Underwater Local Cavity Welding of S460N Steel

Influence of Butter Layer Thickness on Microstructure and Mechanical Properties of Underwater Wet 16Mn/304L Dissimilar Welded Joint

Butter layers of different thicknesses were successfully deposited on ferritic steel by using the tungsten arc welding (TIG) process. The effects of butter layer thickness on the microstructural characteristics, elemental distribution, and mechanical properties of underwater wet 16Mn/304L dissimilar welded joints were investigated. The results showed that the butter layer significantly changed the microstructure and elemental distribution of 16Mn/304L joints. As the thickness of butter increased, the heat-affected zone (HAZ) at the ferritic steel side changed from the original 16Mn steel to the ERNiCrMo-3 butter layer. The martensite content in HAZ also exhibited a downward trend. When the thickness of the butter layer exceeded 6 mm, the microstructure of HAZ at the ferritic steel side was composed of ferrite and pearlite, instead of quenched martensite. The microhardness of underwater dissimilar steel welded joints significantly reduced due to the absence of martensite. The addition of the butter layer increased the ultimate tensile strength from 515 MPa to 565 MPa. The results of this work could provide a robust basis for future applications of dissimilar steel structures.

Advanced Comparison of Phased Array and X-rays in the Inspection of Metallic Welding

The most common nondestructive weld inspection technique is X-rays and, since a few years ago, the ultrasound-based phased array. Their comparison has been done from the top view of both, with the result that the phased array is much more efficient in discovering flaws. From the last studies of the authors, a welding flaw can be three-dimensionally reconstructed from the sectorial phased array information. The same methodology is applied to compare quantitatively X-rays and phased array on 15 metal inert/active (MIG/MAG) welding specimens covering pores, slag intrusion and cracks. The results can be summarized in the correlation of the top views and in the correlation profiles between the X-ray top-view and the reconstructed top-view at the depths from phased array in the weld. The maximum correlation is the depth when the flaw in the X-ray looks like that in the phased array records at some depth, leading to an effective quantitative comparison of X-rays and phased array.

A Fast Finite Element Simulation Method of Phased Array Ultrasonic Testing and Its Application in Sleeve Fillet Weld Inspection

Numerical simulation can provide quantitative information on ultrasonic beam propagation and plays an important role in analyzing its detection ability and in optimizing the corresponding parameters of the phased array ultrasonic testing (PAUT). In this paper, a fast finite element simulation method of PAUT is developed using an improved explicit integration algorithm and a non-zero element compressed storage method. The new method is applied for the simulation of PAUT of a type-B sleeve weld, and compared with the commercial finite element software and experiment results. We found that the computation time and memory consumption of the new method is only about a 15th and a 40th of the commercial finite element software, respectively.

Research on Underwater Wet Laser Self-Fusion Welding Process and Analysis of Microstructure and Properties of TC4 Titanium Alloy Weld

In order to explore the feasibility of underwater wet laser welding of the TC4 titanium alloy, research on the underwater laser self-fusion welding process was carried out. The weld structure and mechanical properties in both the air environment and the underwater environment were compared and analyzed. The results show that increasing the laser power and reducing the welding speed are beneficial to obtain a larger water depth threshold. Off-focus amount has little effect on water depth threshold; when the laser power is 3000 W and the welding speed is 5 mm/s, and the water depth exceeds 7 mm, a continuous weld cannot be formed. Compared with welding in the air, underwater welding has narrower weld width, smaller heat affected zone and finer crystal grains. The weld structure is mainly composed of α′ martensite and secondary acicular α′ phase, it is distributed in a net basket shape and the grain size at the top of the weld is finer. The hardness of the weld center is above 600 HV0.1, and the residual stress of the underwater welding weld is approximately symmetrically distributed. There is a large tensile stress along the welding direction at the weld, reaching 458 MPa. The larger residual tensile stress leads to the decrease of weld tensile strength, the tensile strength and elongation of the middle sample are only 52% and 77% of the base metal. Furthermore, the fracture mode is typical brittle fracture.

A New Insight on Phased Array Ultrasound Inspection in MIG/MAG Welding

Weldment inspection is a critical process in the metal industry. It is first conducted visually, then manually and finally using instrumental techniques such as ultrasound. We made one hundred metal inert/active gas (MIG/MAG) weldments on plates of naval steel S275JR+N with no defects, and inducing pores, slag intrusion and cracks. With the objective of the three-dimensional reconstruction of the welding defects, phased array ultrasound inspections were carried out. Error-free weldment probes were used to provide the noise level. The results can be summarized as follows. (i) The top view obtained from the phased array provided no conclusive information about the welding defects. The values of the echo amplitudes were about 70 mV for pores and cracks, and greater than 150 mV for slag intrusion, all of which showed great variability. (ii) The sectional data did not lie at the same depths and they needed to be interpolated. (iii) The interpolated sectional views, or C-scans, allowed the computation of top views at any depth, as well as the three-dimensional reconstruction of the defects. (iv) The use of the simplest tool, consisting of the frequency histogram and its statistical moments, was sufficient to classify the defects. The mean echo amplitudes were 33 mV for pores, 72.16 mV for slag intrusion and 43.19 mV for cracks, with standard deviations of 8.84 mV, 24.64 mV and 12.39 mV, respectively. These findings represent the first step in the automatic classification of welding defects.

