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49
ABSTRACT
Magnetically Impelled Arc Butt (MIAB) welding is mainly used in the automotive industry for butt welding of tubes
and tubular parts 8-100 mm in diameter and 0.8-6 mm wall thickness. To extend the range of MIAB welding applications research work was conducted on different hollow and solid parts, special attention being given to welding of
parts, the cross section of which is commensurable with of the active spot diameter of the rotating arc.
IIW-Thesaurus keywords: MIAB welding; Sections; Induction; Electromagnetic fields; Rotating arcs; Heating;
Influencing factors; Dimensions; Welded joints; Microstructure; Arc physics.
1 INTRODUCTION
The magnetically impelled arc butt (MIAB) welding
process found a wide range of application in different
industries (hollow parts of different shapes) in the 80s
and the 90s [1, 2, 3, 4]. However, during the last years
there has been a trend to reduce the range of MIAB
welding applications. One of the reasons is the difficulty
of welding parts with wall thicknesses exceeding 6 mm.
In order to assure a good weld quality in conventional
MIAB welding, the following conditions must be met:
the wall thickness of hollow parts should be commensurable with the sizes of the active spots of the
rotating arc;
the non-uniformity of a gap between the faying surfaces of the parts to be welded should not exceed
0.7 mm.
To assure steady arcing between the faying surfaces of
thick-walled hollow parts or solid rods it is necessary to
provide the specific allocation of magnetic field induction
by controlling the correlation between axial and radial
induction vector values in the gap between the parts to
be welded. For conventional MIAB welding, the value of
the axial magnetic field induction vector usually constitutes 5-10% of the radial vector value. After the initial arc
is charged, under the action of the radial magnetic field
induction vector, the welding arc is displaced toward the
central axial line of the hollow or solid parts. In the case
of tube welding, the arc is displaced toward the internal
edge of the tube. As a result, the overheating of localized areas (internal edge of tube wall, central area of
solid rod, etc.) is observed and at the same time inadequate heating of other areas of welded parts takes
place. During this research work the arc motion pattern
(rotation) along and across the faying surfaces of the
Doc. IIW-1564-02 (ex-doc. III-1208-02) recommended
for publication by Commission III Resistance and solid
state welding and allied processes
Welding in the World, Vol. 46, n 7/8, 2002
50
F Br = k I a * B r
(1)
In MIAB welding a pre-programmed arc current control
is used. The control of the welding current is one of the
main technological parameters making it possible to
obtain a uniform heating of the faying surfaces of the
tubes, and to reach the required weld quality.
The linear speed of the arc movement reaches 200 m/s
under definite conditions. This results in a relatively uniform heating of the tube faying surfaces. The welded
joint is formed by upset and simultaneous plastic deformation of the tubes. MIAB welding is performed in air,
without using shielding gases.
In conventional MIAB welding the quality of the preparation of the tube ends is of great importance. The values of the gap between the faying surfaces of the tubes
is usually from 1.5 to 2.8 mm and refer to the setting
parameters, which define the arc length, arc voltage,
energy consumption, mobility of the moving arc. The
wedge-like gap creates different arc lengths. This could
cause an arc interruption during welding. The important
technological parameters for MIAB welding are as fol-
lows: arc voltage and welding current. The use of conventional MIAB welding for tubes with a wall thickness
exceeding 6 mm and for solid parts cannot provide the
required weld quality. This is due to different factors.
The main factor is that the anode and cathode spots of
the welding arc should be commensurable with the wall
thickness of the faying surfaces of the hollow and of the
solid parts to be welded.
The research and experimental work on welding thickwalled tubes and solid parts became one of the new
trends in the development of MIAB welding.
The main aim of the investigations was to find control
methods making it possible to move the arc over the
entire cross section area of different shapes.
The initial stage of the investigations addressed the
movement of the welding arc at the external edges of
the thick-walled tube faying surfaces to the area of
maximum magnetic field induction and make it move
there by creating the optimum magnetic field induction
distribution in the arc gap. With such a movement the
uniform distribution of the heat energy of welding arc at
the edges occurs at a lower welding current density over
the larger area of the section welded, than that occupied
by the active spots of the arc column. The dispersal
emission of the heat energy provides a uniform heating
of the faying surfaces as compared with that in movement of the welding arc on the internal tube edges.
This is not suitable for welding thick-walled tubes, as
one of the conditions for uniform and stable heating of
faying surfaces in conventional MIAB welding is the commensurability of the tube wall thickness with the sizes
of the arc column active spots. Figure 3 shows the traces
of the arc column active spots, which remained on the
internal edges of the faying surfaces after heating in
conventional MIAB welding.
The traces of the arc column active spots are smaller
than the cross section of the faying surfaces. The welding process is unstable, with short-circuiting. Under the
action of the natural magnetic field of the welding arc
and the existence of a high external magnetic field induction gradient the arc is forced out from the arc gap at the
initial moment and moves along the internal edges of the
faying surfaces. The arc column is bent to the side of a
geometric axis of the tubes. During heating of the inside
edges of the faying surfaces, the distribution gradient
of the magnetic field induction in the arc gap is
a) 180
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b) 180
52
b) 180
a) 180
Fig. 6. Microstructure of HAZ when the arc moves on the external edge of the tube faying surfaces:
a) outside edges clearly defined overheated region;
b) inside edges recrystallization zone with random coarse grains.
The principle of the new MIAB tube welding process is
as follows (Fig. 2). Interaction of the radial component
F Ba = k I r * B a
(2)
Heating of the faying surfaces occurs during the welding arc movement along the external edges. When the
required heating is reached, the forces, F Ba, F Br and the
value of the welding current are changed, thus leading
to the scanning of the welding arc along the faying surfaces. Then the upset is performed.
As a result of the investigations, the arc control method
that makes it possible to displace the welding arc over
the entire area of the thick-walled tube cross section
was found.
cathode
anode
Fig. 7. Traces made by the anode and cathode
spots of the arc column on the rod faying surfaces.
53
a)
b)
c)
Fig. 8. Traces made by the welding arc
on the faying surfaces of rods:
a) traces of motion of an arc to the rod edges
just after striking;
b) traces of arc motion along rod edges;
c) traces of arc scanning at the centre of rods.
4 FORMATION OF JOINTS
IN MIAB WELDING
Formation of welded joints in thick wall tubes and solid
parts during MIAB welding occurs during forging resulting in deformation of surfaces of hollow and solid parts
being heated to the plastic state. The uniform heating of
faying surfaces is a basic but not sufficient condition for
the formation of a quality joint. During MIAB welding
shielded gases are not used, leading to the oxidation of
faying surfaces and to the formation of oxides. The main
specific feature is the conditions for the removal of the
oxides existing on the faying surfaces of the workpieces.
It is possible to prevent oxidation in two ways:
1. To protect the heating surfaces from oxidation (solidphase welding).
2. To transform the oxidized metal into the liquid state
and press it out.
In principle, both procedures can be used for the formation of MIAB welded joints.
The quality of MIAB welding of hollow and solid parts is
achieved without any gas shielding provided that the
arc rotation frequency at the moment of upset is such
that the melted metal at any point of the surface is not
solidified.
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Fig. 13. Welded joint of reinforcement rods: a) macrosection of welded joint; b) microstructure
of reinforcement 150; c) microstructure of metal at edges of welded joint 150.
55
The investigations conducted resulted in the development of a technology for MIAB welding of rods from 8
to 25 mm in diameter.
Mechanical properties of the faying surfaces of welded
rods and re-bars joints are given in Table 3.
6 CONCLUSIONS
The new MIAB welding process has several engineering advantages, such as:
no strict requirements regarding tube and rod end
(faying surfaces) preparation;
short welding time (from ten to hundred seconds);
uniform and concentrated heating around the faying
surface perimeter;
minimum allowances for flashing and upset;
absence of pores, inclusions, volume defects typical
for fusion welds;
small external and internal flash and upset metal reinforcement;
high efficiency for industrial mass production;
control and real-time recording of main welding parameters during the welding process;
automation of the welding process.
The equipment for welding of different hollow shapes
with wall thicknesses over 10 mm and solid parts has
been developed and used in pipeline construction, in
automobile and other industries.
Si
Mn
Cu
Ni
Cr
Mo
20
35
12Kh1MF
C75
35GS
25G2S
St3
35KhGF
0,23
0,39
0,09
0,463
0,34
0,23
0,18
0,32
0,35
0,35
0,36
0,35
0,7
0,76
0,25
0,15
0,64
0,75
0,54
1,75
1,1
1,32
0,5
1,07
0,035
0,035
0,030
0,013
0,04
0,04
0,04
0,02
0,04
0,04
0,025
0,013
0,045
0,045
0,05
0,007
0,25
0,25
0,20
0,05
0,3
0,3
0,3
0,15
0,25
0,25
0,30
0,05
0,3
0,3
0,3
0,13
0,25
0,25
1,1
0,1
0,3
0,3
0,3
1,22
0,3
-
0,03
56
Pipe
Dimensions,
mm
Impact Toughness
KCV, J/cm2
Base metal
Welded joint
20
D=32
=5
488...509
502
488...509
502
94...100
98
88...94
90
20
D=89
=12
488...509
502
488...509
502
92...100
97
78...86
82
20
D=108
=8
488...509
502
486...506
500
90...100
95
76...92
84
20
D=219
=8
488...509
502
488...509
502
92...100
97
79...94
85
35
D=48
=4
538...565
551
538...565
551
56...64
60
47...68
56
35
D=76
=16
538...565
551
538...565
551
56...64
60
37...54
44
12Kh1MF
D=32
=5
536...566
550
536...566
550
133...144
138
56...116
86
C75
D=48
=5
826...870
852
822...862
838
58...66
61
33...80
57
Rods
Dimensions,
mm
Impact Toughness
KCV, J/cm2
Base metal
Welded joint
35GS
D=10
498...610
604
498...610
604
St3
D=25
380...398
388
375...408
390
37...43
40
34...43
39
20
D=22
487...510
504
480...520
500
91...100
96
84...94
88
35GS
D=20
498...610
604
588...618
603
25G2S
D=18
603...616
607
592...628
610
20
D=14
487...510
504
477...519
495
90...102
96
86...97
89
KCU, J/cm2
35KhGF
D=20
7 REFERENCES
1. Ganovski F.J., The Magnetarc welding process. Welding
and Metal Fabrication, June, 1974.
2. Edson D.A., Magnetically Impelled Arc Faying surfaces
Welding of Thick Wall Tubes. International Institute of
Welding, III-726-82, July 1982.
3. Takagi K., Aracida F., Magnetically Impelled Arc Faying
surfaces Welding of gas pipeline. Metal Construction, 1982,
No. 10, p. 542-548.
115...127
121
100...118
109