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Procedia
Procedia CIRP
CIRP 00
00 (2018)
(2018) 000–000
000–000
ScienceDirect
ScienceDirect www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
th
th
10
10
10thCIRP
CIRP
CIRPConference
Conference
Conferenceon
on
onPhotonic
Photonic
PhotonicTechnologies
Technologies
Technologies[LANE
[LANE
[LANE2018]
2018]
2018]
Influence of heat28th
input
CIRPand preheating
Design Conference, on
Maythe cooling
2018, rate, microstructure
Nantes, France
and mechanical properties at the hybrid laser-arc welding of API 5L X80
A new methodology to analyze thesteel functional and physical architecture of
existing products
aa
for ana,b,*
assembly oriented
a,b,* aa
product
cc
familyddidentification
dd
G.
G. Turichin
Turichin ,, M.M. Kuznetsov
Kuznetsov ,, A. A. Pozdnyakov
Pozdnyakov ,, S. S. Gook
Gook ,, A. A. Gumenyuk
Gumenyuk ,, M. M. Rethmeier
Rethmeier
aa Paul
Saint-Petersburg
Stief
Saint-Petersburg State
*,
State Marine
Jean-Yves
Marine Technical
Dantan,
Technical University,
Alain
University, Lotsmanskaya
Lotsmanskaya str.
str. 3,
Etienne,
3, Saint
Ali
Saint Petersburg,
Siadat
Petersburg, 190121,
190121, Russian
Russian Federation
Federation
bb
Peter
Peter
École the
the Great
Great
Nationale Saint-Petersburg
Saint-Petersburg
Supérieure d’Arts etPolytechnic
Polytechnic
Métiers, Arts University,
University, Polytechnicheskaya
et MétiersPolytechnicheskaya
ParisTech, LCFC EA str.
str.4495,
29,
29, Saint
Saint Petersburg,
Petersburg,
4 Rue Augustin 195251,
195251, Russian
Fresnel, Russian
Metz Federation
Federation
57078, France
cFraunhofer Institute
cFraunhofer Institute for
for Production
Production Systems
Systems and
and Design
Design Technology
Technology IPK,
IPK, Berlin,
Berlin, Germany
Germany
dFederal Institute
dFederal Institute for
for Materials
Materials Research
Research and
and Testing
Testing BAM,
BAM, Berlin,
Berlin, Germany
Germany
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
** Corresponding
Corresponding author.
author. Tel.:+7-812-552-9843
Tel.:+7-812-552-9843 ;; fax:
fax: +7-812-552-9843. E-mail address:
+7-812-552-9843. E-mail address: kuznetsov_mich@ltc.ru
kuznetsov_mich@ltc.ru
Abstract
Abstract
Abstract
In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of
agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production
This
This study
study investigates
investigates the the influence
influence of of hybrid
hybrid laser-arc
laser-arc welding
welding parameters:
parameters: heat heat input
input and
and preheating
preheating on on the
the cooling
cooling rates,
rates, microstructure
microstructure and and
systems
mechanical properties
mechanical
as well as to choose
properties of of the
the optimal
the welding
welding joint.
product
joint. Samples
matches,
Samples from from API
product
API 5L5L X80
analysis
X80 steel
methods
steel with
with root
are needed. 14
root thickness
thickness 14
Indeed,
mm were
mm
mostwelded
of the using
were welded
known methodswire
using welding
welding wire
aimMF
MF
to
analyze
940 M.
940
a product
M. Decreasing
or one
Decreasing cooling
product
cooling rate
family
rate of
on
of welds
the
welds from
physical
from 588
level.
588 °C/sec
°C/sec up
Different
up to
to 152
product
152 °C/sec,
families,
°C/sec, weld
weld metal
however,
metal hardness
may differ
hardness from
largely
from 343±12
343±12 HV
in terms
HV up
of
up to
the
to 276±6
number
276±6 HVHV and
and
and
nature of tensile
ultimate
ultimate components.
tensile strength
strength This
from
fromfact1019.5±14
impedes an
1019.5±14 MPa
MPaefficientto comparison
up to
up 828±10 MPa
828±10 MPaand andchoice
and of appropriate
increasing
increasing product
bainite phase
bainite phase termfamily
term thecombinations
of the
of weld metal
weld metal wasfor detected
was the production
detected at the
at the
system. A new
increasing
increasing methodology
preheating
preheating is proposed
temperature
temperature up to
up to to analyze
180
180 °C and
°C andexisting
maximal
maximal products in view
heat input.
heat input. Theofmathematical
The their functional
mathematical and physical
relations
relations of the
of architecture.
the input
input The parameters
and output
and output aim is to cluster
parameters were
were
these products
created
created in newregression
using linear
using linear assembly oriented
regression equations.
equations. product families
Preheating
Preheating for the optimization
temperature
temperature 180 °C
180 °C allowsof existing
allows assembly
increasing
increasing maximal
maximal lines and thespeed
welding
welding creation
speed of
up to
up future
to more reconfigurable
more than
than 3.0 m/min
3.0 m/min
assembly systems.
with acceptable
with Based
acceptable welding on
welding joint Datum
joint quality.
quality.Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a©©functional analysis
Authors.isPublished
performed. Moreover, a hybrid functional and article
physical architecture graph (HyFPAG) licenseis the output which depicts the
2018
© 2018
similarity
The
2018 The
The Authors.
Authors.
between
Published
Published
product
by Elsevier
by
by
families
Elsevier Ltd.
Elsevier
by
Ltd.
Ltd.
providing
This is
This
This is an
is
design
an open
an open access
open
support
access
access
to
article under
article
both,
under
under
production
the CC
the
the CC BY-NC-ND
CC
system
BY-NC-ND
BY-NC-ND
planners
license
license
and product designers. An illustrative
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
example of a under
Peer-review
Peer-review nail-clipper
under is used to
responsibility
responsibility of
of explain
the
the the proposed
Bayerisches
Bayerisches methodology.
Laserzentrum
Laserzentrum GmbH.
GmbH. An industrial case study on two product families of steering columns of
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The
Keywords:
Keywords: Authors.
Hybrid
Hybrid Published
laser-arc
laser-arc welding;
welding;byAPIElsevier
API 5L X80B.V.
5L X80 steel;
steel; cooling
cooling rate;
rate; microstructure;
microstructure; mechanical
mechanical properties;
properties; regression
regression equations
equations
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
2. Experimental procedure Three test samples for Charpy impact test, two for ultimate
tensile strength and one for hardness test were made from
2.1. Welding equipment and test materials every weld.
a b
Experimental part was carried out using a 20 kW fiber laser
YLR – 20000 (IPG) and semiautomatic welding machine
Qineo Pulse 600А (Cloos). Preheating of the test samples was
performed using current source GLW 450 I-H-P-R (Cloos)
with electric heating element.
Welding samples from API 5L X80 steel with overall
dimensions 240x100x23.7 mm3, root face thickness 14 mm Fig. 1. Scheme of (a) ultimate tensile strength sample with boundary
dimensions and (b) ultimate tensile strength samples location in weld metal
and groove angle 22.5° were welded using metal cored welding
wire MF 940 M (EN ISO 18276) with diameter 1.2 mm.
Chemical compositions of the steel and welding wire are given All tests results were controlled in accordance with DIN
in Table 1 and Table 2 accordingly. EN ISO 3183-2011 «Petroleum and Natural Gas Industries -
Steel Pipe for Pipeline Transportation Systems».
Table 1. Chemical compositions of the API 5L X80 steel (wt %)
C Si Mn P S Cr Ni
2.3. Design of the experimental work
0.052 0.33 1.82 0.008 0.0008 0.17 0.01
Mo Cu V Nb Ti N Fe The study was carried out using DOE 2k type. The
0.14 0.02 0.004 0.04 0.012 0.004 Bal. mathematical relations of the input and output parameters were
created using linear regression equations. Input parameters are
Table 2. Chemical compositions of the welding wire MF 940 M (wt %)
welding speed (S) and preheating temperature (T). Output
C Si Mn P S Ni N Fe parameters are average weld metal hardness (HV), average
0.05 0.6 1.4 0.015 0.015 2.0 0.004 Bal. weld metal ultimate tensile strength (G).
Heat input depends from welding speed and laser power.
HLAW was carried out in the PC welding position. Arc Welding speed diapason was chosen from 1.8 m/min up to 3
torch had angle of 30° from laser beam with wire stick out 16 m/min. Laser power (PL) and wire rate (R) values depended
mm. Laser head and arc torch were mounted on an industrial from welding speed for creating welds with stable through
robot. Arc had a leading position. Distance from the axes of penetrations.
the electrode to the laser beam was 3.5 mm. Laser beam focal Preheating temperature was varied from 20 °C (room
plane was below the top surface on 4 mm. Gas mixture M21 temperature) up to 180 °C. Upper limit of the preheating
(82% Ar and 18% CO2) with supply rate of 20 l/min was used. temperature was chosen for avoiding unnecessary changes in
the structure of the base material.
2.2. Testing equipment and welds inspections
3. Experimental results
Defects classification was carried out according to DIN EN
ISO 13919-1. Measuring of thermo cycle of the HLAW was The HLAW parameters are shown in the Table 3.
performed using four alumel-chromel thermocouples which
were soldered on the back side of the welded joint by a Table 3. HLAW parameters
resistance welding machine PSG 1000/3 with starting point of Weld, T, S, PL, R, IA, UA, Q,
1-1.5 mm from the joint edge and 30 mm interval. No 0
C m/min kW m/min A V kW*min/m
Examination of the welds microstructure was performed 1 180 3.0 18.3 18 491 34.7 11.8
using optical microscope Polyvar Met with 500x magnification 2 180 1.8 15.6 11 334 30.6 14.3
3 20 3.0 18.3 18 507 36.2 12.2
in three points on vertical axis of the weld metal: 2 mm from 4 20 1.8 15.6 11 327 30.4 14.2
the root, at the middle and 2 mm from the top. 5 100 2.4 18 14.5 420 32.6 13.2
Hardness tests were performed across the weld metal, 6 100 2.4 18 14.5 420 32.6 13.2
fusion zone, HAZ and the base metal according to DIN EN 7 100 2.4 18 14.5 420 32.6 13.2
ISO 14577 at room temperature in three lines: 2 mm from the
root, at the middle and 2 mm from the top of the weld. 3.1. Welds appearance
Charpy impact tests were carried out according to DIN EN
10045 at temperature -20 °C with V-notch located at the middle All welds (except weld 5) had a stable full penetration.
of weld metal. Weld 5 had instability full penetration partly. Minor undercuts
Weld 3 with the highest cooling rate of the weld metal was were observed in the weld 2 and weld 3.
chosen for ultimate tensile strength testing. Test samples were
made using electric discharge sawing with boundary 3.2. X-ray inspection
dimensions in 2 times less than minimal boundary dimensions
from DIN 50125-2009. Scheme of ultimate tensile strength Insignificant number of the pores were detected in the
sample and the samples location in weld metal are shown on metal of the welds 6 and 7. Other welds didn’t have inner
Fig. 1. Testing of the samples was carried out according to defects and had high quality accordingly standard EN ISO
DIN EN ISO 6892-1:2009 using Material Test System 810 13919-1. All welds metal zones with inner defects were cut
machine. and were not researched.
750 G. Turichin et al. / Procedia CIRP 74 (2018) 748–751
Author name / Procedia CIRP 00 (2018) 000–000 3
3.3. Thermal cycle of the HLAW element Mn (Table 1) also. The alloying elements suppressed
carbon diffusion at the polymorphic transformation because of
The thermo cycles of the HLAW for different welding decrease of the point Ac3. Therefore weld metal with
parameters are presented on the Fig. 2. martensite and bainite phase was formed because of high
cooling rate. Proportion of the martensite and bainite of the
weld metal was depend from cooling rate. Weld metal had
more martensite at the cooling rate increasing and opposite
phase composition at the cooling rate decreasing (regime 3 -
51.7% martensite and 48.3% bainite; regime 4 - 43.3%
martensite and 56.7% bainite).
Martensite phase increased in the upper part of the weld
metal because of irregular mixing welding wire alloying
elements (Ni and Mn) in the welds and their higher
concentration in the upper part of the weld metal [10,11].
Charpy test results didn’t show any correlation between • Regression equations were created for prediction weld
input and output parameters. But it can be noted that test metal hardness and ultimate tensile strength for HLAW pipe
samples were broke at the weld metal with elastic character of steel X80-X120 with welding wire MF 940M or others
the fracture had average value of impact energy 75±24 J. Test wires with similar chemical composition.
samples were broke partly at the weld metal-base metal had
plastic-elastic character of the fracture with average value of Reference
impact energy 226±82 J. And test samples were broke at the
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𝑯𝑯𝑯𝑯𝑯𝑯𝑯𝑯(𝑺𝑺𝑺𝑺, 𝑻𝑻𝑻𝑻) = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐, 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 + 𝟑𝟑𝟑𝟑𝟓𝟓𝟓𝟓, 𝟐𝟐𝟐𝟐𝟓𝟓𝟓𝟓𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐– 𝟐𝟐𝟐𝟐, 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟎𝟎𝟎𝟎𝟐𝟐𝟐𝟐𝟎𝟎𝟎𝟎– 𝟐𝟐𝟐𝟐, 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟎𝟎𝟎𝟎 (1) International 2005; 19: 882 – 887.
[9] Turichin G., Kuznetsov M., Sokolov M., Salminen A. Hybrid Laser Arc
Welding of X80 Steel: Influence of Welding Speed and Preheating on the
𝛔𝛔𝛔𝛔в(𝟐𝟐𝟐𝟐, 𝟎𝟎𝟎𝟎) = 𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖, 𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖 + 𝟓𝟓𝟓𝟓𝟐𝟐𝟐𝟐, 𝟏𝟏𝟏𝟏𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖– 𝟐𝟐𝟐𝟐, 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐– 𝟐𝟐𝟐𝟐, 𝟏𝟏𝟏𝟏𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 (2)
Microstructure and Mechanical Properties. Physics Procedia 2015; 78: 35 –
44.
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[13] Ohata M., Morimoto G., Fukuda Y., Minami F., Inose K., Handa T.
In this study set of experiments of HLAW X80 pipeline Prediction of ductile fracture path in Charpy V-notch specimen for laser
steel with high power fiber laser and welding wire MF 940M beam welds. Welding in the World 2015; 59, 5: 667- 674.
was conducted. Influence of the welding speed and preheating [14] Rethmeier M., Gook S., Gumenyuk A. Prospects of application of laser-
GMA hybrid welding for manufacturing of large diameter longitudinal
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acceptable quality in the experiments. The main conclusions application” 2013; 130-140.
can be summarized in the following: