EP2969361A1 - Création de matériaux revêtus par soudage à résistance en ligne continue - Google Patents

Création de matériaux revêtus par soudage à résistance en ligne continue

Info

Publication number
EP2969361A1
EP2969361A1 EP13878125.7A EP13878125A EP2969361A1 EP 2969361 A1 EP2969361 A1 EP 2969361A1 EP 13878125 A EP13878125 A EP 13878125A EP 2969361 A1 EP2969361 A1 EP 2969361A1
Authority
EP
European Patent Office
Prior art keywords
substrate
surface activation
layer
cladding layer
activation layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13878125.7A
Other languages
German (de)
English (en)
Other versions
EP2969361A4 (fr
Inventor
Jerry E. Gould
Wendell Johnson
Dave WORKMAN
James CRUZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Edison Welding Institute Inc
Original Assignee
Edison Welding Institute Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Edison Welding Institute Inc filed Critical Edison Welding Institute Inc
Publication of EP2969361A1 publication Critical patent/EP2969361A1/fr
Publication of EP2969361A4 publication Critical patent/EP2969361A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/0013—Resistance welding; Severing by resistance heating welding for reasons other than joining, e.g. build up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
    • B23K11/065—Resistance welding; Severing by resistance heating using roller electrodes for welding curved planar seams
    • B23K11/066—Resistance welding; Severing by resistance heating using roller electrodes for welding curved planar seams of tube sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B23K11/20—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of different metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001—Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/004—Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of a metal of the iron group
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001—Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/005—Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of a refractory metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron

Definitions

  • Clad materials offer opportunities to maximize the characteristics of individual materials for utility in such environments.
  • Current fabrication approaches for creating clad materials in heavy industries include technologies ranging from arc deposition to explosion bonding. These technologies offer various mechanisms for material deposition, but all include high implicit costs.
  • Clad pipe typically uses a steel outer case and a nickel base liner, which are on the order of 3 mm thick.
  • Current fabrication methods or processes include roll bonding and mechanical cladding.
  • the former is a complex method of diffusion bonding the cladding material to steel plates at a mill, rolling the product to service thicknesses, then fabricating pipe using the UOE (U-forming, O-forming and final expansion) process.
  • UOE U-forming, O-forming and final expansion
  • This method creates a high metallurgical integrity bond, but is very expensive.
  • Mechanical cladding includes forming the cladding material into a tube, inserting this tube into the candidate pipe, and mechanically expanding the liner. This is a more cost effective method of lining pipe, but no metallurgical bond is formed between the liner and the substrate.
  • a first system for creating a clad material includes at least one substrate; at least one cladding layer; at least one surface activation layer disposed between the at least one substrate and the at least one cladding layer; and a resistance seam welder, wherein the resistance seam welder is operative to generate heat and pressure sufficient to react the at least one surface activation layer and form a bond between the at least one substrate and the at least one cladding layer when the at least one surface activation layer is cooled.
  • a second system for creating a clad material includes at least one metal substrate; at least one oxidation and corrosion resistant cladding layer; at least one surface activation layer disposed between the at least one substrate and the at least one cladding layer, wherein the at least one surface activation layer further includes at least one Ni-Cr-Fe-B eutectic alloy; and a resistance seam welder.
  • the resistance seam welder is operative to generate heat and pressure sufficient to melt or otherwise react the at least one surface activation layer and form a bond between the at least one substrate and the at least one cladding layer when the at least one surface activation layer is cooled.
  • a clad material in yet another aspect of this invention, includes at least one substrate; at least one cladding layer; and at least one surface activation layer disposed between the at least one substrate and the at least one cladding layer.
  • the at least one surface activation layer is adapted to be responsive to a resistance seam welder, wherein the resistance seam welder is operative to generate heat and pressure sufficient to melt or otherwise react the at least one surface activation layer and form a bond between the at least one substrate and the at least one cladding layer when the at least one surface activation layer is sufficiently cooled.
  • FIG. 1 is a first perspective view of a clad structure in accordance with an exemplary embodiment of the present invention
  • FIG. 2 is a second perspective view of a clad structure in accordance with an exemplary embodiment of the present invention showing the placement of a welding wheel on the interior of the structure;
  • FIG. 3 is a third perspective view of a clad structure in accordance with an exemplary embodiment of the present invention showing the placement of a welding wheel on the interior of the structure, a welding wheel on the exterior of the structure, and a base plate and rollers on one end of the structure; and
  • FIG. 4 is an end view of a clad structure in accordance with an exemplary embodiment of the present invention showing the placement of a welding wheel on the interior of the structure, a welding wheel on the exterior of the structure, and conduits on both the interior and exterior of the structure for providing flood cooling.
  • Products i.e., clad structures manufactured using the system of the present invention may be flats or rounds, with respect to their geometry.
  • a single cladding layer may be deposited on the inside or outside surface of the clad structure and/or the top and bottom surfaces using the device disclosed in U.S. Patent Application No. 12/412,685 or a suitable commercially available device such as, for example, a 400-kVA alternating current (AC) resistance seam welder with a MedWeld 3005 controller.
  • the clad structures manufactured with this system include a substrate component, a cladding layer, and a surface activation layer.
  • the substrate component is typically metal, such as steel.
  • a specific example of the substrate material is 1018 hot-rolled steel, nominally 12.5-mm thick, which is representative of pipeline steel.
  • the cladding layer is typically a refractory metal, stainless steel, tool steel, or Iconel alloy. Inconel alloys are oxidation and corrosion resistant materials well suited for service in extreme environments subjected to pressure and heat. Specific examples of the cladding layer include 1.8-mm-thick Inconel 625, 3.1-mm-thick Inconel 825, and 2-mm-thick 316 stainless steel. Surface activation may be accomplished by using specific coatings (e.g., Ni-P or Ni-B) or by using braze materials. A specific example of a braze material or alloy is 0.08-mm-thick AWS BNi-9 foil.
  • the surface activation layer may be chemically deposited, cold sprayed, and/or plated onto either the substrate or the cladding layer.
  • Specific advantages of this invention include: (i) texturing of surfaces is not required; (ii) the thickness of the cladding layer may be much greater than with prior art structures; (iii) system power requirements are reduced; (iv) the combinations of materials that may be used with one another is greatly expanded over prior art systems; (v) processing speed is increased over prior art systems; and (vi) the resultant surface profile is of high quality, i.e., there is low distortion.
  • the final product has the appearance of having a solid state weld.
  • FIG. 1 provides a generalized illustration of an exemplary embodiment of a tubular clad structure 10, in accordance with this invention, that includes cladding layer 20 (having a cut line 22), surface activation layer 25, and substrate 30.
  • a specific example of a product made using the system of this invention includes a demonstrator pipe nominally 350-mm in diameter, 300-mm long, and clad with 2-mm of ⁇ 625.
  • the clad product was manufactured using overlapping seams nominally 6-mm to 7-mm wide. Joining was conducted circumferentially, using overlapping seams to create a nominally full bonded product.
  • the product was sectioned and the bond line integrity examined. The results show a highly localized bond with virtually no dilution between clad and substrate. These initial results also indicate the interdependence of weld forces, currents, and travel speeds.
  • the present invention is based, at least in part, on the technology disclosed in U.S.
  • Patent Application No. 12/412,685 to Workman et al. entitled Method of Creating a Clad Structure Utilizing a Moving Resistance Energy Source (filed March 27, 2009), which is incorporated by reference herein, in its entirety, for all purposes.
  • Previous research largely addressed fusion-based attachment of stainless steel and nickel-based cladding to flat carbon steel plates. Processing was based on previously applied approaches to dissimilar metal thickness resistance seam welding ⁇ see, Gould, J. E., Johnson, W., and Workman, D., Development of a New Resistance Seam Cladding Process, Deep Offshore Technology Monaco 2009, PennWell Publications, Tulsa, OK, Paper 127 (2009); and Gould, J.
  • the present invention utilizes a technology referred to as resistance seam weld cladding that uses resistance heating to create a localized bond. This bond is then driven over an extended area to create a product.
  • Product forms include both tubular (pipe) and flat (plate) configurations.
  • the approach offers significant cost advantages over other cladding methods in high volume production.
  • Resistance seam weld cladding (RSeWC) is a variant of resistance seam welding (RSEW), which is a well-established technology for the joining of sheet materials ⁇ see, Welding Handbook, 9 th Ed., Vol. 3, Welding Processes, Part 2, American Welding Society, Miami, FL, pp.
  • the process is typically conducted with at least one electrode wheel, which is used to allow current flow into the workpieces, as well as to apply a welding force.
  • the resultant resistance heating of the workpieces, combined with the applied normal forces, results in the formation of a localized bond. This bond is then propagated as the wheel(s) traverse the workpieces to make continuous seams.
  • Bonding can be the result of either melting and re-solidification of individual weld nuggets or by local deformation (see, Buer, F. Y. and Begeman, M., L., Evaluation of Resistance Seam Welds by a Shear Peel Test, Welding Journal Research Supplement, 41(3):120s-122s (1962); and Gould, J. E., Theoretical Analysis of Bonding Characteristics during Resistance Mash Seam Welding Sheet Steels, Welding Journal Research Supplement, 82(10):263s-267s (2003), both of which are incorporated by reference herein, in their entirety, for all purposes). Processes are available not only for joining steel sheet, but also a range of stainless steel and Ni- based alloys.
  • clad material is prepared as an insert
  • the process is analogous to resistance welding dissimilar materials with dissimilar thicknesses.
  • a specific application of this process is for welding a relatively thin layer of clad material onto a much thicker substrate. Additionally, the clad layer is typically of substantially higher resistivity.
  • Electroless nickel has a composition of nominally Ni- 11% to 13% P.
  • the coating may be applied by a commercial vendor or by other means. This volume of phosphorus provides a nominal 500°C melting point suppression of the deposited nickel.
  • the deposition process itself results in only about a 10- ⁇ coating of the completed assembly.
  • Single side coating allows the addition of the melting point suppressant to only the area where bonding is to occur, thereby minimizing any potential damage to the welding electrodes. Alternate coating approaches many include electroless or electrolytic methods.
  • the CRA layer may be manufactured from strip stock nickel base CRA with the nominally 10- ⁇ eutectic material on one side. While current methods for mechanical cladding employ pre-formed tube sections of CRA (which could also be done) there is advantage to using the clad strip stock directly. In this approach, strip material is mechanically coiled parallel to the axis of the pipe and inserted. The strip is cut to a width matching that to the substrate pipe inner diameter (ID). Once the strip is inserted, it is allowed to expand. Springback of the strip then creates fit-up between the CRA and the substrate pipe. The clad then can be welded into place using the RSeWC process.
  • ID substrate pipe inner diameter
  • the CRA will typically show a gap at the locations where the coiled ends meet.
  • the remaining gap may be closed with a range of secondary joining technologies such as, for example, gas metal arc welding (GMAW), thereby completing the process of cladding.
  • GMAW gas metal arc welding
  • RSeWC is typically done with normal loads ranging from several kilo- Newtons to several lO's of kilo-Newtons. Additionally, the process is known to cause small surface deformations (on the order of ⁇ - ⁇ ), so complex forces act on the tool during processing. This combination of high normal forces and local surface deformations can cause tracking inaccuracies during processing.
  • Initial research on flat plates used rigid tooling, and demonstrated tracking appropriate for the process. This invention provides an improvement in this technology wherein the tooling used to both retain the pipe during welding, as well as to provide indexing as part of the welding process.
  • One embodiment of this tooling uses a spring loaded baseplate to support the pipe, rollers to provide for pipe rotation under the welding wheels, and a threaded mechanism to index the pipe as RSeWC progresses.
  • the generalized system illustrated in FIG. 3 includes baseplate 70, support 72, rollers 74, and axle 76.
  • the wheels are designed both to create a defined contact area for joining and to be sufficiently robust to any flexure of the welding machine.
  • Wheel diameter is largely defined by the inner diameter of the clad surface for bonding.
  • wheels are designed with a maximum diameter providing a contact length under force on the order of 4-6 times the contact width or, alternately, 6-8 times the contact width (see FIG. 2). This design also prevents or minimizes surface marking.
  • Wheels also include a width and face radius that enable both some flexure of the welding machine, and provides adequate bond width.
  • One embodiment of this invention includes a wheel design has a width of roughly 20-mm, with a face radius of 150-mm.
  • This wheel design combined with the processing discussed below, results in per-pass bond widths on the order of 8-mm for a 2-mm thick clad.
  • this aspect of the present invention is enabled by proper thermal management, thereby allowing appropriate temperatures at the joint interface without excessively heating either the substrate steel pipe or the electrode/clad contact surface. Either will lead to degradation of product performance.
  • heating is done resistively, cooling is done by flooding with water. Flooding is done at both the inner diameter and outer diameter surfaces of the product. Flooding is typically done with an excessive amount of water. More specifically, flooding is not done to actively control temperature profiles in the workpiece and electrodes, but rather provide a maximum cooling capability associated with the fluid medium. Without proper flood cooling, damage would likely occur to the welding wheels and clad exposed surface, as well as the metallurgy of the substrate steel pipe. Cooling of the wheels to achieve the same purpose may also be employed (see FIG. 4).
  • the generalized system illustrated in FIG. 4 includes clad structure 10, inner welding wheel 50, outer welding wheel 60, internal cooling fluid conduits 80, and external cooling fluid conduits 90.
  • BNi-9 is a Ni-Cr-Fe-B eutectic alloy with a distinct melting point of 1055°C. This melting point can be compared to the solidus points of the 1018 substrate (1495°C) and the various cladding materials (1270-1370°C). Brazing with BNi-9 is typically done in vacuum and is effective as the RSEW process results in high contact pressures (supplied by a properly designed welding wheel) over a specified area.
  • This pressure has the effect of excluding the environment from joint area, allowing the braze alloy to flow. This is termed a "micro- environment", and combined with the temperatures provided by the resistance heating facilitates localized brazing. Joining is also enabled by the active character of the braze alloy itself. Effectively, on melting, the braze locally alloys with the substrate(s), dissociating any residual surface. This effect facilitates wetting of the braze alloy, and formation of a joint. The combination of proper thermal balance, wide temperature operating window, appropriate micro- environment, and active alloy characteristics results in effective resistance brazing.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Arc Welding In General (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un système destiné à créer un matériau revêtu comprenant au moins un substrat; au moins une couche de revêtement; au moins une couche d'activation de surface disposée entre le ou les substrats et la ou les couches de revêtement; et un appareil de soudage par résistance en ligne continue, ledit appareil de soudage par résistance en ligne continue étant utilisable pour générer une chaleur et une pression suffisantes pour faire fondre la ou les couches d'activation de surface et former une liaison entre le ou les substrats et la ou les couches de revêtement lorsque la ou les couches d'activation de surface sont refroidies.
EP13878125.7A 2013-03-15 2013-06-05 Création de matériaux revêtus par soudage à résistance en ligne continue Withdrawn EP2969361A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361788405P 2013-03-15 2013-03-15
PCT/US2013/044320 WO2014143113A1 (fr) 2013-03-15 2013-06-05 Création de matériaux revêtus par soudage à résistance en ligne continue

Publications (2)

Publication Number Publication Date
EP2969361A1 true EP2969361A1 (fr) 2016-01-20
EP2969361A4 EP2969361A4 (fr) 2016-11-16

Family

ID=51537410

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13878125.7A Withdrawn EP2969361A4 (fr) 2013-03-15 2013-06-05 Création de matériaux revêtus par soudage à résistance en ligne continue

Country Status (9)

Country Link
EP (1) EP2969361A4 (fr)
JP (1) JP6054533B2 (fr)
CN (1) CN104703745A (fr)
BR (1) BR112014032737A2 (fr)
CA (1) CA2880389A1 (fr)
MX (1) MX2014015399A (fr)
RU (1) RU2014153121A (fr)
SG (1) SG11201408592WA (fr)
WO (1) WO2014143113A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107030359B (zh) * 2017-06-01 2020-01-14 中国石油大学(华东) 双金属机械复合管焊接工艺
CN107457475A (zh) * 2017-07-24 2017-12-12 南昌大学 金属表面耐磨涂层的涂覆装置及方法

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60196279A (ja) * 1984-03-16 1985-10-04 Nippon Sharyo Seizo Kaisha Ltd 刃付方法
JP2904727B2 (ja) * 1995-07-06 1999-06-14 株式会社昭和鉛鉄 クラッド材
WO1997002137A1 (fr) * 1995-07-06 1997-01-23 Showa Entetsu Co., Ltd. Materiau plaque
GB2302901B (en) * 1995-07-06 1999-06-02 Showa Entetsu Co Ltd Cladding material
JP3243184B2 (ja) * 1996-07-12 2002-01-07 新日本製鐵株式会社 酸化雰囲気中で接合可能な液相拡散接合用合金箔
US6551421B1 (en) * 2000-11-20 2003-04-22 Honeywell International Inc. Brazing foil performs and their use in the manufacture of heat exchangers
KR100578511B1 (ko) * 2004-03-06 2006-05-12 한국과학기술연구원 접합강도와 내식성이 우수한 내환경성 클래드 판재 및 그제조방법
US20090250439A1 (en) * 2008-04-07 2009-10-08 David Workman Method of creating a clad structure utilizing a moving resistance energy source

Also Published As

Publication number Publication date
WO2014143113A1 (fr) 2014-09-18
MX2014015399A (es) 2015-05-15
CA2880389A1 (fr) 2014-09-18
SG11201408592WA (en) 2015-02-27
CN104703745A (zh) 2015-06-10
JP2015529563A (ja) 2015-10-08
BR112014032737A2 (pt) 2017-06-27
EP2969361A4 (fr) 2016-11-16
JP6054533B2 (ja) 2016-12-27
RU2014153121A (ru) 2016-07-20

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