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December
18th IoRW Technical Seminar Developments in rail inspection Wed 1 Great Abington WJS Seminar Standards for offshore power and low carbon energy Wed 8 Middlesbrough
Workshops and seminars are recognised Continuous Professional Development events
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September/October 2010
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Aker Solutions (Drilling Risers) USA Oil and gas engineering Cytec Industries UK Ltd UK Coatings and composites Fotolec Technologies Ltd UK Shatterproof coatings application to standard lamps ILVA SpA Italy Steel production of flat products and welded pipe ITER Organisation Magnet Division France Development of magnet technology for the ITER programme Johnson & Starley Ltd UK Manufacturer of heating and ventilation products Swagelining Limited UK Provision of integrated lining systems TATA Steel Ltd India Design, manufacture and supply of plant equipment and cranes Woodside Energy Ltd Australia Oil and gas exploration, production and development
Welding Alloys Ltd UK Welding consumables, machines and service
Cross-section of hot wire, narrow gap gas tunsten arc welding in180mm P91 steel
Single pass, fully penetrating electron beam weld in 280mm thickness C-Mn steel
cell environment were also investigated and reported. The results of TWIs work were published in a Nagra report and presented at a meeting in Wettinngen, Switzerland. TWIs report was subsequently issued
publicly along with a previously published material selection report. This work formed a precursor for a multi-year study to develop designs for carbon steel canisters, which was issued as an open tender in March 2010.
TWI (with Hitachi Zosen Corporation as a subcontractor) successfully bid for this competitive tender. Nagra evaluated the offers received on the basis of the financial offer, qualification and experience of the bidder, qualification and experience of the experts, proposed project work plan and an oral presentation made to Nagra. For more information about this project and TWIs services to the nuclear industry please contact: simon.pike@twi.co.uk, rajesh.patel@twi.co.uk chris.punshon@twi.co.uk or colin.walters@twi.co.uk
Details will follow in due course and more information can be obtained by contacting Richard Freeman, the Aerospace Industry Sector Manager at richard.freeman@twi.co.uk
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September/October 2010
Encapsulation
HDI substrate
Mother board
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Technolog y Transfer
Job Knowledge
108 Welding of nickel alloys Part 2
In Part 1 the importance of cleanliness, particularly the removal of all sulphur containing compounds, was mentioned. With respect to defect free welding of nickel and its alloys this cannot be over-emphasised. As well as sulphur, however, there are several other substances that can lead to embrittlement of the nickel alloys when they are exposed to high temperatures. Amongst these are lead, phosphorus, boron and bismuth. These may be present in oils, grease, cutting fluids, paints, marker pen inks, temperature indicating crayons, etc; it may not be possible to avoid using these during fabrication so it is essential that these are removed if the component is to be welded, heat treated or is to enter high temperature service. Fuel gases frequently contain sulphur and it may be necessary to use radiant gas heaters or electrical elements for local heating or in heat treatment furnaces. Nickel alloys can be welded using all the conventional arc welding and power beam processes, the commonest processes being TIG or MIG with pure argon, argon/hydrogen or argon/helium mixtures as shield gases and MMA where basic flux coatings provide the best properties. However, if argon/helium mixes are used it is only when there is more than 40% helium that any significant benefits with respect to penetration and improved fusion will be noticed. Submerged arc welding is restricted to welding solid solution alloys using basic fluxes. Matching welding consumables are available for most of the nickel alloys. See Job Knowledge 22 for recommendations for a range of alloys. Slag from MMA welding and particularly submerged arc welding can be difficult to remove from the nickel alloys and often needs to be ground between runs to remove it completely. It is also often necessary to grind the surface of each run when welding with the gas shielded processes to remove oxide scabbing, wire brushing simply polishing these oxides. Failure to remove slag or oxide scabs will result not only in weld metal inclusions but also reduce corrosion resistance if left on exposed surfaces. Total welding times can therefore be substantially longer than the equivalent joint in stainless or carbon steel and welders need to be fully acquainted with these differences when converting from welding steels to nickel alloys. Comments regarding the recommended weld preparations were included in Part 1. Although the weld preparations are similar to those used for steel it is worth considering the use of double V or U type preparations at thicknesses less than would be considered with steels. The additional cost of the preparation is offset by savings in consumable costs (nickel being an expensive metal) and welding time. The majority of nickel alloys are best welded in the annealed or solution treated condition, particularly if the alloys have been cold worked. As mentioned in Part 1, preheat is not required except to remove condensation or if the ambient
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temperature is below about 5OC when a moderate preheat of 40-50OC is recommended. Interpass temperature should not be allowed to rise above 250OC although some alloy suppliers recommend an interpass as low as 100OC for certain alloys such as Alloy C276. Remember the potential hot crack problems if thermal crayons are used to measure this temperature! For most alloys heat input should be controlled to moderate levels (say 2kJ/mm maximum) to limit grain growth and HAZ size although for some Alloys 718, C22, and C276 for example, a maximum heat input of 1kJ/mm is recommended. Conversely if too fast a travel speed is used in an attempt to maintain a low heat input this can result in a narrow weld bead sensitive to centre line cracking. Adequate testing during welding procedure development should be used to optimise the range of acceptable welding parameters. The solid solution alloys such as Alloy 200 or 625 do not require post weld heat treatment to maintain corrosion resistance but may be subject to PWHT either to reduce the risk of stress corrosion cracking if the alloy is to be used in caustic soda service or in contact with fluoro-silicates or to provide dimensional stability. A typical stress relief treatment would be 700OC for an hour for Alloy 200; 790OC for four hours for the higher chromium content alloys such as Alloy 600 or 625. The nickel-molybdenum alloys are identified with the prefix B eg B1, B2, etc. and are used in reducing environments, such as hydrogen
Technolog y Transfer
chloride gas and sulphuric, acetic and phosphoric acids. Alloy B2 is the most frequently encountered alloy and matching filler metals are available. Unlike Alloy B1, Alloy B2 does not form grain boundary carbide precipitates in the weld heataffected zone, so it may be used in most applications in the as-welded condition. Alloy 400, a 70Ni-30Cu alloy, has good corrosion resistance when exposed to hydrofluoric acid, strong alkaline solutions and sea water. A matching filler metal, Alloy 190, is available but this can become anodic in salt solutions, leading to galvanic corrosion and it is recommended that one of the Ni-Cr alloy fillers such as Alloy 600 or 625 is used in this environment. The age hardened alloy K-500 does not have a matching filler metal and is generally welded using the Alloy 190 filler, the reduction in strength being taken into account during the design phase. Precipitation hardened alloys are best welded in the solution treated condition; welding these alloys in the age hardened condition is likely to result in HAZ cracking. The ageing process in the alloys is sufficiently sluggish that the components can be welded in the solution treated condition and then aged at around 750OC without the mechanical properties being degraded. A solution treatment of the welded item followed by ageing will provide the highest tensile strength. The sensitivity of the age hardened alloy to cracking causes problems when attempts are made to repair
items, particularly when these have been in high temperature service and additional precipitation on the grain boundaries has occurred. Little can be done to overcome this problem apart from a full solution heat treatment but this is often not possible with a fully fabricated component. If repair is to be attempted, small weld beads and controlled low heat input welds are recommended. If the design permits, a low strength filler metal, eg Alloy 200 or 600, may be used to reduce the risk. Buttering the faces of the repair weld preparation, sometimes combined with a peening operation, has been successful. Many of the nickel alloy filler metals have been used for making dissimilar metal joints with excellent results; dilution when welding joints between ferritic, stainless and duplex steels being less important than when using a type 309 stainless steel filler. Nickel also has a coefficient of thermal expansion between that of ferritic and austenitic steels and therefore suffers less from thermal fatigue when high
temperature plant is thermally cycled. Alloy 625 has been a popular choice, the weld tensile strength matching or exceeding that of the parent metal. There are limitations to this approach, and caution needs to be exercised when selecting a suitable filler. For example, Alloy 625 has been extensively used for welding dissimilar joints in austenitic and duplex steels. Use of this filler metal has resulted in the formation of niobium rich precipitates adjacent to the fusion line and has been discontinued. Alloy 59 or C22 filler metals has replaced Alloy 625 as the filler of choice. The moral of this is, if there is any uncertainty, ask an expert!
Erratum: In the table included in Job Knowledge 107, the percentage of Fe in Alloy 825 should read 28% and not 38%.
Connect September/October 2010
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September/October 2010
In-service inspection
In general terms, inspection may be applied to three main sectors of industry: manufacturing, fabrication and in-service.
The manufacturing and fabrication sectors have developed inspection regimes specific to their products. These products are in many ways repetitive, predictable and inspection procedures have been proven to be effective when applied by competent inspection personnel. In-service has not been subject to the same level of development and scrutiny. With ageing assets and capital investment at a premium, it is necessary to try and develop noninvasive inspection techniques to locate and quantify failure mechanisms at an early stage in order to manage and control the possible interruption to production and possibly safety and revenue. By identifying the defined possible failure modes and mechanisms in a timely manner, it is then possible to re-schedule planned maintenance shutdown of plant to accommodate repair and if necessary replacement of components.
TWI recognises the importance of this sector of industry and has the necessary knowledge, Why is preheat used when resources and arc welding steel and how is it applied? experience to assist in the management, Are duplex and superduplex control and development steels fit for purpose under of relevant and appropriate conditions of cathodic protection? inspection processes and procedures. Are there any standard tests for plastics welds? These include:
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Connect September/October 2010
Q JoinIT A
in accordance with BS EN 473 and ISO 9712. Recent developments include: Specific training and certification in corrosion monitoring using manual ultrasonic techniques Training and CSWIP certification scheme for personnel inspecting drillstem components (rotary tool and drillpipe). For more information, please contact: bill.brown@twi.co.uk
Integrity management Appropriate research and development facilities NDT Validation Centre Appropriate and relevant personnel training and certification, including Employer Specific Schemes
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September/October 2010
News in brief
WJS/DVS Conference on Joining Plastics International Conference on the latest developments in joining plastics in mass production and fabrication 2 November 2010 Handwerkskammer, Dsseldorf, Germany
This event, which will be conducted in English, is organised jointly by the WJS of The Welding Institute and the German Welding Society (DVS). Twenty papers will be presented in two parallel sessions. Areas covered will include new developments in laser welding, infrared welding, ultrasonic welding and adhesive bonding; welding of thermoplastic tanks and pipes; joining of composites; testing of welded joints; and qualification of plastics welders. For further information please contact simone.mahlstedt@dvs-hg.de or visit www.dvs-ev.de/joiningplastics2010.
Advanced manufacturing and engineering in the US Midwest and Indiana. New opportunities for the UK businesses. Joint event organised by UK Trade & Investment East and the State of Indiana Thursday 11 November 2010
9:00-14:00 TWI, Granta Park, Great Abington, Cambridge The United States is the worlds largest manufacturing economy, employing nearly 12 million Americans and producing manufactured products worth up to $1.6 trillion. The US market represents 18%of the worlds manufactured goods, largely due to Midwestern manufacturing companies that have a strong orientation toward knowledgeintensive manufacturing. The state of Indiana and the UK Trade & Investment East would like to extend an invitation to join UK specialists and an Indiana business delegation and explore new
opportunities in the Midwest advanced manufacturing and engineering sector. For the full programme or to book your place at this FREE event, please call 01707398382 or email bookevents@uktieast.org.uk
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