International Scientific-Technical and Production Journal
September
2010
#9
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
Founders: E.O. Paton Electric Welding Institute of the NAS of Ukraine
International Association «Welding»
Editor-in-Chief B.E.Paton
Publisher: International Association «Welding»
CONTENTS
Editorial board:
Yu. <...> N.Lankin I.K.Pokhodnya
V.N.Lipodaev V.D.Poznyakov
V.I.Makhnenko K.A.Yushchenko
O.K.Nazarenko A.T.Zelnichenko
I.A.Ryabtsev
International editorial council:
N.P.Alyoshin
U.Diltey
Guan Qiao
D. von Hofe
V.I.Lysak
N.I.Nikiforov
B.E.Paton
Ya. <...> The main results
of the research, in particular, on the peculiarities of weld formation in different regions of circumferential joints,
mechanical properties of the welded joints, and potentialities of the available equipment for construction of main pipelines
are generalized. <...> K e y w o r d s : hybrid laser-arc welding, orbital welding,
high-pressure pipelines, fibre-optic lasers
One of the key components of the world energy system
is a network of main pipelines. <...> Construction of these
pipelines demonstrated advantages of manual and
mechanised methods of arc welding, such as manual
covered-electrode arc welding, mechanised gasshielded welding using solid or flux-cored wire, and
mechanised twin-arc tandem welding. <...> The arc welding methods
employed are characterised by a relatively low speed. <...> This limitation may be quite appreciable, for example,
in construction of pipeline with a diameter of 1229 mm
and wall thickness of 35 mm or more. <...> Furthermore,
the oil and gas industry is in a state of search for
solutions concerning application of modern highstrength structural materials, as this would allow reducing wall thickness of pipelines in order to cut their
metal intensity or increase a working pressure in the
pipeline to provide a more efficient transportation of
product. <...> Instead of standard pipeline steel grades of
strength classes X60 and X70 with a yield point of
up to 500 MPa, according to classification of the
American Petroleum Institute, steels of a higher
strength class, such as X80 or X100, are introduced
into practice, as a result of which the working pressure
in new pipelines that are designed now can <...>
The_Paton_Welding_Journal_№9_2010.pdf
International Scientific-Technical and Production Journal
September
2010
# 9
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
Editor-in-Chief B.E.Paton
Yu.S.Borisov V.F.Khorunov
A.Ya.Ishchenko I.V.Krivtsun
B.V.Khitrovskaya L.M.Lobanov
V.I.Kirian A.A.Mazur
S.I.Kuchuk-Yatsenko
Yu.N.Lankin I.K.Pokhodnya
V.N.Lipodaev V.D.Poznyakov
V.I.Makhnenko K.A.Yushchenko
O.K.Nazarenko A.T.Zelnichenko
I.A.Ryabtsev
CONTENTS
SCIENTIFIC AND TECHNICAL
. and
. and
.
Investigation of structure and phase composition of alloys
based on the Ti—Zr—Fe system .............................................................. 9
. Analytical study of current controller of power
N.P.Alyoshin (Russia)
U.Diltey (Germany)
Guan Qiao (China)
D. von Hofe (Germany)
V.I.Lysak (Russia)
N.I.Nikiforov (Russia)
B.E.Paton (Ukraine)
Ya.Pilarczyk (Poland)
P.Seyffarth (Germany)
G.A.Turichin (Russia)
Zhang Yanmin (China)
A.S.Zubchenko (Russia)
V.N.Lipodaev, V.I.Lokteva
A.T.Zelnichenko (exec. director)
A.A.Fomin, O.S.Kurochko,
I.N.Kutianova, T.K.Vasilenko
PE «Melnik A.M.»
N.A.Dmitrieva
D.I.Sereda, T.Yu.Snegiryova
source for microplasma welding .......................................................... 15
. and
. Technological strength and analysis of
causes of weldability deterioration and cracking .................................. 20
. and
. Treatment of the surface of
aluminium-matrix composite materials by concentrated energy
sources .............................................................................................. 24
INDUSTRIAL
and
.
. Repair of ship hull structures of aluminium
alloy AMg6 using electrodynamic treatment ......................................... 31
. and
. High-quality hose
packs for underwater welding and cutting ........................................... 33
. and
. Ultrasonic
diagnostics of service defects in structures of oil and gas
industry .............................................................................................. 36
NEWS
State Registration Certificate
KV 4790 of 09.01.2001
$324, 12 issues per year,
postage and packaging included.
Back issues available.
All rights reserved.
This publication and each of the articles
contained herein are protected by copyright.
Permission to reproduce material contained in
this journal must be obtained in writing from
the Publisher.
Copies of individual articles may be obtained
from the Publisher.
© PWI, International Association «Welding», 2010
INFORMATION
News .................................................................................................. 48
Developed in PWI ................................................................................ 49
10th Jubilee European Conference-Exhibition on
Non-Destructive Testing ...................................................................... 41
International Conference on Welding Consumables .............................. 42
10th International Conference-Exhibition «Problems of
Corrosion and Anticorrosion Protection of Structural Materials.
Corrosion-2010» ................................................................................. 45
L.M. Lobanov is 70 ............................................................................. 46
.
Peculiarities of the process of orbital laser-arc welding of
thick-walled large-diameter pipes ......................................................... 2
Pub
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Стр.1
PECULIARITIES OF THE PROCESS
OF ORBITAL LASER-ARC WELDING
OF THICK-WALLED LARGE-DIAMETER PIPES
S. GOOK, A. GUMENYUK, M. LAMMERS and M. RETHMEIER
Federal Institute for Materials Research and Testing (BAM), Berlin, Germany
The results of development and testing of hybrid laser-arc welding of large-diameter pipes are given. The main results
of the research, in particular, on the peculiarities of weld formation in different regions of circumferential joints,
mechanical properties of the welded joints, and potentialities of the available equipment for construction of main pipelines
are generalized.
Keywords: hybrid laser-arc welding,
high-pressure pipelines, fibre-optic lasers
orbital welding,
One of the key components of the world energy system
is a network of main pipelines. Construction of these
pipelines demonstrated advantages of manual and
mechanised methods of arc welding, such as manual
covered-electrode arc welding, mechanised
gasshielded
welding using solid or flux-cored wire, and
mechanised twin-arc tandem welding. Worthy of note
among the non-arc processes is flash butt welding,
which has not yet found wide application for construction
of modern oil and gas pipelines despite the simplicity
of its principle of operation [1]. Position butt
welding of pipelines is a labour-consuming process,
which determines to a considerable degree the rate of
laying a line as a whole. The arc welding methods
employed are characterised by a relatively low speed.
This limitation may be quite appreciable, for example,
in construction of pipeline with a diameter of 1229 mm
and wall thickness of 35 mm or more. Furthermore,
the oil and gas industry is in a state of search for
solutions concerning application of modern highstrength
structural materials, as this would allow reducing
wall thickness of pipelines in order to cut their
metal intensity or increase a working pressure in the
pipeline to provide a more efficient transportation of
product. Instead of standard pipeline steel grades of
strength classes X60 and X70 with a yield point of
up to 500 MPa, according to classification of the
American Petroleum Institute, steels of a higher
strength class, such as X80 or X100, are introduced
into practice, as a result of which the working pressure
in new pipelines that are designed now can be raised
from 7—10 to 15—20 MPa. Despite the fact that increase
of strength characteristics of steel in terms of
welding metallurgy leads to deterioration of its weldability,
traditional arc welding is capable of providing
the required quality of welded joints, and the use of
fully automated welding processes solves the problem
of its reproducibility. It is likely that the choice of
© S. GOOK, A. GUMENYUK, M. LAMMERS and M. RETHMEIER, 2010
2
these welding processes or the other for construction
of advanced pipelines from high-strength steel will be
based primarily on the technical-economical factors,
allowing for the volumes of construction and assurance
of the quality of building and assembly operations.
This strategy is inseparably connected with application
of the latest achievements in the field of welding
technologies, among which the most attractive ones
today are highly efficient combined (hybrid) welding
processes based on the synergic, complex effect of the
laser beam and electric arc on the weld.
The idea of using beam welding to make circumferential
welds on pipelines is not new. For instance,
the possibilities of using electron beam [2], gas CO2laser
[3] and solid-state Nd:YAG-laser [4] to implement
the orbital welding process have been considered
in a number of publications approximately since 2000.
The feasibility of applying electron beam welding for
making single-pass circumferential welds was demonstrated
on the 762 mm diameter pipes with a wall
thickness of 19 mm. However, the use of the said
welding method under field conditions is hampered
by technical difficulties associated mainly with the
need of creating vacuum within the welding zone and
ensuring protection from X-radiation generated when
electrons hit a workpiece. In the case of the laser
beam, the maximal wall thickness of a pipe is limited
to 10 mm, which is caused by the maximal output
power of laser units employed at that time (12 kW
for the CO2-laser, and 4.4 kW for the Nd:YAG-laser).
With emergence of the high-power solid-state lasers,
such as fibre-optic and disk ones, the welding
industry began using up to 20 kW continuous-wave
laser units featuring an excellent quality of emission
and compact design. Utilisation of the said advantages
of modern lasers combined with the hybrid laser-arc
welding process made it possible, for the first time
ever, to perform single-pass butt welding of materials
with a wall thickness of up to 20 mm [5].
Potentialities of the up-to-date fibre-optic lasers
for welding pipelines have been intensively studied at
a number of research centres of Germany and other
9/2010
Стр.2