Closed-loop temperature control of friction stir welding
- Authors: Pothier, Raymond Peter
- Date: 2015
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/10362 , vital:26656
- Description: This study develops and presents a friction stir weld (FSW) quality assurance tool based on control of weld zone temperature. Apart from correct tool geometry, tool tilt angle, traverse speed and forge force during welding, one important requirement is that the weld material be sufficiently plasticised (softened). The level of plasticisation is related to weld zone temperature which is primarily dependent on spindle speed, traverse speed and forge force. When all other conditions are correct, sufficiently plasticised material flows around and consolidates behind the tool without the production of voids in the weld. Typically, weld temperature varies along the weld length which may result in variations in weld quality. Weld zone temperature control makes constant weld zone temperature possible. In this study, thermocouple sensors were embedded in the FSW tool and a weld zone temperature control algorithm was developed. Spindle speed was the actuating mechanism for controlling weld temperature. The system was modelled and controllers were designed using Matlab tools. The system was simulated and the performance was compared to the system performance during welding. The control system ensures that the weld zone temperature can be maintained irrespective of the presence of thermal disturbances. Tensile testing was conducted which confirmed a range of temperature in which the welds resulted in consistent strength.
- Full Text:
- Date Issued: 2015
- Authors: Pothier, Raymond Peter
- Date: 2015
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/10362 , vital:26656
- Description: This study develops and presents a friction stir weld (FSW) quality assurance tool based on control of weld zone temperature. Apart from correct tool geometry, tool tilt angle, traverse speed and forge force during welding, one important requirement is that the weld material be sufficiently plasticised (softened). The level of plasticisation is related to weld zone temperature which is primarily dependent on spindle speed, traverse speed and forge force. When all other conditions are correct, sufficiently plasticised material flows around and consolidates behind the tool without the production of voids in the weld. Typically, weld temperature varies along the weld length which may result in variations in weld quality. Weld zone temperature control makes constant weld zone temperature possible. In this study, thermocouple sensors were embedded in the FSW tool and a weld zone temperature control algorithm was developed. Spindle speed was the actuating mechanism for controlling weld temperature. The system was modelled and controllers were designed using Matlab tools. The system was simulated and the performance was compared to the system performance during welding. The control system ensures that the weld zone temperature can be maintained irrespective of the presence of thermal disturbances. Tensile testing was conducted which confirmed a range of temperature in which the welds resulted in consistent strength.
- Full Text:
- Date Issued: 2015
Friction hydro pillar riveting process of Ti-6AI-4V titanium sheet
- Authors: Tsikayi, Davies Shamiso
- Date: 2015
- Subjects: Friction welding , Titanium alloys -- Welding , Sheet-metal
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: http://hdl.handle.net/10948/6357 , vital:21078
- Description: Mechanical fasteners are used extensively in the joining of two or more metal plates or sheets. Riveted joints have been the joints of choice mainly for the Aerospace Industry. However for this research, Friction Hydro Pillar Processing has been used to develop and characterise a new riveting technique termed Friction Hydro Pillar Riveting (FHPR). Two overlapping 3.17 mm Ti-6Al-4V sheets were joined together using Ø6 mm rivet which was friction processed. This research has focussed on the initial development of Friction Hydro Pillar Riveting thereby establishing a basic understanding of the influences of main process parameters, rotational speed and axial force - and also joint configurations. The results showed that with a decrease in the bottom hole chamfer angle, there was resulting overall increase in the rivet joint pull off strength. From the best performing joint configuration in pull off tests, shear tests were conducted whilst a blind hole FHPR joint was also done and tested in pull off and shear strength. The shear test fracture surfaces exhibited ductile failure. The microstructure of the joints was thus evaluated. From parent material, heat affected zone and to weld zone there was a variation in the microstructure analysed. The hardness profiles showed increased hardness in the weld zone which partly explained the shear results. The hardness increase was mainly due to grain refinement in the weld zone by the Friction Hydro Pillar Riveting process.
