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4 AUTHORS, INCLUDING:
R.M. Miranda
Lusa Quintino
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ORIGINAL ARTICLE
1 Introduction
1.1 Butting bimetal pipes
Butting bimetal pipes, also known as BuBi pipes, are the
subsequent generation of bimetal pipes after clad pipes.
They are comprised of an outer thick layer of high strength
carbon steel and a thin liner layer of corrosion-resistant
alloy such as austenitic stainless steel, duplex or super
duplex stainless steel, or nickel-based alloy which is in
close contact with the outer layer [1]. In the manufacturing
process, this thin layer is expanded to close contact with the
outer layer by being aligned inside the thicker pipe and then
expanded to the outer layer by an internal hydraulic
expansion force [2].
The benefits of choosing BuBi pipes over conventional
metallurgically bonded clad pipes include cost efficiency in
the manufacturing process and better properties of the
interface between outer and liner layers due to the absence
of fusion bonding and thermal effects [3]. Additionally, it
has the advantage of having various options in selecting
combinations for the outer layer and liner layer; hence, it
results in increased cost-effectiveness by choosing more
corrosion-resistant materials with better mechanical properties less prone to failure [2]. The thick layer of carbon steel
Si
Mn
Cr
Ni
Mo
2205
0.02
0.5
1.6
0.17
23.0
8.5
3.1
2 Experimental procedures
2.1 Materials
The material used in this study is an ASTM A240 S32506
duplex stainless steel pipe with 254-mm internal diameter
and 14-mm wall thickness. Tables 1 and 2 present the
compositions of the base material and the wire filler
material applied in GMAW, respectively.
2.2 Welding
2.2.1 Equipment
The selected power source for TIG welding was a
MIGATRONIC A/S TIG COMMANDER which is a three
phase machine based on inverter technology. All functions
can be set on a one control knob. For TIG welding it has
functions such as
Si
Mn
Cr
Mo
Ni
0.015
0.32
0.44
0.025
<0.005
25.0
3.19
6.34
2.00
Fig. 4 Experimental setup for GTA welding of the pipe
1
2
3
4
5
6
7
8
9
10
11
12
WFS
(m/min)
TS
(m/min)
CTWD
(mm)
Trim
Wave
control
Gas
(l/min)
Back shielding
(l/min)
Real WFS
(m/min)
Current
(A)
Voltage
(V)
8
7
7
8
9
7.2
7.5
7.2
8
9
9
9
0.5
0.5
0.5
0.5
0.5
0.4
0.4
0.4
0.4
0.5
0.5
0.5
12
12
12
12
12
12
12
12
12
12
12
12
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
10
10
10
10
10
10
10
10
10
10
10
10
16
16
16
16
16
16
16
16
16
16
16
16
30
30
16
16
16
16
16
16
16
16
16
16
7.62
6.64
6.68
7.62
8.39
8.45
6.82
6.74
6.69
6.69
7.63
7.71
166.90
152.48
152.25
166.59
163.67
163.62
154.30
154.30
155.79
154.82
165.13
164.70
24.87
25.12
24.00
24.88
24.54
24.49
25.21
25.00
25.39
25.42
25.02
24.38
Power
(W)
4,792.20
4,502.31
4,263.65
4,764.99
4,535.96
4,532.88
4,529.72
4,493.24
4,587.47
4,584.88
4,725.60
4,614.08
Heat input
(kJ/mm)
0.5751
0.5403
0.5116
0.5718
0.5443
0.6799
0.6795
0.6740
0.6881
0.5502
0.5671
0.5537
1
2
3
4
5
6
7
8
9
10
WFS
(m/min)
TS
(m/min)
CTWD
(mm)
Trim
Wave
control
Gas
(l/min)
Real WFS
(m/min)
Current
(A)
Voltage
(V)
10
9.8
9.8
9.8
9.8
9.8
9.8
9
9
9
0.5
0.5
0.8
1
0.95
0.95
0.95
0.9
1
0.8
11
11
11
11
11
11
11
11
11
11
1.5
1.5
1.5
1.5
1.5
1
1
1
1
1
10
10
10
10
10
10
10
10
10
10
16
16
16
16
16
16
16
16
16
16
9.58
9.30
9.23
9.25
9.16
9.35
9.28
8.65
8.56
8.51
188.33
185.99
187.26
188.41
186.10
181.35
184.69
167.18
165.43
167.55
24.83
24.86
23.38
23.05
23.33
20.71
20.64
20.55
20.68
20.28
Power
(W)
5,209.887
5,143.675
4,952.209
4,950.702
4,917.364
4,199.567
4,289.015
3,778.55
3,794.611
3,826.418
Heat input
(kJ/mm)
0.6252
0.6172
0.3714
0.2970
0.3106
0.2652
0.2709
0.2519
0.2277
0.2870
200
Flat
He25%Ar 14
30
Fig. 7 Macrographs of tests 5 (a) and 9 (b) welded by GMA showing full penetration and re-melted from the inner side with GTAW (c)
400 mm/min
2.5
2
1.5
1
0.5
e
%
Ar
-5
.5
%
%
H
Ar
-1
.5
%
C
O
2
%
H
e44
H
150 A
200 A
250 A
0.24
30
0.22
60
%
Ar
25
-1
.
5%
Ar
-5
.5
e44
H
D/W ratio
%
H
e
H
0%
2.
eH
0%
eH
5%
C
%
Ar
-2
Ar
-3
2
O
2
O
Ar
-2
C
.7
%
Ar
-0
0.2
Ar
e25
3.2.1 Argon
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Ar
-3
0
Ar
Ar
-0
.7
%
C
O
2
Ar
-2
%
Ar
C
O
-2
2
0%
H
e2.
5%
N
0.18
0.16
0.14
0.12
0.1
100
125
150
175
200
Current (A)
Fig. 11 Variation of D/W ratio with the current intensity and the
electrode angle (welding speed=200 mm/min, shielding gas=argon)
3.2.4 Nitrogen
Nitrogen did not make a significant change in penetration
for high welding speeds (see Figs. 9 and 10) though it
increases penetration at high current intensities and low
travel speed. Its major benefit derives from its ability to
stabilise austenite in the weld metal preventing fully ferritic
microstructures.
3.2.5 Helium
Argon has a low ionisation potential in comparison with
some other inert gases as well as helium [17]. So the
addition of such elements to argon can increase the total
amount of heat in the weld pool. Mixtures as 70%Ar30%
He did not make a significant change in penetration due to
the predominance of Marangoni forces. High heat input
contributes to increase bead width. Increasing the helium
content to obtain a mixture of 75%He25%Ar introduces
more heat and increase the penetration. However, according to [17], it does not enhance the D/W ratio considerably
but still sustains a good quality in the weld. This shows
that, although by increasing the heat input higher molten
metal would be achieved, surface tension still plays the
major role because of the low content of sulphur. So, D/W
ratio is limited when higher heat input is introduced into
the weld.
1.2
1
0.8
0.6
0.4
0.2
0
12h
3h
6h
9h
Orbital position
4 Conclusions
The present study aimed at optimising GTA orbital welding
in butting bimetal pipes in duplex stainless steel that results
in an adequate penetration on the inner surface. The effect
of operating parameters such as current intensity, welding
speed, electrode angle and shielding gas composition in
various orbital positions inside the pipe was investigated.
The following conclusions were drawn:
1. Changing the current and the welding speed does not
increase penetration when the flow pattern is dominantly outwards due to Marangoni effect unless the
current exceeds a value such that the depression force
overcomes the surface tension force. However, this
results in unsatisfactory weld surfaces and undercuts.
2. Sharper electrode angles resulted in higher penetration
which is also as a result of the Marangoni effect.
3. Adding CO2 to argon increased penetration but caused
electrode deterioration and increased the possibility of
weld pool oxidation.
4. Additions of hydrogen significantly increased penetration.
However, the use of hydrogen has an associated safety
and porosity risk.
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