Professional Documents
Culture Documents
Rezumat
n procesul complex de fabricaie al conductelor magistrale de gaze naturale se utilizeaz, n ultima perioad, oteluri cu rezisten
mecanic ridicat i reziliena la temperaturi sczute foarte bun. Din punct de vedere tehnico-economic, pentru realizarea mbinrilor
sudate, trebuie consumate cantiti ct mai reduse de energie i materiale de adaos, ceea ce recomand noul procedeu LaserHibrid drept
una dintre cele mai adecvate soluii n acest sens.
Concentrarea de energie mult superioar altor procedee, lexibilitatea reglrii procesului (se pot controla separat energia destinat
topirii metalului de baz ct i cantitatea de material de adaos) dar mai ales posibilitatea de a lucra cu rosturi de circa 20, fa de
5560 la procedeele clasice, recomand acest procedeu drept o soluie deosebit din punct de vedere tehnico-economic.
n lucrare sunt prezentate determinri experimentale pentru diferite probe sudate prin procedeul LaserHibrid, con iguraia sistemului
utilizat i calcule tehnico-economice comparative cu alte procedee clasice de sudare.
Abstract
In the complex manufacturing processes of pipelines, steels with higher strength and toughness at low temperatures are required.
In terms of costs, in order to achieve the welded joints, low amount of energy and iller material should be consumed. From this point of
view, Laser-Arc Hybrid welding is an attractive solution in the pipelines fabrication.
The higher concentration of the heat energy than other processes, the lexibility to adjust the process (can be controlled individually the
melting energy and the amount of iller material introduced in the process) and mainly the opportunity to work with grooves angles of
20 degrees, instead off 55-60 degrees in the classical procedures, highly recommends this processes as an optimal solution from technical
and economical point of view.
Weld samples achieved by LaserArc Hybrid process are presented and discussed in the second part of the paper. Also, LaserArc Hybrid
system con iguration and technical-economic comparison with other conventional welding processes is highlighted in the inal part of
the study.
Cuvinte cheie: LaserHibrid, sudare hibrid Laser-MAG,
productivitate, conducte magistrale.
1.Introducere
1. Introduction
During the last half of the century, there have been developed new submerged arc welding processes employing
multiple arcs, especially used in the effective fabrication of
large welded pipes - existing nowadays up to 6 electrode
wire variants of the process - as well as a wide range of modern automatic systems for pipe sections orbital butt welding. The development of the orbital welding systems over
the last decades is based on the following benchmarks [1, 2]:
For root welding:
1970 inside root welding system with three, four or ive
welding heads, simultaneously operated;
1980 outside root welding system, provided with inner
ring and copper shoe;
1990 system for root welding without support, using MAG
DIP transfer welding.
The use of the internal welding systems proves impossible
when welding small diameter pipes and in this case there
will be used side lap welds, from outside to inside. The development of the modern welding systems with accurate
control of the digital transfer of metal drops allowed the
external one-sided welding, without requiring the root face
support provided by the inner copper shoe.
For welding the illing layers:
1960 - insertion of a weld head for narrow grooves;
1990 - use of two weld heads, each with a single wire;
2000 - operation of the TANDEM process;
2004 - employment of the DUAL TANDEM process (CAPS
system- Cran ield automated pipe welding system)
2007 - automatic control of the position of the weld head by
means of the computerized acquisition of characteristic parameters for the welding conditions.
Presently, the manufacturing the offshore and onshore pipelines, especially when coupling different pipeline sections,
requires the powered MAG welding process with one or more passages, depending on the thickness of the pipe wall [4].
Striving to control the high costs incurred
in fabrication of pipelines and to increase
the maintainability and dependability
of pipelines by implementing innovative
technologies, the manufacturers have focused on several state-of-art welding technologies, using steels with higher strength,
multi-arc / multi-wire automatic welding,
ultrasound inspection systems, modern
painting systems and product integrity
Figura 1. Dispoziia capetelor de sudare i macrostructura unei mbinri sudate validation processes. Therefore the cost
procedeul dual TANDEM utiliznd sistemul CAPS [1,2]
incurred in manufacturing a single pipeFigure 1. Placement of the weld heads and the macrostructure of a joint welded
line stands for almost a half of the overall
through the TANDEM dual process using the CAPS system [1,2]
costs of the entire project where the costs
procedeul mecanizat MAG, cu una sau mai multe treceri n afferent to the welding processes hold the irst position [1,
funcie de grosimea peretelui conductei[4]. ntr-o ncer- 3]. In order to considerably reduce such costs, there have
care de a controla costul ridicat al construciei conductei i been developed new highly productive (sub-) processes,
de a spori sigurana n exploatare prin punerea n aplicare such as: CM, CMT, CMT-pulse, STT, TIME, FastROOT SHORTa unor tehnologii inovatoare, productorii au urmrit o se- ARC++, ColdWeld or LINFAST used for back welding and
rie de tehnologii de sudare de ultim generaie, utiliznd SUPERPULS, RAPID ARC, RAPID MELT, TWIN, TANDEM for
oeluri de nalt rezisten, sudarea automat multiarc-arc/ welding the ill layers [4]. Figure 1 shows how to place the
multi-srm, sisteme de inspecie cu ultrasunete, sisteme weld heads for orbital welding through the TANDEM dual
SUDURA, XXII - 4/2012
welding process is highly sensitive to any changes of the welding speed as well as to the relative position of the weld heads
and the distance between the weld heads etc. (Figure 6).