- Full Text:
- Date Issued: 2015
- Authors: Tsikayi, Davies Shamiso
- Date: 2015
- Subjects: Friction welding , Titanium alloys -- Welding , Sheet-metal
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: http://hdl.handle.net/10948/6357 , vital:21078
- Description: Mechanical fasteners are used extensively in the joining of two or more metal plates or sheets. Riveted joints have been the joints of choice mainly for the Aerospace Industry. However for this research, Friction Hydro Pillar Processing has been used to develop and characterise a new riveting technique termed Friction Hydro Pillar Riveting (FHPR). Two overlapping 3.17 mm Ti-6Al-4V sheets were joined together using Ø6 mm rivet which was friction processed. This research has focussed on the initial development of Friction Hydro Pillar Riveting thereby establishing a basic understanding of the influences of main process parameters, rotational speed and axial force - and also joint configurations. The results showed that with a decrease in the bottom hole chamfer angle, there was resulting overall increase in the rivet joint pull off strength. From the best performing joint configuration in pull off tests, shear tests were conducted whilst a blind hole FHPR joint was also done and tested in pull off and shear strength. The shear test fracture surfaces exhibited ductile failure. The microstructure of the joints was thus evaluated. From parent material, heat affected zone and to weld zone there was a variation in the microstructure analysed. The hardness profiles showed increased hardness in the weld zone which partly explained the shear results. The hardness increase was mainly due to grain refinement in the weld zone by the Friction Hydro Pillar Riveting process.
- Full Text:
- Date Issued: 2015
Development of a creep sample retrieval technique and friction weld site repair procedure
- Authors: Wedderburn, Ian Norman
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: vital:9635 , http://hdl.handle.net/10948/d1020116
- Description: The remnant life monitoring of creep loaded high temperature and pressure components in power stations is critical to ensuring their safe and cost effective operation as failures can have severe consequences. Effective creep life condition monitoring allows for optimising component life predictions and subsequent plant maintenance decisions. In South Africa many power generation stations have been in operation well beyond their 30 year design service life, as such knowledge of the remnant creep life of high temperature and pressure components, such as steam pipelines, becomes of utmost importance. Techniques for the remnant creep life assessments of critical high temperature and pressure components must therefore be as effective as possible. The common and well accepted in-situ inspection technique for assessing creep damage in steam pipes is by the metallographic replication technique. The technique is however limited to the outer surface of the pipe, without information on damage within the wall. This research will illustrate a means of obtaining a sample for creep life analysis with depth through the wall of a pipe, as wells as an alternative technique for the repair of the sample retrieval site. A sample retrieval technique was developed that would retrieve a small diameter cylindrical sample from a cored blind hole for creep analysis by visual creep void assessment or by the small punch creep test. The small punch creep test requires only a small diameter thin disc of material for testing for which its results are comparable with conventional uniaxial creep testing which requires a much larger sample of material. The smaller sample requirement of the small punch creep test therefore allows for a vastly reduced invasive sample retrieval operation and consequently smaller repair size area. Also the fact that the sample is retrieved from a blind hole is advantageous since the pipe wall is not penetrated which would require full plant shutdown. A friction welding technique was identified as an alternative to traditional arc fusion welding for the repair of the sample retrieval site, this technique being the Friction Hydro Pillar Processing technique. Friction Hydro Pillar Processing is a solid-state welding technique and as such has a number of inherent benefits over arc fusion welding as the weld is performed below the melting temperature of the material. From a process point of view Friction Hydro Pillar Processing is ideally suited for automation, has virtually no fumes generated, minimal distortion is experienced and no spatter has to be removed afterwards. The technique has yet to see industrial application and as such development of suitable process parameters was undertaken. Finally, to apply the sample retrieval and repair operations in-situ to a steam pipe in a power plant suitable equipment was developed. Existing friction welding equipment is generally bulky workshop based equipment and is unsuitable for on-site work due to its size and weight. Therefore development of dedicated equipment was required to enable Friction Hydro Pillar Processing to be applied to steam pipes within a power plant environment.
- Full Text:
- Date Issued: 2013
- Authors: Wedderburn, Ian Norman
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: vital:9635 , http://hdl.handle.net/10948/d1020116
- Description: The remnant life monitoring of creep loaded high temperature and pressure components in power stations is critical to ensuring their safe and cost effective operation as failures can have severe consequences. Effective creep life condition monitoring allows for optimising component life predictions and subsequent plant maintenance decisions. In South Africa many power generation stations have been in operation well beyond their 30 year design service life, as such knowledge of the remnant creep life of high temperature and pressure components, such as steam pipelines, becomes of utmost importance. Techniques for the remnant creep life assessments of critical high temperature and pressure components must therefore be as effective as possible. The common and well accepted in-situ inspection technique for assessing creep damage in steam pipes is by the metallographic replication technique. The technique is however limited to the outer surface of the pipe, without information on damage within the wall. This research will illustrate a means of obtaining a sample for creep life analysis with depth through the wall of a pipe, as wells as an alternative technique for the repair of the sample retrieval site. A sample retrieval technique was developed that would retrieve a small diameter cylindrical sample from a cored blind hole for creep analysis by visual creep void assessment or by the small punch creep test. The small punch creep test requires only a small diameter thin disc of material for testing for which its results are comparable with conventional uniaxial creep testing which requires a much larger sample of material. The smaller sample requirement of the small punch creep test therefore allows for a vastly reduced invasive sample retrieval operation and consequently smaller repair size area. Also the fact that the sample is retrieved from a blind hole is advantageous since the pipe wall is not penetrated which would require full plant shutdown. A friction welding technique was identified as an alternative to traditional arc fusion welding for the repair of the sample retrieval site, this technique being the Friction Hydro Pillar Processing technique. Friction Hydro Pillar Processing is a solid-state welding technique and as such has a number of inherent benefits over arc fusion welding as the weld is performed below the melting temperature of the material. From a process point of view Friction Hydro Pillar Processing is ideally suited for automation, has virtually no fumes generated, minimal distortion is experienced and no spatter has to be removed afterwards. The technique has yet to see industrial application and as such development of suitable process parameters was undertaken. Finally, to apply the sample retrieval and repair operations in-situ to a steam pipe in a power plant suitable equipment was developed. Existing friction welding equipment is generally bulky workshop based equipment and is unsuitable for on-site work due to its size and weight. Therefore development of dedicated equipment was required to enable Friction Hydro Pillar Processing to be applied to steam pipes within a power plant environment.
- Full Text:
- Date Issued: 2013
Development of thick section friction stir welding using a sliding tool shoulder
- Authors: Chetty, Shamalin
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9633 , http://hdl.handle.net/10948/d1015081
- Description: Sliding shoulder friction stir welding (SSFSW) is an alternative joining technique to the conventional friction stir welding process. The welding mechanism comprises of a rotating probe and a non-rotating shoulder. The shoulder therefore does not contribute to any heat generation or plastic deformation. When welding thicker section material, the contribution of heat generation from the shoulder becomes less significant and most of the heat and plastic deformation must be generated by the tool probe. For this reason it was decided to develop the process for thick section AA6082-T6. Due to the stationary (non-rotating) shoulder the weld track is smooth and there is no reduction in cross-sectional area. This research is based on the development of a sliding shoulder friction stir welding tool with the ability to create joints of up to 25mm thick on aluminium alloy 6082-T6 plate as well as the associated process development. The sliding shoulder friction stir welding tool was designed, manufactured and tested by initially performing partial penetration welds with various size tool probes and then finally by performing a sliding shoulder friction stir butt weld on 25mm thick plate. As welds were performed and more knowledge gained about the process, design modifications were made. These included varying the clearance between the tool probe and stationary shoulder; the profile of the shoulder which contributes to material flow during the process; and supporting the tool probe to prevent deflection when welding thicker sections at high forge forces. From the sliding shoulder friction stir welds performed, an understanding of material flow during the process was gained when analysing the macro-sections and exit holes of the welds. Typical process forces and torques associated with the process were measured to assist with future head unit and tool designs with regard to sliding shoulder friction stir welding.
- Full Text:
- Date Issued: 2013
- Authors: Chetty, Shamalin
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9633 , http://hdl.handle.net/10948/d1015081
- Description: Sliding shoulder friction stir welding (SSFSW) is an alternative joining technique to the conventional friction stir welding process. The welding mechanism comprises of a rotating probe and a non-rotating shoulder. The shoulder therefore does not contribute to any heat generation or plastic deformation. When welding thicker section material, the contribution of heat generation from the shoulder becomes less significant and most of the heat and plastic deformation must be generated by the tool probe. For this reason it was decided to develop the process for thick section AA6082-T6. Due to the stationary (non-rotating) shoulder the weld track is smooth and there is no reduction in cross-sectional area. This research is based on the development of a sliding shoulder friction stir welding tool with the ability to create joints of up to 25mm thick on aluminium alloy 6082-T6 plate as well as the associated process development. The sliding shoulder friction stir welding tool was designed, manufactured and tested by initially performing partial penetration welds with various size tool probes and then finally by performing a sliding shoulder friction stir butt weld on 25mm thick plate. As welds were performed and more knowledge gained about the process, design modifications were made. These included varying the clearance between the tool probe and stationary shoulder; the profile of the shoulder which contributes to material flow during the process; and supporting the tool probe to prevent deflection when welding thicker sections at high forge forces. From the sliding shoulder friction stir welds performed, an understanding of material flow during the process was gained when analysing the macro-sections and exit holes of the welds. Typical process forces and torques associated with the process were measured to assist with future head unit and tool designs with regard to sliding shoulder friction stir welding.
- Full Text:
- Date Issued: 2013
Analysis and modelling of the temperature distribution during the friction taper stud welding of 10CrMo910
- Van Zyl, Carlo Angelo Antonio
- Authors: Van Zyl, Carlo Angelo Antonio
- Date: 2008
- Subjects: Friction welding , Pressure welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9630 , http://hdl.handle.net/10948/720 , http://hdl.handle.net/10948/d1012898 , Friction welding , Pressure welding
- Description: Heat generation during the FTSW process plays and important role in determining the characteristics of the weld. In order to obtain temperature fields, a transient temperature heat analysis is required. An area is the maximum temperatures reached within the base material during the FTSW process. These temperatures will be measured during experimentation, and compared to the welding simulation done using FEA. From the literature search it appeared that no heat transfer analysis had been done using finite element methods.
- Full Text:
- Date Issued: 2008
- Authors: Van Zyl, Carlo Angelo Antonio
- Date: 2008
- Subjects: Friction welding , Pressure welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9630 , http://hdl.handle.net/10948/720 , http://hdl.handle.net/10948/d1012898 , Friction welding , Pressure welding
- Description: Heat generation during the FTSW process plays and important role in determining the characteristics of the weld. In order to obtain temperature fields, a transient temperature heat analysis is required. An area is the maximum temperatures reached within the base material during the FTSW process. These temperatures will be measured during experimentation, and compared to the welding simulation done using FEA. From the literature search it appeared that no heat transfer analysis had been done using finite element methods.
- Full Text:
- Date Issued: 2008
A fuzzy logic control system for a friction stir welding process
- Authors: Majara, Khotso Ernest
- Date: 2006
- Subjects: Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9594 , http://hdl.handle.net/10948/405 , Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Description: FSW is a welding technique invented and patented by The Welding Institute in 1991. This welding technique utilises the benefits of solid-state welding to materials regarded as difficult to weld by fusion processes. The productivity of the process was not optimised as the real-time dynamics of the material and tool changes were not considered. Furthermore, the process has a plastic weld region where no traditional modelling describing the interaction between the tool and work piece is available. Fuzzy logic technology is one of the artificial intelligent strategies used to improve the control of the dynamics of industrial processes. Fuzzy control was proposed as a viable solution to improve the productivity of the FSW process. The simulations indicated that FLC can use feed rate and welding speed to adaptively regulate the feed force and tool temperature respectively, irrespective of varying tool and material change. The simulations presented fuzzy logic technology to be robust enough to regulate FSW process in the absence of accurate mathematical models.
