I8Cp =440J/kg-C
0.351287.73524.463848586I9density =8140kg/m3
0.41311.27420.8262118396I10Q =17422.7884009371J/s
0.451330.15337.5304212748I11 =4388.36693776361/m
0.51345.29270.5501351106I12c1 =-0.03
0.551357.42216.6476684309I13c2 =-555.9544494204
0.61367.13173.2174903654I14fe=0.05
0.651374.88138.1602782556I15fb=0.0083333333fraction heat soak
into the base plate
0.71381.06109.7814408514
0.751385.9586.7092053665
0.81389.8067.8283088914
0.851392.7952.226088951810.0697567001
0.91395.0639.14836734
0.951396.7327.9629947414
11397.8818.1292939773
1.051398.569.1719248179
1.11398.800.6579070433
1.151398.63-7.8243089007
1.21398.02-16.6847353355
1.251396.94-26.3516664752
1.31395.36-37.2923812599
1.351393.18-50.0357306287
1.41390.32-65.1977010515
1.451386.61-83.5111900083
1.51381.90-105.86143269812378.0096
1.551375.94-133.3287924301
1.61368.46-167.2409830945
1.651359.08-209.2372480338
1.71347.37-261.3475975886
1.751332.74-326.0909354899
1.81314.49-406.5968173209
1.851291.75-506.7567265939
1.91263.41-631.4121808064
1.951228.10-786.5887601241
21184.12-979.7873711412
2.051129.34-1220.3468247903
2.11061.10-1519.8952546476
2.15976.12-1892.9121962377
2.2870.29-2357.4284970588
2.25738.48-2935.8978894933
2.3574.34-3656.2823565891
2.35369.92-4553.4037549914
2.4115.33-5670.6270296086
2.45-201.71-7061.9563830385
2.5-596.54-8794.6457241371
2.55-1088.25-10952.449579275
2.6-1700.60-13639.6716084338
2.65-2463.19-16986.2064228205
2.7-3412.88-21153.8184147666
2.75-4595.58-26343.9611052248
2.8-6068.46-32807.5149795333
2.85-7902.72-40856.9145177647
2.9-10187.02-50881.2506145767
2.95-13031.77-63365.0784074968
3-16574.49-78911.8396441523
1D analysis
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(C)
d/dx (C/mm)
Distance Through CRA (mm)
Temperature (C)
Temp. Gradient (C/mm)
Model element
Influence of Speed
x(mm)50-mm/min, 6.9-kA100-mm/min, 9.7-kA300-mm/min, 16.7-kA
01202.39283109051100.407642541851.5708655752
0.051222.24505728231139.1153011334961.0933757124
0.11240.36425026931173.1966286011049.0346474354
0.151256.89589694121203.19929859691119.6455752275
0.21271.9727370871229.60544233771176.3393415176
0.251285.71582922061252.83939626431221.8564026769
0.31298.23552261261273.27452096341258.3969568646
0.351309.63234333221291.23920092671287.7272969395
0.41319.99780141531307.02212156131311.2651893083
0.451329.41512563771320.87690825221330.1484057459
0.51337.95993179621333.02620202311345.2897208692
0.551345.70082985961343.66523729111357.4210337245
0.61352.6999748691352.96497920761367.1287462355
0.651359.0135660071361.07487100151374.8821086272
0.71364.69229784591368.1252354741381.055901987
0.751369.78176739611374.22936923521385.9485543862
0.81374.32284022451379.48536333621389.7965662609
0.851378.35197858211383.97767955411392.7859423404
0.91381.90153417511387.77850766031395.0611827217
0.951385.00000793081390.94892548141396.7322676971
11387.6722788441393.53988039651397.8799739688
1.051389.93980374141395.59300804161398.5597792226
1.11391.82078956771397.14130137791398.8045438024
1.151393.33033957711398.2096408761398.6260991084
1.21394.48057460381398.81519433551398.0158195027
1.251395.28073038571398.96769276451396.9442053642
1.31395.7372317221398.66958675331395.359457139
1.351395.85374406071397.91608585441393.1849714606
1.41395.631202931396.69508160211390.3156383048
1.451395.06782145031394.98695293371386.6127601951
1.51394.15907598651392.76425088711381.8973478604
1.551392.89766982541389.99125750641375.9414682733
1.61391.27347458791386.62341186851368.4572268518
1.651389.27344890321382.60659400631359.0828512453
1.71386.88153369431377.87625522181347.3652040274
1.751384.07852323251372.35638081381332.7378789938