Transient Phase-Driven Cyclic Deformation in Additively Manufactured 15-5 PH Steel

The present work extends the examination of selective laser melting (SLM)-fabricated 15-5 PH steel with the 8%-transient-austenite-phase towards fully-reversed strain-controlled low-cycle fatigue (LCF) test. The cyclic-deformation response and microstructural evolution were investigated via in-situ neutron-diffraction measurements. The transient-austenite-phase rapidly transformed into the martensite phase in the initial cyclic-hardening stage, followed by an almost complete martensitic transformation in the cyclic-softening and steady stage. The compressive stress was much greater than the tensile stress at the same strain amplitude. The enhanced martensitic transformation associated with lower dislocation densities under compression predominantly governed such a striking tension-compression asymmetry in the SLM-built 15-5 PH.

An Experimental Study of Damage Detection on Typical Joints of Jackets Platform Based on Electro-Mechanical Impedance Technique

Many methods have been used in the past two decades to detect crack damage in steel joints of the offshore structures, but the electromechanical impedance (EMI) method is a comparatively recent non-destructive method that can be used for quality monitoring of the weld in structural steel joints. The EMI method ensures the direct assessment, analysis and particularly the recognition of structural dynamics by acquiring its EM admittance signatures. This research paper first briefly introduces the theoretical background of the EMI method, followed by carrying out the experimental work in which damage in the form of a crack is simulated by using an impedance analyser at different distances. The EMI technique is used to identify the existence of damage in the welded steel joints of offshore steel jacket structures, and Q345B steel was chosen as the material for test in the present study. Sub-millimetre cracks were found in four typical welded steel joints on the jacket platform under circulating loads, and root average variance was used to assess the extent of the crack damage.

Microstructure and Corrosion Resistance of Underwater Laser Cladded Duplex Stainless Steel Coating after Underwater Laser Remelting Processing

Combined with the technologies of underwater local dry laser cladding (ULDLC) and underwater local dry laser remelting (ULDLR), a duplex stainless steel (DSS) coating has been made in an underwater environment. The phase composition, microstructure, chemical components and electrochemical corrosion resistance was studied. The results show that after underwater laser remelting, the phase composition of DSS coating remains unchanged and the phase transformation from Widmanstätten austenite + intragranular austenite + (211) ferrite to (110) ferrite occurred. The ULDLR process can improve the corrosion resistance of the underwater local dry laser cladded coating. The corrosion resistance of remelted coating at 3 kW is the best, the corrosion resistance of remelted coating at 1kW and 5kW is similar and the corrosion resistance of (110) ferrite phase is better than grain boundary austenite phase. The ULDLC + ULDLR process can meet the requirements of efficient underwater maintenance, forming quality control and corrosion resistance. It can also be used to repair the surface of S32101 duplex stainless steel in underwater environment.

Numerical and Experimental Investigations of Fracture Behaviour of Welded Joints with Multiple Defects

Current standards related to welded joint defects (EN ISO 5817) only consider individual cases (i.e., single defect in a welded joint). The question remains about the behaviour of a welded joint in the simultaneous presence of several different types of defects, so-called multiple defects, which is the topic of this research. The main focus is on defects most commonly encountered in practice, such as linear misalignments, undercuts, incomplete root penetration, and excess weld metal. The welding procedure used in this case was metal active gas welding, a common technique when it comes to welding low-alloy low-carbon steels, including those used for pressure equipment. Different combinations of these defects were deliberately made in welded plates and tested in a standard way on a tensile machine, along with numerical simulations using the finite element method (FEM), based on real geometries. The goal was to predict the behaviour in terms of stress concentrations caused by geometry and affected by multiple defects and material heterogeneity. Numerical and experimental results were in good agreement, but only after some modifications of numerical models. The obtained stress values in the models ranged from noticeably lower than the yield stress of the used materials to slightly higher than it, suggesting that some defect combinations resulted in plastic strain, whereas other models remained in the elastic area. The stress-strain diagram obtained for the first group (misalignment, undercut, and excess root penetration) shows significantly less plasticity. Its yield stress is very close to its ultimate tensile strength, which in turn is noticeably lower compared with the other three groups. This suggests that welded joints with misalignment and incomplete root penetration are indeed the weakest of the four groups either due to the combination of the present defects or perhaps because of an additional unseen internal defect. From the other three diagrams, it can be concluded that the test specimens show very similar behaviour with nearly identical ultimate tensile strengths and considerable plasticity. The diagrams shows the most prominent yielding, with an easily distinguishable difference between the elastic and plastic regions. The diagrams are the most similar, having the same strain of around 9% and with a less obvious yield stress limit.

Investigation on Microstructure and Properties of Duplex Stainless Steel Welds by Underwater Laser Welding with Different Shielding Gas

Taking S32101 duplex stainless steel as the research object, underwater laser wire filling welding technology was used for U-groove filling welding. The influence of different shielding gas compositions on the ferrite content, microstructure, mechanical properties and pitting corrosion resistance was studied by simulating a water depth of 15 m in the hyperbaric chamber. The results show that, under the same process parameters, the size and proportion of austenite in the weld when using pure nitrogen as the shielding gas are larger than those protected by other shielding gases. In a mixed shielding gas, the increase in nitrogen content has little effect on the strength and toughness of the weld. Regardless of the shielding gas used, the base metal was the weakest part of the weld. At the same time, intermetallic inclusions have an adverse effect on the impact toughness of the weld. The pitting corrosion resistance of the welds depends on the Cr₂N content in the heat-affected zone. The precipitation and enrichment of Cr₂N causes local chromium deficiency, which is the main factor for the weak pitting corrosion ability of the heat-affected zone. Pure nitrogen protection has a better corrosion resistance than other gas protection.

The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints

The purpose of the following study was to compare the effect of the shape of a tool on the joint and to obtain the values of Friction Stir Welding (FSW) parameters that provide the best possible joint quality. The material used was an aluminium alloy, EN AW-3004 (AlMn1Mg1). To the authors' best knowledge, no investigations of this alloy during FSW have been presented earlier. Five butt joints were made with a self-developed, cylindrical, and tapered threaded tool with a rotational speed of 475 rpm. In order to compare the welding parameters, two more joints with a rotational speed of 475 rpm and seven joints with a welding speed of 300 mm/min with the use of a cylindrical threaded pin were performed. This involved a visual inspection as well as a tensile strength test of the welded joints. It was observed that the value of the material outflow for the joints made with the cylindrical threaded pin was higher than it was for the joints made with the tapered threaded pin. However, welding defects in the form of voids appeared in the joints made with the tapered threaded tool. The use of the cylindrical tool resulted in higher values for about 37% of mechanical properties compared with the highest result for the tapered threaded joint. As far as the parameters were concerned, it was concluded that most of the specimens were properly joined for a rotational speed of 475 rpm. In the joints made with a welding speed of 300 mm/min, the material was not stirred properly. The best joint quality was given for a rotational speed of 475 rpm as well as a variety of welding speed values between 150 and 475 mm/min.

Weldability of Underwater Wet-Welded HSLA Steel: Effects of Electrode Hydrophobic Coatings

The paper presents the effects of waterproof coatings use to cover electrodes on the weldability of high-strength, low-alloy (HSLA) steel in water. With the aim of improving the weldability of S460N HSLA steel in water, modifications of welding filler material were chosen. The surfaces of electrodes were covered by different hydrophobic substances. The aim of the controlled thermal severity (CTS) test was to check the influence of these substances on the HSLA steel weldability in the wet welding conditions. The visual test, metallographic tests, and hardness Vickers HV10 measurements were performed during investigations. The results proved that hydrophobic coatings can reduce the hardness of welded joints in the heat-affected zone by 40–50 HV10. Additionally, the number of cold cracks can be significantly reduced by application of waterproof coatings on the filler material. The obtained results showed that electrode hydrophobic coatings can be used to improve the weldability of HSLA steel in underwater conditions.

Effect of Water Environment on Fatigue Behavior in X80 High Strength Steel CO2 Arc Welding Welded Joint

Fatigue life tests and fatigue crack growth rate (FCGR) tests in the air and water environment were conducted on X80 pipeline steel welded joints (welded by CO2 arc welding). Scanning electron microscope (SEM) and electron backscatter diffraction (EBSD) were utilized to investigate the internal influential mechanisms of the water environment during fatigue crack initiation and propagation stages, respectively. Results show that a great many oxide particles induced by the water environment gradually formed the fatigue crack initiation site and decreased fatigue life of welded joints. Meanwhile, the preferred grain orientation of <001>//ND and CSL boundaries of Σ3, Σ11, Σ13c, Σ17b, Σ25a, and Σ25b are both prone to fatigue propagation when loading in the water environment. In addition, a coalescence of the stress intensity factor (SIF) range and water environment accelerated FCGR by motivating secondary slip systems of {112}<111> and {123}<111> in bcc crystalline structures.