WO2011068201A1 - 突合せ溶接継手及びその製造方法 - Google Patents
突合せ溶接継手及びその製造方法 Download PDFInfo
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- WO2011068201A1 WO2011068201A1 PCT/JP2010/071688 JP2010071688W WO2011068201A1 WO 2011068201 A1 WO2011068201 A1 WO 2011068201A1 JP 2010071688 W JP2010071688 W JP 2010071688W WO 2011068201 A1 WO2011068201 A1 WO 2011068201A1
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- weld metal
- energy density
- width
- high energy
- weld
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- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0006—Electron-beam welding or cutting specially adapted for particular articles
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0053—Seam welding
- B23K15/006—Seam welding of rectilinear seams
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/06—Electron-beam welding or cutting within a vacuum chamber
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/06—Tubes
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/18—Sheet panels
-
- 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
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- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T403/00—Joints and connections
- Y10T403/47—Molded joint
- Y10T403/477—Fusion bond, e.g., weld, etc.
Definitions
- the present invention relates to a butt weld joint and a method for manufacturing the same.
- the plate thickness of the steel plate used in the foundation portion of the tower for wind power generation must be increased according to the length of the foundation portion to ensure strength and rigidity.
- a jacket-type foundation uses a steel plate having a thickness of 30 mm or more.
- a plate thickness of 50 mm or more (for example, about 100 mm) is used.
- the base portion has a tube structure having a large cross section with a diameter of about 4 m, and the overall height of the tower is 80 m or more.
- high energy density beam welding such as electron beam welding or laser beam welding is a welding method that can be efficiently welded.
- electron beam welding it is necessary to perform welding while maintaining a high vacuum state in a vacuum chamber. The size of the steel plate that can be produced was limited.
- RPEBW reduced-pressure electron beam welding
- Offshore wind power towers are constantly exposed to strong winds and waves as described above. For this reason, the structure of the foundation portion of the tower is constantly subjected to repeated loads due to strong winds, waves, and vibrations caused by the rotation of the turbine blades. Under such circumstances, the welded portion at the base portion of the tower is required to have fatigue resistance against vibrations in a gigacycle region whose order is different from the normal fatigue cycle. In particular, the stress concentration is increased at the toe portion of the weld bead (welded metal), resulting in a problem that the fatigue strength against repeated load of the welded joint is reduced.
- FIG. 3A is a schematic cross-sectional view showing an example of a weld bead of a conventional butt weld joint.
- 3B is an enlarged schematic cross-sectional view of the vicinity of the toe portion T of the weld bead shown in FIG. 3A.
- Patent Document 6 proposes to increase the curvature radius ⁇ and the contact angle ⁇ by adjusting the flux component and the shield gas component.
- Patent Document 7 it is proposed to reduce the stress concentration at the toe portion of the weld bead by setting the ratio of the weld bead width to the thickness of the steel sheet to 0.2 or less.
- the degree of stress concentration increases at the toe portion of the weld bead.
- the fatigue strength of the butt-welded joint decreases due to repeated loads caused by vibrations in the gigacycle region due to wind force, wave force, turbine blade rotation, and the like.
- the above-described conventional technology which is a countermeasure against such stress concentration at the toe, has the following problems.
- Patent Document 6 The method of Patent Document 6 is based on gas shielded arc welding and cannot be applied to this problem of welding without using shield gas by high energy density beam welding.
- Patent Document 7 merely specifies the shape of the weld bead, and specifically discloses how to form the weld bead width as described above, and the welding conditions for that purpose. Absent. Therefore, there is a problem that the reproducibility is lacking and it is extremely difficult to use industrially. Furthermore, the improvement of the fatigue strength of 2 million times in the welded joint is only mentioned, and it cannot be applied to this problem of improving the fatigue resistance against vibrations in the gigacycle region.
- the present invention alleviates stress concentration at the toe portion of the weld bead when performing high energy density beam welding such as electron beam welding on a pair of steel plates without causing such problems, It is an object of the present invention to provide a butt-welded joint having fatigue characteristics that can withstand vibrations of the above and having sufficient fracture toughness with ease and reproducibility.
- the present invention relieves stress concentration at the toe of the weld bead by remelting the weld bead and forming a remelt bead at the weld in high energy density beam welding such as electron beam welding. This improves the fatigue characteristics.
- a butt-welded joint according to one aspect of the present invention is directed to a pair of steel plates and a butt portion of the pair of steel plates by irradiation with a first high energy density beam from the first surface side of the pair of steel plates.
- a first weld metal formed from the first surface side to the second surface side opposite to the first surface, and an end surface of the first weld metal on the first surface side;
- a second weld metal formed by irradiation with a high energy density beam, and a width W1 of the first weld metal on the first surface and a width W of the second weld metal on the first surface.
- the butt weld joint according to (1) includes a third weld metal formed by a third high energy density beam that covers an end surface of the first weld metal on the second surface side,
- the width W 4 of the first weld metal on the second surface and the width W 5 of the third weld metal on the second surface of the steel sheet satisfy the following formula (2), and the third weld
- the depth of the metal from the second surface may be 2.0 to 10.0 mm.
- the steel plate may be a steel plate having a plate thickness of 30 mm or more and a yield strength of 355 MPa or more.
- the butt-welded joint described in (1) or (2) may be used for a structure or a steel pipe column that forms a basic portion of a wind power tower.
- a butt portion of a pair of steel plates is irradiated with a first high energy density beam, and the first high energy density beam of the pair of steel plates is irradiated.
- the width W 3 of the first weld metal at the center of the plate thickness of the steel sheet may be less than 15% of the plate thickness of the steel plate .
- both the first high energy density beam and the second high energy density beam may be electron beams.
- the irradiation of the first high energy density beam and the irradiation of the second high energy density beam are both performed by welding a pair of the steel plates. Only the part formation region and its periphery may be performed under vacuum.
- a steel plate having a thickness of 30 mm or more and a yield strength of 355 MPa or more may be used as the steel plate. .
- the first weld metal is remelted, and the stop is smoother than the toe portion of the first weld metal.
- the second weld metal having the end, stress concentration at the toe is relieved.
- FIG. 3B is an enlarged schematic cross-sectional view in the vicinity of the toe portion T of the weld bead shown in FIG. 3A.
- the present invention relates to a weld bead (first weld metal) formed by welding (high energy density beam welding) in which a pair of high strength steel plates are irradiated with a high energy density beam such as an electron beam or a laser beam. ) Is remelted to form a remelted bead (second weld metal), which reduces stress concentration at the toe of the first weld metal and improves fatigue resistance in vibration environments in the gigacycle range.
- FIG. 1A is a schematic cross-sectional view in a direction perpendicular to the longitudinal direction of the first weld metal of the butt weld joint according to the present embodiment.
- the butt weld joint according to the present embodiment is formed by irradiating a butt portion of a pair of steel plates 1 with a first high energy density beam from the first surface 1A side of the pair of steel plates 1.
- 1st weld metal 2 and 2nd weld metal 3A formed by irradiation of the 2nd high energy density beam which covers all the end faces by the side of 1st surface 1A of 1st weld metal 2 are provided. .
- the first weld metal 2 is formed from the first surface 1A side to the second surface 1B side opposite to the first surface 1A. Further, the width W 1 of the first first side 1A of the weld metal 2, the width W 2 of the second weld metal 3A on the first surface 1A satisfies the following formula (1), second weld metal 3A the depth D 1 of the from the first surface 1A of a 2.0 ⁇ 10.0 mm. 1.2 ⁇ W 2 / W 1 ⁇ 3.5 (1)
- W 1 is the estimated width of the first weld metal 2 on the first surface 1A on the first high energy density beam irradiation side (the estimation method of W 1 will be described later).
- W 2 is the width of the first surface 1A of the second weld metal 3A formed by irradiation with the second high energy density beam.
- the end surface on the irradiation side of the first high energy density beam in the first weld metal 2 is covered with the second weld metal 3A.
- the shape of the toe portion of the second weld metal 3A is gentle compared to the conventional weld bead shown in FIG. 3A. Thereby, the stress concentration in the toe portion is relaxed.
- the width W 2 of the second weld metal 3A needs to satisfy 1.2 ⁇ W 2 / W 1 ⁇ 3.5 with respect to the width W 1 of the first weld metal. is there. If the ratio W 2 / W 1 between the width W 1 and the width W 2 of the second weld metal 3A first weld metal is too small, to reduce the effect of stress concentration, the W 2 / W 1 1.2 or more. If necessary, the W 2 / W 1 may be 1.2 or more, or 1.8 or more.
- W 2 / W 1 when the width W2 of the second weld metal 3A is increased, the adverse effect of the tensile residual stress in the direction perpendicular to the weld line generated at the toe portion of the second weld metal 3A on the first surface 1A can be ignored. Disappear. Furthermore, if W 2 / W 1 becomes too large, the coarse grain region increases and the joint toughness may decrease. For these reasons, W 2 / W 1 is set to 3.5 or less. Further, if necessary, W 2 / W 1 may be 3.2 or less or 2.8 or less.
- the shape of the end surface on the first surface 1A side of the first weld metal 2 formed by irradiation with the first high energy density beam cannot be directly confirmed after the formation of the second weld metal 3A.
- the width W1 of the first weld metal 2 on the first surface 1A side can be estimated by the following method.
- FIG. 2 is a cross-sectional view in a direction perpendicular to the longitudinal direction of the first weld metal 2.
- C1 and C2 both end points in the width direction of the first weld metal 2 are defined as C1 and C2.
- L1 which is the boundary line between one base material (steel plate 1) and the first weld metal 2 in the same cross section
- S2 is similarly defined on the boundary line L2 between the other base material and the first weld metal 2.
- L1 ′ and L2 ′ be straight lines connecting S1 and S2 with C1 and C2, respectively. And let the intersection of L1 'and L2' and the 1st surface 1A be t1, t2.
- the distance t between t1 and t2 approximates the width W1 of the first weld metal before the formation of the second weld metal 3A with sufficient accuracy. Therefore, it is possible to consider the distance t between W 1.
- the depth D 1 of the from the first surface 1A of the steel sheet 1 in the second weld metal 3A is required to be 2.0 ⁇ 10.0 mm. If the depth D 1 of the second weld metal 3A is too shallow, the shape change of the first toe of the weld metal 2 is small, there is a possibility to reduce the effect of stress concentration, the depth D 1 Is 2.0 mm or more. May optionally be the depth D 1 as 3.0mm or more or 4.0mm or more. On the other hand, when the depth D 1 of the second weld metal 3A is too deep, the tensile residual stress becomes larger applied to the second weld metal 3A near the inner steel plate 1, which may lower the fatigue resistance.
- the depth D 1 or less 10.0 mm since there is a possibility of causing brittleness deterioration of the welded portion and the vicinity thereof, the depth D 1 or less 10.0 mm. If necessary, the depth D 1 9.0 mm or less, may be less or 7.0mm or less 8.0 mm. Note that the depth D 1 of the present embodiment, the distance from the first surface 1A of the second high-energy density beam irradiation side deepest part of the second weld metal 3A.
- the end surface on the second surface 1B side opposite to the first surface 1A is covered.
- Third weld metal 3B may be formed.
- the width W 4 of the first weld metal 2 on the second surface 1B and the width W 5 of the third weld metal on the second surface 1B satisfy the following expression (2), and the third weld metal 3B it is preferable the depth D 2 from the second side 1B of a 2.0 ⁇ 10.0 mm. 1.2 ⁇ W 5 / W 4 ⁇ 3.5 (2)
- the third weld metal 3B can be formed by a third high energy density beam.
- the shape of the end surface on the second surface 1B side of the first weld metal 2 formed by irradiation with the first high energy density beam cannot be confirmed directly after the formation of the third weld metal 3B.
- the width W 4 of the first weld metal 2 on the second surface 1B side can be estimated by a method similar to the method for estimating the width W 1 of the first weld metal 2.
- the fatigue resistance can be improved on both the front and back surfaces of the steel plate 1.
- an electron beam, a laser beam, etc. can be used as the above-mentioned first high energy density beam, second high energy density beam, and third high energy density beam.
- the acceleration voltage is 150 V
- the beam current is 180 mA
- the welding speed is about 100 to 300 mm / min. May be irradiated.
- a butt weld joint may be manufactured by inserting a metal foil having a thickness of about 0.1 mm into the butt surfaces of the pair of steel plates 1 and welding them.
- a metal foil Ni foil etc. can be illustrated, for example.
- the irradiation with the second high energy density beam described above is performed at a heat input amount that is about 1/10 of the heat input amount in the first high energy density beam welding, for example, an acceleration voltage of 90 V, a beam current of 60 mA, and a welding speed of more than 500 mm / min. Irradiation may be performed under conditions. This is because if the amount of heat input when remelting the first weld metal is too small, the effect of relaxing the stress concentration at the toe portion is low, while if the amount of heat input is too large, the toughness of the welded portion is deteriorated. Because it can be.
- the target width W 2 and depth D 1 are adjusted by adjusting the acceleration voltage, beam current, welding speed, oscillation conditions, etc. based on the measured width W 1. Can be easily achieved.
- the irradiation condition of the third high energy density beam for forming the third weld metal 3B may be substantially the same as the irradiation condition of the second high energy density beam described above, but the gist of the present embodiment. You may change suitably in the range which does not deviate from.
- the first weld is compared with a welded joint manufactured using electron beam welding (EBW welding) in a high vacuum state in a vacuum chamber.
- EBW welding electron beam welding
- the width W1 of the first weld metal is set to 30% or less or 20% or less of the plate thickness of the steel plate. It is preferable that Further, the first weld metal width W 3 of the center of the plate thickness of the steel sheet, it is preferably 15% or less or 10% or less. Simply, the width W 1 15 mm or less, may be limited to 11mm or less, or 7mm or less. The width W 3 7 mm or less, may be limited to 6mm or less, or 5mm or less.
- the widths W 1 and W 3 of the first weld metal are too narrow, it becomes difficult to completely melt the groove surface depending on the incident direction and stability of the first high energy density beam.
- the width W 1 of the weld metal, together with more than 2% of the thickness of the steel plate, the first width W 3 of the weld metal, in the center of the plate thickness of the steel sheet, to 2% or more the thickness of the steel sheet Is preferred.
- the welded joint according to the present embodiment is used to weld a high-strength steel plate with high energy density to form a welded structure.
- the steel plate used is not limited to this, but preferably has a yield strength of 355 MPa or more.
- Such a high-strength steel plate may be manufactured from a structural steel for welding having a known component composition.
- the yield strength of the steel plate may be 600 MPa or less.
- the tensile strength of the steel plate may be limited to 400 MPa or more, 490 MPa or more, 780 MPa or less, or 690 MPa or less.
- C 0.02 to 0.20%, Si: 0.01 to 1.0%, Mn: 0.3 to 2.1%, Al: 0.001 to 0.20%, N: 0.02% or less, P: 0.01% or less, S: 0.01% or less, Ni: 0.50 to 4.0% as basic components, and improvements in base material strength and joint toughness are required.
- 1 type or 2 types of Cr, Mo, Cu, W, Co, V, Nb, Ti, Zr, Ta, Hf, REM, Y, Ca, Mg, Te, Se, B Steel containing the above in a total of 8% or less or 3% or less can be used.
- the plate thickness of the steel plate is not particularly limited, but it is a high-strength steel plate having a plate thickness of 30 mm or more that reveals the above-described problems. However, it is not necessary to limit the plate thickness to 30 mm or more. Since the effect of this invention can be exhibited if it is 6 mm or more in board thickness, it is good also as 6 mm or more in board thickness. As needed, it is good also as board thickness 12mm or more or board thickness 20mm or more. Since a higher effect is obtained when the plate thickness is 50 mm or more, the plate thickness may be 50 mm or more.
- the plate thickness becomes very large, high energy density beam welding becomes difficult, so the plate thickness may be limited to 200 mm or less, 150 mm or less, or 100 mm or less.
- the plate thickness may be limited to 200 mm or less, 150 mm or less, or 100 mm or less.
- the present invention can also be applied to welding for manufacturing a steel pipe from such a bent steel sheet and welding between steel pipes.
- the hardness of the first weld metal, the second weld metal, and the third weld metal is preferably 110% or more and 150% or less of the hardness of the base material of the steel plate.
- the hardness of these weld metals is preferably 110% or more of the hardness of the base material of the steel plate in order to ensure hardenability and prevent the formation of coarse ferrite.
- 150% or less is preferable.
- the hardness difference as described above can be achieved by adjusting the cooling rate after welding so that the hardness of the weld metal does not become too high.
- the second weld metal and the third weld metal in which the first weld metal is remelted and have a toe portion that is gentler than the toe portion of the first weld metal. Is formed.
- stress concentration at the toe portion of the second weld metal and the third weld metal is relaxed, and fatigue resistance characteristics in a vibration environment in the gigacycle region can be improved.
- sufficient fracture toughness can be obtained.
- the irradiation with the first high energy density beam, the second high energy density beam, and the third high energy density beam is performed only on the welded portion formation region of the steel plate and its periphery. It is preferable to carry out under vacuum. By irradiating the beam under such conditions, for example, a huge structure such as a tower for offshore wind power generation can be easily and efficiently welded near the construction site. As a result, the butt weld joint according to the present embodiment can be manufactured easily and efficiently.
- the present invention can adopt various conditions or combinations of conditions as long as the object of the present invention is achieved without departing from the gist of the present invention.
- Electron beam welding (welding with a first high energy density beam) was performed under the welding conditions shown in Table 3 using steel sheets having the chemical composition shown in Table 1 and the yield strength and tensile strength at each thickness.
- a butt weld joint having a first weld metal having a width W 1 on the surface of the steel plate on the irradiation side was prepared. Further, the width W 3 of the first weld metal at the center (t / 2) of the plate thickness t of the steel plate was adjusted to be as shown in Table 5. If necessary, a butt welded joint was prepared by inserting a 0.1 mm thick metal foil having the components shown in Table 2 into the groove surface.
- the welding with the first high energy density beam, the second high energy density beam, and the third high energy density beam were all performed at the degree of vacuum shown in Table 5.
- the lower numerical value (the numerical value in parentheses) in test number 19 in Table 5 is the remelting condition at the time of irradiation with the third high energy density beam, the width (W 4 ) of the first weld metal on the back surface of the steel plate, The width (W 5 ), remelting ratio (W 5 / W 4 ), and depth (D 2 ) of the third weld metal formed by irradiation with the third high energy density beam are shown. .
- the joint characteristics shown in Table 5 were evaluated.
- the Charpy value vE (J) was obtained by taking a 2 mm V notch Charpy test piece with the notch position at the center of the second weld metal from directly below the surface of the welded joint, and in the impact test at a test temperature of ⁇ 40 ° C. This is the calculated value.
- the results are shown in Table 5.
- the Charpy impact test was performed in accordance with JIS Z 2242.
- the fatigue test was performed using a hydraulic servo fatigue tester (Hz) by collecting a fatigue test piece based on JIS Z 3103-1987 from the obtained butt weld joint.
- the atmosphere was room temperature air
- the stress ratio was 0.1
- the repetition rate was 5 to 40 Hz
- the stress range was 80 to 200 MPa.
- Fatigue strength was measured joint fatigue strength F2 corresponding to as shown in Table 5, the joint rupture life at repeated several 2,000,000 (2 ⁇ 10 6 times) Fatigue strength F1 and gigacycle (109 times).
- ultrasonic fatigue test pieces were collected from the obtained butt welded joints, and the fatigue strength F1 ′ with 2 ⁇ 10 6 repetitions and the gigabit with 2 ⁇ 10 9 repetitions were obtained.
- the fatigue strength F2 ′ in the cycle was determined. And the result of these 2 conditions was compared and the reduction
- test numbers 1 to 19 are examples of the present invention, satisfy all the requirements of the present invention, and joint fatigue of 2 million cycles (2 ⁇ 10 6 times) and gigacycle (10 9 times). All mechanical properties including strength and Charpy values were good.
- Test number 19 is the present invention in which remelted beads (second weld metal and third weld metal) are formed on both the front and back surfaces of the steel material. Thus, on both the front and back surfaces of the steel material, the first weld metal was remelted, and the second weld metal and the third weld metal were formed. Therefore, the joint fatigue strength of 2 million repetitions and gigacycles, All mechanical properties including the Charpy value could be further improved.
- Test No. 22 is the case where the second weld metal was not formed, but the contact angle of the first weld metal toe portion was large as it was, and the joint fatigue strength during the gigacycle was significantly reduced.
- Test No. 27 since the depth D 1 of the second weld metal is too shallow, the melting of the toe portion of the first weld metal was insufficient. As a result, the contact angle of the first weld metal toe cannot be made gentle, and the effect of relaxing the stress concentration has decreased. Therefore, the joint fatigue strength at the time of the gigacycle was significantly reduced.
- Test No. 28 since the depth D 1 of the second weld metal is too deep, high excess prime height formed by second weld metal, since larger contact angle of toe portion, significantly The joint fatigue strength during gigacycle decreased. In addition, the Charpy value was greatly reduced due to the severe embrittlement of the structure near the steel plate surface by the second weld metal.
- Test number 30 is the case where the second weld metal was formed by TIG welding, but the width W2 of the second weld metal was too wide, and the first weld metal toe was sufficiently melted. although, since the depth D 1 of the second weld metal becomes shallow, it is not possible to slow the contact angle of the first weld metal toe, the effect to relax the stress concentration has been reduced. Furthermore, the embrittlement of the structure near the steel plate surface by the second weld metal was severe. As a result, the joint fatigue strength during the gigacycle was greatly reduced.
- the welded joint of the present invention Since the welded joint of the present invention has fatigue resistance and sufficient fracture toughness in a vibration environment in the gigacycle region, it can be applied to a foundation member of an offshore wind power tower. For this reason, it has sufficient industrial applicability.
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Abstract
Description
本願は、2009年12月4日に、日本に出願された特願2009-277007号に基づき優先権を主張し、その内容をここに援用する。
ここで、風力発電に最も適している地域は、絶えず強風を期待できる地域である。特に、このような条件を満足する洋上での風力発電(洋上風力発電)も世界的規模で計画及び実現されている(特許文献1~4参照)。
このような環境下において、塔の基礎部分における溶接部には、通常の疲労サイクルとはオーダーが異なるギガサイクル域の振動に対する耐疲労特性が要求されていた。特に、溶接ビード(溶接金属)の止端部では応力集中が大きくなり、溶接継手の繰り返し荷重に対する疲労強度が低下するという問題が生じていた。
なお、図3Aは、従来の突合せ溶接継手の溶接ビードの一例を示す断面模式図である。また、図3Bは、図3A中に示す溶接ビードの止端部T近傍の拡大断面模式図である。
しかし、このような止端部の応力集中への対応策とする上記従来技術では、次のような課題がある。
さらに、溶接継手における200万回疲労強度の向上について言及されているにすぎず、ギガサイクル域の振動に対する耐疲労特性を向上させる本課題に適用することはできない。
(1)本発明の一態様に係る突合せ溶接継手は、一対の鋼板と、一対の前記鋼板の突合せ部に、一対の前記鋼板の第1面側からの第1高エネルギー密度ビームの照射により、前記第1面側から、前記第1面の反対の第2面側に渡って形成された第1の溶接金属と、前記第1の溶接金属の前記第1面側の端面を覆う、第2高エネルギー密度ビームの照射により形成された第2の溶接金属と、を備え、前記第1面における前記第1の溶接金属の幅W1と、前記第1面における前記2の溶接金属の幅W2とが下記式(1)を満たし、前記第2の溶接金属の前記第1面からの深さが2.0~10.0mmである。
1.2≦W2/W1≦3.5 ・・・(1)
(2)上記(1)に記載の突合せ溶接継手では、前記第1の溶接金属の前記第2面側の端面を覆う、第3高エネルギー密度ビームにより形成された第3の溶接金属を備え、前記第2面における前記第1の溶接金属の幅W4と、前記鋼板の前記第2面における前記第3の溶接金属の幅W5とが下記式(2)を満たし、前記第3の溶接金属の前記第2面からの深さが2.0~10.0mmであってもよい。
1.2≦W5/W4≦3.5 ・・・(2)
(3)上記(1)または(2)に記載の突合せ溶接継手では、前記鋼板の板厚の中心における前記第1の溶接金属の幅W3が、前記鋼板の板厚の15%以下であってもよい。
(4)上記(1)または(2)に記載の突合せ溶接継手では、前記鋼板が、板厚が30mm以上であり、降伏強さが355MPa以上である鋼板であってもよい。
(5)上記(1)または(2)に記載の突合せ溶接継手は、風力発電塔の基礎部分を構成する構造体又は鋼管柱に使用されていてもよい。
1.2≦W2/W1≦3.5 ・・・(3)
(7)上記(6)に記載の突合せ溶接継手の製造方法では、前記鋼板の板厚の中心における前記第1の溶接金属の幅W3を、前記鋼板の板厚の15%以下としてもよい。
(8)上記(6)または(7)に記載の突合せ溶接継手の製造方法では 前記第1高エネルギー密度ビーム及び前記第2高エネルギー密度ビームがともに電子ビームであってもよい。
(9)上記(6)または(7)に記載の突合せ溶接継手の製造方法では、前記第1高エネルギー密度ビームの照射及び前記第2高エネルギー密度ビームの照射はともに、一対の前記鋼板の溶接部形成領域及びその周辺のみを真空下として行われてもよい。
(10)上記(6)または(7)に記載の溶接継手の形成方法では、前記鋼板として、前記鋼板の板厚が30mm以上であり、降伏強さが355MPa以上である鋼板を用いてもよい。
以下に、図を参照しながら本発明の一実施形態に係る突合せ溶接継手について説明する。
また、第1の溶接金属2の第1面1Aにおける幅W1と、第1面1Aにおける第2の溶接金属3Aの幅W2とが下記式(1)と満たし、第2の溶接金属3Aの第1面1Aからの深さD1が2.0~10.0mmである。
1.2≦W2/W1≦3.5 ・・・(1)
図1Aに示すように、第1の溶接金属2のうち、第1高エネルギー密度ビームの照射側の端面は、第2の溶接金属3Aに覆われている。また、この第2の溶接金属3Aの止端部の形状は、図3Aに示す従来の溶接ビードと比較してなだらかになっている。これにより、止端部における応力集中が緩和される。
第2の溶接金属3Aの幅W2と第1の溶接金属の幅W1との比W2/W1が小さすぎると、応力集中を緩和する効果が減少するため、W2/W1を1.2以上とする。また、必要に応じて、W2/W1を1.2以上又は1.8以上としてもよい。
一方、第2の溶接金属3Aの幅W2が広くなると、第1面1A上において、第2の溶接金属3Aの止端部に生じる溶接線に垂直な方向の引張残留応力の悪影響が無視できなくなる。さらに、W2/W1が大きくなりすぎると粗粒域が増加して、継手靭性が低下するおそれがある。これらの理由により、W2/W1を3.5以下とする。また、必要に応じて、W2/W1を3.2以下又は2.8以下としてもよい。
この断面における第1の溶接金属2と第2の溶接金属3Aの境界線のうち、第1の溶接金属2の幅方向の両端点を、C1、C2とする。
次に、同断面における一方の母材(鋼板1)と第1の溶接金属2の境界線であるL1上において、第2の溶接金属3Aの最深部と概略同一の深さの位置をS1とする。なお、また、他方の母材と第1の溶接金属2との境界線L2上においても同様にS2を定義する。
一方、第2の溶接金属3Aの深さD1が深すぎると、鋼板1内部の第2の溶接金属3A近傍に付与される引張残留応力が大きくなり、耐疲労特性を低下させるおそれがある。さらに、溶接部及びその近傍の脆性劣化を引き起こす可能性もあるため、深さD1を10.0mm以下とする。必要に応じて、深さD1を9.0mm以下、8.0mm以下又は7.0mm以下としてもよい。
なお、本実施形態における深さD1とは、第2高エネルギー密度ビーム照射側の第1面1Aから第2の溶接金属3Aの最深部までの距離である。
1.2≦W5/W4≦3.5 ・・・(2)
また、第3の溶接金属3Bは、第3高エネルギー密度ビームにより形成することができる。
なお、第1高エネルギー密度ビームの照射により形成された第1の溶接金属2の第2面1B側の端面の形状は、第3の溶接金属3Bの形成後は直接確認することはできないが、第1の溶接金属2の幅W1の推定方法と同様の方法により、第2面1B側における第1の溶接金属2の幅W4を推定することができる。
このように、第2の溶接金属3Aと第3の溶接金属3Bとを設けることにより、鋼板1の表裏面ともに耐疲労特性を向上させることができる。
なお、第3の溶接金属3Bを形成するための第3高エネルギー密度ビームの照射条件としては、上述した第2高エネルギー密度ビームの照射条件と概略同一としても構わないが、本実施形態の要旨を逸脱しない範囲で適宜変更してもよい。
また、鋼板の板厚の中心における第1の溶接金属の幅W3を、15%以下または10%以下とすることが好ましい。単に、幅W1を15mm以下、11mm以下又は7mm以下に制限してもよい。幅W3を7mm以下、6mm以下又は5mm以下に制限してもよい。
また、第1の溶接金属の幅W1及びW3が狭すぎると第1高エネルギー密度ビームの入射方向や安定性によっては開先面を完全に溶融させることが困難となるため、第1の溶接金属の幅W1は、鋼板の板厚の2%以上とするともに、第1の溶接金属の幅W3は、鋼板の板厚の中心において、鋼板の板厚の2%以上とすることが好ましい。
なお、風力発電塔などでは、鋼板を曲げ加工した後に鋼管に溶接したり、または、鋼管同士を溶接したりすることも行われている。この場合も基本的には、曲げ加工された鋼板の突合せ溶接である。したがって、このような曲げ加工された鋼板から鋼管を製造するための溶接や、鋼管同士の溶接にも、本発明は適用できる。
このような条件でビームの照射を行うことにより、例えば洋上風力発電用の塔等の巨大構造物を建設現場近くで、簡易にかつ高能率に溶接することができる。その結果、本実施形態にかかる突合せ溶接継手を簡易かつ高能率に製造することができる。
なお、必要に応じて、表2に示す成分を有する、厚さ0.1mmの金属箔を開先面に挿入して突合せ溶接継手を作成した。
また、試験番号19については、表4に示す再溶融条件E3で、第2高エネルギー密度ビームによる溶接を行い、第1の溶接金属の照射側の端面を覆うように第2の溶接金属を形成するとともに、再溶融条件E1で、第3高エネルギー密度ビームによる溶接を行い、第1の溶接金属の第1高エネルギー密度ビーム照射側とは反対側の端面を覆うように、第3の溶接金属を形成した。この際、第3の溶接金属の深さD2、入熱量及び幅W5を調整しながら、表5に示すような形状を有する第3の溶接金属を形成した。
なお、第1高エネルギー密度ビーム、第2高エネルギー密度ビーム及び第3高エネルギー密度ビームによる溶接はともに、表5に示す真空度においてそれぞれ行った。また、表5の試験番号19における下段の数値(括弧内の数値)は、第3高エネルギー密度ビームの照射の際の再溶融条件、鋼板裏面における第1の溶接金属の幅(W4)、第3高エネルギー密度ビームの照射により形成された第3の溶接金属の幅(W5)、再溶融比率(W5/W4)、第3の溶接金属の深さ(D2)をそれぞれ示す。
まず、シャルピー値vE(J)は、溶接継手の表面直下からノッチ位置が第2の溶接金属の中央となるような2mmVノッチシャルピー試験片を採取し、衝撃試験において、-40℃の試験温度で求めた値である。その結果を表5に示す。なお、シャルピー衝撃試験は、JIS Z 2242に準拠して行った。
また、上記の疲労試験片とは別に、得られた突合せ溶接継手から超音波用疲労試験片を採取し、繰り返し数2×106回の疲労強度F1´、および2×109回までのギガサイクルでの疲労強度F2´を求めた。そしてこの2条件の結果を比較して、その間の低下比率(F2´/F1´)を求めた。
次いで、上記継手疲労試験で求めた2×106回の継手疲労強度F1にこの低下比率(F2´/F1´)をかけて、ギガサイクル下での継手疲労強度(推定値)F2を評価した。
以上の結果を表5に示す。
また、試験番号19については、鋼材の表裏面ともに再溶融ビード(第2の溶接金属及び第3の溶接金属)を形成した本発明である。このように、鋼材の表裏面ともにおいて、第1の溶接金属を再溶融させ、第2の溶接金属及び第3の溶接金属を形成したため、繰り返し数200万回とギガサイクルの継手疲労強度や、シャルピー値をはじめとする全ての機械的特性をより向上させることができた。
一方、試験番号28は、第2の溶接金属の深さD1が深すぎたため、第2の溶接金属で形成された余盛り高さが高く、止端部の接触角が大きかったため、顕著にギガサイクル時の継手疲労強度が低下した。さらに、第2の溶接金属による鋼板表面近傍の組織の脆化が激しかったために、シャルピー値が大きく低下した。
1A 第1面
1B 第2面
2 第1の溶接金属
3A 第2の溶接金属
3B 第3の溶接金属
D1 第2の溶接金属の深さ
D2 第3の溶接金属の深さ
W1 (第1面1Aにおける)第1の溶接金属の幅
W2 (第1面1Aにおける)第2の溶接金属の幅
W3 鋼板の板厚中心における第1の溶接金属の幅
W4 (第2面1Bにおける)第1の溶接金属の幅
W5 (第2面1Bにおける)第3の溶接金属の幅
21 鋼板
22 溶接ビード
ρ 溶接ビード止端部曲率半径
θ 溶接ビード止端部接触角
Claims (10)
- 一対の鋼板と;
一対の前記鋼板の突合せ部に、一対の前記鋼板の第1面側からの第1高エネルギー密度ビームの照射により、前記第1面側から、前記第1面の反対の第2面側に渡って形成された第1の溶接金属と;
前記第1の溶接金属の前記第1面側の端面を覆う、第2高エネルギー密度ビームの照射により形成された第2の溶接金属と;
を備え、
前記第1面における前記第1の溶接金属の幅W1と、前記第1面における前記第2の溶接金属の幅W2とが下記式(1)を満たし;
前記第2の溶接金属の前記第1面からの深さが2.0~10.0mmである;
ことを特徴とする突合せ溶接継手。
1.2≦W2/W1≦3.5 ・・・(1) - 前記第1の溶接金属の前記第2面側の端面を覆う、第3高エネルギー密度ビームにより形成された第3の溶接金属を備え:
前記第2面における前記第1の溶接金属の幅W4と、前記鋼板の前記第2面における前記第3の溶接金属の幅W5とが下記式(2)を満たし;
前記第3の溶接金属の前記第2面からの深さが2.0~10.0mmである;
ことを特徴とする請求項1に記載の突合せ溶接継手。
1.2≦W5/W4≦3.5 ・・・(2) - 前記鋼板の板厚の中心における前記第1の溶接金属の幅W3が、前記鋼板の板厚の15%以下であることを特徴とする請求項1または請求項2に記載の突合せ溶接継手。
- 前記鋼板が、板厚が30mm以上であり、降伏強さが355MPa以上である鋼板であることを特徴とする請求項1または請求項2に記載の突合せ溶接継手。
- 風力発電塔の基礎部分を構成する構造体又は鋼管柱に使用されていることを特徴とする請求項1または2に記載の突合せ溶接継手。
- 一対の鋼板の突合せ部に、第1高エネルギー密度ビームを照射し、前記一対の鋼板の前記第1高エネルギー密度ビームの照射側である第1面における幅がW1である第1の溶接金属を形成する工程と;
前記第1の溶接金属に、前記第1高エネルギー密度ビームのエネルギー密度よりも低いエネルギー密度である第2高エネルギー密度ビームを照射し、前記鋼板の前記第1面における幅がW2である第2の溶接金属を形成する工程と;
を有し、
前記幅W1と前記幅W2が下記式(3)を満たし;
前記第2の溶接金属の前記第1面からの深さが2.0~10.0mmである;
ことを特徴とする突合せ溶接継手の製造方法。
1.2≦W2/W1≦3.5 ・・・(3) - 前記鋼板の板厚の中心における前記第1の溶接金属の幅W3を前記鋼板の板厚の15%以下とする;
ことを特徴とする請求項6に記載の高エネルギー密度ビーム溶接継手の形成方法。 - 前記第1高エネルギー密度ビーム及び前記第2高エネルギー密度ビームがともに電子ビームであることを特徴とする請求項6または請求項7に記載の突合せ溶接継手の製造方法。
- 前記第1高エネルギー密度ビームの照射及び前記第2高エネルギー密度ビームの照射はともに、一対の前記鋼板の溶接部形成領域及びその周辺のみを真空下として行われることを特徴とする請求項6または請求項7に記載の突合せ溶接継手の製造方法。
- 前記鋼板として、板厚が30mm以上であり、降伏強さが355MPa以上である鋼板を用いることを特徴とする請求項6または請求項7に記載の突合せ溶接継手の製造方法。
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- 2010-12-03 JP JP2011518613A patent/JP4995348B2/ja active Active
- 2010-12-03 DK DK10834651.1T patent/DK2508290T3/en active
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- 2010-12-03 KR KR1020127014119A patent/KR101218892B1/ko active IP Right Grant
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EP2508290B1 (en) | 2017-02-08 |
EP2508290A4 (en) | 2014-02-19 |
CN102639278A (zh) | 2012-08-15 |
KR20120088799A (ko) | 2012-08-08 |
US20120237287A1 (en) | 2012-09-20 |
EP2508290A1 (en) | 2012-10-10 |
KR101218892B1 (ko) | 2013-01-09 |
CN102639278B (zh) | 2014-07-09 |
MY182963A (en) | 2021-02-05 |
JP4995348B2 (ja) | 2012-08-08 |
JPWO2011068201A1 (ja) | 2013-04-18 |
ES2617438T3 (es) | 2017-06-19 |
DK2508290T3 (en) | 2017-04-10 |
US8653403B2 (en) | 2014-02-18 |
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