CA2450369A1 - Method for processing welded metalwork joints by high-frequency hummering - Google Patents
Method for processing welded metalwork joints by high-frequency hummering Download PDFInfo
- Publication number
- CA2450369A1 CA2450369A1 CA002450369A CA2450369A CA2450369A1 CA 2450369 A1 CA2450369 A1 CA 2450369A1 CA 002450369 A CA002450369 A CA 002450369A CA 2450369 A CA2450369 A CA 2450369A CA 2450369 A1 CA2450369 A1 CA 2450369A1
- Authority
- CA
- Canada
- Prior art keywords
- welded
- treatment
- stress
- sigma
- stresses
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D7/00—Modifying the physical properties of iron or steel by deformation
- C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
- C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Thermal Sciences (AREA)
- Physics & Mathematics (AREA)
- Arc Welding In General (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
- Nitrogen And Oxygen Or Sulfur-Condensed Heterocyclic Ring Systems (AREA)
- Heat Treatment Of Articles (AREA)
Abstract
The inventive method relates to reinforcing treatment of welded metalwork joints using a power ultrasound. Said method can be used for mechanical engineering, shipbuilding, bridge engineering and other branches of industry and construction producing welded structures which can be safely used at conditions of static, dynamic and repeated-variable loading. The inventive method consists in specifying the method for calculating normalised residual compressive stresses to be produced by an ultrasound impact processing. Said stresses are related to the geometrical dimensions of a groove formed when the area disposed along a line between the joint and a base metal is treated. Said invention makes it possible to maximally increase the fatigue limit and the cyclic life duration of welded joints.
Description
METHOD OF TREATMENT OF WELDED JOINTS OF METALLIC
STRUCTURES BY HIGH-FREQUENCY PEENING
The invention falls into the technological application of high power ultrasonic vibrations for sur-face hardening treatment of metal products and, first of all, of welded joints of metallic structures with shock impulses of high frequency. It can be utilized in mechanical engineering, shipbuild-ing, bridge engineering and other branches of industries and construction that are dealing with the manufacturing and maintenance of parts and welded structures working in conditions of dy-namic and especially cyclic loading, for prevention of premature fatigue cracks and failures in the zones of stress concentrations and welded joints.
For hardening and relaxation treatment of welded joints and structures different impact methods are employed: magneto-pulsing, low-frequency hammer peering, shot peering, etc. (G. Danilov et al. Efficiency of technological methods of cyclic life improving of welded elements of sleet proof offshore platforms. Problems of Materials Science. 1996. # 2. p. I S-22). The existing tech-niques are characterized by considerable power consumption, relatively low efficiency and con-siderable noise. The high power ultrasonic vibrations are also utilized in fatigue improvement by transforming the ultrasonic energy into the high-frequency impacts of working elements (spheres or rods) that strike the surface of parts or structures with the goal to create plastic deformation of the treated surface (IV. Krilov and A. Polishchuk Application of ultrasonic apparatus for metal texture stabilization. Physical background of industrial application of ultrasound. Part 1.
LDNTP. Leningrad. 1970. P. 70-79). The striking force of these elements depends on weight, vibration amplitude of the tip of the ultrasonic horn, radius of the tip of the striking element and on the velocity at the moment of impact.
The velocity and frequency determine the efficiency of treatment of different materials and welded joints (Patent of Ukraine ' 12741. Published 28. 02.97). In a known approach the opti-mum duration of treatment is evaluated by special operating technological complex (Patent of Ukraine # 12741 of 07/16/1993. Method for ultrasonic impact treatment and operational techni-cal system for its realization. B.E. Paton, L.M. Lobanov, E.Sh. Statnikov, E.A. Yostrukhin, S.Zh.
Chirtsov, L).E. Aranovsky, Y.L Trufyakov, P.P. Mikheev). For this purpose the alternating electri-cal voltage in pulsed condition is applied to the magnetostrictive transducer.
When voltage is ab-sent the transducer continues to oscillate with some attenuation. When this attenuation is stabi-lized the treatment is completed. Apparently, the described above technique can be applied to a limited number of materials where mechanical characteristics are essentially changed during treatment. Stronger materials that require considerable duration of treatment, will be handled less than it is required for beneficial effect because the attenuation of oscillations of transducer will be practically identical to initial one at the beginning of treatment.
Therefore, for each material and type of welded joint it is necessary to create the optimum technology of treatment that pro-vides the maximum possible effect with minimum power and labor consumption.
The basic criterion of the increasing of fatigue life of welded elements is the inducing of the normalized on value and character of the distribution of the beneficial compressive residual stresses in the weld zone. These beneficial residual stresses could be induced by impact treat-ment with the help of high power Ultrasonics.
Closest to the proposed method is a known method of treatment of welded metallic structures made mainly from steel. This method includes the action by an ultrasonic impact instrument in the weld toe zone with pre-selected vibration amplitude of the transducer's tip. The purpose of the treatment is the increasing of fatigue life of welded metallic structures by inducing normal-ized on value and character of distribution of residual compressive stresses in the weld zone (Patent of Ukraine ' 23001. Published 30.0b.98). The vibration amplitude A of ultrasonic horn tip in this case is selected based on empirical relationship:
STRUCTURES BY HIGH-FREQUENCY PEENING
The invention falls into the technological application of high power ultrasonic vibrations for sur-face hardening treatment of metal products and, first of all, of welded joints of metallic structures with shock impulses of high frequency. It can be utilized in mechanical engineering, shipbuild-ing, bridge engineering and other branches of industries and construction that are dealing with the manufacturing and maintenance of parts and welded structures working in conditions of dy-namic and especially cyclic loading, for prevention of premature fatigue cracks and failures in the zones of stress concentrations and welded joints.
