Advanced M aterials and Laser Advanced M aterials and Laser based - - PowerPoint PPT Presentation

Advanced M aterials and Laser Advanced M aterials and Laser based based Welding Technologies Welding Technologies

Automotive sector

Industry trends

Need to reduce CO2 emissions in exhaust gases to fight global warming

 Improvement of combustion efficiency  Reduction of vehicle weight  Reduction of loss of efficiency through friction  M aterials development  Welding Processes  M aterials development  Welding Processes

• High tensile strength steel materials- Advanced High Strength Steels (AHSS),

Ultra High Strength Steels (UHSS)

• Galvanised steel
• Aluminium
• M agnesium
• Composites

Advanced materials

Trend towards light-weight design is widely established Steels with very high ultimate tensile strength increasingly applied Trend towards light-weight design is widely established Steels with very high ultimate tensile strength increasingly applied

5 out of 38 Advanced Transportation T ech Projects of US DoE (Sept 2013)

• Oak Ridge National Laboratory - Body-in-white Joining of Aluminum to

Advanced High Strength Steel at Prototype Scale: - solid-state spot joining technology

• Johns Hopkins University - heat-generating foils to provide strong and

stable bonds between aluminum alloys, magnesium alloys and steels.

• Oak Ridge National Laboratory - laser-assisted joining of aluminum and

carbon fiber components

• The Ohio State University - Vapor-assisted collision welding of dissimilar

metals.

• M ichigan State University, Composite Vehicle Research Center - bonding,

reparability and reassembly of dissimilar materials using thermoplastic adhesives

Some candidate components

4

Aluminium Steel Plastic

Aluminium outer skin – Steel inner support of roof; closures such as doors, bonnet and hood Reinforced plastic floor sections – Aluminium body frame Reinforced plastic sections – to steel pillars and side members

M ulti-M aterials Joining for Lightweighting (M ultiJoin) Project being implemented in India with support of Technology Development Board

aluminum

Robotic CM T weld brazed prototype

“M UL TIJ OIN” Project: Demonstrator assembly (2 m X 1m)

 Useable for joining Steel/Aluminium, Steel/ Steel and Aluminium/Aluminium  Car body: M ass reduction up to 26% (AUDI) through mixed materials and smaller

flanges

 Adapted joining configurations

Overlap Flange Al St Al St Al St

 Short cycle times through high brazing speed (4 m/min)  Flexible seam geometries by using a robot for laseroptic and wire feed  Systems for Quality assurance available (SmartRay 3D for surface porosity, undercut, geometry)

Laser Brazing

Automotive sector

Advanced High Strength Steels (AHSS)

M icrohardness M apping: Local hardness variation and HAZ Softening Static Tensile Failure Location Correlates to HAZ Softening Region

* Zhili Feng, Oak Ridge National Laboratory

Automotive sector

Laser welding of Advanced High Strength Steels (AHSS)

Tensile strength Formability

Fully penetrating butt welds could be achieved at 5- 8m/ min, with 4kW of laser power and a 0.6mm diameter laser spot, depending on

• thickness. welding speed

could be increased to 10- 17m/ min for the same laser power when a 0.4mm diameter laser spot was used. Fully penetrating lap welds could be achieved in 0.8-1.5mm thickness at 2.5-6.5m/ min with 4kW of laser power and a 0.6mm diameter laser spot. welding speed could be increased by 40% and 200-700% respectively, depending on thickness of steels, when 0.4 and 0.2mm diameter laser spots were used. Tensile strength of butt welds in a range of steels produced with 4kW of laser power and a 0.6mm diameter spot

* Steve Shi, Steve Westgate, TWI Ltd

Laser processing of AHSS

• Use of Advanced High

Strength Steels – Hard cut edges – Soft weld heat affected

zones

• Solution a hybrid laser

beam source, fiber laser for cutting & joining and diode laser for local heat treatment

Source: IL T Aachen

Power- Nuclear

Evolution of four generations of ferritic steels (Viswanathan and Bakker,2000)

• M odified 9Cr-1M o Steel- High temperature components of fossil-fired power

plants, steam generators of nuclear power plants

• Oxide dispersion strengthened (ODS) ferritic steels -clad tube material for
• xide fuels, better creep properties up to 700°C
• Reduced Activation Ferritic-M artensitic Steels- candidate structural materials

for TBM to be installed in the ITER Fusion Reactor

Trends of welding processes for nuclear power plant (Courtesy: Satoru Asai)

Power - Nuclear

Power- Thermal

Ratio change of high temperature materials with steam parameters development Steam parameters development of coal fired power plants

Problems in fusion joining of Ni based super alloys

• Liquation cracking at grain boundary in PM Z
• Sluggish nature of molten pool
• M icrofissuring in reheat zones of multipass welds

Bead on Plate welding trials M ount Id Laser power (kW) Proc speed (m/ min ) Wire feed (m/ min ) Shielding gas INLHW- 1 3.5 1 8 He:Ar=80: 20 INLHW- 2 3.5 1 10 He:Ar=80: 20 INLHW- 3 3.5 1 8 He=100% INLHW- 4 3.5 1 10 He=100%

Laser hybrid BOP welding of 10 mm thick IN 617 Super Alloy

LHW-1 LHW-2 LHW-3 LHW-4 Hardness survey across the weld Hardness survey across the weld Hardness survey along the weld Hardness survey along the weld SEM images of LHW-3 FZ, HAZ & Laser SEM images of LHW-3 FZ, HAZ & Laser SEM images of LHW-4 FZ, HAZ & Laser SEM images of LHW-4 FZ, HAZ & Laser

M IG-FZ

Precipitate coarsening

Laser-FZ M IG-FZ

Precipitate coarsening

Laser-FZ

M IG Fusion zone M IG-HAZ

• EDS images of LHW-3 indicate enrichment of FZ dendritic

boundary & HAZ coarsened precipitate with M o

C Ni Co M o Ti Al Fe 0.01 18 7.75 4.9 0.40 0.10 Bal As received solution annealed at 820°C very low C, tough and ductile Fe-Ni martensitic matrix Aged 480 °C for 3 h fine, coherent intermetallic precipitates Ni3M o, Ni3Ti,

Rocket motor casing M icrostructure Composition (wt%) Properties

• High strength and high strength-to-

weight ratio

• High notched strength
• M aintains high strength up to at least

350°C

• High impact toughness and plane strain

fracture toughness

• Excellent weldability either in the

annealed or aged conditions. Pre- heat not required.

• Good machinability.
• Good castability.

High Fracture Toughness KIC = 120 M Pa √m Ultra High Strength UTS = 1800 M Pa

Rocket motor cases, cryogenic missiles, submarine hulls, landing gears, tooling and machinery

Applications

Defence

Defence

Laser- GMAW hybrid welding process set up

Laser- M IG hybrid welding process of 10mm thick M araging Steel plates M acrostructures

Single pass hybrid weld 3 pass M IG weld

Process Fusion zone area (sq.mm) Eyebrow zone width from top to bottom

• f bead (mm)

Hybrid 34.5 0.6 to 1.2 M IG 108.4 2

Defence

Treatment 0.2% YS M Pa UTS, M Pa % El Fracture location Base metal as-received 862 970 18 Base metal Aged 1735 1690 1750 1850 10 LHW as welded 929 817 980 930 14 Base metal M IG as welded 1035 911 1060 1056 14 Base metal LHW PWHT 1590 1643 1751 1753 2 3 Weld M IG PWHT 1575 1650 1755 1746 3 4.1 Weld

Tensile properties of M 250 plate in different conditions

Aerospace

Al-Li alloys

Commercial Aluminum-Lithium Alloys Weldalite 049 Cu - 5.4, Li - 1.3, Ag - 0.4, M g - 0.4, Zr - 0.14 Alloy 2090 Cu - 2.7, Li - 2.2, Ag - 0.4, Zr - 0.12 Alloy 2091 Cu - 2.1, Li - 2.0, Zr - 0.10 Alloy 8090 Li - 2.45, Zr - 0.12, Cu - 1.3, M g - 0.95 http:/ / aluminumlithium.com/

Oil and Gas

Emerging technologies High-Strength Steel Line Pipe: The use of higher strength steel requires less wall thickness for a given pipeline design or higher operating pressures for a pipeline design

• f a given wall thickness.

Hybrid Welding Process: High efficiency lasers, which are becoming increasingly available, may make the use of hybrid welding processes feasible in the field. These processes are much more productive/ less labour intensive than even the most advanced mechanised welding systems. Seam tracking will be an integral part of this technology since the welding speeds are high. The offshore oil and gas industry is moving into deeper waters. Several issues arise:

• The pipe wall thickness needs to be increased to resist hydrostatic collapse.
• The pipelines may have to be laid by J-lay, instead of the more conventional S
• lay

method to reduce the weight supported by the laybarge.

• The hydrocarbons are higher pressure and temperature and often containing a higher

concentration of acid gases making the fluids more corrosive. In J-lay it is generally

• nly possible to have a single welding station. Presently automatic gas welding is used

but this has limitations.

Higher Higher Strength Strength M aterials M aterials M ore M ore Corrosive Corrosive Environment Environment Higher well Higher well head head pressures pressures

Welding Welding Challenges Challenges

Shipbuilding

Laser technology – A revolution in shipbuilding

• Combining laser cutting and laser welding in one production line, along with complex

clamping technology that renders exact pre-positioning and tack-welding of components unnecessary.

• Automating the precision manufacture of shipbuilding panels with considerably less

thermal distortion than when using conventional joining methods.

• A new approach to designing steel ship internal structures from modular,

standardised, precision steel subassemblies, referred to as parts families. J

• ining Non-traditional M aterials:
• There is a need for increased performance (e.g. speed and manoeuvrability) and this is

driving the requirement to reduce ship weight.

• This results in the use of non-traditional materials including non-metallic composites,

high-strength steel, aluminium, and titanium.

• There are needs for materials joining processes for these materials and processes to

join dissimilar combinations of these materials.

Industrial Sectors M aterial challenges

Auto- genous laser Laser- arc hybrid Laser hot/ co ld wire Laser brazing Laser spot Laser remote Laser metal- plastic Automotive

• AHSS
• M ulti-material design

    

Aerospace/ Defence

• Al-Li alloys
• Composites
• M araging steels
• Ti- alloys

   

Nuclear

• Fusion- RAFM S
• ODS



• 

Thermal

• AUSC- Ni based alloys

 

Oil & gas

• 13Cr-4Ni M artensitic

S.S

• “ Super M artensitic S.S”



Shipbuilding

• High-alloy steel-

distortion control

  

Laser based joining processes in different industrial sectors

Thanks for your attention Email: gp@arci.res.in; director@arci.res.in