1.81380.84191092631365.95826855151314.4938222883
1377.14570860641358.5791032637
1372.96023785511350.1003046394
1368.25189170521340.3856216885
1362.98286479561329.2789432412
1357.1108498151316.6017893024
1350.58869779841302.1504429479
1343.36403954771285.6926766725
1335.37886513611266.9640205849
1326.56905812151245.6635124791
1316.86388072761221.4488614895
1306.18540585941193.9309476096
1294.44789139281162.6675686856
1281.55709171371127.1563343995
1267.40950097881086.8265930529
1251.89152202221041.0302614167
1234.8785542344989.0314102854
1216.2339930894929.9944383822
1195.8081332881862.970644572
1173.4369667087786.8829826032
1148.9408655142700.5087533949
1122.1231398427602.4599567387
1092.7684584983491.160986676
1060.6411199633364.8233121245
1025.4831598485221.4167358805
Influence of Speed
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50-mm/min, 6.9-kA
100-mm/min, 9.7-kA
300-mm/min, 16.7-kA
Distance Through CRA (mm)
Temperature (C)
Influence of clad thickness
1.8-mm, 16.7-kA1-mm, 16.7-kA3-mm, 16.6-kA
f(thick)x(mm) (C)f(thick)x(mm) (C)f(thick)x(mm) (C)
00851.5708655752001110.60190663800481.0258660343
0.02777777780.05961.09337571240.050.051172.15035763840.01666666670.05663.5661447882
0.05555555560.11049.03464743540.10.11221.49740742040.03333333330.1810.143350071
0.08333333330.151119.64557522750.150.151261.02838766720.050.15927.842712982
0.11111111110.21176.33934151760.20.21292.65414208790.06666666670.21022.3535709929
0.13888888890.251221.85640267690.250.251317.90339254850.08333333330.251098.2443784489
0.16666666670.31258.39695686460.30.31337.9966342430.10.31159.1835359592
0.19444444440.351287.72729693950.350.351353.90513184160.11666666670.351208.1167130987
0.22222222220.41311.26518930830.40.41366.3978683640.13333333330.41247.4092358251
0.250.451330.14840574590.450.451376.07871618680.150.451278.960421317
0.27777777780.51345.28972086920.50.51383.41562695310.16666666670.51304.2953869365
0.30555555560.551357.42103372450.550.551388.76325136230.18333333330.551324.6387711666
0.33333333330.61367.12874623550.60.61392.38008223170.20.61340.973930037
0.36111111110.651374.88210862720.650.651394.44094949150.21666666670.651354.0904704677
0.38888888890.71381.0559019870.70.71395.04547109220.23333333330.71364.622418193
0.41666666670.751385.94855438620.750.751394.22286832560.250.751373.0788652194
0.44444444440.81389.79656626090.80.81391.93337831910.26666666670.81379.8685782534
0.47222222220.851392.78594234040.850.851388.06633198360.28333333330.851385.319757617
0.50.91395.06118272170.90.91382.43480450440.30.91389.6959017544
0.52777777780.951396.73226769710.950.951374.76657979180.31666666670.951393.2085441878
0.555555555611397.8799739688111364.69099213350.333333333311396.0274785997
0.58333333331.051398.55977922261.051351.72100900030.351.051398.2889662982
0.61111111111.11398.80454380241.11335.2296889270.36666666671.11400.1023228004
0.63888888891.151398.62609910841.151314.41987649190.38333333331.151401.555201912
0.66666666671.21398.01581950271.21288.28566951580.41.21402.7178327266
0.69444444441.251396.94420536421.251255.56379588450.41666666671.251403.6464143509
0.72222222221.31395.3594571391.31214.67254965490.43333333331.31404.3858324505
0.751.351393.18497146061.351163.63533474650.451.351404.9718289273
0.77777777781.41390.31563830481.41099.98512048010.46666666671.41405.4327296078
0.80555555561.451386.61276019511.451020.64519054940.48333333331.451405.7908134528
0.83333333331.51381.89734786041.5921.78042108340.51.51406.0633894757
0.86111111111.551375.94146827331.55798.61189889460.51666666671.551406.263633423
0.88888888891.61368.45722685181.6645.18591895670.53333333331.61406.4012246624
0.91666666671.651359.08285124531.65454.08619493480.551.651406.4828140624
0.94444444441.71347.36520402741.7216.07537164050.56666666671.71406.5123454814
0.97222222221.751332.73787899381.75-80.35148911860.58333333331.751406.4912464056
11.81314.49382228831.8-449.52303284040.61.81406.4184969505
1.851291.75115491951.85-909.28422864920.61666666671.851406.2905805618
1.91263.41054460161.9-1481.85895724020.63333333331.91406.1013140325
1.951228.10206636441.95-2194.92426611830.651.951405.8415486203
21184.11898328642-3082.94821935020.666666666721405.4987278164
2.051129.33524645392.05-4188.85601064730.68333333332.051405.0562803904
2.11061.10272626732.1-5566.10487615280.72.11404.4928193725
2.15976.12320747482.15-7281.2681038120.71666666672.151403.7811082528
2.2870.28896044542.2-9417.25304485830.73333333332.21402.8867444256
2.25738.48418223442.25-12077.30867926090.752.251401.7664962414
2.3574.33770952322.3-15390.01645234560.76666666672.31400.3662132797
2.35369.91505010282.35-19515.50562904030.78333333332.351398.6182088333
2.4115.3348463562.4-24653.19360278390.82.41396.4379880762
2.45-201.70876860432.45-31051.42530920570.81666666672.451393.7201637628
2.5-596.54101042982.5-39019.47769338150.83333333332.51390.3333620324
2.55-1088.2472319452.55-48942.50950114280.852.551386.1138720755
2.6-1700.59546860752.6-61300.17903562890.86666666672.61380.8577327004
2.65-2463.18533491212.65-76689.82982193380.88333333332.651374.3108732819
2.7-3412.87880695122.7-95855.36492568130.92.71366.1568325269
2.75-4595.58205212672.75-119723.2056488190.91666666672.751356.0014614062
2.8-6068.46443587932.8-149447.07276970.93333333332.81343.3538708272
2.85-7902.72196751382.85-186463.7549575690.952.851327.6027030968
2.9-10187.01876422612.9-232562.560088290.96666666672.91307.9865801873
2.95-13031.7728864042.95-289971.806590560.98333333332.951283.5573003382
3-16574.49371238353-361466.535630754131253.1340039951
Influence of clad thickness
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1-mm, 16.7-kA
1.8-mm, 16.7-kA
3-mm, 16.6-kA
Fractional Distance Through the CRA
Temperature (C)
MBD00ECDFDB.unknown
MBD00ED03CD.unknown
MBD04DA4671.unknown
MBD04DA467F.unknown
MBD04DA4661.unknown
MBD00ECEEBF.unknown
MBD00EAE688.unknown
MBD00EC2EDF.unknown
MBD00ECB6D1.unknown
MBD00EB1E4D.unknown
MBD00EA42E5.unknown
MBD00EABBEC.unknown
MBD001D3753.unknown
MBD001DB22D.unknown
-
Speed Effect on Thermal Profile in Joint
Chart2
1202.39283109051100.407642541851.5708655752
1222.24505728231139.1153011334961.0933757124
1240.36425026931173.1966286011049.0346474354
1256.89589694121203.19929859691119.6455752275
1271.9727370871229.60544233771176.3393415176
1285.71582922061252.83939626431221.8564026769
1298.23552261261273.27452096341258.3969568646
1309.63234333221291.23920092671287.7272969395
1319.99780141531307.02212156131311.2651893083
1329.41512563771320.87690825221330.1484057459
1337.95993179621333.02620202311345.2897208692
1345.70082985961343.66523729111357.4210337245
1352.6999748691352.96497920761367.1287462355
1359.0135660071361.07487100151374.8821086272
1364.69229784591368.1252354741381.055901987
1369.78176739611374.22936923521385.9485543862
1374.32284022451379.48536333621389.7965662609
1378.35197858211383.97767955411392.7859423404
1381.90153417511387.77850766031395.0611827217
1385.00000793081390.94892548141396.7322676971
1387.6722788441393.53988039651397.8799739688
1389.93980374141395.59300804161398.5597792226
1391.82078956771397.14130137791398.8045438024
1393.33033957711398.2096408761398.6260991084
1394.48057460381398.81519433551398.0158195027
1395.28073038571398.96769276451396.9442053642
1395.7372317221398.66958675331395.359457139
1395.85374406071397.91608585441393.1849714606