[1,2,5,9].
1.Flan de ixare pe robot;
2.Cuplarea optic a ghidului de
und;
3.Fasciculului laser;
4.Perdea de aer (jet ncruciat)
pentru protecia lentilelor;
5.Axa cu servomotor integrat;
6.Dispozitiv de avans srm;
7.Cap de sudare cu arc electric;
8.Cablu alimentare la surs de
sudare cu arc electric;
9.Cupl controler robot de
sudare.
Sistemul din igura alturat a
fost dezvoltat la inele ultimului
deceniu de ctre unul dintre
liderii europeni ai sudrii robotizate mpreun cu SLV Halle.
Figura 7. Componentele capului pentru sudarea hibrid
robotizat LHM [13]
Figure 7. Components of the weld head in LHM robotized
hybrid welding process [13]
The pipes orbital welding has been covered by several studies focused on inding the optimum arrangement of the laserarc weld heads and the angle of inclination to the vertical
axis. When executing the circular welding seam, the relative
9
Tabel 3. Modaliti de dispunere relativ a fasciculului laser fata de arcul electric MAG [5]
Table 3. Relative positions of the laser beam compared to the electric arc MAG [5]
n schema din igura 5 sunt prezentate aspectele de care trebuie inut cont atunci cnd se utilizeaz procedeul LaserHibrid. [10]. n tabelul 2 sunt prezentate efectele parametrilor
de proces semni icativi asupra geometriei mbinrii [9]. Procesul de sudare LHM este extrem de sensibil la modi icarea
position between the weld heads may be changed (ex: depending on the change of the laser head inclination, and
the welding position de) in order to have a proper control
on proper welding formation and to avoid the low of the
molten metal bath. Table 3 de ines the usual arrangement
variants of the weld heads [5].
Figure 7 shows the components of the LHM robotized hybrid weld head in the variant that allows a separate laser
head from the electric arc weld head [13].
Figure 8 shows the LHM embedded compact weld heads
manufactured by different manufacturers especially for the
robotized welding. As you can see, that there are several structural variants for the weld heads designed to support standard hybrid welding and also several variants for the operation under intensive conditions [12].
The LaserHybrid welding with one or two arcs and a laser head (Laser-Arc or Laser Tandem), sharing a common
molten metal bath, is one of the most productive processes
used for welding of pipelines [1]. This new process allows
the illing of the groove by one or more passages, eliminating
several phases of the welding process and reducing thus the
fabrication costs.
The hybrid welding processes are also more and more attractive for the industrial ield due to the bene its derived from the
combination of the two processes. So, the high welding speeds
and the deep penetration of the laser welding combine with
SUDURA, XXII - 4/2012
the bene its provided by the electric arc welding, i.e. higher
tolerances, control of the iller material that has been added
and better mechanical proprieties. The existing combinations of the CO2 laser welding, plasma welding, WIG or MAG
have been already used for achieving qualitative structures
under higher welding speed conditions. Moreover, the postwelding processing, which is basically a manual operation,
has been considerably reduced.
4.1. Particularities of the equipments used for orbital
welding of pipelines
The equipments used for the orbital welding of pipelines
are characterized by several particularities, on the one hand
caused by the orbital movement of the weld heads, the changes in the relative position of the laser head depending on
the position of the system around the pipe and, on the other
hand, prescribed by the need for more accurate processing
of the groove edges in pipelines. Another issue is linked to
the need for a customized system designed to protect the optic system of the laser head. This is required because, due to
the relative movement between the system and the welded
11
made on pipe sections up to 6m length. In this case, we observed higher tolerances than those entered for a pipeline with
gauged ends, especially in respect to the quality and misalignment of edges. Figure 5 shows the welding equipment [5].
Another application related to the LHM welding of X80
hotel pipes of 15mm thickness, against a welding speed
vs= 3m/min, using a 15kW laser, performed by the Laser
Technology Center from Sankt-Petersburg is highlighted by
Figure 13 [11]
4.2 Current results when welding the steel LaserHibrid
for pipelines X70
In the complex manufacturing processes of pipelines, steels
with higher strength and toughness at low temperatures are
required. Hereinafter we present the recent outcomes when
applying the LaserHybrid welding for X70 steel pipeline of 14
mm thickness, using the parameters described by Table 4 and
achieving the welds described by igure 14, 15, 16, [7].
