Betydelsen av Svetsteknologin, sett ur ett värdeskapande...
Transcript of Betydelsen av Svetsteknologin, sett ur ett värdeskapande...
Betydelsen av Svetsteknologin, sett ur ett värdeskapande perspektiv.
The significance of Welding Technology, from a value added perspective.
SVK 1
• What is welding? • Development & Economy • The Arc • Pipelines • Summary
”Inom svetsningstekniken finnas dock en hel ouppklarade problem, vilka äro
ägnade att bearbetas vid de tekniska högskolornas laboratorier …
värmespänningar … lämpliga konstruktioner … lämpliga provningsmetoder
Hand i hand därmed bör självfallet undervisning bedrivas vid högskolorna…”
Teknisk Tidskrift 10, SEPT. 1932 SVETSNINGSTEKNIK SOM LÄROÄMNE
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What is welding? This…?
3
…or this?
4
Tandem arc
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Development & Economy
“Solve customers problems. Give them
the possibility to increased profitability,
safety and quality in their business.
Help them to introduce new and better
technology. “
Gustaf Dalén, AGA
Welding of lead 1840,
de Richemond
Carbon arc 1881, Bernardos Nikolay Nikolayevich
Metallic arc 1888, Slavianoff
Coated electrode 1904, Kjellberg Swedish patent: 27152, June 29, 1907
Gas welding
Le Chatelier 1895
Oxy-Acetylene1901
Picard, Fouche
Oxy-Hydrogen 1898,
Wiss
Gas shielded arc, 1930
Hobart, Devers
MAG-welding (CO2) 1946,
Gibson
MIG-welding 1948,
Airco
Submerged arc, 1930
Kennedy
TIG-welding 1941,
Meredith
Demonstration 1902
Dalén & Gylling
Development of fusion welding
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Manual Metal Arc – MMA 10 % (50%)
Gas Metal Arc Welding – GMAW (MIG/MAG) 85 % (40%)
Submerged Arc Welding – SAW 5 % (8%)
Estimated Weld Metal Deposited 1976 – 2006, ESAB.
30 years of conversion
Sweden; steel consumption ca 500 kg per capita
finished steel products. EU average 370 kg per
capita. World Steel Association, 2008
Weight reduction of welding power sources
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400 Amp power sources
1955 - 1990
100 Amp and 65 years
ESAB
1920 Welding transformer
1910 Welding converter
1950 Rectifier
1970 Thyristor controlled rectifier
1980 Primary switched inverter
M G
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Space frame welding
GMAW/GTAW, Steel & AL
Laser welding
& brazing
Stud welding
Structural gluing
Spot welding
Hybrid methods
Laser + GMAW Gas Metal
Arc Welding
Folding Clinching
Riveting
Press joining
bolts, nuts, inserts
MIG brazing
Joining complexity – Processes, Design and Materials
Car body joining
technologies
Gas Metal
Arc Welding
Space frame welding
GMAW/GTAW, Steel & AL
Laser welding
& brazing
Hybrid methods
Laser + GMAW
Spot welding
Stud welding
Structural gluing
Folding Clinching
Riveting
Press joining
bolts, nuts, inserts
MIG brazing
AGA
IWE
Materials
Capability
What is Welding Technology?
Simulation Modeling
Experiments
Karlöf, DVS
Productivity
To do it right. Units/hour.
Efficiency
Customer value. Value/price. Right things.
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Choquet
Efficiency and Productivity, an act of balance
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Low High
High
Efficiency
Customer value,
“right things”
Productivity
“to do it right”, units/h
Karlöf
Trabant
Saab
Methods
Materials
Automatization
QA, Simulation & Design
Safety & Health
2008
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DVS research areas (founding spent)
Methods Spending
Gas shielded arc
welding
38%
Other welding
methods
19%
Laser welding 14%
Hybrid methods 14%
Resistance welding 10%
Electron beam welding 5%
DVS Forschung in der Fügetechnik 2008
Cap
ital c
ost
SE
K
Welding speed m/min
Oxy-Acetylene
Arc welding
Electron Beam & Laser
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105
106
107
0,05 5 0,5 50 Mendez & Eager
Investments and welding speed
Investment
Complexity & Analysis
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W/mm2
106
105
104
103
Plasma welding
Is it…?
• Cheap filler materials
• High welding speed
• Small amount of rework
• No distortions
Or is it…?
• High process throughput
• Low non-value added time
• Low part support time
• Stability in the process
• No “bottlenecks”
What is efficient welding ?
VCE, ABB T50 14
Example: ABB T50 program
• Total value adding time: 18%
• Non-value adding time + support time: 82%
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Growth sectors
Sector
• High Strength Steels
• Stainless Steels
• Duplex Steels and other high-alloyed
• Aluminium alloys
• Thermal Spraying
• Robotic Welding
• Lasers
• Customer Services
Growth rates p.a.
5 -10 %
5 - 7 %
> 25 % (small it is a niche)
8 %
10 %
10%
10%
> 25 %
Global welding segments and comparison
Sector Annual growth to 2015 Comment
Aerospace Volatile Highly specified
Automotive
Heavy Vehicles
1,5 to 2% Highly specified
Specialist area
Construction 2 to 2,5% Lower end technology
Electrical industries
generally
2 to 3% Interesting growing niches
Machinery 3 to 3,5% Many and varied
applications
Process, Chemical, Oil %
Gas
1,5 – 2,5% Processing, Tanks,
Pipelines
Rail Several big projects Line & Track
Rolling stock
Ship building Volatile Specialist area
AGA, Metra 16
Cost versus low price - what’s the risk?
“It’s unwise to pay too much, but it’s also unwise to pay too little ….
• too much - you loose a little,
• too less - you sometimes loose everything.
Thus for a lowest bidder, it is well to add something to the risk you run,
then you will have enough to pay for something better”
Professor in Art
at Oxford
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The Arc
Der Schweißlichtbogen - ein technologisches Werkzeug by M. Schellhase
GMAW material transfer (solid wire)
Also IIW classification 19
• Spray
Streaming
Free flight
• Globular
• Rotating
• Explosive
• Dip
Penetration profiles – GMAW solid wire
AGA 20
• Tailored welding arcs
• Digital feedback and
control systems
• Constant current feed-
back systems
Cost ˜ a2
a = throat thickness
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Same weld – Gain in productivity 100%!
Traditional spray arc
Forced short arc
AGA
Ar + 8%CO2
Conventional spray and Rotating spray arc: +160% in productivity!
Rotating MAG
Plate thickness [mm] 10 10
Welding speed [cm/min] 55 3x63
Deposition rate [kg/h] 14.4 7.4
Throat thickness [mm] 8.0 8.0
1 pass 3 passes
AGA
Rotating spray
Conventional spray
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Ar + 8%CO2
Process parameter windows
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Short
arc
Spray
arc
Forced short arc
Moderated spray arc
Rotating spray arc Arc voltage
Wire feed speed © AGA AB
CMT
AGA
Fume emission vs arc voltage at different wire feed speeds
mg/s
V
Carbon steel
AGA
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Short arc / Dip transfer Spray arc / Free flight transfer
AGA
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Forced short arc welding
AGA
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Moderated spray Rotating spray
AGA
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Pipelines
“The front gang”
CRC-Evans
Pipeline projects is an international business
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• Laser based vision system
• Control systems (QA)
• Tandem welding (two wire solution)
• Digital-to-Digital system communication
CRC-Evans Pipeline International
30 CRC-Evans
High Strength Steel Pipeline Economics
CAPEX ($M)
X70 (490 MPa)
X120 (827 MPa)
X120 Savings
Linepipe 1 850 1 820 30
Freight 800 530 270
Other material 490 480 10
Construction 1 620 1 300 320
Compr. Stations 1 100 1 050 50
Indirect Costs 910 830 80
Total Project 6 770 6 010 760
Optimum OD 35” 32”
Corbett et al. 31
Present development; X120 pipelines (TMCP steels)
Tensile property Charpy-V impact property DWTT
YS TS E, -30 C vTrs SA -20 C
827 MPa 931 MPa 231 J - 50 C 75%
Parent metal (target values), 16 mm thickness
Tensile property Charpy-V impact Fracture toughness
Welded joint HAZ WM HAZ WM
TS E, -30 C E, -30 C CTOD, -20 C CTOD, -20 C
931 MPa 84 J 84 J 0,08 mm 0,08 mm
Mechanical properties for the weldment (target values)
C Si Mn Others Ec Pcm
0,05 0,06 1,56 Cu, Ni, Cr, Mo, Nb, V, Ti, B 0,52 0,20
P < 0,008 % & S < 0,001 %. Vacuum degassed. Martensite + low temprature bainite.
Chemical analysis of parent metal
Okaguchi et al. 32
“Leak-before-break” criterion (thin walled pressure vessels)
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K1c > 1,908*Rel* a
• Irwin’s model and the Dugdale-model (1970)
• Jc plane stress and flow controlled fracture (1980, CEGB)
• Modern pipelines (X70) BM, WM & HAZ; > 180 – 390 kN/m
SSAB, SV & KTH
FAD
• Cleavage fracture speeds 500 – 800 m/s, or even higher
• Ductile fracture speeds 200 m/s - Fast Running Ductile Fractures
• Rupture times in the order of 0,1 - 1 ms for through wall rupture
• Maxey et al. 1972 (ASTM & Batelle) and Shoemaker, AISI, Mannesmann (1980)
• Empirical equations [f = (Rel, D, t)] : Jc > 150 kN/m
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“Crack arrest” criterion (pipelines)
Summary
• Longer life time, less corrosion and lower life cycle costs.
• Focus on working environment.
• New design rules and standards, e.g. new Eurocode and EN 3834
Safety, quality,
environment…
• Overall drive to reduce total supply costs
• Reduction of transactions costs
• Reduction of weight
• Process optimization
• Increasing degree of automatisation and robotisation
Productivity and
efficiency…
• Use of “new” materials…
• Development of new production technologies Applications and
technologies…
AGA, Linde