1395.631202931396.69508160211390.3156383048
1395.06782145031394.98695293371386.6127601951
1394.15907598651392.76425088711381.8973478604
1392.89766982541389.99125750641375.9414682733
1391.27347458791386.62341186851368.4572268518
1389.27344890321382.60659400631359.0828512453
1386.88153369431377.87625522181347.3652040274
1384.07852323251372.35638081381332.7378789938
1380.84191092631365.95826855151314.4938222883
50-mm/min, 6.9-kA
100-mm/min, 9.7-kA
300-mm/min, 16.7-kA
Distance Through CRA (mm)
Temperature (C)
Rosenthal
Z (mm)Current =4900A
x0.20.5125clad =0.00000113Ohm-m
-22509.69423058862423.3940793582162.45145003681530.13862274497.9982511741tclad
=3mm
-1.83001.25455501362878.63749215762519.94918172521713.4043328445530.9186291704rcontact
=5mm
-1.63632.11153887623452.24582433162948.61528477311914.5282112009564.6932188467k
=51.9W/m-C
-1.44461.75222489994187.34866862373463.20340865152132.5530157633599.1317486032V
=0.00508m/s
-1.25587.49674998945147.79162154884079.11692735422365.0367064416634.0172120501
=0.0000135693m2/s
-17179.34772673816429.26129752224808.65131751692607.5999301083669.1088949886Cp
=486J/kg-C
-0.89560.34193979078172.91442490875652.43165846472853.5942119415704.1467219206density
=7870kg/m3
-0.613414.634044704410564.915201076583.3904441013094.0882675626738.8568382333
-0.420389.750639311513735.26658446717524.8354512763318.388309289772.9582344712
-0.234514.636368781117280.82217993238339.12847166553515.2084476339806.1701135223
051464.988941860719461.82202227118861.47881332623674.3592236082838.2196145506
0.237198.132769929318624.39780487148987.49170526083788.51421617868.8494526651
0.423683.593072555815954.11686410778740.42767459663854.4541208073897.8250205769
0.616793.156815189913225.72625682548241.44048469623873.3452812847924.9405318906
0.812898.665420668211026.76968486747626.17333510623850.0251578862950.0238621499
110439.36731035739348.67940288416992.17801974343791.6666673605972.939853491
1.28756.37417573988067.29589902766392.53599969893706.3370714267993.5919770478
1.47535.81650260867072.35400098855849.28612870063601.84237017711011.9223773037
1.66611.5285976726284.11923738015367.36112593113485.01357513961027.9104386954
1.85887.93997795835647.38660498194943.70246093163361.40160217661041.5701049127
25306.39032211455123.92096720044572.19501350433235.25976999081052.9462387299
2.24828.95731309414686.8499534364246.05111638753109.68620709311062.1103336005
2.44430.06928776994316.92437905413958.84530322012986.82985670041069.1558811354
2.64091.87088391444000.08184694283704.89025541982868.10146276541074.1936676466
2.83801.5241414813725.85366992543479.31159464042754.36057768761077.3472263568
33549.56570838163486.30885427093277.99662281162646.06846249751078.7486177299
3.23328.86854235233275.34184235823097.49917714552543.40685619551078.5346556077
4.8989794856
Rosenthal
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
Z = 0
Z = 0.5
Z = 1.0
Z = 1.5
Z = 2
Distance along centerline (mm)
Temp (deg C)
1D analysis
x(mm) (C)d/dx (C/mm)I1Current =16600A
0851.572439.58090393I2clad =0.00000113Ohm-m
0.05961.091958.8817367996I3tclad =1.8mm
0.11049.031572.8707565185I4rcontact =3.2mm
0.151119.651262.8890113285I5k =11.1W/m-C
0.21176.341013.952641379I6V =0.3m/s3452.8
0.251221.86814.0285907336I7 =0.0000030992m2/s
0.31258.40653.4529549783I8Cp =440J/kg-C
0.351287.73524.463848586I9density =8140kg/m3
0.41311.27420.8262118396I10Q =17422.7884009371J/s
0.451330.15337.5304212748I11 =4388.36693776361/m
0.51345.29270.5501351106I12c1 =-0.03
0.551357.42216.6476684309I13c2 =-555.9544494204
0.61367.13173.2174903654I14fe=0.05
0.651374.88138.1602782556I15fb=0.0083333333fraction heat soak
into the base plate
0.71381.06109.7814408514
0.751385.9586.7092053665
0.81389.8067.8283088914
0.851392.7952.226088951810.0697567001
0.91395.0639.14836734
0.951396.7327.9629947414
11397.8818.1292939773
1.051398.569.1719248179
1.11398.800.6579070433
1.151398.63-7.8243089007
1.21398.02-16.6847353355
1.251396.94-26.3516664752
1.31395.36-37.2923812599
1.351393.18-50.0357306287
1.41390.32-65.1977010515
1.451386.61-83.5111900083
1.51381.90-105.86143269812378.0096
1.551375.94-133.3287924301
1.61368.46-167.2409830945
1.651359.08-209.2372480338
1.71347.37-261.3475975886
1.751332.74-326.0909354899
1.81314.49-406.5968173209
1.851291.75-506.7567265939
1.91263.41-631.4121808064
1.951228.10-786.5887601241
21184.12-979.7873711412
2.051129.34-1220.3468247903
2.11061.10-1519.8952546476
2.15976.12-1892.9121962377
2.2870.29-2357.4284970588
2.25738.48-2935.8978894933
2.3574.34-3656.2823565891
2.35369.92-4553.4037549914
2.4115.33-5670.6270296086
2.45-201.71-7061.9563830385
2.5-596.54-8794.6457241371
2.55-1088.25-10952.449579275
2.6-1700.60-13639.6716084338
2.65-2463.19-16986.2064228205
2.7-3412.88-21153.8184147666
2.75-4595.58-26343.9611052248
2.8-6068.46-32807.5149795333
2.85-7902.72-40856.9145177647
2.9-10187.02-50881.2506145767
2.95-13031.77-63365.0784074968
3-16574.49-78911.8396441523
1D analysis
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
(C)
d/dx (C/mm)
Distance Through CRA (mm)
Temperature (C)
Temp. Gradient (C/mm)
Model element
Influence of Speed
x(mm)50-mm/min, 6.9-kA100-mm/min, 9.7-kA300-mm/min, 16.7-kA
01202.39283109051100.407642541851.5708655752
0.051222.24505728231139.1153011334961.0933757124
0.11240.36425026931173.1966286011049.0346474354
0.151256.89589694121203.19929859691119.6455752275
0.21271.9727370871229.60544233771176.3393415176
0.251285.71582922061252.83939626431221.8564026769
0.31298.23552261261273.27452096341258.3969568646
0.351309.63234333221291.23920092671287.7272969395
0.41319.99780141531307.02212156131311.2651893083
0.451329.41512563771320.87690825221330.1484057459
0.51337.95993179621333.02620202311345.2897208692
0.551345.70082985961343.66523729111357.4210337245
0.61352.6999748691352.96497920761367.1287462355
0.651359.0135660071361.07487100151374.8821086272
0.71364.69229784591368.1252354741381.055901987
0.751369.78176739611374.22936923521385.9485543862
0.81374.32284022451379.48536333621389.7965662609
0.851378.35197858211383.97767955411392.7859423404
0.91381.90153417511387.77850766031395.0611827217
0.951385.00000793081390.94892548141396.7322676971
11387.6722788441393.53988039651397.8799739688
1.051389.93980374141395.59300804161398.5597792226
1.11391.82078956771397.14130137791398.8045438024
1.151393.33033957711398.2096408761398.6260991084
1.21394.48057460381398.81519433551398.0158195027
1.251395.28073038571398.96769276451396.9442053642
1.31395.7372317221398.66958675331395.359457139
1.351395.85374406071397.91608585441393.1849714606
1.41395.631202931396.69508160211390.3156383048
1.451395.06782145031394.98695293371386.6127601951
1.51394.15907598651392.76425088711381.8973478604
1.551392.89766982541389.99125750641375.9414682733
1.61391.27347458791386.62341186851368.4572268518
1.651389.27344890321382.60659400631359.0828512453
1.71386.88153369431377.87625522181347.3652040274
1.751384.07852323251372.35638081381332.7378789938
1.81380.84191092631365.95826855151314.4938222883
1377.14570860641358.5791032637
1372.96023785511350.1003046394
1368.25189170521340.3856216885
1362.98286479561329.2789432412
1357.1108498151316.6017893024
1350.58869779841302.1504429479
1343.36403954771285.6926766725
1335.37886513611266.9640205849
1326.56905812151245.6635124791
1316.86388072761221.4488614895
1306.18540585941193.9309476096
1294.44789139281162.6675686856
1281.55709171371127.1563343995
1267.40950097881086.8265930529
1251.89152202221041.0302614167
1234.8785542344989.0314102854
1216.2339930894929.9944383822
1195.8081332881862.970644572
1173.4369667087786.8829826032
1148.9408655142700.5087533949
1122.1231398427602.4599567387
1092.7684584983491.160986676
1060.6411199633364.8233121245
1025.4831598485221.4167358805
Influence of Speed
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
50-mm/min, 6.9-kA
100-mm/min, 9.7-kA
300-mm/min, 16.7-kA
Distance Through CRA (mm)
Temperature (C)
Influence of clad thickness
1.8-mm, 16.7-kA1-mm, 16.7-kA3-mm, 16.6-kA
f(thick)x(mm) (C)f(thick)x(mm) (C)f(thick)x(mm) (C)
00851.5708655752001110.60190663800481.0258660343
0.02777777780.05961.09337571240.050.051172.15035763840.01666666670.05663.5661447882
0.05555555560.11049.03464743540.10.11221.49740742040.03333333330.1810.143350071
0.08333333330.151119.64557522750.150.151261.02838766720.050.15927.842712982
0.11111111110.21176.33934151760.20.21292.65414208790.06666666670.21022.3535709929
0.13888888890.251221.85640267690.250.251317.90339254850.08333333330.251098.2443784489
0.16666666670.31258.39695686460.30.31337.9966342430.10.31159.1835359592
0.19444444440.351287.72729693950.350.351353.90513184160.11666666670.351208.1167130987
0.22222222220.41311.26518930830.40.41366.3978683640.13333333330.41247.4092358251
0.250.451330.14840574590.450.451376.07871618680.150.451278.960421317
0.27777777780.51345.28972086920.50.51383.41562695310.16666666670.51304.2953869365
0.30555555560.551357.42103372450.550.551388.76325136230.18333333330.551324.6387711666
0.33333333330.61367.12874623550.60.61392.38008223170.20.61340.973930037
0.36111111110.651374.88210862720.650.651394.44094949150.21666666670.651354.0904704677
0.38888888890.71381.0559019870.70.71395.04547109220.23333333330.71364.622418193
0.41666666670.751385.94855438620.750.751394.22286832560.250.751373.0788652194
0.44444444440.81389.79656626090.80.81391.93337831910.26666666670.81379.8685782534
0.47222222220.851392.78594234040.850.851388.06633198360.28333333330.851385.319757617
0.50.91395.06118272170.90.91382.43480450440.30.91389.6959017544
0.52777777780.951396.73226769710.950.951374.76657979180.31666666670.951393.2085441878
0.555555555611397.8799739688111364.69099213350.333333333311396.0274785997
0.58333333331.051398.55977922261.051351.72100900030.351.051398.2889662982
0.61111111111.11398.80454380241.11335.2296889270.36666666671.11400.1023228004
0.63888888891.151398.62609910841.151314.41987649190.38333333331.151401.555201912
0.66666666671.21398.01581950271.21288.28566951580.41.21402.7178327266
0.69444444441.251396.94420536421.251255.56379588450.41666666671.251403.6464143509
0.72222222221.31395.3594571391.31214.67254965490.43333333331.31404.3858324505
0.751.351393.18497146061.351163.63533474650.451.351404.9718289273
0.77777777781.41390.31563830481.41099.98512048010.46666666671.41405.4327296078
0.80555555561.451386.61276019511.451020.64519054940.48333333331.451405.7908134528
0.83333333331.51381.89734786041.5921.78042108340.51.51406.0633894757
0.86111111111.551375.94146827331.55798.61189889460.51666666671.551406.263633423
0.88888888891.61368.45722685181.6645.18591895670.53333333331.61406.4012246624
0.91666666671.651359.08285124531.65454.08619493480.551.651406.4828140624
0.94444444441.71347.36520402741.7216.07537164050.56666666671.71406.5123454814
0.97222222221.751332.73787899381.75-80.35148911860.58333333331.751406.4912464056
11.81314.49382228831.8-449.52303284040.61.81406.4184969505
1.851291.75115491951.85-909.28422864920.61666666671.851406.2905805618
1.91263.41054460161.9-1481.85895724020.63333333331.91406.1013140325
1.951228.10206636441.95-2194.92426611830.651.951405.8415486203
21184.11898328642-3082.94821935020.666666666721405.4987278164
2.051129.33524645392.05-4188.85601064730.68333333332.051405.0562803904
2.11061.10272626732.1-5566.10487615280.72.11404.4928193725
2.15976.12320747482.15-7281.2681038120.71666666672.151403.7811082528
2.2870.28896044542.2-9417.25304485830.73333333332.21402.8867444256
2.25738.48418223442.25-12077.30867926090.752.251401.7664962414
2.3574.33770952322.3-15390.01645234560.76666666672.31400.3662132797
2.35369.91505010282.35-19515.50562904030.78333333332.351398.6182088333
2.4115.3348463562.4-24653.19360278390.82.41396.4379880762
2.45-201.70876860432.45-31051.42530920570.81666666672.451393.7201637628
2.5-596.54101042982.5-39019.47769338150.83333333332.51390.3333620324
2.55-1088.2472319452.55-48942.50950114280.852.551386.1138720755
2.6-1700.59546860752.6-61300.17903562890.86666666672.61380.8577327004
2.65-2463.18533491212.65-76689.82982193380.88333333332.651374.3108732819
2.7-3412.87880695122.7-95855.36492568130.92.71366.1568325269
2.75-4595.58205212672.75-119723.2056488190.91666666672.751356.0014614062
2.8-6068.46443587932.8-149447.07276970.93333333332.81343.3538708272
2.85-7902.72196751382.85-186463.7549575690.952.851327.6027030968
2.9-10187.01876422612.9-232562.560088290.96666666672.91307.9865801873
2.95-13031.7728864042.95-289971.806590560.98333333332.951283.5573003382
3-16574.49371238353-361466.535630754131253.1340039951
Influence of clad thickness
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0
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0
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1-mm, 16.7-kA
1.8-mm, 16.7-kA
3-mm, 16.6-kA
Fractional Distance Through the CRA
Temperature (C)
MBD00ECDFDB.unknown
MBD00ED03CD.unknown
MBD04DA58B8.unknown
MBD04DA58C1.unknown
MBD04DA4661.unknown
MBD00ECEEBF.unknown
MBD00EAE688.unknown
MBD00EC2EDF.unknown
MBD00ECB6D1.unknown
MBD00EB1E4D.unknown
MBD00EA42E5.unknown
MBD00EABBEC.unknown
MBD001D3753.unknown
MBD001DB22D.unknown
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State of TechnologyShown to meet or exceed user quality
specifications for flat plate applicationsRound pipe applications
require significant equipment investment to reach quality level of
flat plate trialsTo date results are above required levelsFurther
improvements are expected with tooling enhancementCost analysis
shows that the process is lower cost than competitive
technologies
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Questions?David WorkmanSenior Engineer, Resistance and
Solid-State WeldingEmail: [email protected]: 614.688.5244
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ALTHOUGH THERE ARE MANY CORROSION RESISTANT ALLOYS THE MOST
COMMONLY USED ARE STAINLESS STEEL AND A FEW OF THE HIGH NICKEL
ALLOYS.
THE NEED FOR CORROSION RESISTANT ALLOYS IN PIPING SYSTEMS IS TO
CONDUCT FLUIDS AND GASES THAT CONTAIN HIGHLY CORROSIVE CONTAMINANTS
NOT NORMALLY SUITABLE FOR CARBON STEEL PIPING.
FULL TUBE WALL THICKNESS OF CRAS CAN BE USED FOR CORROSIVE
FLUIDS BUT THE COST IS EXTREME - SO INTERIOR LINING OF LOWER COST
STEEL PIPING WITH THIN LAYER OF CORROSION RESISTANT ALLOYS PRESENTS
HIGH VALUE.
WHEN A CRA IS APPLIED TO THE PIPE INSIDE DIAMETER COST PER FOOT
OF THE PIPE SYSTEM IS REDUCED THE PIPING SYSTEM CAN CONDUCT HIGHLY
CORROSIVE MATERIALS STRUCTURAL INTEGRITY IS MAINTAINED BY THE HEAVY
WALL LOWER COST STEEL PIPING.
CLAD PIPING CAN BE FOUND IN DIAMETERS RANGING FROM 25MM TO OVER
400-MM WITH COMBINED WALL THICKNESSES OF OVER 20-MM. THE CLAD LAYER
NEED ONLY BE 2 3 MM THICK.