- Full Text:
- Date Issued: 2006
- Authors: Majara, Khotso Ernest
- Date: 2006
- Subjects: Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9594 , http://hdl.handle.net/10948/405 , Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Description: FSW is a welding technique invented and patented by The Welding Institute in 1991. This welding technique utilises the benefits of solid-state welding to materials regarded as difficult to weld by fusion processes. The productivity of the process was not optimised as the real-time dynamics of the material and tool changes were not considered. Furthermore, the process has a plastic weld region where no traditional modelling describing the interaction between the tool and work piece is available. Fuzzy logic technology is one of the artificial intelligent strategies used to improve the control of the dynamics of industrial processes. Fuzzy control was proposed as a viable solution to improve the productivity of the FSW process. The simulations indicated that FLC can use feed rate and welding speed to adaptively regulate the feed force and tool temperature respectively, irrespective of varying tool and material change. The simulations presented fuzzy logic technology to be robust enough to regulate FSW process in the absence of accurate mathematical models.
- Full Text:
- Date Issued: 2006
Monitoring and intelligent control for complex curvature friction stir welding
- Hua, Tao
- Authors: Hua, Tao
- Date: 2006
- Subjects: Friction welding , Fuzzy systems
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9612 , http://hdl.handle.net/10948/420 , Friction welding , Fuzzy systems
- Description: A multi-input multi-output system to implement on-line process monitoring and intelligent control of complex curvature friction stir welding was proposed. An extra rotation axis was added to the existing three translation axes to perform friction stir welding of complex curvature other than straight welding line. A clamping system was designed for locating and holding the workpieces to bear the large force involved in the process between the welding tool and workpieces. Process parameters (feed rate, spindle speed, tilt angle and plunge depth), and process conditions (parent material and curvature), were used as factors for the orthogonal array experiments to collect sensor data of force, torque and tool temperature using multiple sensors and telemetry system. Using statistic analysis of the experimental data, sensitive signal features were selected to train the feed-forward neural networks, which were used for mapping the relationships between process parameters, process conditions and sensor data. A fuzzy controller with initial input/output membership functions and fuzzy rules generated on-line from the trained neural network was applied to perceive process condition changes and make adjustment of process parameters to maintain tool/workpiece contact and energy input. Input/output scaling factors of the fuzzy controller were tuned on-line to improve output response to the amount and trend of control variable deviation from the reference value. Simulation results showed that the presented neuro-fuzzy control scheme has adaptability to process conditions such as parent material and curvature changes, and that the control variables were well regulated. The presented neuro-fuzzy control scheme can be also expected to be applied in other multi-input multi-output machining processes.
- Full Text:
- Date Issued: 2006
- Authors: Hua, Tao
- Date: 2006
- Subjects: Friction welding , Fuzzy systems
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9612 , http://hdl.handle.net/10948/420 , Friction welding , Fuzzy systems
- Description: A multi-input multi-output system to implement on-line process monitoring and intelligent control of complex curvature friction stir welding was proposed. An extra rotation axis was added to the existing three translation axes to perform friction stir welding of complex curvature other than straight welding line. A clamping system was designed for locating and holding the workpieces to bear the large force involved in the process between the welding tool and workpieces. Process parameters (feed rate, spindle speed, tilt angle and plunge depth), and process conditions (parent material and curvature), were used as factors for the orthogonal array experiments to collect sensor data of force, torque and tool temperature using multiple sensors and telemetry system. Using statistic analysis of the experimental data, sensitive signal features were selected to train the feed-forward neural networks, which were used for mapping the relationships between process parameters, process conditions and sensor data. A fuzzy controller with initial input/output membership functions and fuzzy rules generated on-line from the trained neural network was applied to perceive process condition changes and make adjustment of process parameters to maintain tool/workpiece contact and energy input. Input/output scaling factors of the fuzzy controller were tuned on-line to improve output response to the amount and trend of control variable deviation from the reference value. Simulation results showed that the presented neuro-fuzzy control scheme has adaptability to process conditions such as parent material and curvature changes, and that the control variables were well regulated. The presented neuro-fuzzy control scheme can be also expected to be applied in other multi-input multi-output machining processes.
- Full Text:
- Date Issued: 2006
Development and analysis of a friction stir spot welding process for aluminium
- Authors: Stephen, Michael George
- Date: 2005
- Subjects: Friction welding , Electric welding , Aluminum alloys -- Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9631 , http://hdl.handle.net/10948/1351 , Friction welding , Electric welding , Aluminum alloys -- Welding
- Description: Friction Stir Spot Welding (FSSW) has been developed from the conventional Friction Stir Welding (FSW) process, developed at The Welding Institute (TWI). FSSWs have been done without the keyhole being eliminated. Elimination of the keyhole would result in the process being more commercially viable. This dissertation focuses on an attempt of eliminating the keyhole using a retractable pin tool as well as a comparison of the weld integrity of a FSSW to that of a conventional Resistance Spot Weld (RSW). Welds were conducted on aluminium alloy 6063 T4. Comparisons between different weld procedures were done. Further analysis of the weld integrity between FSSW and RSW were conducted, comparing tensile strengths, microstructure and hardness. For the above welding procedure to take place, the current retractable pin tool, patented by PE Technikon, was redesigned. Problems associated during the welding process and the results obtained are documented. Reasons for the keyhole not being eliminated as well as recommendations for future work in the attempt to remove the keyhole are discussed.
- Full Text:
- Date Issued: 2005
- Authors: Stephen, Michael George
- Date: 2005
- Subjects: Friction welding , Electric welding , Aluminum alloys -- Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9631 , http://hdl.handle.net/10948/1351 , Friction welding , Electric welding , Aluminum alloys -- Welding
- Description: Friction Stir Spot Welding (FSSW) has been developed from the conventional Friction Stir Welding (FSW) process, developed at The Welding Institute (TWI). FSSWs have been done without the keyhole being eliminated. Elimination of the keyhole would result in the process being more commercially viable. This dissertation focuses on an attempt of eliminating the keyhole using a retractable pin tool as well as a comparison of the weld integrity of a FSSW to that of a conventional Resistance Spot Weld (RSW). Welds were conducted on aluminium alloy 6063 T4. Comparisons between different weld procedures were done. Further analysis of the weld integrity between FSSW and RSW were conducted, comparing tensile strengths, microstructure and hardness. For the above welding procedure to take place, the current retractable pin tool, patented by PE Technikon, was redesigned. Problems associated during the welding process and the results obtained are documented. Reasons for the keyhole not being eliminated as well as recommendations for future work in the attempt to remove the keyhole are discussed.
- Full Text:
- Date Issued: 2005
Characterization of friction hydro pillar process weld properties as applied to 10CrMo910 creep resistant steel for application in the power generation Industry
- Authors: Bulbring, Daniel Louis Hans
- Subjects: Materials -- Creep , Friction welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: vital:9636 , http://hdl.handle.net/10948/d1020586
- Description: Creep degradation of steam carrying vessels in the power generation industry is a concern that needs to be constantly monitored. The Weldcore® process has been earmarked as a potential method of creep sampling which will allow for thick-walled sections to be analysed. A component of the process involves plugging the resultant hole after removing a creep sample using a novel welding technique called friction hydro pillar processing. At the commencement of this study, insufficient data was available to warrant safe industrial application of the process. This research was conducted to evaluate the performance of 10CrMo910 friction hydro pillar process welds. The effects of downward force, stud taper angle, hole taper angle and hole base diameter on process response, defect population, static properties and dynamic performance were evaluated. The variation of downward force showed that higher forces produce significantly smaller defects and higher fatigue life. The occurrence of defects was linked to process parameters and geometry thereby identifying the correct parameters for safe use in the power generation industry. Flash formation was identified as an early indicator of weld defects and can assist with quality control in industrial applications. Methods of standardising the plunge depth and forge force were developed to identify the correct magnitudes for different geometries, without the need for testing. Defects were shown to populate specific regions of the weld and produce variations in fatigue life. Crack initiation sites were detected which will aid in identifying areas of focus in further research and development. Temperature measurements were linked to the occurrence of defects and crack initiation sites and have been identified as a method of identifying defective welds. The effects of process parameters and stud and hole taper angles on energy inputs and near interface temperatures were statistically evaluated. Downward force was shown to have the largest effect on energy input rates, total energy input and temperatures at the 11.5mm and 20.5mm positions. Smaller hole and stud taper angles produced lower energy inputs and were identified as more energy efficient than the larger taper angles. A regression model was also developed to predict the fatigue life of welds and can assist with critical process related decision making. A range of hole base diameters were identified which produced welds with low defect populations and fatigue performance similar to that of the parent plate. Larger hole base diameters were shown to produce significant defects along the hole bottom fillet, in the weld nugget and along the bond line. Temperature measurements of the larger diameter welds showed a delay in response and are attributed to a delayed contact of plasticised stud material with the sidewall. Welds with hole base diameters larger than 11mm produced unrepeatable and defective welds, and also required higher energy inputs making smaller diameters more desirable. Analysis of all welds in this study revealed that clearance and interfacial pressures characterise the quality of friction hydro pillar process welds, therefore models were developed to aid in critical decision making with respect to downward force and geometry. This study has successfully evaluated the effects of process parameters and geometry on the properties of friction hydro pillar process welds and thereby has increased understanding of the process.
- Full Text:
- Authors: Bulbring, Daniel Louis Hans
- Subjects: Materials -- Creep , Friction welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: vital:9636 , http://hdl.handle.net/10948/d1020586
- Description: Creep degradation of steam carrying vessels in the power generation industry is a concern that needs to be constantly monitored. The Weldcore® process has been earmarked as a potential method of creep sampling which will allow for thick-walled sections to be analysed. A component of the process involves plugging the resultant hole after removing a creep sample using a novel welding technique called friction hydro pillar processing. At the commencement of this study, insufficient data was available to warrant safe industrial application of the process. This research was conducted to evaluate the performance of 10CrMo910 friction hydro pillar process welds. The effects of downward force, stud taper angle, hole taper angle and hole base diameter on process response, defect population, static properties and dynamic performance were evaluated. The variation of downward force showed that higher forces produce significantly smaller defects and higher fatigue life. The occurrence of defects was linked to process parameters and geometry thereby identifying the correct parameters for safe use in the power generation industry. Flash formation was identified as an early indicator of weld defects and can assist with quality control in industrial applications. Methods of standardising the plunge depth and forge force were developed to identify the correct magnitudes for different geometries, without the need for testing. Defects were shown to populate specific regions of the weld and produce variations in fatigue life. Crack initiation sites were detected which will aid in identifying areas of focus in further research and development. Temperature measurements were linked to the occurrence of defects and crack initiation sites and have been identified as a method of identifying defective welds. The effects of process parameters and stud and hole taper angles on energy inputs and near interface temperatures were statistically evaluated. Downward force was shown to have the largest effect on energy input rates, total energy input and temperatures at the 11.5mm and 20.5mm positions. Smaller hole and stud taper angles produced lower energy inputs and were identified as more energy efficient than the larger taper angles. A regression model was also developed to predict the fatigue life of welds and can assist with critical process related decision making. A range of hole base diameters were identified which produced welds with low defect populations and fatigue performance similar to that of the parent plate. Larger hole base diameters were shown to produce significant defects along the hole bottom fillet, in the weld nugget and along the bond line. Temperature measurements of the larger diameter welds showed a delay in response and are attributed to a delayed contact of plasticised stud material with the sidewall. Welds with hole base diameters larger than 11mm produced unrepeatable and defective welds, and also required higher energy inputs making smaller diameters more desirable. Analysis of all welds in this study revealed that clearance and interfacial pressures characterise the quality of friction hydro pillar process welds, therefore models were developed to aid in critical decision making with respect to downward force and geometry. This study has successfully evaluated the effects of process parameters and geometry on the properties of friction hydro pillar process welds and thereby has increased understanding of the process.
- Full Text:
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