US20180043467A1 - System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter - Google Patents

System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter Download PDF

Info

Publication number
US20180043467A1
US20180043467A1 US15/555,647 US201615555647A US2018043467A1 US 20180043467 A1 US20180043467 A1 US 20180043467A1 US 201615555647 A US201615555647 A US 201615555647A US 2018043467 A1 US2018043467 A1 US 2018043467A1
Authority
US
United States
Prior art keywords
piece
steel
alloy
adapter
based alloy
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.)
Abandoned
Application number
US15/555,647
Other languages
English (en)
Inventor
Staf Huysmans
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.)
Laborelec CVBA
Original Assignee
Laborelec CVBA
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=52627079&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20180043467(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Laborelec CVBA filed Critical Laborelec CVBA
Assigned to LABORELEC CVBA reassignment LABORELEC CVBA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Huysmans, Staf
Publication of US20180043467A1 publication Critical patent/US20180043467A1/en
Abandoned legal-status Critical Current

Links

Images

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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/16—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/121—Control circuits therefor
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/129—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding specially adapted for particular articles or workpieces
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F3/1055—
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to methods for connecting of materials, at least in part by use of welding, selected materials therefore, resulting connected systems and various use cases.
  • the advanced martensitic and austenitic stainless steels are the new and improved versions of the formerly known martensitic steels, e.g. X20, and austenitic stainless steels, e.g. Tp321, Tp347H, Tp304H, wherein the improvement lays in the fact that for advanced martensitic steels a higher creep resistance is present, whereas for austenitic steels there is even so a better corrosion and oxidation resistance determined.
  • the DMWs are welded using conventional welding processes and a number of potential filler metals, mostly Ni-based are used.
  • Rotational friction welding is well known for welding heavy-duty components such as e.g. critical aircraft engine components (jet compressor wheels), camshafts and axle tubes. It is not a fusion welding methodology but rather a solid-state process (cold weld).
  • the advantage of friction welding is that in the use described above no fusion is obtained and no filler metals are required.
  • Another advantage is that it is a simple and strictly controlled welding mechanism where welds are made within very short time (i.e. typically less than 1 minute). This makes the process ready for production welding of large series of components.
  • the invention aims at providing methods for connecting of materials, at least in part by use of welding, as well as providing selected materials therefore, including resulting connected systems, suited for the heavy duty use cases described above.
  • a system comprising: a two-sided adapter, made of a Ni-based alloy, connected to either a first piece of metal, e.g. steel at one side of the two-sided adapter, and/or to a second piece of metal, e.g. steel at the other side of the two-sided adapter, wherein the first and second piece differ in at least one chemical or physical parameter; wherein the connection of at least the first or the second piece with the adapter is characterized in that it is made by use of friction welding.
  • the term connected is defined as being fixed or else joined, and for which welded is interpreted as an example.
  • Analogue is the term connection referring to either a fixing or a joining contact, amongst which a welding contact is given as an example.
  • a method for linking a first piece of metal, e.g. steel, to a second piece of metal, e.g. steel, wherein the first and second piece differ in at least one chemical or physical parameter comprises the steps of (i) providing a connection between the first piece and one side of a two-sided adapter, made of an Ni-based alloy; and (ii) providing a connection between the second piece and the other side of the two-sided adapter, wherein at least for one of the steps (i) or (ii) friction welding is used.
  • the term linking is defined as indirectly connecting by means of adding an intermediate piece in between, a so-called two-sided adapter.
  • the first piece of steel has a Cr content between 8 and 13% and the second piece of steel has a Cr content between 17 and 35%.
  • one of the steps (i) or (ii) comprises of welding, preferably laser beam welding the first or second piece to one or the other side of a two-sided adapter.
  • one of the step (i) or (ii) comprises of additive manufacturing on the first or second piece of the two-sided adapter, thereby connecting the first or second piece to one or the other side of the two-sided adapter.
  • FIG. 1 illustrates in accordance with the prior-art, a direct joining system characterized by means of friction welding martensitic steel to austenitic stainless steel.
  • FIG. 2 illustrates a connecting system in accordance with the present invention (a) comprising martensitic steel, onto which a Ni-alloy is laser beam welded, wherein the Ni-alloy is subsequently friction welded to austenitic stainless steel, (b) comprising martensitic steel, onto which a Ni-alloy is grown by means of additive manufacturing, and wherein that Ni-alloy is subsequently friction welded to austenitic stainless steel.
  • FIG. 3 illustrates a connecting system in accordance with the present invention comprising martensitic steel, that is friction welded to a Ni-alloy, made in advance by means of additive manufacturing, and that is further friction welded to austenitic stainless steel.
  • FIG. 4 illustrates the prior-art, i.e. a direct joining method characterized by friction welding martensitic steel to austenitic stainless steel.
  • FIG. 5 illustrates a connecting method in accordance with the present invention (a) comprising of laser beam welding a Ni-alloy onto martensitic steel, followed by friction welding that Ni-alloy onto austenitic stainless steel, (b) comprising of additive manufacturing a Ni-alloy onto martensitic steel, followed by friction welding that Ni-alloy onto austenitic stainless steel.
  • FIG. 6 illustrates a connecting method in accordance with the present invention comprising of additive manufacturing a Ni-alloy, followed by friction welding that Ni-alloy at one side onto martensitic steel, and at the other side onto austenitic stainless steel.
  • FIG. 7 shows (a) two-piece spacer comprising of martensitic or austenitic stainless steel, and a Ni-alloy respectively in accordance with the present invention, (b) a three-piece spacer comprising of martensitic steel, a Ni-alloy and austenitic stainless steel in accordance with the present invention.
  • FIG. 8 shows schematically in accordance with the present invention, a power plant tube in martensitic steel, which is conventionally welded to a three-piece spacer tube, in turn conventionally welded to a power plant tube in austenitic stainless steel.
  • FIG. 9 illustrates a connecting system in accordance with the present invention comprising austenitic steel, onto which a Ni-alloy is either laser beam welded or grown by additive manufacturing, wherein the Ni-alloy is subsequently friction welded to another and different Ni-alloy.
  • FIG. 10 illustrates a tubular two-sided adapter, shaped with edges in (a) side view, (b) front view, in accordance with the present invention.
  • FIG. 11 illustrates joint configurations or joint types of tubes in accordance with the present invention.
  • FIG. 12 schematically shows the present invention aspect of friction welding combined with respectively forging and piercing process.
  • the invention provides the understanding that, when one requires connecting two dissimilar materials, especially metals, for instance by use of welding techniques, that need to be used in connected mode, in harsh conditions, either represented in terms of high temperature, high pressure or the occurrence of frequent thermal cycles, or corrosion, and most often combinations of those conditions, that then the used connecting technique has to be selected and optimized therefore. Note that selecting each of the materials is often not possible as they are selected as suited for the place they are used mostly without considering ad initio the connecting technique (and issues thereof) as described further.
  • Ni-based filler metals generally including post weld heat treatments (PWHT).
  • PWHT post weld heat treatments
  • the choice for Ni-basis in filler metals is mainly nourished by two phenomena, being carbon migration on one hand, and thermal expansion on the other.
  • the Ni-based barrier for carbon migration typically occurring when conventional welding different Cr-alloyed steels, doesn't seem to be full proof, due to the presence of type I or II carbides at the fusion line.
  • the invention makes an abrupt different choice for the field of use considered, being hollow tubes (in the examples/embodiments mentioned tube material thicknesses varying typically between 4, 6 to 8 mm, however 10 mm or even 15 mm could also be interpreted under this invention), especially for the power plants outlined above.
  • the invention however has further contributions. Indeed while the selection of technique is inspired by considering the temperatures as occurring during the connecting process, which are higher for the conventional fusion welding than for the friction welding, the invention indicates that even when applying the friction welding technique, temperatures might be too high to achieve a sufficiently good weld, and for instance lead to hard and/or brittle martensitic material and/or still C-migration (be it less). The invention hence brings forward the consideration that just changing welding process, especially by the alternative with a lower temperature, is not sufficient, and that the final outcome, for instance in terms of hardness, is still not sufficient. Moreover, while typically (also for the conventional approach) in such circumstances one might seek for further process windows to cure the above, for example in case of too high hardness being resolved by applying PWHT, the invention further selects a fundamental solution to the problem.
  • an exemplary embodiment of the invention is to connect martensitic and austenitic stainless steel, martensitic steel having 9-12% Cr content, or percentages slightly lower or higher within a margin of +or ⁇ 1%, and austenitic stainless steel having typically between 18-25% Cr content, however up to 35% or even higher Cr content is not particularly excluded, while depending on further development and feasibility of austenitic stainless steel. It is further noted that carbon migration can also appear between other dissimilar metals, such as for instance bainitic steel and martensitic steel wherein percentages of e.g. 21 ⁇ 4% Cr for bainitic steel and 9-12% Cr for martensitic steel respectively need to be joined.
  • the solution as searched for according to the present invention is not necessarily exclusively for joining martensitic steel with austenitic stainless steel, but is potentially also applicable for other dissimilar metals, and thus by default not excluded for other joined types of steel, particularly when representing a large difference in Cr content amongst each other.
  • the purposely defined context of the invention determines that the further material should be selected in terms of difference in % of Cr and in terms of thermal expansion coefficient in that for the temperatures as reached by use of friction welding (still going beyond 800 degrees Celsius but far below the 1400 degrees Celsius as found in fusion welding) yields the desired performance for the defined harsh condition use.
  • Ni-based alloys in a particular embodiment EPRI P87 alloy
  • EPRI P87 alloy Ni-based alloys
  • the invented selection of combined friction welding and EPRI P87 alloy (which can also be used in fusion welding by the way) further benefits from the advantages (as described above and in addition reduced residual stress levels and optimal alignment avoiding bending moments) of friction welding in that such process is highly automated and hence less affected in process variability, i.e. operator influence.
  • the EPRI P87 alloy is specifically developed with Cr content equal to that of martensitic steel (9%), including having similar carbon content and a comparable thermal expansion as of martensitic steel. With the high ductility characterizing Ni-alloys, P87 may absorb stress during creep-fatigue loading.
  • EPRI P87 alloy instead of EPRI P87 alloy, other Ni-based alloys such as A617 alloy or A82 alloy are also suitable.
  • A617 alloy or A82 alloy are also suitable.
  • the advantage of using one of these latter alloys is for example the fact that A617 and A82 are more common, and hence directly and standard available for use.
  • these alternatives have higher Cr content than EPRI P87 and therefore will still represent some remaining carbon migration, being entirely eliminated in case of using EPRI P87.
  • friction welding whenever friction welding is applied, A617 and A82 are likely suitable due to low residual stress levels induced after welding. Compared to conventional welding, there is less risk for stress relaxation cracking as a result of residual stress.
  • the invention also deliberately chooses the use of the automated friction welding on tubes and the steam flow conditions as described above although a little more critical operating thereof, due to the need for having protrusion free hollow tubes, might be required therefore.
  • An embodiment of the invention hence provides for a Ni-based transition piece, comprising: a first piece made of martensitic steel; a second piece made of austenitic stainless steel; and a two-sided adapter, made of e.g. EPRI P87 alloy, A617 alloy or else A82 alloy, connected at one side to the first piece and at the other side to the second piece, wherein connecting the first piece is achieved by means of (laser beam) welding or the two-sided adapter is additive manufactured, and wherein connecting the second piece is achieved by use of friction welding.
  • a two-sided adapter made of e.g. EPRI P87 alloy, A617 alloy or else A82 alloy
  • said pieces are tubes.
  • Other combinations of transition pieces can be made with either only the first or otherwise second piece, or both first and second pieces already pre-connected to the adapter, thereby creating respectively a two-piece spacer or a three-piece spacer.
  • a spacer is therefore defined as a combined structure of the adapter and at least one piece of steel, whereas the adapter is connected to at least one piece of steel.
  • a possible use of such transition pieces is that thousands of welds could be prepared in advance.
  • installing the at least partially friction welded DMW transition parts would only require a classic or similar weld (i.e. welding two similar steels such as e.g. M-M or A-A where M stands for martensitic steel and A representing austenitic stainless steel) at each martensitic respectively austenitic tube end.
  • M-M or A-A where M stands for martensitic steel and A representing austenitic stainless steel
  • the invention further provides for a method for connecting by use of welding a first piece made of martensitic steel to a second piece made of austenitic stainless steel, however in an indirect way, wherein the method comprises the steps of (i) welding the first piece to one side of a two-sided adapter, made of e.g. EPRI P87 alloy, A617 alloy or else A82 alloy, and possibly additive manufactured; and (ii) welding the second piece to the other side of the two-sided adapter, wherein for at least one of the welding steps friction welding is used, while the other welding step could be e.g. laser beam welding.
  • a two-sided adapter made of e.g. EPRI P87 alloy, A617 alloy or else A82 alloy, and possibly additive manufactured
  • welding the second piece to the other side of the two-sided adapter, wherein for at least one of the welding steps friction welding is used, while the other welding step could be e.g. laser beam welding.
  • the invention also considers a system, comprising: a two-sided adapter, made of a Ni-based alloy, connected to either a first piece of steel and/or to a second piece of steel, wherein the first and second piece differ in at least one chemical or physical parameter; wherein the connection of the first or the second piece with the adapter is characterized in that it is made by use of additive manufacturing.
  • the first piece of material of this system is made of martensitic steel, more in particular CSEF (Creep Strength Enhanced Ferritic Steels) whereas the second piece of material of the system is made of austenitic steel, more in particular advanced stainless steels (such as e.g. Super304H, HR3C, 347HFG).
  • the Ni-based alloy described for the system above is made of EPRI P87 alloy.
  • the Ni-based alloy is made of A617 alloy, or alternatively the Ni-based alloy is made of A82 alloy.
  • the invention further includes a method for linking a first piece of steel to a second piece of steel, wherein the first and second piece differ in at least one chemical or physical parameter, the method comprises the steps of (i) providing a connection between the first piece and one side of a two-sided adapter, made of an Ni-based alloy; and (ii) providing a connection between the second piece and the other side of the two-sided adapter, wherein for one of the steps (i) or (ii) additive manufacturing is used, whereas for the other step (ii) or (i) friction welding is performed.
  • the first piece of material is e.g. made of martensitic steel, more in particular CSEF (Creep Strength Enhanced Ferritic Steels) and/or the second piece of material is e.g. made of austenitic steel, more in particular advanced stainless steels (such as e.g. Super304H, HR3C, 347HFG).
  • martensitic and advanced austenitic stainless steels that are characterized by respectively improved creep, and corrosion and oxidation resistance on the other hand. Whereas corrosion typically occurs on the outside, oxidation is taking place on the inside of the power installation parts. Martensitic steel is mainly used for the collectors or so-called headers of the power installation. The 9% Cr is also common for the grades P91 and P92 improved version, including further elements such as e.g. molybdenum, vanadium, niobium, boron, tungsten or nitrogen to better withstand creep, and occurring more often in modern boiler systems. Alternatively, VM12 can also be mentioned as a useful martensitic steel type.
  • Austenitic stainless steel is particularly used in so-called super heaters and re-heaters, wherein higher temperatures and far more aggressive environment are present. Mainly due to the higher Cr-alloying, i.e. typically 18-25%, possibly up to 35%, the austenitic material is better performing in this strong corrosive area. Metal temperatures here may arise up to 650-680° C., whereas currently operating steam temperature of 600° C. is applied.
  • Ni-based alloy made of EPRI P87 alloy
  • the Ni-based alloy is made of A617 alloy, or alternatively of A82 alloy.
  • the two-sided adapter alloy preferably has a Cr percentage and/or C percentage and preferably both close to those of one of the pieces of materials to be connected to, while the other piece of material differs substantially in Cr percentage.
  • the alloy especially has an extra component, such as Ni, at least partially preventing the C migration from the first to the second piece of different material.
  • FIG. 1 illustrates a direct joining system 100 , connecting two different types of steel 101 , 102 , and wherein the connecting mechanism is determined by means of friction welding.
  • the connection made between the two different types of steel is a friction welded contact 103 .
  • the different steel types are martensitic steel 101 and austenitic stainless steel 102 .
  • FIG. 1 The prior-art as illustrated in FIG. 1 is now compared with several embodiments according to the present invention.
  • the edge of a tube or pipe end for instance is not cut perpendicularly with respect to the tube or pipe axis, but under a certain angle, and hence less material is present at the outer edge side compared to the inner edge side, or vice versa.
  • the two different materials particularly martensitic steel and austenitic stainless steel according to the invention, are brought together to be friction welded, there is less material present in the joint area than if a perpendicular cut is performed. In other words, there is less abundance or too much of material where the weld is made. A low penetration or low protrusion weld is thus achieved.
  • an induction coil can be mounted onto the martensitic steel. Through electromagnetic radiation of the induction coil, the martensitic steel will become ‘softer’ and less brittle. This reduction in Vickers hardness of martensitic steel, having become untempered due to local high temperatures induced by the friction welding process, is alternatively obtained by PWHT or automatically after e.g. more than 500 h of service.
  • the induction coil method however is interpreted as being beneficial because of the local application of the method resulting in only local effect of this method, and hence not deteriorating or degrading other parts of the connecting system.
  • FIG. 2 a connecting system 200 in accordance with the present invention is depicted.
  • the connecting system of FIG. 2 is characterized by a three-part structure, wherein again two different types of steel 201 , 202 can be distinguished, moreover an intermediate part 205 between both is now also shown.
  • This intermediate part 205 further referred to as two-sided adapter is defined as a Ni-based alloy, particularly chosen to link or indirectly connect a martensitic 201 with an austenitic stainless steel 202 .
  • the Ni-based alloy 205 as intermediate between the martensitic 201 and the austenitic stainless steel 202 , carbon migration from lower Cr-alloyed steel, e.g.
  • the Ni-based alloy 205 is connected to each one of the different types of steel 201 , 202 , though in a rather different way.
  • both connections 203 , 204 are welding connections
  • the welding connection 204 with martensitic steel 201 is realized by laser beam welding the Ni-based alloy 205 onto the martensitic steel 201 .
  • the Ni-based alloy 205 is for example provided as a wire being targeted by a laser beam, thereby melting the wire and applying the melted alloy directly onto the martensitic steel 201 .
  • the welding connection 203 between the Ni-based alloy 205 and the austenitic stainless steel 202 is obtained by friction welding.
  • a Ni-based alloy 205 is grown by means of additive manufacturing onto a martensitic steel 201 , forming a fixed grown connection 206 defined by this additive manufacturing.
  • a friction welding connection 203 is provided between the Ni-based alloy 205 and an austenitic stainless steel 202 .
  • FIG. 3 illustrates a connecting system 300 in accordance with the present invention, again characterized by a three-part structure, however in this case both connections 303 , i.e. with martensitic steel 301 at one side of the two-sided adapter, and with austenitic stainless steel 302 at the other side of the two-sided adapter, are obtained by friction welding.
  • the two-sided adapter 305 depicted here is a Ni-based alloy, such as e.g. P87, A617 or else A82, being made in advance by additive manufacturing.
  • the additive manufactured two-sided adapter 305 is brought into a set-up to friction weld both sides with either martensitic steel and austenitic stainless steel respectively.
  • the steel parts 301 , 302 are typically delivered as tubes or pipes
  • the additive manufactured two-sided adapter is made and placed in the welding set-up as a ring shape or donut shaped three-dimensional model.
  • the additive manufactured two-sided adapter 305 is only at one side friction welded to a piece of steel 301 , 302 .
  • the martensitic steel 301 is chosen to be friction welded to the two-sided adapter 305 , as being more critical in welding applications compared to austenitic stainless steel 302 .
  • a two-piece structure is now formed, having a martensitic steel end on one side, and a Ni-based alloy adapter end on the other side. Both ends can be further subject for conventional welding on site, i.e. respectively the martensitic steel end with martensitic steel being part of a power plant, and the Ni-based alloy adapter end with austenitic stainless steel being part of a power plant.
  • FIG. 4 illustrates a direct joining method 410 for connecting, more particularly friction welding two different types of steel, characterized by the steps of:
  • FIG. 5 a connecting method 510 , 520 in accordance with the present invention is illustrated in FIG. 5 .
  • the connecting method 510 , 520 representing one connecting means determined by friction welding, is further defined by either a connecting means using laser beam welding, or else applying additive manufacturing by growing one material onto the other. More specifically, as shown in FIG. 5 ( a ) , the connecting method 510 comprises the steps of:
  • Ni-based alloy 205 mentioned above is e.g. EPRI P87 alloy, alternatively A617 alloy or else A82 alloy.
  • the connecting method 520 depicted in FIG. 5 ( b ) is characterized by the steps of:
  • FIG. 6 Another connecting method 610 , in accordance with the present invention, and only applying friction welding as a connecting means, is illustrated by FIG. 6 , comprising the steps of:
  • transition pieces or so-called spacers to easily install as a replacement in a power plant are also part of the present invention.
  • the transition piece 730 of FIG. 7 ( a ) is a two-piece spacer comprising of a martensitic steel 731 that is connected to a Ni-based alloy 735 .
  • Alternative but less common two-piece spacer embodiment comprises an austenitic stainless steel connected (e.g. by means of friction welding) to a Ni-based alloy.
  • FIG. 7 ( b ) illustrating a three-piece spacer 740 comprising of a martensitic steel 741 , connected to a Ni-based alloy 745 , subsequently connected to an austenitic stainless steel 742 .
  • a transition piece 840 in accordance with the present invention can be installed as a tube connection.
  • Depicted in FIG. 8 is part of a power plant tube in martensitic steel 801 , that is conventionally welded onto the martensitic side of a three-piece spacer tube 840 , comprising of a martensitic steel 841 , connected to a Ni-based alloy 845 , subsequently connected to an austenitic stainless steel 842 .
  • the three-piece spacer tube 840 is conventionally welded to part of a power plant tube in austenitic stainless steel 802 .
  • the tube wall of the different parts mentioned has a thickness of preferably between 3 and 15 mm, more preferably between 4 and 10 mm, whereas the outer diameter of the tubular parts is for instance 50-60 mm.
  • larger dimensions are also applicable. For example shifting rather towards pipe configurations instead of tube systems, wall thicknesses of 40 mm can occur and diameters of about 220 mm are more likely.
  • FIG. 9 illustrates a further embodiment, particularly referring to the application within e.g. a nuclear installation instead of a USC power plant, wherein different types of materials can appear compared to examples previously discussed.
  • a connecting system 900 in accordance with the present invention is represented, comprising austenitic steel 901 , onto which a Ni-based alloy 905 , such as for instance A52 alloy, is either laser beam welded or grown by additive manufacturing, wherein the Ni-based alloy 905 is now acting as a two-sided tubular adapter which is subsequently friction welded to another and different type of Ni-based alloy 902 , such as e.g. A690 alloy in case of nuclear power plants.
  • Ni-based alloy 905 such as for instance A52 alloy
  • the two-sided adapter Ni-based alloy 905 is additive manufactured in advance, and hence friction welded onto its two sides 903 , 904 respectively with austenitic steel 901 onto one side 904 , and with another different Ni-based alloy 902 onto the other side 903 .
  • Haynes 230 can also be mentioned as possible other Ni-based alloy 902 , onto which a Ni-based alloy adapter 905 is connected, to be typically used at high temperatures, such as occurring in the Concentrated Solar Power (CSP) plants.
  • CSP Concentrated Solar Power
  • a two-sided tubular adapter 1005 is shaped with edges 1008 , 1009 , as for example illustrated in FIG. 10 . Particularly with the side view of FIG. 10 ( a ) it is shown that less material is present at tubular ends 1003 , 1004 , due to occurring edges 1008 , 1009 onto respectively the outer and inner ring of a donut alike shape 1005 , further represented by the front view of FIG. 10 ( b ) .
  • FIG. 10 ( a ) suggest the presence of the donut inner ring and its corresponding edge, although not being visible in side view.
  • the concentric circles in FIG. 10 ( b ) represent the borders of an edge-shaped tubular end 1003 , wherein the most inner circle also defines the border of the donut hole.
  • the light dotted lines in FIG. 10 further relate to the presence of the donut hole.
  • FIG. 11 illustrates so-called joint configurations or joint types of tubes, meaning several tube wall profile architectures, particularly considered at surface ends to be friction welded, amongst which FIG. 11 ( b ) is another zoomed-in representation of what has been described above for FIG. 10 .
  • Tube profile dimensions are determined by tube diameter d, wall thickness t and reduced wall thickness r, as illustrated in FIG. 10 ( a ) , 11 ( a ), 11 ( b ).
  • tube diameter d is for instance in the range of 20-500 mm, wall thickness tin the range of 3-25 mm and reduced wall thickness in the range of 2-20 mm.
  • the edges are also characterized by an angle ⁇ and/or another angle ⁇ , which may be different or equal in order of magnitude, and by a respective length l ⁇ and/or l ⁇ .
  • the tubular surface end 1003 , 1004 as in FIG. 10 characterized by reduced wall thickness r, is not necessarily perfectly centred, while considering inner and outer diameter of the tubular shape, but can also be positioned more to the inner of more to the outer ring edge, depending e.g. on the angles ⁇ , ⁇ chosen, or on the dimensions of the contact surface 1003 , 1004 required.
  • An angle ⁇ of e.g. 45° may determine an oblique cut off surface end as in FIG. 11 ( c ) further reduced in material by an angle ⁇ , ⁇ .
  • a measure for the reduced wall thickness here is given by height h.
  • FIG. 12 schematically shows an alternative of the present invention basic principle combined with respectively forging (or re-forging) and piercing process.
  • a connecting system 1200 is depicted characterized by means of friction welding a first bar or rod like piece 1201 with a second bar or rod like piece 1202 .
  • the first bar 1201 is for instance made of martensitic steel, whereas the second bar 1202 is possibly a Ni-based alloy.
  • the connecting system 1200 is subsequently brought into a forging (or re-forging) process, during which the materials of the connecting system 1200 are plastically deformed under high temperature conditions, and by using a hydraulic press in order to deform the bar structure to a sheet like—possibly circular/cylindrical—component 1200 ′ comprising of two disc-parts 1202 ′, 1201 ′ originating from the two friction welded bars 1202 , 1201 .
  • the result of the forging (or re-forging) process is shown in FIG. 12 ( b ) .
  • the sheet like component can be hollowed consecutively, piercing out a central part, for example by means of using a hydraulic press.
  • the tubular or ring like structure 1200 ′′ of FIG. 12 ( c ) comprising of two ring-parts 1202 ′′, 1207 ′′ is obtained.
  • the two bars each made of one particularly type of steel or metal are chosen for this combined friction welding and forging (or re-forging) process, followed by a piercing process.
  • This ‘quick and less alignment sensitive’ connecting method eliminates alignment difficulties that may occur when friction welding hollow tubes, whereas the tolerances on the alignment in case of using bars are omitted, allowing much more flexibility in the connecting process.
  • one of the bars may comprise a first part of a first type of metal and a second part of a second type of metal, wherein first and second parts are previously connected by means of e.g. laser beam welding or additive manufacturing.
  • three bars are friction welded and subsequently forged (or re-forged) and pierced afterwards, such that a 3-layered ring-shaped stack is achieved, for example resulting in a three-piece spacer as referred to in FIG. 7 ( b ) .
  • this alternative embodiment may be associated with complex and cumbersome after treatments for accomplishing for instance the right physical and chemical characteristics.
  • the present invention of (partially) friction welded adapter applied in combination with the aspect of dissimilar metal welds is not limited to the examples of austenitic steel and martensitic steel using a Ni-base alloy adapter, or bainitic steel and martensitic steel using a Ni-based alloy adapter, or either austenitic steel and a Ni-based alloy using another Ni-based alloy, but includes other possible combinations of metals, particularly enabling welding constructions of advanced with less advanced materials to be operative at high temperature conditions.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Laser Beam Processing (AREA)
US15/555,647 2015-03-05 2016-03-03 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter Abandoned US20180043467A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP15157893.7 2015-03-05
EP15157893.7A EP3064307A1 (de) 2015-03-05 2015-03-05 System und Verfahren zum Verbinden durch Reibungsschweissen eines ersten Stahlelements mit einem zweiten Stahlelement durch Verwendung eines Adaptierselementes aus Ni-basierten Legierungen
PCT/EP2016/054560 WO2016139311A1 (en) 2015-03-05 2016-03-03 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2016/054560 A-371-Of-International WO2016139311A1 (en) 2015-03-05 2016-03-03 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US17/176,384 Continuation US11292078B2 (en) 2015-03-05 2021-02-16 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of Ni-based alloys adapter

Publications (1)

Publication Number Publication Date
US20180043467A1 true US20180043467A1 (en) 2018-02-15

Family

ID=52627079

Family Applications (2)

Application Number Title Priority Date Filing Date
US15/555,647 Abandoned US20180043467A1 (en) 2015-03-05 2016-03-03 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of ni-based alloys adapter
US17/176,384 Active US11292078B2 (en) 2015-03-05 2021-02-16 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of Ni-based alloys adapter

Family Applications After (1)

Application Number Title Priority Date Filing Date
US17/176,384 Active US11292078B2 (en) 2015-03-05 2021-02-16 System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of Ni-based alloys adapter

Country Status (3)

Country Link
US (2) US20180043467A1 (de)
EP (2) EP3064307A1 (de)
WO (1) WO2016139311A1 (de)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180209280A1 (en) * 2017-01-25 2018-07-26 Rolls-Royce Plc Bladed disc and method of manufacturing the same
US20210107087A1 (en) * 2018-03-20 2021-04-15 Osaka University Metal material solid-phase bonding method and solid-phase bonding device
US11167375B2 (en) 2018-08-10 2021-11-09 The Research Foundation For The State University Of New York Additive manufacturing processes and additively manufactured products
US11383280B2 (en) 2013-03-22 2022-07-12 Battelle Memorial Institute Devices and methods for performing shear-assisted extrusion, extrusion feedstocks, extrusion processes, and methods for preparing metal sheets
US11517952B2 (en) 2013-03-22 2022-12-06 Battelle Memorial Institute Shear assisted extrusion process
US11534811B2 (en) 2013-03-22 2022-12-27 Battelle Memorial Institute Method for forming hollow profile non-circular extrusions using shear assisted processing and extrusion (ShAPE)
US11919061B2 (en) 2021-09-15 2024-03-05 Battelle Memorial Institute Shear-assisted extrusion assemblies and methods
US12122120B2 (en) 2021-11-08 2024-10-22 The Research Foundation For The State University Of New York Additive manufacturing processes and additively manufactured products

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107699793B (zh) * 2017-10-23 2019-07-05 中国电建集团河南工程有限公司 奥氏体耐热钢Super304H接头焊材及其焊接工艺
DE102017219416A1 (de) 2017-10-30 2019-05-02 Sms Group Gmbh Verfahren und Vorrichtung zum Verbinden von Warmbrammen
CN110666340A (zh) * 2019-11-01 2020-01-10 西安西工大超晶科技发展有限责任公司 一种铸造高温合金与马氏体不锈钢摩擦焊接方法
US11872651B2 (en) * 2019-11-12 2024-01-16 Osaka University Dissimilar material solid phase bonding method, dissimilar material solid phase bonded structure, and dissimilar material solid phase bonding device
CN114054960B (zh) * 2021-11-23 2024-05-28 中北大学 一种钛与铝的超威弧mig+激光双面复合高速焊接方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4333671A (en) * 1980-05-05 1982-06-08 General Atomic Company Friction welded transition joint
US20100119870A1 (en) * 2007-03-29 2010-05-13 Fukui Prefectural Government Dissimilar metal joint product and joining method therefor
US20100233501A1 (en) * 2006-08-30 2010-09-16 Fluor Technologies Corporation Compositions and Methods for Dissimilar Material Welding
US7874471B2 (en) * 2008-12-23 2011-01-25 Exxonmobil Research And Engineering Company Butt weld and method of making using fusion and friction stir welding
US20120299288A1 (en) * 2011-05-24 2012-11-29 Electric Power Research Institute, Inc. FUNCTIONALLY GRADED COMPOSITIONAL CONTROL METHODS TO ELIMINATE DISSIMILAR METAL WELDS (DMWs) DURING MANUFACTURE OF INTEGRAL HEADERS
US20140252198A1 (en) * 2013-03-11 2014-09-11 General Electric Company Support structure with dissimilar metal welds

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH069750B2 (ja) 1986-01-16 1994-02-09 川崎重工業株式会社 摩擦圧接方法
US6308882B1 (en) * 1999-09-13 2001-10-30 Dana Corporation Method for joining ductile iron and steel
DE19953079B4 (de) * 1999-11-04 2013-12-19 Alstom Technology Ltd. Verfahren zum Verschweißen von Bauteilen
US7562807B2 (en) 2004-05-05 2009-07-21 Electric Power Research Institute Weld filler for welding dissimilar alloy steels and method of using same
US10543549B2 (en) 2013-07-16 2020-01-28 Illinois Tool Works Inc. Additive manufacturing system for joining and surface overlay
CN104014928A (zh) * 2014-06-19 2014-09-03 西安特种设备检验检测院 一种马氏体耐热钢和奥氏体耐热钢的异种钢的焊接方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4333671A (en) * 1980-05-05 1982-06-08 General Atomic Company Friction welded transition joint
US20100233501A1 (en) * 2006-08-30 2010-09-16 Fluor Technologies Corporation Compositions and Methods for Dissimilar Material Welding
US20100119870A1 (en) * 2007-03-29 2010-05-13 Fukui Prefectural Government Dissimilar metal joint product and joining method therefor
US7874471B2 (en) * 2008-12-23 2011-01-25 Exxonmobil Research And Engineering Company Butt weld and method of making using fusion and friction stir welding
US20120299288A1 (en) * 2011-05-24 2012-11-29 Electric Power Research Institute, Inc. FUNCTIONALLY GRADED COMPOSITIONAL CONTROL METHODS TO ELIMINATE DISSIMILAR METAL WELDS (DMWs) DURING MANUFACTURE OF INTEGRAL HEADERS
US20140252198A1 (en) * 2013-03-11 2014-09-11 General Electric Company Support structure with dissimilar metal welds

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Friel "Power ultrasonics for additive manufacturing and consolidating of materials." In Power Ultrasonics, pp. 313-335. Woodhead Publishing, 2015 *

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11383280B2 (en) 2013-03-22 2022-07-12 Battelle Memorial Institute Devices and methods for performing shear-assisted extrusion, extrusion feedstocks, extrusion processes, and methods for preparing metal sheets
US11517952B2 (en) 2013-03-22 2022-12-06 Battelle Memorial Institute Shear assisted extrusion process
US11534811B2 (en) 2013-03-22 2022-12-27 Battelle Memorial Institute Method for forming hollow profile non-circular extrusions using shear assisted processing and extrusion (ShAPE)
US11684959B2 (en) 2013-03-22 2023-06-27 Battelle Memorial Institute Extrusion processes for forming extrusions of a desired composition from a feedstock
US20180209280A1 (en) * 2017-01-25 2018-07-26 Rolls-Royce Plc Bladed disc and method of manufacturing the same
US20210107087A1 (en) * 2018-03-20 2021-04-15 Osaka University Metal material solid-phase bonding method and solid-phase bonding device
US11745287B2 (en) * 2018-03-20 2023-09-05 Osaka University Metal material solid-phase bonding method and solid-phase bonding device
US11167375B2 (en) 2018-08-10 2021-11-09 The Research Foundation For The State University Of New York Additive manufacturing processes and additively manufactured products
US11426818B2 (en) 2018-08-10 2022-08-30 The Research Foundation for the State University Additive manufacturing processes and additively manufactured products
US11919061B2 (en) 2021-09-15 2024-03-05 Battelle Memorial Institute Shear-assisted extrusion assemblies and methods
US12122120B2 (en) 2021-11-08 2024-10-22 The Research Foundation For The State University Of New York Additive manufacturing processes and additively manufactured products

Also Published As

Publication number Publication date
EP3265266B1 (de) 2020-04-01
EP3064307A1 (de) 2016-09-07
US20210308785A1 (en) 2021-10-07
WO2016139311A1 (en) 2016-09-09
EP3265266A1 (de) 2018-01-10
EP3265266B2 (de) 2023-06-14
US11292078B2 (en) 2022-04-05

Similar Documents

Publication Publication Date Title
US11292078B2 (en) System for and method of linking by friction welding a first piece of steel to a second piece of steel with use of Ni-based alloys adapter
JP5955125B2 (ja) タービンロータ及びその製造方法及び当該タービンロータを用いた蒸気タービン
EP2233876B1 (de) Geschweisste header-/düsenstruktur
CN102220884B (zh) 多合金物品及涡轮机构件以及制造多合金物品的方法
US20090092494A1 (en) Disk rotor and method of manufacture
EP2080951A1 (de) Kesselwasserwandpaneel
US20100028705A1 (en) Dissimilar metal transition for superheater or reheater tubes
CN104266003B (zh) 一种双金属复合钢管的生产方法
RU2711168C2 (ru) Способ изготовления трубного устройства, трубное устройство и печь, снабженная таким трубным устройством
CN116174978A (zh) 用于焊接导管连接件以用于高温应用的工艺
US20130004317A1 (en) Turbine disk preform, welded turbine rotor made therewith and methods of making the same
JP5025369B2 (ja) 表面肉盛方法
EP2716873A2 (de) Bimetallische Turbinenummantelung und Herstellungsverfahren
JP6043190B2 (ja) 燃料ノズル及び燃料ノズルの製造方法
JP3170720B2 (ja) 異材の溶接方法
CN107002914B (zh) 流体导管元件以及用于形成流体导管元件的方法
US20110100961A1 (en) Welding process for producing rotating turbomachinery
EP2527063B1 (de) Funktional abgestufte Zusammensetzungssteuerverfahren zur Beseitigung ungleicher Metallschweißungen bei der Herstellung von integralen Kopfzeilen
JP6118714B2 (ja) 厚肉大径管の溶接継手構造とその溶接施工方法
JPWO2016111232A1 (ja) 薄板部材の溶接継手、その溶接継手を備えた缶体の製造方法、およびその溶接継手を備えた管体の配管方法
US11298774B2 (en) Method to eliminate dissimilar metal welds
US10119473B2 (en) Component, gas turbine component and method of forming
JP2015034622A (ja) ボルト及びボルトの製造方法、このボルトを使用した原子炉内構造物、この原子炉内構造物の補修方法
Krstevska et al. Welding technology of martensitic steel P91 and austenitic steel 304H–State of the art
CN103978299A (zh) 利用高频电阻焊法生产双金属冶金复合管工艺及复合管

Legal Events

Date Code Title Description
AS Assignment

Owner name: LABORELEC CVBA, BELGIUM

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HUYSMANS, STAF;REEL/FRAME:043865/0253

Effective date: 20160305

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: FINAL REJECTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: FINAL REJECTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: ADVISORY ACTION MAILED

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION