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Process Optimization Framework for Temper Bead Welding Procedures

Luo, Yuxiang
http://orcid.org/0000-0001-5542-0326
http://rave.ohiolink.edu/etdc/view?acc_num=osu1689865013393691

Abstract Details

2023, Master of Science, Ohio State University, Welding Engineering.
Post-Weld Heat Treatment (PWHT) is a common process applied to welded structures in the oil and gas, petrochemical, and power generation industries. These industries utilize matching filler metal welds (MFWs), dissimilar metal welds (DMWs), and weld overlays (WOLs) in large, welded structures exposed to various temperatures and corrosive environments. PWHT helps restore desirable service properties in the weld metal heat affected zone (HAZ) of welded structures that were lost during welding due to overheating. However, traditional PWHT can be inefficient, expensive, and difficult to apply to large structures or in field work situations. Temper Bead Welding (TBW) is a more efficient, less expensive, and versatile alternative to PWHT. By applying additive weld beads to the target steel substrate, TBW provides tempering directly to the heat-affected zone (HAZ) that formed during deposition of previous weld beads. However, improperly defined TBW procedure parameters, such as welding current, voltage, travel speed, wire feeding rate, bead sequence, etc., can have detrimental effect on the steel HAZ properties. The common trial and error approach in development of TBW procedures involves experimental welding, testing, and adjustment of welding parameters, which can be labor, materials, and time intensive. The objective of this work is to develop a Computational Design of Experiment (CDoE) approach for development and optimization of TBW procedures. The CDoE framework is composed of Design of Experiment (DoE), Finite Element Analysis (FEA), heat source calibration, post-processing, and optimization modules. It utilizes a database of experimentally developed continuous cooling transformation (CCT) diagrams and tempering response relationships of steels used in TBW. The DoE module generates a matrix of welding procedures with welding parameters varying in practically applied ranges and runs the DOE matrix to the FEA module. The latter generates an FEA model of a WOL and utilizes the SysWeld software to predict TBW thermal histories in the steel substrate. The post-processing module uses the predicted thermal histories, the CCT diagrams, and tempering response relationships to predict the local microstructure and hardness in the HAZ of the WOL. This module also calculates tempering efficiency parameters as number of effective tempering reheats, peak tempering reheat temperature, and sum of peak temperatures of tempering reheat cycles. The post-processing module predictions are utilized in the optimization module to define optimal windows of TBW parameters that reflect predetermined HAZ properties. The accuracy of the CDoE modules and framework, in predicting local HAZ properties and quantifying tempering efficiency parameters, has been experimentally validated in this work and in a parallel project. The CDoE framework can be utilized in the development of industry applied TBW procedures. In a series of parallel projects, the CDoE framework is being further developed for application in groove welding and additive manufacturing.
Andrew Perrault, Dr. (Committee Member)
Boian Alexandrov, Dr. (Advisor)
146 p.
Computer Science; Materials Science

Recommended Citations

Citations

  • Luo, Y. (2023). Process Optimization Framework for Temper Bead Welding Procedures [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1689865013393691

    APA Style (7th edition)

  • Luo, Yuxiang. Process Optimization Framework for Temper Bead Welding Procedures. 2023. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1689865013393691.

    MLA Style (8th edition)

  • Luo, Yuxiang. "Process Optimization Framework for Temper Bead Welding Procedures." Master's thesis, Ohio State University, 2023. http://rave.ohiolink.edu/etdc/view?acc_num=osu1689865013393691

    Chicago Manual of Style (17th edition)

osu1689865013393691
52
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This open access ETD is published by The Ohio State University and OhioLINK.