Investigation of Optimal Parameter Settings in Super Duplex Welding

Authors: R. M. Chandima Ratnayake, Daniel Dyakov

Abstract:

Super steel materials play a vital role in the construction and fabrication of structural, piping and pipeline components. In assuring the integrity of onshore and offshore operating systems, they enable life cycle costs to be minimized. In this context, Duplex stainless steel (DSS) material related welding on constructions and fabrications plays a significant role in maintaining and assuring integrity at an optimal expenditure over the life cycle of production and process systems as well as associated structures. In DSS welding, factors such as gap geometry, shielding gas supply rate, welding current, and type of the welding process are vital to the final joint performance. Hence, an experimental investigation has been performed using an engineering robust design approach (ERDA) to investigate the optimal settings that generate optimal super DSS (i.e. UNS S32750) joint performance. This manuscript illustrates the mathematical approach and experimental design, optimal parameter settings and results of the verification experiment.

Keywords: Duplex stainless steel welding, engineering robust design, mathematical framework, optimal parameter settings.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1106951

References:

[1] HSE, “Chloride stress corrosion cracking in austenitic stainless steel: assessing susceptibility and structural integrity,” Health and Safety Laboratory, Health and Safety Executive, 2011, http://www.hse.gov.uk/ research/rrpdf/rr902.pdf (accessed on 29.12.2014).
[2] R. M. C. Ratnayake, “An algorithm to prioritize welding quality deterioration factors: A case study from a piping component fabrication process,” Int. J. Qual. Reliab. Manag., vol. 30, no. 6, pp. 616–638, 2013.
[3] J. Xu, L. Chen, C. Ni, “Effect of vibratory weld conditioning on the residual stresses and distortion in multipass girth-butt welded pipes,” Int. J. Pres. Ves. Pip., vol. 84, no. 5, pp. 298–303, 2007.
[4] P. Sathiya, M. Y. Abdul Jaleel, “Grey-based taguchi method for optimization of bead geometry in laser bead-on-plate welding,” Adv. Prod. Eng. Manag., vol. 5, no. 4, pp. 225–234, 2010. http://maja.uni-mb.si/files/apem/APEM5-4_225-234.pdf (accessed on 01.09.2013).
[5] R.M.C. Ratnayake, "A methodology for assessing most vulnerable welding procedure specifications and imperfection factors," Int. J. of Data Anal. Techniques and Strategies, vol. 6, no. 4, pp. 362–383, 2014. http://www.inderscience.com/info/ingeneral/forthcoming.php?jcode =ijdats (accessed on 29.12.2014).
[6] J. Mirapeix, P. B. García-Allende, A. Cobo, O. M. Conde, and López-J. M. Higuera, “Real-time arc-welding defect detection and classification with principal component analysis and artificial neural networks,” NDT & E Int., vol. 40, no. 4, pp. 315–323, 2007.
[7] R. M. C. Ratnayake, “A mathematical framework for parameter designing under the noise: A case study from a conventional turning machine,” Proc. IEEE Int. Conf. Industrial Engineering and Engineering Management, DOI: 10.1109/IEEM.2013.6962420, 2013, pp. 290–294.
[8] M. S. Phadke, Quality Engineering using Robust Design. Englewood Cliffs, New Jersey: PTR Prentice-Hall, Inc., 1989.
[9] R. Unal, “Taguchi approach to design optimization for quality and cost: an overview,” Ann. Conf. International Society of Parametric Analysts, 1991. ftp://ns1.ystp.ac.ir/ystp/ 1/1/ROOT/DATA/ PDF/INNOVATION/ conf-13-ispa-unal+dean.pdf (accessed on 04.04.2013).
[10] S. Kamaruddin, A. Zahid Khan, and S. H. Foong, “Application of Taguchi method in the optimization of injection moulding parameters for manufacturing products from plastic blend,” IACSIT International Journal of Engineering Technology, vol. 2, no. 6, ISSN: 1793–8236, Dec. 2010.
[11] F. M. Pati, Study of Parametric Optimization of Microdrilling Operation using Taguchi Method, 2010. http://ethesis. nitrkl.ac.in/ 2066/ 1/PROJECT_REPORT4.docxnew1.pdf (accessed on 04.04.2013).
[12] G. Taguchi, and M. S. Phadke, “Quality engineering through design optimization,” Conf. Rec., GLOBECOM 84 Meeting, IEEE Communications Society, Atlanta, GA, November 1984.
[13] M. S. Phadke, “Optimization of product and process design for quality and cost,” Qual. Reliab. Eng. Int., vol. 4, no. 2, pp. 105–112, 1988.
[14] J. C. Lippold, W. Lin, S. Brandi, I. Varol, W. A. Baeslack III, Proc.4th Int. Conf. Duplex Stainless Steels, Glasgow, Scotland, 1994 November 13–16, vol. 2, Paper 116.
[15] J. O. Nilsson, “Super duplex stainless steels,” Mater. Sci. Tech., vol. 8, pp. 685–700, 1992.
[16] The International Molybdenum Association (IMOA), Practical Guidelines for the Fabrication of Duplex Stainless Steel. London, UK, 2009, pp. 1–64, ISBN 978-1-907470-00-4.
[17] W. A. Baeslack, W. F. Savage, and D. J. Duquette, “Effect of nitrogen on the microstructure and stress corrosion cracking of stainless steel weld metals,” Weld. Res. Supplement, pp. 83s–90s, 1979. http://www.aws.org/wj/supplement/WJ_1979_03_s83.pdf (accessed on 29.12.2014).
[18] TWI, “Duplex stainless steel - Part 22,” 2014, http://www.twiglobal. com/technical- knowledge/job-knowledge/duplex-stainless-steelpart- 2-106/ (accessed on 29.12.2014).
[19] R. Francis, Papers presented. Proc. 4th Int. Conf. Duplex Stainless Steels, Glasgow, Scotland, 13-16 November 1994, Abington Publ., 1995, vol. 2: Welding processes.
[20] Lincoln, Guidelines for welding Zeron 100 super duplex stainless steel, Lincoln Smitweld, http://www.lasgroepzuid.com/documenten/ Guidelines _Zeron.pdf (accessed on 29.12.2014).
[21] C. Daniel, Applications of Statistics to Industrial Experimentation. New York: John Wiley and Sons, 1976.
[22] F. Kolahan, M. Manoochehri, and A. Hosseini, “Application of Taguchi method and ANOVA analysis for simultaneous optimization of machining parameters and tool geometry in turning,” World Acad. Sci., Eng. Tech., vol. 74, pp. 82–85, 2011.
[23] F. Kolahan, M. Manoochehri, and A. Hosseini, “Simultaneous optimization of machining parameters and tool geometry specifications in turning operation of AISI1045 steel,” World Acad. Sci., Eng. Tech., vol. 50, pp. 785–788, 2011.
[24] S. Kumar, M. Gupta, P. S. Satsangi, and H. K. Sardana, “Modeling and analysis for surface roughness and material removal rate in machining of UD-GFRP using PCD tool,” Int. J. Eng. Sci. & Tech., vol. 3, no. 8, 2011, pp. 248–270.