Escolar Documentos
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I.
INTRODUCTION
SEAM
WELDING
-~ u
Velocity,
Heat
Source
,- rl Weld Fusion
U/Pool / z o n e
(o)
(a)
GIRTH
WELDING
Heat
Source
0/
Angular
LYe I~ Q'
Weld Pool
I/Tt~" -'- z
(0)
(b)
Fig. 1 --Schematic sketches of pipe welding: (a) seam welding; (b) girth
welding.
II.
MATHEMATICAL MODEL
fff o(p").
T
(kVT - pHV)dS
[1]
A . S e a m Welding
_._.._....7
B
Fig. 2 - - V o l u m e element for calculation of heat flow.
[2]
3Q exp
q = 7raZ
at
r =R
and
d< a
iii
[3]
where
k,r~AOA z
aE = _
rE-
rp
kwrwA OA z
aw-
re - rw
k, F A O A r
au--
ZN -- Zp
k,7"AOAr
a s --
ze - Zs
k, A r A z
aT
r.( O~ - Oj
kbArAz
On)
t" = (re + r w ) / 2
ii
-[h(T-
r = R
and
Ta) + o ' e ( T 4 -
d > a,
and at
Za4)] at
r =R'
ae + aw + aN + as + ar + aB
1
b = - --f p(HN - Hs) UT"A OA r
iv
T=To
as
OT/Oz = 0
z---->-oo
as
z--*
B. Girth Welding
3,
-~
dtd'; =
[41
The fully implicit scheme was employed in the present
study, which according to Patankar 7 can be expressed below:
'+a'Tdt = T 1At
[5]
METALLURGICAL TRANSACTIONS A
where H i and /~p denote the new and old values of lip,
respectively.
The initial condition is T = To at t = 0 for all positions of
the pipe. Since the end surfaces of the pipe are much smaller
than its outer and inner surfaces, and since the temperature
gradients near the end surfaces are very small, heat loss
from the end surfaces is negligible. Therefore, boundary
conditions (i) and (ii) shown previously should now be
at
M E T H O D OF SOLUTION
Eq. [3], boundary conditions (i) to (iv), and the enthalpytemperature relationship 8 were used to solve the temperature
distribution during seam welding. The heat of fusion was
included in the enthalpy-temperature relationship. As observed previously, 2 the effect of the temperature dependence
of the thermal conductivity of solid aluminum on heat flow
was very small and was, therefore, neglected. Since heat
flow is symmetrical with respect to its axial plane, only the
temperature distribution in one-half of the pipe was calculated in the case of seam welding. In order to enhance the
accuracy of calculation, a grid mesh of variable spacing was
used, i.e., finer spacing near the heat source and coarser
far away from it. An example of the grid meshes used is
shown in Figure 3. The successive overrelaxation method
with a relaxation parameter of 1.4 was used. The iterative
procedure of temperature calculation was carried out with a
digital computer until the following convergence criterion
was satisfied:
T~ - T O maximum
1.0 ~
over r, 0, z
METALLURGICAL TRANSACTIONS A
-< 1 pct
~,QAt
z = +-L/2
III.
E e ( n ' - n o)
[6]
V = -flrO
OT/Oz = 0
IV.
EXPERIMENTAL
PROCEDURE
Element
Wt Pct
TL = 652 ~
Ts = 582 ~
Mg
1.0
Si
0.60
Cu
0.28
Cr
0.20
AI
balance
Fig. 3 - - A n example of the grid mesh for calculating heat flow during
seam welding: (a) side view; (b) front view.
Steady
Qs
CA
C~
,.=,
W JoCp(Tout
o,
,A
0
Fig. 4--Power input
during girth welding.
off
toff
TIME, t
time relationship used for calculating heat flow
vs
where
W =
Cp =
To,t =
Tin =
t =
--
Tin)dt
= rlElt
[7]
8 0 0 2---
q.OeeE. STOPPER
Calculated
PIPE
WATER,
N
I
I IHEAT
USOURCE
I
T.C. r ( m m ) O(radians)
Observed
I
2
L,
'////////////////////////"
l~C.
17.5
18.0
0.079
0.594
Seam W e l d i n g
LJ
INSULATION
2 400
I
5O
o
Q.
tS
n~ 4 0
l--
I
0
I
I0
Time, Sec
n~
ILl
a.
b.I
I--
I
20
50
30
20
I
0
I
I00
TIME,
I
200
sec
SEAM WELDING
Front View
--Calculated
- - - Observed
-20mm
V.
IOmm
I?mm
120mm
A. Seam Welding
Figure 7 shows the calculated and the measured thermal
cycles for a pipe welded with a voltage of 10 V and a current
of 120 A. The welding speed was 5.50 mm per second
(13 ipm), and the measured radius of the arc was 3 ram.
With an arc efficiency of 78 pct and an effective liquid
conductivity 1.5 times the value of the solid thermal conductivity, very good agreement between the calculated and the
measured thermal cycles was obtained. This arc efficiency
is less than 4 pct off the measured value, thus indicating the
validity of the heat flow calculation.
The calculated isotherms and fusion boundary (TD are
shown in Figure 8. As can be seen, the calculated and the
observed fusion boundaries are in excellent agreement.
METALLURGICAL TRANSACTIONS A
SEAM WELDING
Side View
IOmrn
20mm
4000C
(b)
Fig. 8 --Calculated isotherms for the seam weld. The dashed lines indicate
the observed fusion boundary.
GIRTH WELDING
Front View
Calculated
---
Observed
8 = 0.097
\:L/T,
B. Girth Welding
,,o~
i
-....
V
e
J
O0
Calculated
Observed
Girth Welding
TC.
r(mm)
z(mm)
~,
17.5
1.0
.097
I/
/l'
18.0
6.0
,''
2 ,8.o 5.0
A
,,I,
O(radians)
]
I
,,,
2OO
I0
30
20
Time,
40
Sec
8mm
8mm
(a)
Front
View
0 = 0.487
\\
,so.c,
8mm
8mm
(b)
Fig. 10--Calculated isotherms for the girth weld. The dashed lines indicate the observed fusion boundary.
It is, therefore, clear from the above results and discussion that in girth welding, especially pipes of small diameters, the heat input per unit length of weld should be
high at the beginning and reduced continuously as welding
proceeds. In the case of automatic girth welding, the welding current and hence the heat input can be preprogrammed
through the use of a programmable power source. The preprogramming of the welding current, however, has been
done on a trial-and-error basis so far. The unsteady state
model developed in the present study is expected to help
preprogram the power source more effectively, so that sound
girth welds of uniform size can be produced.
VI.
CONCLUSIONS
METALLURGICAL TRANSACTIONS A
ACKNOWLEDGMENTS
METALLURGICALTRANSACTIONS A