For hardening and relaxation treatment of welded joints and structures different impact methods are employed: magneto-pulsing, low-frequency hammer peering, shot peering, etc. (G. Danilov et al. Efficiency of technological methods of cyclic life improving of welded elements of sleet proof offshore platforms. Problems of Materials Science. 1996. # 2. p. I S-22). The existing tech-niques are characterized by considerable power consumption, relatively low efficiency and con-siderable noise. The high power ultrasonic vibrations are also utilized in fatigue improvement by transforming the ultrasonic energy into the high-frequency impacts of working elements (spheres or rods) that strike the surface of parts or structures with the goal to create plastic deformation of the treated surface (IV. Krilov and A. Polishchuk Application of ultrasonic apparatus for metal texture stabilization. Physical background of industrial application of ultrasound. Part 1.
LDNTP. Leningrad. 1970. P. 70-79). The striking force of these elements depends on weight, vibration amplitude of the tip of the ultrasonic horn, radius of the tip of the striking element and on the velocity at the moment of impact.
The velocity and frequency determine the efficiency of treatment of different materials and welded joints (Patent of Ukraine ' 12741. Published 28. 02.97). In a known approach the opti-mum duration of treatment is evaluated by special operating technological complex (Patent of Ukraine # 12741 of 07/16/1993. Method for ultrasonic impact treatment and operational techni-cal system for its realization. B.E. Paton, L.M. Lobanov, E.Sh. Statnikov, E.A. Yostrukhin, S.Zh.
Chirtsov, L).E. Aranovsky, Y.L Trufyakov, P.P. Mikheev). For this purpose the alternating electri-cal voltage in pulsed condition is applied to the magnetostrictive transducer.
When voltage is ab-sent the transducer continues to oscillate with some attenuation. When this attenuation is stabi-lized the treatment is completed. Apparently, the described above technique can be applied to a limited number of materials where mechanical characteristics are essentially changed during treatment. Stronger materials that require considerable duration of treatment, will be handled less than it is required for beneficial effect because the attenuation of oscillations of transducer will be practically identical to initial one at the beginning of treatment.
Therefore, for each material and type of welded joint it is necessary to create the optimum technology of treatment that pro-vides the maximum possible effect with minimum power and labor consumption.
The basic criterion of the increasing of fatigue life of welded elements is the inducing of the normalized on value and character of the distribution of the beneficial compressive residual stresses in the weld zone. These beneficial residual stresses could be induced by impact treat-ment with the help of high power Ultrasonics.
Closest to the proposed method is a known method of treatment of welded metallic structures made mainly from steel. This method includes the action by an ultrasonic impact instrument in the weld toe zone with pre-selected vibration amplitude of the transducer's tip. The purpose of the treatment is the increasing of fatigue life of welded metallic structures by inducing normal-ized on value and character of distribution of residual compressive stresses in the weld zone (Patent of Ukraine ' 23001. Published 30.0b.98). The vibration amplitude A of ultrasonic horn tip in this case is selected based on empirical relationship:
2,24 <_ 4a RZm <_ 3,36 (1) Y
Where f is the frequency of impact impulses, m is the weight of deforming element, ~Y is the yield strength of the considered material, R is the radius of pin's tip. For welded structures made from low-carbon steel the treatment is performed in the zone restricted by line on the primary recrystallization. In welded structures from alloyed and high-strength steels the treatment is per-formed in the zone restricted by the line on the low tempering. As an optimum value of induced residual compressive stresses the values of the 1.2 - 1.5 of the yield strength of material in sur-face layer with thickness of 0.1 - 0.2 mm and the total depth of the of the compressive residual stresses equals to 1.0 - 1.2 mm are accepted. 'The level of residual stresses is achieved by the using of the parameters of treatment chosen from the relation (1). The value of amplitude A is also evaluated from relation (1). This amplitude can be generated by ultrasonic equipment with different power, but the range of optimum power is not specified in the proposed earlier method.
The main disadvantage of the above-mentioned method is that the treatment of welded joints of different steels should be made in zones restricted by isothermal curves or low tempering. These parameters should be determined experimentally. At the same time, normalized on value and character of distribution of the compressive residual stresses are assumed by such, which are equal to their maximum achievable values exceeding a yield strength of material in 1.2 - 1.5 times. However, the conditions of in-service cyclic loading such as stress range, stress ratio and stress concentration caused by joint configuration and other factors that essentially effect the fa-tigue strength of welded joints and a degree of the influence of residual stresses on the fatigue life are not taken into account. 'The normalized value of residual compressive stresses, created by ultrasonic impact treatment, in zones of stress concentrators leading to the maximum possible increase of the limit stress range and fatigue life of welded joint should be determined differen-tially, i.e. depending on above mentioned factors.
The value of these beneficial compressive residual stresses depends under other equal conditions on the treatment time of considered element or productivity of treatment. But in the known method the amplitude A is determined from the relation ( 1 ) where the treatment time is not pres-ent. The absence of this parameter does not allow providing the recommendations concerning parameters of treatment in terms of optimum application of welded elements.
