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Title: Novel Optimization Methodology for Welding Process/Consumable Integration

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Publication Date:
Research Org.:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN
Sponsoring Org.:
USDOE Assistant Secretary for Energy Efficiency and Renewable Energy (EE)
OSTI Identifier:
Report Number(s):
DOE Contract Number:
Resource Type:
Technical Report
Country of Publication:
United States

Citation Formats

Quintana, M.A., DebRoy, T., Vitek, J.M., and Babu, S. Novel Optimization Methodology for Welding Process/Consumable Integration. United States: N. p., 2006. Web. doi:10.2172/940356.
Quintana, M.A., DebRoy, T., Vitek, J.M., & Babu, S. Novel Optimization Methodology for Welding Process/Consumable Integration. United States. doi:10.2172/940356.
Quintana, M.A., DebRoy, T., Vitek, J.M., and Babu, S. Sun . "Novel Optimization Methodology for Welding Process/Consumable Integration". United States. doi:10.2172/940356.
title = {Novel Optimization Methodology for Welding Process/Consumable Integration},
author = {Quintana, M.A. and DebRoy, T. and Vitek, J.M. and Babu, S.},
abstractNote = {},
doi = {10.2172/940356},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sun Jan 15 00:00:00 EST 2006},
month = {Sun Jan 15 00:00:00 EST 2006}

Technical Report:

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  • Advanced materials are being developed to improve the energy efficiency of many industries of future including steel, mining, and chemical, as well as, US infrastructures including bridges, pipelines and buildings. Effective deployment of these materials is highly dependent upon the development of arc welding technology. Traditional welding technology development is slow and often involves expensive and time-consuming trial and error experimentation. The reason for this is the lack of useful predictive tools that enable welding technology development to keep pace with the deployment of new materials in various industrial sectors. Literature reviews showed two kinds of modeling activities. Academic andmore » national laboratory efforts focus on developing integrated weld process models by employing the detailed scientific methodologies. However, these models are cumbersome and not easy to use. Therefore, these scientific models have limited application in real-world industrial conditions. On the other hand, industrial users have relied on simple predictive models based on analytical and empirical equations to drive their product development. The scopes of these simple models are limited. In this research, attempts were made to bridge this gap and provide the industry with a computational tool that combines the advantages of both approaches. This research resulted in the development of predictive tools which facilitate the development of optimized welding processes and consumables. The work demonstrated that it is possible to develop hybrid integrated models for relating the weld metal composition and process parameters to the performance of welds. In addition, these tools can be deployed for industrial users through user friendly graphical interface. In principle, the welding industry users can use these modular tools to guide their welding process parameter and consumable composition selection. It is hypothesized that by expanding these tools throughout welding industry, substantial energy savings can be made. Savings are expected to be even greater in the case of new steels, which will require extensive mapping over large experimental ranges of parameters such as voltage, current, speed, heat input and pre-heat.« less
  • The possibility of applying the gas-shielded consumable-electrode process to the automatic butt welding of Croloy 2 1/4 piping for eventual adaptation to remotely controlled operation was investigated. Satisfactory results have been obtained in horizontally fixed pipe when weld beads are started at the top (12 o'clock position) and ending at the bottom (6 o'clock position), alternating from side to side, and overlapping starts and stops. A mixture of helium and carbon dioxide gases with 3/64-in. diameter wire has produced the best results. Difficulties encountered are maintenance of bead contour, arc stability, and satisfactory root penetration. Results show that a satisfactorymore » technique can be developed. More work is required to design automatic welding equipment for remote-control. (auth)« less
  • The potential to save trillions of BTU’s in energy usage and billions of dollars in cost on an annual basis based on use of higher strength steel in major oil and gas transmission pipeline construction is a compelling opportunity recognized by both the US Department of Energy (DOE). The use of high-strength steels (X100) is expected to result in energy savings across the spectrum, from manufacturing the pipe to transportation and fabrication, including welding of line pipe. Elementary examples of energy savings include more the 25 trillion BTUs saved annually based on lower energy costs to produce the thinner-walled high-strengthmore » steel pipe, with the potential for the US part of the Alaskan pipeline alone saving more than 7 trillion BTU in production and much more in transportation and assembling. Annual production, maintenance and installation of just US domestic transmission pipeline is likely to save 5 to 10 times this amount based on current planned and anticipated expansions of oil and gas lines in North America. Among the most important conclusions from these studies were: • While computational weld models to predict residual stress and distortions are well-established and accurate, related microstructure models need improvement. • Fracture Initiation Transition Temperature (FITT) Master Curve properly predicts surface-cracked pipe brittle-to-ductile initiation temperature. It has value in developing Codes and Standards to better correlate full-scale behavior from either CTOD or Charpy test results with the proper temperature shifts from the FITT master curve method. • For stress-based flaw evaluation criteria, the new circumferentially cracked pipe limit-load solution in the 2007 API 1104 Appendix A approach is overly conservative by a factor of 4/π, which has additional implications. . • For strain-based design of girth weld defects, the hoop stress effect is the most significant parameter impacting CTOD-driving force and can increase the crack-driving force by a factor of 2 depending on strain-hardening, pressure level as a % of SMYS, and flaw size. • From years of experience in circumferential fracture analyses and experimentation, there has not been sufficient integration of work performed for other industries into analogous problems facing the oil and gas pipeline markets. Some very basic concepts and problems solved previously in these fields could have circumvented inconsistencies seen in the stress-based and strain-based analysis efforts. For example, in nuclear utility piping work, more detailed elastic-plastic fracture analyses were always validated in their ability to predict loads and displacements (stresses and strains). The eventual implementation of these methodologies will result in acceleration of the industry adoption of higher-strength line-pipe steels.« less
  • In this project, mathematical models that predict the microstructure in pipeline steel welds were to be developed. These models were to be integrated with thermal models that describe the time-temperature history in the weld as a function of location in order to derive the spatial variation of microstructure in the weld. The microstructure predictions were also to be combined with microstructure-hardness relations, based on the additivity principle, to determine the spatial variation of hardness in the weld. EMC2 also developed microstructural models based on empirical relationships. ORNL was to pursue the development of more fundamental, theoretically based models. ORNL appliedmore » a previously developed model for inclusion formation to predict the extent and nature of inclusions that form during weld cooling from the liquid. This inclusion model was directly integrated with computational thermodynamics capability. A convenient user interface was developed for both the inclusion model and the thermodynamic phase-stability calculations. The microstructure model was based on the simultaneous transformation theory analysis as applied to the transformation of austenite to various ferrite constituents during weld cooling. The model available on the Materials Algorithm Project web site was used. Extensive modification of this model was required to correct problems with compilation and calculations as a function of the computational platform (Unix, Linux, Windows, etc.) that was used. The user interface for the inclusion model and thermodynamic phase-stability calculations was delivered to EMC2 along with the modified and correct microstructure model. Evaluation of the theoretically based model will be carried out and the predictions will be compared with experimental results as well as predictions based on the empirical models developed by EMC2.« less
  • The objective of this project was to support Texaco`s effort to develop the zinc titanate hot-gas desulfurization process for gases produced from their oxygen-blown coal gasifier by answering two key questions that had remained unanswered to date. These questions were: Will chloride in the coal gas affect the performance of the sorbent? Where would the chloride end up following sulfidation and regeneration? Previously, Research Triangle Institute (RTI) completed a bench-scale test series, under a subcontract to Texaco, Inc., for their contract with the US Department of Energy/Morgantown Energy Technology Center (DOE/METC), in which zinc titanate was shown to be amore » highly promising sorbent for desulfurizing the Texaco O{sub 2}-blown simulated coal gas. The next step was to evaluate the effect of coal gas contaminants, particularly chloride, on the sorbent. No tests have been carried out in the past that evaluate the effect of chloride on zinc titanate. If ZnO in the sorbent reacts with the chloride, zinc chloride may form which may evaporate causing accelerated zinc loss. Zinc chloride may revert back to the oxide during oxidative regeneration. This may be enhanced in the presence of steam. This report provides results of a three-test series which was designed to give some definitive answers about the fate of chloride in the hot-gas desulfurization process and the effect of chloride on the performance of zinc titanate.« less