Figura 17. mbinri sudate LHM a tablelor din oel naval cu diferite grosimi
Figure 17. LHM welded joints of naval steel plates having different thicknesses
15
6.Concluzii
Utilizarea procedeului de sudare LHM la fabricarea conductelor pentru transportul petrolului i a gazelor naturale
reprezint o soluie viabil care satisface toate cerinele de
calitate i productivitate, chiar i pentru oeluri de nalt
rezisten. Acest lucru se datoreaz avantajelor care acesta
le ofer: productivitate mare, formarea corect a rdcinii
mbinrii, consum redus de materiale de adaos, defecte
reduse, posibiliti de sudare dintr-o singur trecere a
materialelor cu grosime mare, viteze de rcire mici, rezultnd o duritate relativ redus. n timpul sudrii, energia
liniar introdus n piese este mai redus avnd ca rezultat
micorarea deformaiilor. Comparativ cu procedeul de sudare
laser, utilizarea unor materiale de adaos permite umplerea
corect a rostului i mbuntirea proprietilor mbinrii
prin rezultarea unor microalieri n baia de metal topit.
6.Conclusions
BIBLIOGRAFIE
[1]
Olsen F. O., Hybrid laserarc welding, Woodhead Publishing Limited, CRC Press LLC, London, 2009
[2]
Yapp D., Liratzis T., Development of High Productivity Girth Welding, In: Proceedings of the 2nd South East European IIW intl. Congress, pp.25-41 So ia, Bulgaria, 21-24 October, 2010
[3]
Reutzel E.W., Sullivan M.J.,. Mikesic D. A., Joining Pipe with the Hybrid Laser-GMAW Process: Weld Test Results and
Cost Analysis, Welding Journal, june. 2006
[4]
Joni N., Mistodie L.R., Procedee MSG derivate din sudarea clasic MIG/MAG In: Lucrrile Conferinei Naionale SUDURA 2012, pp. Cluj, Romnia, 26-27 Aprilie, 2012
[5]
Keitel, St. Neubert, J. et al. Laser GMA Hybrid Girth Welding Technologies for Transmission Pipelines In : Proc. Of the
2nd South Eastern European Congress of the IIW, So ia, 21-24 October.2010, pp. 64-69
16
[6]
Gumenyuk, S. Gook, M. Lammers, M. Rethmeier, High Power Fibre Laser Welding for Pipeline Applications, Proceedings of LAMP2009, 5th International Congress on Laser Advanced Materials Processing,June 29-July 02nd Kobe,Japan..
[7]
Grnenwalda S., Seefelda T., Vollertsena F., Kocak M., Solutions for joining pipe steels using laser-GMA-hybrid
welding processes, Physics Procedia 5 (2010) 7787, 2010
[8]
Reis P. R., Norrish J., Cuiuri D., Initial assessment of a new approach for laser: tandem GMA welding, Avaliao inicial
de uma nova verso para soldagem laser: MIG/MAG duplo-arame, Estudos Tecnolgicos - Vol. 7, n 2:71-85 (mai/dez 2011), 2011
http://www.estudostecnologicos.unisinos.br/index.php?e=20&s=9&a=173
[9]
Brian M. Victor, Hybrid Laser Arc Welding, ASM Handbook, Volume 6A, Welding Fundamentals and Processes, 2011
[10] Kah P., Usability of laserarc hybrid welding processes in industrial applications, Thesis, Lappeenranta University of
Technology, Finland ISBN 978-952-265-100-6 (PDF), 2011
https://dspace.lib.cran ield.ac.uk/bitstream/1826/72/Wojcieh_Suder_Thesis_2011.pdf
[11] Lopota A,V., Turichin G.A., Harlamov, V.V.,
, [ ], 1 (13) , 2009
http://elibrary.ru/item.asp?id=15232672
[12] Petring D., Fraunhofer/ILT weld heads, www.ilt.fraunhofer.de/eng/101067.html
[13] *** MSG-Laser-Hybrid welding process, http://www.cloos.com.cn/download/jg h.pdf
[14] *** Prozess Cloos http://www.cloos.de/cloos/de/produkte/prozess/index.php
[15] *** Strahltechnische Fertigungsverfahren, Block IV: Anwendungen der Lasertechnik, Strahltechnische Fertigungsverfahren, Grundlagen der Lasertechnik, Institut fr Fge- und Schweitechnik, Braunschweig, 2011
http://www.ifs.tu-braunschweig.de/module.php?id=23&action=download& ileid=753
17