The above-mentioned disadvantages do not allow the selection of unique technological parameters of treat-ment for the considered welded element made from different materials.
The important problem in improvement of ultrasonic impact technology or high frequency peering is the optimization of the technological parameters of treatment by criteria of induced residual compressive stresses in the zones of stress concentrators. Thus it is necessary to deter-mine the values of normalized residual compressive stresses for metals with different strength to ensure the maximum possible increase of limit stress range and fatigue life of welded joints of different types. Besides, it is necessary to create the simplified algorithm for the estimation of the optimum parameters of improvement treatment of welded joint without performing of compli-cated preliminary experimental investigations.
The improvement of method of treatment of welded joints of metallic structures made from steels and alloys by high-frequency peering is a subject of present invention.
The method in-cludes the action of the ultrasonic impact instrument in zones of stress concentration located along the weld toe zone. The beneficial effect is achieved by relieving of harmful tensile residual stresses and introducing of beneficial compressive residual stresses normalized on value, at which the minimum stresses of loading cycle achieve a yield stress - csy of material in the zones of stress concentration. Depending on stress ratio, type of joint and stress concentration factor, mechanical properties of material the value of compressive residual stresses which are necessary for realization of maximum increase of fatigue life essentially varies and can be much less then the - a-Y. Besides, the improvement treatment of welded joints made from steels and alloys of different strength is earned out by ultrasonic impact instrument in zones of stress concentrations - weld toe by creating a so called "groove" with the width 2-7 mm and the depth from 0.2 up to 1.0 mm.
The proposed method allows selecting the parameters of high-frequency peering of welded joints depending on mechanical properties of material, type of welded element and stress con-centration factor, parameters of cyclic loading and other factors. For achievement of the maxi-mum increase of the fatigue strength of welded joints there is no need to introduce of compres-sive residual stresses equal to (1.2 - I.S) ~~Y. Due to the process of relaxation of residual stresses under the action of external loading the induced compressive residual stresses that provide the maximum possible increase in fatigue strength of welded elements could be significantly lower than the yield strength of material.
The so called normalized value of residual compressive stresses in the stress concentration zone, depending on the mechanical properties of material, type of welded element and stress concen-tration factor, parameters of cyclic loading is determined according to the following relationship (Y. Trufyakov, P. Mikheev and Y. Kudryavtsev. Fatigue strength of Welded Structures. Residual Stresses and Strengthening Treatments. Harwood Academic Publishers GmbH. 1995.
100 p.):
2a,aRa aS + o-'''' ores sY + (2) (1-Ra aQaa +2 t~Vhere CSYes is the normalized compressive residual stresses, at which the minimum stresses in the stress concentration zone during the cyclic loading reaches the yield stress of material - ~,:, 6's is ultimate strength of material; (xQ is a stress concentration factor; RQ
is a stress ratio; a a is a limit stress amplitude of welded joint in as-welded condition (with high tensile residual stresses).
The high-frequency peening is applied to all types of welded elements not to the zones with the width of 3-15 mrn as in other known prototypes of present invention, but only to the weld toe zone - the zone with maximum stress concentration. The width of the treated zone is usually 2-5 mm. 'The width depends mainly on the diameter of striking tools. The zone of treatment - weld toe in as-welded condition is characterized by maximum level of harmful tensile residual stresses and high stress concentration. The improvement treatment of wider zone does not provide any beneficial effect for fatigue life improvement and increases the time of treatment only.
The parameters of improvement treatment: vibration amplitude of ultrasonic horn, size and num-ber of striking tools, speed of treatment, force of pressing of the instrument to the treated element are selected to provide a necessary level of induced compressive residual stresses. At the same time, the so-called groove after treatment has practically the same geometrical parameters:
2-5 mm in width and depth from 0,2 mm to 1 mm. The geometrical parameters of a groove are correlated with the level of residual stresses. Therefore the evaluation of these geometrical pa-rameters and visual inspection of a groove considerably simplify quality control and estimation of the sufficient number of time for optimum treatment of welded elements.
The inducing of normalized values of residual compressive stresses 6pes provides the maximum possible increase of fatigue strength of welded joints. From the other side, such approach allows essentially decreasing the time of treatment and vibration amplitude of ultrasonic horn. It leads to lowering labor and energy consumption as well as the cost of equipment for high-frequency peemng.
Figure 1 represents the relationship between the normalized compressive residual stresses ayes and stress ratio of cyclic loading for butt joint made from steels of different grade of strength:
low-carbon steels - 6Y ~ 300 MPa (1), low alloy steels - cr,. ~ 400 MPa (2), high strength steels -c~'Y ~ b00 MPa {3). Figure 2 shows the same relationship between ayes and Rb for steeds of dif ferent strength grades (1 - low-carbon steel, 2 - low alloy, 3 - high-tensile steel) for a fillet welded joint. The presented data shows the effect of stress ratio on the optimum value of com-pressive residual stresses that should be induced by high frequency peeving in the zones of stress concentrations along the weld toe zone. These optimum residual stresses provide the maximum possible increasing of the limit stress range and fatigue life of welded joints. As can be seen from Fig. 1 and Fig. 2 the Levels of optimum residual stresses to be induced by high-frequency peev-ing, can be much lower than the yield stress csY of considered material and could be as low as O.Scs',. of considered material. Only at Ro = 0 the level of these residual stresses is equal to 6'Y.
The data an optimum level of compressive residual stresses far different structural materials, types of welded joints are calculated with the help of computation and are used during the high-frequency peeving.
Realization of the proposed method of high-frequency peeving of welded joints of metallic structures is based, first of all, on computation of normalized compressive residual stresses ores' which are required for maximum possible increasing of fatigue life.
After computation of csres it is necessary to select the parameters of improvement treatment by setting the parameters of the ultrasonic generator and the piezoceramic or magneto-strictive transducer. The vibrations of the transducer are transformed to high-frequency impacts of special strikers - pins. Depending on the mechanical properties of the material, the power of ultrasonic equipment is selected in the range 0.25. . .1.0 kW, the amplitude of ultrasonic horn - 20 - 35 microns, the diameter of peens -2 - 7 mm. The power and the amplitude are in direct proportion to the a'5..
The diameter of peens must be larger for materials with lower mechanical properties. The basic parameters of im-provement treatment are: d - the diameter of pins, n -the quantity of pins, R -the radius of the tip of the pin, Q = TlL - the treatment intensity, where L is the length of the weld and T is the time of treatment, A - the amplitude of ultrasonic oscillations of the horn tip, FSt - the force applied to the transducer during the treatment, V - the advancement velocity of the instrument along the weld. Usually, Fst is equal to 40-SO N and it is a constant parameter for a specific application.
The optimization of high frequency peering parameters is earned out on samples of welded ele ments with the purpose to reach the predetermined value of residual stresses, GIs in the short res est possible time. These residual stresses could be measured by different techniques such as X
ray, ultrasonic or other non-destructive methods. After determination of the optimum treatment time, the geometrical parameters of the treated weld groove are measured.
Width and depth of the groove are correlated to the degree of plastic deformation and the residual stresses als . The yes high-frequency peeving of real welded elements is performed using the parameters that were predetermined during the above-mentioned procedure.
Example. Vt~elded specimens made of steel having medium mechanical properties (for example steel 1 SOANIA) are selected for high frequency peering. The optimum value of residual stresses als is calculated in accordance with the relationship (2). The parameter a'ls for a butt res res welded joint at symmetric loading cycle and a stress ratio R = - 1 is equal to 180 MPa. The pa rameter Yes could be determined also with the help of curves presented in Figure 1. 'Then, the oscillation amplitude of the tip of the transducer is selected as A = 25 microns. The pins are se lected with the following parameters: the diameter d = 3 mm, number of pins, n = 4, the radius of the tip, R = 3 mm. The advancement rate of the instrument during treatment, Y
= 1 m/minute.
The length of the weld to be treated is chosen as L = 0.28 m. The improvement treatment along the weld toe is performed in a few passes with the advancement rate V and with intermediate measurements of residual stresses 61s . When the measured value of 6ls coincides with the res res predetermined value or exceeds it by 5-10 %, the treatment is considered complete and the time of treatment Uis registered.
In the presented example O= 1.12 minutes and the treatment intensity of the considered sample is Q = 4 minute/m. Further, the welded elements of the whale structure are treated with the above-mentioned treatment intensity. After the high frequency peering, a weld groove with the width b ~ 3ii and depth h ~O.Sii is produced along the weld toe line. The uniformity and quality of treatment is verified by visual survey. In areas with insufficient width or depth of the groove or visible weld defect, the treatment is repeated, if necessary.
Samples in as-welded condition and after high-frequency peering were tested in a fatigue testing machine ZDM-10 with the following parameters: stress ratio Ro = -l, frequency 12 Hz, maxi-mum level of cyclic stresses 0.25~o's (mss - ultimate strength of material).
The fatigue life of the considered welded element in as-welded condition, when averaged through a number of samples, was 105 cycles of loading and after application of improvement treatment - 7~
I OS cycles. The ap-plication of high-frequency peeving increased the fatigue life of welded samples seven times.
The technical and economical efficiency of the proposed method is determined by a significant increase in fatigue life of the welded elements with the simultaneous optimization of process of high-frequency peering of welds due to lowering of the time of treatment and power consump-tion.
The Formula of the Invention 1. A method of improvement treatment of welded joints of metallic structures by high-frequency peering that uses the effect of application of an ultrasonic impact device with determined oscil lation amplitude of the horn tip in the zone of the weld. The proposed method differs from other ones by followings parameters: the treatment is performed in stress concentration zones of welds which are located along the transition line from weld to base metal - weld toe, by inducing the predetermined level of compressive residual stresses 6'1s providing that the minimum cyclic res
Where f is the frequency of impact impulses, m is the weight of deforming element, ~Y is the yield strength of the considered material, R is the radius of pin's tip. For welded structures made from low-carbon steel the treatment is performed in the zone restricted by line on the primary recrystallization. In welded structures from alloyed and high-strength steels the treatment is per-formed in the zone restricted by the line on the low tempering. As an optimum value of induced residual compressive stresses the values of the 1.2 - 1.5 of the yield strength of material in sur-face layer with thickness of 0.1 - 0.2 mm and the total depth of the of the compressive residual stresses equals to 1.0 - 1.2 mm are accepted. 'The level of residual stresses is achieved by the using of the parameters of treatment chosen from the relation (1). The value of amplitude A is also evaluated from relation (1). This amplitude can be generated by ultrasonic equipment with different power, but the range of optimum power is not specified in the proposed earlier method.
The main disadvantage of the above-mentioned method is that the treatment of welded joints of different steels should be made in zones restricted by isothermal curves or low tempering. These parameters should be determined experimentally. At the same time, normalized on value and character of distribution of the compressive residual stresses are assumed by such, which are equal to their maximum achievable values exceeding a yield strength of material in 1.2 - 1.5 times. However, the conditions of in-service cyclic loading such as stress range, stress ratio and stress concentration caused by joint configuration and other factors that essentially effect the fa-tigue strength of welded joints and a degree of the influence of residual stresses on the fatigue life are not taken into account. 'The normalized value of residual compressive stresses, created by ultrasonic impact treatment, in zones of stress concentrators leading to the maximum possible increase of the limit stress range and fatigue life of welded joint should be determined differen-tially, i.e. depending on above mentioned factors.
The value of these beneficial compressive residual stresses depends under other equal conditions on the treatment time of considered element or productivity of treatment. But in the known method the amplitude A is determined from the relation ( 1 ) where the treatment time is not pres-ent. The absence of this parameter does not allow providing the recommendations concerning parameters of treatment in terms of optimum application of welded elements.
The above-mentioned disadvantages do not allow the selection of unique technological parameters of treat-ment for the considered welded element made from different materials.
The important problem in improvement of ultrasonic impact technology or high frequency peering is the optimization of the technological parameters of treatment by criteria of induced residual compressive stresses in the zones of stress concentrators. Thus it is necessary to deter-mine the values of normalized residual compressive stresses for metals with different strength to ensure the maximum possible increase of limit stress range and fatigue life of welded joints of different types. Besides, it is necessary to create the simplified algorithm for the estimation of the optimum parameters of improvement treatment of welded joint without performing of compli-cated preliminary experimental investigations.
The improvement of method of treatment of welded joints of metallic structures made from steels and alloys by high-frequency peering is a subject of present invention.
The method in-cludes the action of the ultrasonic impact instrument in zones of stress concentration located along the weld toe zone. The beneficial effect is achieved by relieving of harmful tensile residual stresses and introducing of beneficial compressive residual stresses normalized on value, at which the minimum stresses of loading cycle achieve a yield stress - csy of material in the zones of stress concentration. Depending on stress ratio, type of joint and stress concentration factor, mechanical properties of material the value of compressive residual stresses which are necessary for realization of maximum increase of fatigue life essentially varies and can be much less then the - a-Y. Besides, the improvement treatment of welded joints made from steels and alloys of different strength is earned out by ultrasonic impact instrument in zones of stress concentrations - weld toe by creating a so called "groove" with the width 2-7 mm and the depth from 0.2 up to 1.0 mm.
The proposed method allows selecting the parameters of high-frequency peering of welded joints depending on mechanical properties of material, type of welded element and stress con-centration factor, parameters of cyclic loading and other factors. For achievement of the maxi-mum increase of the fatigue strength of welded joints there is no need to introduce of compres-sive residual stresses equal to (1.2 - I.S) ~~Y. Due to the process of relaxation of residual stresses under the action of external loading the induced compressive residual stresses that provide the maximum possible increase in fatigue strength of welded elements could be significantly lower than the yield strength of material.
The so called normalized value of residual compressive stresses in the stress concentration zone, depending on the mechanical properties of material, type of welded element and stress concen-tration factor, parameters of cyclic loading is determined according to the following relationship (Y. Trufyakov, P. Mikheev and Y. Kudryavtsev. Fatigue strength of Welded Structures. Residual Stresses and Strengthening Treatments. Harwood Academic Publishers GmbH. 1995.
100 p.):
2a,aRa aS + o-'''' ores sY + (2) (1-Ra aQaa +2 t~Vhere CSYes is the normalized compressive residual stresses, at which the minimum stresses in the stress concentration zone during the cyclic loading reaches the yield stress of material - ~,:, 6's is ultimate strength of material; (xQ is a stress concentration factor; RQ
is a stress ratio; a a is a limit stress amplitude of welded joint in as-welded condition (with high tensile residual stresses).
The high-frequency peening is applied to all types of welded elements not to the zones with the width of 3-15 mrn as in other known prototypes of present invention, but only to the weld toe zone - the zone with maximum stress concentration. The width of the treated zone is usually 2-5 mm. 'The width depends mainly on the diameter of striking tools. The zone of treatment - weld toe in as-welded condition is characterized by maximum level of harmful tensile residual stresses and high stress concentration. The improvement treatment of wider zone does not provide any beneficial effect for fatigue life improvement and increases the time of treatment only.
The parameters of improvement treatment: vibration amplitude of ultrasonic horn, size and num-ber of striking tools, speed of treatment, force of pressing of the instrument to the treated element are selected to provide a necessary level of induced compressive residual stresses. At the same time, the so-called groove after treatment has practically the same geometrical parameters:
2-5 mm in width and depth from 0,2 mm to 1 mm. The geometrical parameters of a groove are correlated with the level of residual stresses. Therefore the evaluation of these geometrical pa-rameters and visual inspection of a groove considerably simplify quality control and estimation of the sufficient number of time for optimum treatment of welded elements.
The inducing of normalized values of residual compressive stresses 6pes provides the maximum possible increase of fatigue strength of welded joints. From the other side, such approach allows essentially decreasing the time of treatment and vibration amplitude of ultrasonic horn. It leads to lowering labor and energy consumption as well as the cost of equipment for high-frequency peemng.
Figure 1 represents the relationship between the normalized compressive residual stresses ayes and stress ratio of cyclic loading for butt joint made from steels of different grade of strength:
low-carbon steels - 6Y ~ 300 MPa (1), low alloy steels - cr,. ~ 400 MPa (2), high strength steels -c~'Y ~ b00 MPa {3). Figure 2 shows the same relationship between ayes and Rb for steeds of dif ferent strength grades (1 - low-carbon steel, 2 - low alloy, 3 - high-tensile steel) for a fillet welded joint. The presented data shows the effect of stress ratio on the optimum value of com-pressive residual stresses that should be induced by high frequency peeving in the zones of stress concentrations along the weld toe zone. These optimum residual stresses provide the maximum possible increasing of the limit stress range and fatigue life of welded joints. As can be seen from Fig. 1 and Fig. 2 the Levels of optimum residual stresses to be induced by high-frequency peev-ing, can be much lower than the yield stress csY of considered material and could be as low as O.Scs',. of considered material. Only at Ro = 0 the level of these residual stresses is equal to 6'Y.
The data an optimum level of compressive residual stresses far different structural materials, types of welded joints are calculated with the help of computation and are used during the high-frequency peeving.
Realization of the proposed method of high-frequency peeving of welded joints of metallic structures is based, first of all, on computation of normalized compressive residual stresses ores' which are required for maximum possible increasing of fatigue life.
After computation of csres it is necessary to select the parameters of improvement treatment by setting the parameters of the ultrasonic generator and the piezoceramic or magneto-strictive transducer. The vibrations of the transducer are transformed to high-frequency impacts of special strikers - pins. Depending on the mechanical properties of the material, the power of ultrasonic equipment is selected in the range 0.25. . .1.0 kW, the amplitude of ultrasonic horn - 20 - 35 microns, the diameter of peens -2 - 7 mm. The power and the amplitude are in direct proportion to the a'5..
The diameter of peens must be larger for materials with lower mechanical properties. The basic parameters of im-provement treatment are: d - the diameter of pins, n -the quantity of pins, R -the radius of the tip of the pin, Q = TlL - the treatment intensity, where L is the length of the weld and T is the time of treatment, A - the amplitude of ultrasonic oscillations of the horn tip, FSt - the force applied to the transducer during the treatment, V - the advancement velocity of the instrument along the weld. Usually, Fst is equal to 40-SO N and it is a constant parameter for a specific application.
The optimization of high frequency peering parameters is earned out on samples of welded ele ments with the purpose to reach the predetermined value of residual stresses, GIs in the short res est possible time. These residual stresses could be measured by different techniques such as X
ray, ultrasonic or other non-destructive methods. After determination of the optimum treatment time, the geometrical parameters of the treated weld groove are measured.
Width and depth of the groove are correlated to the degree of plastic deformation and the residual stresses als . The yes high-frequency peeving of real welded elements is performed using the parameters that were predetermined during the above-mentioned procedure.
Example. Vt~elded specimens made of steel having medium mechanical properties (for example steel 1 SOANIA) are selected for high frequency peering. The optimum value of residual stresses als is calculated in accordance with the relationship (2). The parameter a'ls for a butt res res welded joint at symmetric loading cycle and a stress ratio R = - 1 is equal to 180 MPa. The pa rameter Yes could be determined also with the help of curves presented in Figure 1. 'Then, the oscillation amplitude of the tip of the transducer is selected as A = 25 microns. The pins are se lected with the following parameters: the diameter d = 3 mm, number of pins, n = 4, the radius of the tip, R = 3 mm. The advancement rate of the instrument during treatment, Y
= 1 m/minute.
The length of the weld to be treated is chosen as L = 0.28 m. The improvement treatment along the weld toe is performed in a few passes with the advancement rate V and with intermediate measurements of residual stresses 61s . When the measured value of 6ls coincides with the res res predetermined value or exceeds it by 5-10 %, the treatment is considered complete and the time of treatment Uis registered.
In the presented example O= 1.12 minutes and the treatment intensity of the considered sample is Q = 4 minute/m. Further, the welded elements of the whale structure are treated with the above-mentioned treatment intensity. After the high frequency peering, a weld groove with the width b ~ 3ii and depth h ~O.Sii is produced along the weld toe line. The uniformity and quality of treatment is verified by visual survey. In areas with insufficient width or depth of the groove or visible weld defect, the treatment is repeated, if necessary.
Samples in as-welded condition and after high-frequency peering were tested in a fatigue testing machine ZDM-10 with the following parameters: stress ratio Ro = -l, frequency 12 Hz, maxi-mum level of cyclic stresses 0.25~o's (mss - ultimate strength of material).
The fatigue life of the considered welded element in as-welded condition, when averaged through a number of samples, was 105 cycles of loading and after application of improvement treatment - 7~
I OS cycles. The ap-plication of high-frequency peeving increased the fatigue life of welded samples seven times.
The technical and economical efficiency of the proposed method is determined by a significant increase in fatigue life of the welded elements with the simultaneous optimization of process of high-frequency peering of welds due to lowering of the time of treatment and power consump-tion.
The Formula of the Invention 1. A method of improvement treatment of welded joints of metallic structures by high-frequency peering that uses the effect of application of an ultrasonic impact device with determined oscil lation amplitude of the horn tip in the zone of the weld. The proposed method differs from other ones by followings parameters: the treatment is performed in stress concentration zones of welds which are located along the transition line from weld to base metal - weld toe, by inducing the predetermined level of compressive residual stresses 6'1s providing that the minimum cyclic res
Claims (2)
1. A method of improvement treatment of welded joints of metallic structures by high-frequency peening that uses the effect of application of an ultrasonic impact device with determined oscil-lation amplitude of the horn tip in the zone of the weld. The proposed method differs from other ones by followings parameters: the treatment is performed in stress concentration zones of welds which are located along the transition line from weld to base metal - weld toe, by inducing the predetermined level of compressive residual stresses providing that the minimum cyclic stresses in the stress concentration zone during the loading reach the yield stress of the material .sigma.y . The required value of is calculated, depending on the stress ratio, the type of welded joint, the stress concentration factor and the mechanical properties of the material, by using the following expression:
where, is the normalized compressive residual stress at which the minimum cyclic stresses from external loading in the stress concentration zone achieve the yield strength of the material;
.sigma.y. is the yield strength of the material, .sigma.s is the ultimate strength of the material; .alpha..sigma. is the stress concentration factor; R.sigma. is the stress ratio; .sigma.~ is the limit stress amplitude of welded joint in as-welded condition with high tensile residual stresses
where, is the normalized compressive residual stress at which the minimum cyclic stresses from external loading in the stress concentration zone achieve the yield strength of the material;
.sigma.y. is the yield strength of the material, .sigma.s is the ultimate strength of the material; .alpha..sigma. is the stress concentration factor; R.sigma. is the stress ratio; .sigma.~ is the limit stress amplitude of welded joint in as-welded condition with high tensile residual stresses
2. A method as described in claim 1 that differs by the fact that in welded structures made from steel and alloys of different strength during the high-frequency peening due to plastic deforma-tion of metal the groove of width 2 - 7 mm and depth 0.2 - 1 mm is formed, with the geometrical parameters that depend on treatment parameters and are connected with the value of for selected material and type of welded element.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| UA2001064020 | 2001-06-12 | ||
| UA2001064020 | 2001-06-12 | ||
| PCT/UA2002/000025 WO2002101097A1 (en) | 2001-06-12 | 2002-06-11 | Method for processing welded metalwork joints by high-frequency hummering |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2450369A1 true CA2450369A1 (en) | 2002-12-19 |
Family
ID=33488715
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002450369A Abandoned CA2450369A1 (en) | 2001-06-12 | 2002-06-11 | Method for processing welded metalwork joints by high-frequency hummering |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20040244882A1 (en) |
| EP (1) | EP1447455A4 (en) |
| CA (1) | CA2450369A1 (en) |
| WO (1) | WO2002101097A1 (en) |
Families Citing this family (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6338765B1 (en) | 1998-09-03 | 2002-01-15 | Uit, L.L.C. | Ultrasonic impact methods for treatment of welded structures |
| US20050145306A1 (en) * | 1998-09-03 | 2005-07-07 | Uit, L.L.C. Company | Welded joints with new properties and provision of such properties by ultrasonic impact treatment |
| US20060016858A1 (en) * | 1998-09-03 | 2006-01-26 | U.I.T., Llc | Method of improving quality and reliability of welded rail joint properties by ultrasonic impact treatment |
| US6932876B1 (en) | 1998-09-03 | 2005-08-23 | U.I.T., L.L.C. | Ultrasonic impact machining of body surfaces to correct defects and strengthen work surfaces |
| JP4537649B2 (en) * | 2002-10-08 | 2010-09-01 | 新日本製鐵株式会社 | Rotating welded joint, manufacturing method of Rotated welded joint, and welded structure |
| JP2005192194A (en) * | 2003-12-05 | 2005-07-14 | Yazaki Corp | Communication apparatus and communication system |
| US7301123B2 (en) * | 2004-04-29 | 2007-11-27 | U.I.T., L.L.C. | Method for modifying or producing materials and joints with specific properties by generating and applying adaptive impulses a normalizing energy thereof and pauses therebetween |
| US7276824B2 (en) * | 2005-08-19 | 2007-10-02 | U.I.T., L.L.C. | Oscillating system and tool for ultrasonic impact treatment |
| US20070068605A1 (en) * | 2005-09-23 | 2007-03-29 | U.I.T., Llc | Method of metal performance improvement and protection against degradation and suppression thereof by ultrasonic impact |
| ES2338809T3 (en) * | 2005-10-12 | 2010-05-12 | Palfinger Ag | CRANE WITH REINFORCEMENT SHEET. |
| US20070244595A1 (en) * | 2006-04-18 | 2007-10-18 | U.I.T., Llc | Method and means for ultrasonic impact machining of surfaces of machine components |
| AU2008274933B2 (en) * | 2007-07-11 | 2012-03-08 | Ravenbrick, Llc | Thermally switched reflective optical shutter |
| CN102187262B (en) | 2008-08-20 | 2013-06-19 | 雷文布里克有限责任公司 | Methods for fabricating thermochromic filters |
| CN106191422B (en) * | 2016-07-11 | 2017-12-01 | 广东工业大学 | Automobile booster cast aluminium alloy gold impeller strengthens the method and apparatus lengthened the life |
| CA3052815C (en) | 2017-02-13 | 2021-11-23 | Webco Industries, Inc. | Work hardened welds and methods for same |
| US11339900B2 (en) | 2017-02-13 | 2022-05-24 | Webco Industries, Inc. | Work hardened welds and methods for same |
| CN110955950B (en) * | 2018-09-25 | 2022-08-30 | 湖南工业大学 | Method for predicting fatigue life of weld joint under any stress ratio based on dissipated energy |
| CN111198547B (en) * | 2020-01-15 | 2020-12-29 | 重庆大学 | Self-feedback control method and system for coordinated optimization of flatness and residual stress of accumulated material |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| SU130528A1 (en) * | 1960-01-19 | 1960-11-30 | Б.И. Лазарев | The method of increasing the strength of welded joints of forged austenitic steels |
| FR2444719A1 (en) * | 1978-12-18 | 1980-07-18 | Alsthom Atlantique | PROCESS FOR TREATING A WALL IN AUSTENITIC STAINLESS STEEL AND PERCUSSION APPARATUS FOR APPLYING THIS PROCESS |
| JPS58107292A (en) * | 1981-12-21 | 1983-06-25 | Kawasaki Heavy Ind Ltd | Method and device for treating welded joint part of pipe |
| SU1118509A1 (en) * | 1983-06-30 | 1984-10-15 | Предприятие П/Я М-5671 | Method of straightening welded sheet constructions |
| SU1481044A2 (en) * | 1987-09-28 | 1989-05-23 | Институт Электросварки Им.Е.О.Патона | Method of burnishing metal surfaces |
| JP3002229B2 (en) * | 1990-05-14 | 2000-01-24 | 川崎製鉄株式会社 | Method for improving the fatigue strength of welded joints |
| US6171415B1 (en) * | 1998-09-03 | 2001-01-09 | Uit, Llc | Ultrasonic impact methods for treatment of welded structures |
| US6338765B1 (en) * | 1998-09-03 | 2002-01-15 | Uit, L.L.C. | Ultrasonic impact methods for treatment of welded structures |
| US6932876B1 (en) * | 1998-09-03 | 2005-08-23 | U.I.T., L.L.C. | Ultrasonic impact machining of body surfaces to correct defects and strengthen work surfaces |
| US6467321B2 (en) * | 2000-05-30 | 2002-10-22 | Integrity Testing Laboratory, Inc. | Device for ultrasonic peening of metals |
| US6993948B2 (en) * | 2003-06-13 | 2006-02-07 | General Electric Company | Methods for altering residual stresses using mechanically induced liquid cavitation |
-
2002
- 2002-06-11 WO PCT/UA2002/000025 patent/WO2002101097A1/en not_active Application Discontinuation
- 2002-06-11 CA CA002450369A patent/CA2450369A1/en not_active Abandoned
- 2002-06-11 EP EP02756067A patent/EP1447455A4/en not_active Withdrawn
- 2002-06-11 US US10/480,478 patent/US20040244882A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20040244882A1 (en) | 2004-12-09 |
| EP1447455A4 (en) | 2006-08-23 |
| WO2002101097A1 (en) | 2002-12-19 |
| EP1447455A1 (en) | 2004-08-18 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2450369A1 (en) | Method for processing welded metalwork joints by high-frequency hummering | |
| Malaki et al. | A review of ultrasonic peening treatment | |
| US6843957B2 (en) | Ultrasonic impact methods for treatment of welded structures | |
| Kudryavtsev et al. | Fatigue improvement of welded elements and structures by ultrasonic peening | |
| Qutaba et al. | A review on peening processes and its effect on surfaces | |
| JP2003113418A (en) | Method for improving fatigue life and long-life metal material | |
| US20050230010A1 (en) | Treatment method for improving fatigue life and long-life metal material treated by using same treatment | |
| Roy et al. | Enhancing fatigue strength by ultrasonic impact treatment | |
| Yamaguchi et al. | Micro-needle peening method to improve fatigue strength of arc-welded ultra-high strength steel joints | |
| Lihavainen et al. | Fatigue strength of a longitudinal attachment improved by ultrasonic impact treatment | |
| JP3965106B2 (en) | Girder structure reinforcement method | |
| JP3793501B2 (en) | Rail reinforcement and repair method | |
| Kudryavtsev et al. | Fatigue life improvement of tubular welded joints by ultrasonic peening | |
| Knysh et al. | Influence of the atmosphere corrosion on the fatigue life of welded T-joints treated by high frequency mechanical impact | |
| Gao et al. | Fatigue-performance of PWHT welded joints: As-welded vs. high-frequency mechanical impact treatment | |
| JP4537622B2 (en) | Steel tube column base and method for strengthening steel tube column base | |
| JP4351433B2 (en) | Iron structure products having excellent resistance to liquid metal embrittlement and methods for producing the same | |
| Statnikov et al. | Technology of ultrasound impact treatment as a means of improving the reliability and endurance of welded metal structures | |
| Nitschke-Pagel et al. | Residual stresses and near-surface material condition of welded high strength steels after different mechanical post-weld treatments | |
| Muller et al. | The Influence of Shot Peening on the Fatigue and Corrosion Fatigue Behavior of an Austentic-Ferritic Stainless Steel | |
| Rodriguez-Sanchez et al. | Shot peening effect on fatigue crack repaired weldments | |
| Tateishi et al. | Improvement of extremely low cycle fatigue strength of welded joints by toe finishing | |
| RU2185449C2 (en) | Steel corrosion preventive method | |
| Kleiman et al. | The Effectiveness of Ultrasonic Peening Improvement Treatment in Maintenance and Repair of Bridges | |
| Illés et al. | Post-treatment of welding joints of high strength steels II.: Improving residual stress condition–Overview |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |