Search results for: welding pipes

Authors: H. Shokouhmand, A. Ghanami

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Heat pipe is simple heat transfer device which combines the conduction and phase change phenomena to control the heat transfer without any need for external power source. At hot surface of heat pipe, the liquid phase absorbs heat and changes to vapor phase. The vapor phase flows to condenser region and with the loss of heat changes to liquid phase. Due to gravitational force the liquid phase flows to evaporator section.In HVAC systems the working fluid is chosen based on the operating temperature. The heat pipe has significant capability to reduce the humidity in HVAC systems. Each HVAC system which uses heater, humidifier or dryer is a suitable nominate for the utilization of heat pipes. Generally heat pipes have three main sections: condenser, adiabatic region and evaporator.Performance investigation and optimization of heat pipes operation in order to increase their efficiency is crucial. In present article, a parametric study is performed to improve the heat pipe performance. Therefore, the heat capacity of heat pipe with respect to geometrical and confining parameters is investigated. For the better observation of heat pipe operation in HVAC systems, a CFD simulation in Eulerian- Eulerian multiphase approach is also performed. The results show that heat pipe heat transfer capacity is higher for water as working fluid with the operating temperature of 340 K. It is also showed that the vertical orientation of heat pipe enhances it’s heat transfer capacity.

Keywords: heat pipe, HVAC system, grooved Heat pipe, heat pipe limits

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Authors: A. Ghanami, M.Heydari

Abstract:

Heat pipe is simple heat transfer device which combines the conduction and phase change phenomena to control the heat transfer without any need for external power source. At hot surface of heat pipe, the liquid phase absorbs heat and changes to vapor phase. The vapor phase flows to condenser region and with the loss of heat changes to liquid phase. Due to gravitational force the liquid phase flows to evaporator section. In HVAC systems the working fluid is chosen based on the operating temperature. The heat pipe has significant capability to reduce the humidity in HVAC systems. Each HVAC system which uses heater, humidifier or dryer is a suitable nominate for the utilization of heat pipes. Generally heat pipes have three main sections: condenser, adiabatic region and evaporator. Performance investigation and optimization of heat pipes operation in order to increase their efficiency is crucial. In present article, a parametric study is performed to improve the heat pipe performance. Therefore, the heat capacity of heat pipe with respect to geometrical and confining parameters is investigated. For the better observation of heat pipe operation in HVAC systems, a CFD simulation in Eulerian- Eulerian multiphase approach is also performed. The results show that heat pipe heat transfer capacity is higher for water as working fluid with the operating temperature of 340 K. It is also showed that the vertical orientation of heat pipe enhances it’s heat transfer capacity.used in the abstract.

Keywords: Heat pipe, HVAC system, Grooved Heat pipe, Heat pipe limits.

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Authors: T. Nakkeran, C. Dhamodharan, Win Myint Soe , Ramasamy Deverajan, M. Ganesh Babu

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This manuscript presents the results of an experimental investigation performed to study the material and mechanical properties of two weld joints fabricated within close proximity. The experiment was designed using welded S355 D Z35 with distances between two parallel adjacent weld toes at 8 mm. These distances were less than the distance that has normally been recommended in standards, codes, and specifications. The main idea of the analysis is to determine any significant effects when welding the joints with the close proximity of 8mm using the SAW welding process of the one joint with high heat put and one joint welded with the FCAW welding process and evaluating the destructing and nondestructive testing between the welded joints. Further, we have evaluated the joints with Mechanical Testing for evaluating by performing Tensile test, bend testing, Macrostructure, Microstructure, Hardness test, and Impact testing. After evaluating the final outcome of the result, no significant changes were observed for welding the close proximity of weld of 8mm distance between the joints as compared to the specification minimum distance between the weldments of any design should be 50mm.

Keywords: S355 carbon steel, weld proximity, SAW process, FCAW process, heat input, bend test, tensile test, hardness test, impact test, macro and microscopic examinations

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Authors: H. Li, W. Qin, Ben Ye

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Friction Push Plug Welding (FPPW) is a solid phase welding suitable for repairing defective welds and filling self-reacting weld keyholes in Friction Stir Welds. In FPPW process, a tapered shaped plug is rotated at high speed and forced into a tapered hole in the substrate. The plug and substrate metal is softened by the increasing temperature generated by friction and material plastic deformation. This paper aims to investigate the effect of process parameters on the quality of the weld. Orthogonal design methods were employed to reduce the amount of experiment. Three values were selected for each process parameter, rotation speed (1500r/min, 2000r/min, 2500r/min), plunge depth (2mm, 3mm, 4mm) and plunge speed (60mm/min, 90mm/min, 120r/min). AA6061aluminum alloy plug and substrate plate was used in the experiment. In a trial test with the plunge depth of 1mm, a noticeable defect appeared due to the short plunge time and insufficient temperature. From the recorded temperature profiles, it was found that the peak temperature increased with the increase of the rotation speed, plunge speed and plunge depth. In the initial stage, the plunge speed was the main factor affecting heat generation, while in the steady state welding stage, the rotation speed played a more important role. The FPPW weld defect includes flash and incomplete penetration in the upper, middle and bottom interface with the substrate. To obtain defect free weld, the higher rotation speed and proper plunge depth were recommended.

Keywords: friction push plug welding, process parameter, weld defect, orthogonal design

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Authors: Khaled Al-Badani, James Ren, Lisa Li, David Allanson

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Droplet formation is an important process in many engineering systems and manufacturing procedures, which includes welding, biotechnologies, 3D printing, biochemical, biomedical fields and many more. The volume and the characteristics of droplet formation are generally depended on various material properties, microfluidics and fluid mechanics considerations. Hence, a detailed investigation of this process, with the aid of numerical computational tools, are essential for future design optimization and process controls of many engineering systems. This will also improve the understanding of changes in the properties and the structures of materials, during the formation of the droplet, which is important for new material developments to achieve different functions, pending the requirements of the application. For example, the shape of the formed droplet is critical for the function of some final products, such as the welding nugget during Capacitor Discharge Welding process, or PLA 3D printing, etc. Although, most academic journals on droplet formation, focused on issued with material transfer rate, surface tension and residual stresses, the general emphasis on the characteristics of droplet shape has been overlooked. The proposed work for this project will examine theoretical methodologies, experimental techniques, and numerical modelling, using ANSYS FLUENT, to critically analyse and highlight optimization methods regarding the formation of pendant droplet. The project will also compare results from published data with experimental and numerical work, concerning the effects of key material parameters on the droplet shape. These effects include changes in heating/cooling rates, solidification/melting progression and separation/break-up times. From these tests, a set of objectives is prepared, with an intention of improving quality, stability and productivity in modelling metal welding and 3D printing.

Keywords: computer modelling, droplet formation, material distortion, materials forming, welding

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Authors: Bum Yean Cho, Heung-Youl Kim, Ki-Seok Kwon, Kang-Su Kim

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In this study, a full-scale test and analysis (numerical analysis) of fire resistance performance of bare CFT column on which slot was used instead of existing welding method to connect the steel pipe on the concrete-filled tube were conducted. Welded CFT column is known to be vulnerable to high or low temperature because of low brittleness of welding part. As a result of a fire resistance performance test of slot CFT column after removing the welding part and fixing it by a slot which was folded into the tube, slot type CFT column indicated the improved fire resistance performance than welded CFT column by 28% or more. And as a result of conducting finite element analysis of slot type column using ABAQUS, analysis result proved the reliability of the test result in predicting the fire behavior and fire resistance hour.

Keywords: CFT (concrete-filled tube) column, fire resistance performance, slot, weld

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Authors: Alireza Ghadiri, Soheila Memarzadeh, Arash Ghadiri

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Heat pipes are efficient heat transfer devices for solar hot water heating systems. However, the effective downward transfer of solar energy in an integrated heat pipe system provides increased design and implementation options. There is a lack of literature about flat plate wicked assisted heat pipe solar collector, especially with the presence of finned water-cooled condenser wicked heat pipes for solar energy applications. In this paper, the consequence of incorporating fins arrays into the condenser region of screen mesh heat pipe solar collector is investigated. An experimental model and a transient theoretical model are conducted to compare the performances of the solar heating system at a different period of the year. A good agreement is shown between the model and the experiment. Two working fluids are investigated (water and methanol) and results reveal that water slightly outperforms methanol with a collector instantaneous efficiency of nearly 60%. That modest improvement is achieved by adding fins to the condenser region of the heat pipes. Results show that the collector efficiency increase as the number of fins increases (upon certain number) and reveal that the mesh number is an important factor which affect the overall collector efficiency. An optimal heat pipe mesh number of 100 meshes/in. With two layers appears to be favorable in such collectors for their design and operating conditions.

Keywords: heat pipe, solar collector, capillary limit, mesh number

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Authors: S. Ramesh, A. S. Sasiraaju, K. Sidhaarth, N. Sudhan Rajkumar, V. Manivel Muralidaran

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This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: chromoly, gas metal arc weld (GMAW), hardness, multi pass weld, shielding gas composition

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Authors: Richard Molyneux, Christopher Parrott, Kirill Horoshenkov

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This paper aims to demonstrate how various algorithms can be implemented within swarms of autonomous robots to provide continuous inspection within underground pipeline networks. Current methods of fault detection within pipes are costly, time consuming and inefficient. As such, solutions tend toward a more reactive approach, repairing faults, as opposed to proactively seeking leaks and blockages. The paper presents an efficient inspection method, showing that autonomous swarm robotics is a viable way of monitoring underground infrastructure. Tailored adaptations of various Vehicle Routing Problems (VRP) and path-planning algorithms provide a customised inspection procedure for complicated networks of underground pipes. The performance of multiple algorithms is compared to determine their effectiveness and feasibility. Notable inspirations come from ant colonies and stigmergy, graph theory, the k-Chinese Postman Problem ( -CPP) and traffic theory. Unlike most swarm behaviours which rely on fast communication between agents, underground pipe networks are a highly challenging communication environment with extremely limited communication ranges. This is due to the extreme variability in the pipe conditions and relatively high attenuation of acoustic and radio waves with which robots would usually communicate. This paper illustrates how to optimise the inspection process and how to increase the frequency with which the robots pass each other, without compromising the routes they are able to take to cover the whole network.

Keywords: autonomous inspection, buried pipes, stigmergy, swarm intelligence, vehicle routing problem

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Authors: A. Kouadri-Henni, L. Barrallier

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The objective of the study was to characterize the properties of a magnesium alloy welded by friction stir welding (FSW). The results led to a better understanding of the relationship between this process, the microstructure and anisotropic properties of alloy materials. Welding principally leads to a large reduction in grain size in welded zones due to the phenomenon of dynamic recrystallization. The most remarkable observation was that crystallographic textures changed from a base metal with one texture in two zones: the thermo-mechanically affected and stir welded zones. The latter zone has the peculiarity of possessing a marked texture with two components on the basal plane and the pyramidal plane. These characteristics disappeared in the TMAZ, which had only one component following the basal plane. These modifications have been explained by the nature of the plastic deformation in these zones, which occurs at a moderate temperature in the TMAZ and high temperature in the SWZ. In the same time, we compared this evolution with the nature and the level of the residual stresses obtained by X-ray diffraction.

Keywords: texture christallography, residual stresses, FSW process

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Authors: Waqed H. Almohammed, Mohammed Y. Fattah, Sajjad E. Rasheed

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Dynamic traffic loads cause deformation of underground pipes, resulting in vehicle discomfort. This makes it necessary to reinforce the layers of soil above underground pipes. In this study, the subbase layer was reinforced. Finite element software (PLAXIS 3D) was used to in the simulation, which includes geocell reinforcement, vehicle loading, soil layers and Glass Fiber Reinforced Plastic (GRP) pipe. Geocell reinforcement was modeled using a geogrid element, which was defined as a slender structure element that has the ability to withstand axial stresses but not to resist bending. Geogrids cannot withstand compression but they can withstand tensile forces. Comparisons have been made between the numerical models and experimental works, and a good agreement was obtained. Using the mathematical model, the performance of three different pipes of diameter 600 mm, 800 mm, and 1000 mm, and three different vehicular speeds of 20 km/h, 40 km/h, and 60 km/h, was examined to determine their impact on surface settlement and vertical pressure at the pipe crown for two cases: with and without geocell reinforcement. The results showed that, for a pipe diameter of 600 mm under geocell reinforcement, surface settlement decreases by 94 % when the speed of the vehicle is 20 km/h and by 98% when the speed of the vehicle is 60 km/h. Vertical pressure decreases by 81 % when the diameter of the pipe is 600 mm, while the value decreases to 58 % for a pipe with diameter 1000 mm. The results show that geocell reinforcement causes a significant and positive reduction in surface settlement and vertical stress above the pipe crown, leading to an increase in pipe safety.

Keywords: dynamic loading, finite element, geocell-reinforcement, GRP pipe, PLAXIS 3D, surface settlement

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Authors: Ali Göksenli, Barlas Eryürek

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In this study, failure analysis of pipe system at a micro hydroelectric power plant is investigated. Failure occurred at the pipe system in the powerhouse during shut down operation of the water flow by a valve. This locking had caused a sudden shock wave, also called “Water-hammer effect”, resulting in noise and inside pressure increase. After visual investigation of the effect of the shock wave on the system, a circumference crack was observed at the pipe flange weld region. To establish the reason for crack formation, calculations of pressure and stress values at pipe, flange and welding seams were carried out and concluded that safety factor was high (2.2), indicating that no faulty design existed. By further analysis, pipe system and hydroelectric power plant was examined. After observations it is determined that the plant did not include a ventilation nozzle (air trap), that prevents the system of sudden pressure increase inside the pipes which is caused by water-hammer effect. Analyses were carried out to identify the influence of water-hammer effect on inside pressure increase and it was concluded that, according Jowkowsky’s equation, shut down time is effective on inside pressure increase. The valve closing time was uncertain but by a shut down time of even one minute, inside pressure would increase by 7.6 bar (working pressure was 34.6 bar). Detailed investigations were also carried out on the assembly of the pipe-flange system by considering technical drawings. It was concluded that the pipe-flange system was not installed according to the instructions. Two of five weld seams were not applied and one weld was carried out faulty. This incorrect and inadequate weld seams resulted in; insufficient connection of the pipe to the flange constituting a strong notch effect at weld seam regions, increase in stress values and the decrease of strength and safety factor

Keywords: failure analysis, hydroelectric plant, crack, shock wave, welding seam

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Authors: K. Subbaiah, C. V. Jeyakumar, S. R. Koteswara Rao

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Cast Aluminum-Magnesium-Scandium alloy was Gas Tungsten Arc (GTA) welded, and the microstructure and mechanical properties of the joint and its component parts were examined and analyzed. The global joint fractured in the base metal, and thus possessed slightly greater tensile strength than the base metal. These results clearly show that Gas Tungsten Arc welding is an optimum / suitable welding process for cast Aluminum-Magnesium-Scandium alloys.

Keywords: cast Al-Mg-Sc alloy, GTAW, microstructure, mechanical properties

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Authors: K. Vandenboer, L. Dolphen, A. Bezuijen

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Backward erosion piping is an important failure mechanism for water-retaining structures, a phenomenon that results in the formation of shallow pipes at the interface of a sandy or silty foundation and a cohesive cover layer. This paper studies the effect of two soil types on backward erosion piping; both in case of a homogeneous sand layer, and in a vertically layered sand sample, where the pipe is forced to subsequently grow through the different layers. Two configurations with vertical sand layers are tested; they both result in wider pipes and higher critical gradients, thereby making this an interesting topic in research on measures to prevent backward erosion piping failures.

Keywords: backward erosion piping, embankments, physical modeling, sand

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Authors: P. Mendes, H. Stel, R. E. M. Morales

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This article presents a numerical and experimental study of turbulent flow in corrugated pipes with helically “d-type" grooves, for Reynolds numbers between 7500 and 100,000. The ANSYS-CFX software is used to solve the RANS equations with the BSL two equation turbulence model, through the element-based finite-volume method approach. Different groove widths and helix angles are considered. Numerical results are validated with experimental pressure drop measurements for the friction factor. A correlation for the friction factor is also proposed considering the geometric parameters and Reynolds numbers evaluated.

Keywords: turbulent flow, corrugated pipe, helical, numerical, experimental, friction factor, correlation

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Authors: Dario Basile, Manuela De Maddis, Raffaella Sesana, Pasquale Russo Spena, Roberto Maiorano

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Nowadays, the reduction of CO₂ emissions and the decrease in energy consumption are the main aims of several industries, especially in the automotive sector. To comply with the increasingly restrictive regulations, the automotive industry is constantly looking for innovative techniques to produce lighter, more efficient, and less polluting vehicles. One of the latest technologies, and still developing, is based on the fabrication of the body-in-white and car parts through the stamping of Aluminum Tailor Welded Blanks. Tailor Welded Blanks (TWBs) are generally the combination of two/three metal sheets with different thicknesses and/or mechanical strengths, which are commonly butt-welded together by laser sources. The use of aluminum TWBs has several advantages such as low density and corrosion resistance adequate. However, their use is still limited by the lower formability with respect to the parent materials and the more intrinsic difficulty of laser welding of aluminum sheets (i.e., internal porosity) that, although its use in automated industries is constantly growing, remains a process to be further developed and improved. This study has investigated the effect of the main laser welding process parameters (laser power, welding speed, and focal distance) on the mechanical properties of aluminum TWBs made of 6xxx series. The research results show that a narrow weldability window can be found to ensure welded joints with high strength and limited or no porosity.

Keywords: aluminum sheets, automotive industry, laser welding, mechanical properties, tailor welded blanks

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Authors: A. Nait Salah, M. Kaddami

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This work describes an investigation on the effect of filler metals diameter to weld joint, and low alloy carbon steel A516 Grade 70 is the base metal. Commercially SA516 Grade70 is frequently used for the manufacturing of pressure vessels, boilers and storage tank, etc. In fabrication industry, the hardness of the weld joint is between the important parameters to check, after heat treatment of the weld. Submerged arc welding (SAW) is used with two filler metal diameters, and this solid wire electrode is used for SAW non-alloy and for fine grain steels (SFA 5.17). The different diameters were selected (Ø = 2.4 mm and Ø = 4 mm) to weld two specimens. Both specimens were subjected to the same preparation conditions, heat treatment, macrograph, metallurgy micrograph, and micro-hardness test. Samples show almost similar structure with highest hardness. It is important to indicate that the thickness used in the base metal is 22 mm, and all specifications, preparation and controls were according to the ASME section IX. It was observed that two different filler metal diameters performed on two similar specimens demonstrated that the mechanical property (hardness) increases with decreasing diameter. It means that even the heat treatment has the same effect with the same conditions, the filler metal diameter insures a depth weld penetration and better homogenization. Hence, the SAW welding technique mentioned in the present study is favorable to implicate for the industry using the small filler metal diameter.

Keywords: ASME, base metal, micro-hardness test, submerged arc welding

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Authors: N. H. Othman, N. Udin, M. Ishak, L. H. Shah

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This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.

Keywords: friction stir welding, magnesium AZ31, cylindrical taper tool, taper pin ratio

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Authors: Bharatkumar Doshi

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Electro-Magnetic Pulse Welding (EMPW) is a solid state welding process carried out at almost room temperature, in which joining is enabled by high impact velocity deformation. In this process, high voltage capacitor’s stored energy is discharged in an EM coil resulting in a damped, sinusoidal current with an amplitude of several hundred kiloamperes. Due to these transient magnetic fields of few tens of Tesla near the coil is generated. As the conductive (tube) part is positioned in this area, an opposing eddy current is induced in this part. Consequently, high Lorentz forces act on the part, leading to acceleration away from the coil. In case of a tube, it gets compressed under forming velocities of more than 300 meters per second. After passing the joining gap it collides with the second metallic joining rod, leading to the formation of a jet under appropriate collision conditions. Due to the prevailing high pressure, metallurgical bonding takes place. A characteristic feature is the wavy interface resulting from the heavy plastic deformations. In the process, the formation of intermetallic compounds which might deteriorate the weld strength can be avoided, even for metals with dissimilar thermal properties. In order to optimize the process parameters like current, voltage, inductance, coil dimensions, workpiece dimensions, air gap, impact velocity, effective plastic strain, shear stress acting in the welding zone/impact zone etc. are very critical and important to establish. These process parameters could be determined by simulation using Finite Element Methods (FEM) in which electromagnetic –structural couple field analysis is performed. The feasibility of welding could thus be investigated by varying the parameters in the simulation using COMSOL. Simulation results shall be applied in performing the preliminary experiments of welding the different alloy steel tubes and/or alloy steel to other materials. The single turn coil (S.S.304) with field shaper (copper) has been designed and manufactured. The preliminary experiments are performed using existing EMPW facility available Institute for Plasma Research, Gandhinagar, India. The experiments are performed at 22kV charged into 64µF capacitor bank and the energy is discharged into single turn EM coil. Welding of axi-symetric components such as aluminum tube and rod has been proven experimentally using EMPW techniques. In this paper EM coil design, manufacturing, Electromagnetic-structural FEM simulation of Magnetic Pulse Welding and preliminary experiment results is reported.

Keywords: COMSOL, EMPW, FEM, Lorentz force

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Authors: Sanjeev Kumar, S. K. Nath

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Proper selection of welding parameters for getting excellent weld is a challenge. HAZ simulation helps in identifying suitable welding parameters like heating rate, cooling rate, peak temperature, and energy input. In this study, the influence of weld thermal cycle of heat affected zone (HAZ) is simulated for Submerged Arc Welding (SAW) using Gleeble ® 3800 thermomechanical simulator. A (Micro-alloyed) MA steel plate of thickness 18 mm having yield strength 450MPa is used for making test specimens. Determination of the mechanical properties of weld simulated specimens including Charpy V-notch toughness and hardness is performed. Peak temperatures of 1300°C, 1150°C, 1000°C, 900°C, 800°C, heat energy input of 22KJ/cm and preheat temperatures of 30°C have been used with Rykalin-3D simulation model. It is found that the impact toughness (75J) is the best for the simulated HAZ specimen at the peak temperature 900ºC. For parent steel, impact toughness value is 26.8J at -50°C in transverse direction.

Keywords: HAZ simulation, mechanical properties, peak temperature, ship hull steel, weldability

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Authors: Gor Muradyan

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The paper is about friction and wear, including mechanisms, modeling, characterization, measurement and testing case in Bangladesh. Bangladesh is a country under development, A lot of people live here, approximately 145 million. The territory of this country is very small. Therefore buildings are very close to each other. As the pipe lines are very old, and people get almost dirty water, there are a lot of ongoing projects under ADB. In those projects the contractors using HDD machines (Horizontal Directional Drilling ) and grundoburst. These machines are working underground. As ground in Bangladesh is very sludge, machine can't work relevant because of big friction in the soil. When drilling works are finished machine is pulling the pipe underground. Very often the pulling of the pipes becomes very complicated because of the friction. Therefore long section of the pipe laying can’t be done because of a big friction. In that case, additional problems rise, as well as additional work must be done. As we mentioned above it is not possible to do big section of the pipe laying because of big friction in the soil, Because of this it is coming out that contractors must do more joints, more pressure test. It is always connected with additional expenditure and losing time. This machine can pull in 75 mm to 500 mm pipes connected with the soil condition. Length is possible till 500m related how much friction it will had on the puller. As less as much it can pull. Another machine grundoburst is not working at this soil condition at all. The machine is working with air compressor. This machine are using for the smaller diameter pipes, 20 mm to 63 mm. Most of the cases these machines are being used for the installing of the house connection pipes, for making service connection. To make a friction less contractors using bigger pulling had then the pipe. It is taking down the friction, But the problem of this machine is that it can't work at sludge. Because of mentioned reasons the friction has a big mining during this kind of works. There are a lot of ways to reduce the friction. In this paper we'll introduce the ways that we have researched during our practice in Bangladesh.

Keywords: Bangladesh, friction and wear, HDD machines, reducing friction

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Authors: S. D. El Wakil

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The research work reported here was aimed at investigating the feasibility of joining high-porosity stainless steel discs and wrought iron bars by friction welding. The sound friction-welded joints were then subjected to a metallurgical investigation and an analysis of failure resulting from tensile loading. Discs having 50 mm diameter and 10 mm thickness were produced by loose sintering of stainless steel powder at a temperature of 1350 ^oC in an argon atmosphere for one hour. Minor machining was then carried out to control the dimensions of the discs, and the density of each disc could then be determined. The level of porosity was calculated and was found to be about 40% in all of those discs. Solid wrought iron bars were also machined to facilitate tensile testing of the joints produced by friction welding. Using our previously gained experience, the porous stainless steel disc and the wrought iron tube were successfully friction welded. SEM was employed to examine the fracture surface after a tensile test of the joint in order to determine the type of failure. It revealed that the failure did not occur in the joint, but rather in the in the porous metal in the area adjacent to the joint. The load carrying capacity was actually determined by the strength of the porous metal and not by that of the welded joint. Macroscopic and microscopic metallographic examinations were also performed and showed that the welded joint involved a dense heat-affected zone where the porous metal underwent densification at elevated temperature, explaining and supporting the findings of the SEM study.

Keywords: fracture of friction-welded joints, metallurgy of friction welding, solid-porous structures, strength of joints

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Authors: Ines Oliveira, Ana Reis

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Magnetic Pulse Welding (MPW) is a cold solid-state welding process, accomplished by the electromagnetically driven, high-speed and low-angle impact between two metallic surfaces. It has the same working principle of Explosive Welding (EXW), i.e. is based on the collision of two parts at high impact speed, in this case, propelled by electromagnetic force. Under proper conditions, i.e., flyer velocity and collision point angle, a permanent metallurgical bond can be achieved between widely dissimilar metals. MPW has been considered a promising alternative to the conventional welding processes and advantageous when compared to other impact processes. Nevertheless, MPW current applications are mostly academic. Despite the existing knowledge, the lack of consensus regarding several aspects of the process calls for further investigation. As a result, the mechanical resistance, morphology and structure of the weld interface in MPW of Al/Cu dissimilar pair were investigated. The effect of process parameters, namely gap, standoff distance and energy, were studied. It was shown that welding only takes place if the process parameters are within an optimal range. Additionally, the formation of intermetallic phases cannot be completely avoided in the weld of Al/Cu dissimilar pair by MPW. Depending on the process parameters, the intermetallic compounds can appear as continuous layer or small pockets. The thickness and the composition of the intermetallic layer depend on the processing parameters. Different intermetallic phases can be identified, meaning that different temperature-time regimes can occur during the process. It is also found that lower pulse energies are preferred. The relationship between energy increase and melting is possibly related to multiple sources of heating. Higher values of pulse energy are associated with higher induced currents in the part, meaning that more Joule heating will be generated. In addition, more energy means higher flyer velocity, the air existing in the gap between the parts to be welded is expelled, and this aerodynamic drag (fluid friction) is proportional to the square of the velocity, further contributing to the generation of heat. As the kinetic energy also increases with the square of velocity, the dissipation of this energy through plastic work and jet generation will also contribute to an increase in temperature. To reduce intermetallic phases, porosity, and melt pockets, pulse energy should be minimized. The bond formation is affected not only by the gap, standoff distance, and energy but also by the mandrel’s surface conditions. No correlation was clearly identified between surface roughness/scratch orientation and joint strength. Nevertheless, the aspect of the interface (thickness of the intermetallic layer, porosity, presence of macro/microcracks) is clearly affected by the surface topology. Welding was not established on oil contaminated surfaces, meaning that the jet action is not enough to completely clean the surface.

Keywords: bonding mechanisms, impact welding, intermetallic compounds, magnetic pulse welding, wave formation

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Authors: Lakhya Jyoti Basumatary, M. J. Davidson

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Tailor Welded Blanks (TWBs) have established themselves to be a revolutionary and foremost integral part of the automotive and aerospace industries. Metals sheets with varied thickness, strength and coatings are welded together to form TWBs through friction stir welding and laser welding prior to stamping operations. The formability of the TWBs completely varies from those of conventional blanks due to the diverse strength levels of individual sheets which are made to deform under the same forming load uniformly throughout causing unequal and unsatisfactory deformation in the blank. Limiting Dome Height(LDH) test helps predicting the formability of each blanks and assists in determining the appropriate TWB. Finite Element Simulation of LDH test for both base material and TWBs was performed and analysed for both before and after the solution heat treatment. The comparison and validation of simulation results are done with the experimental data and correlated accordingly. The formability of solution heat treated TWBs had enhanced than those of blanks made from non-heat treated TWBs.

Keywords: tailor welded blanks, friction stir welding, limiting dome height test, finite element simulation

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Authors: Anna Romanova, Morteza A. Alani

Abstract:

Corrosion of concrete sewer pipes induced by sulfuric acid is an acknowledged problem and a ticking time-bomb to sewer operators. Whilst the chemical reaction of the corrosion process is well-understood, the indirect roles of other parameters in the corrosion process which are found in sewer environment are not highly reflected on. This paper reports on a field studies undertaken in Austria and United Kingdom, where the parameters of temperature, pH, H2S and CO2 were monitored over a period of time. The study establishes that (i) effluent temperature and pH have similar daily pattern and peak times, When examined in minutes scale, (ii) H2S and CO2 have an identical hourly pattern, (iii) H2S instant or shifted relation to effluent temperature is governed by the root mean square value of CO2.

Keywords: concrete corrosion, carbon dioxide, hydrogen sulphide, sewer pipe, sulfuric acid

Procedia PDF Downloads 287

Authors: Getachew Demeissie Ayalew, Yongtao Sun, Yang Yang

Abstract:

The spiral welded pipe manufacturing industry requires strict production standards for automated grinders for welding seams. However, traditional grinding machines in this sector are insufficient due to a lack of quality control protocols and inconsistent performance. This research aims to improve the quality of spiral welded pipes by developing intelligent automated abrasive belt grinding equipment. The system has equipped with six degrees of freedom (6 DOF) KUKA KR360 industrial robots, enabling concurrent grinding operations on both internal and external welds. The grinding robot control system is designed with a PLC, and a human-machine interface (HMI) system is employed for operations. The system includes an electric speed controller, data connection card, DC driver, analog amplifier, and HMI for input data. This control system enables the grinding of spiral welded pipe. It ensures consistent production quality and cost-effectiveness by reducing the product life cycle and minimizing risks in the working environment.

Keywords: Intelligent Systems, Spiral Welded Pipe, Grinding, Industrial Robot, End-Effector, PLC Controller System, 3D Laser Sensor, HMI.

Procedia PDF Downloads 251

Authors: M. Zafar, S. Rasheed, Imran Hashmi

Abstract:

Very little is concerned about the bacterial contamination in drinking water biofilm which provide a potential source for bacteria to grow and increase rapidly. So as to understand the microbial density in DWDs, a three-month study was carried out. The aim of this study was to examine biofilm in three different pipe materials including PVC, PPR and GI. A set of all these pipe materials was installed in DWDs at nine different locations and assessed on monthly basis. Drinking water quality was evaluated by different parameters and characterization of biofilm. Among various parameters are Temperature, pH, turbidity, TDS, electrical conductivity, BOD, COD, total phosphates, total nitrates, total organic carbon (TOC) free chlorine and total chlorine, coliforms and spread plate counts (SPC) according to standard methods. Predominant species were Bacillus thuringiensis, Pseudomonas fluorescens , Staphylococcus haemolyticus, Bacillus safensis and significant increase in bacterial population was observed in PVC pipes while least in cement pipes. The quantity of DWDs bacteria was directly depended on biofilm bacteria and its increase was correlated with growth and detachment of bacteria from biofilms. Pipe material also affected the microbial community in drinking water distribution network biofilm while Similarity in bacterial species was observed between systems due to same disinfectant dose, time period and plumbing pipes.

Keywords: biofilm, DWDs, pipe material, bacterial population

Procedia PDF Downloads 324

Authors: Khaled Ayfi

Abstract:

In industrial oxygen systems at high temperature and high pressure, contamination by solid particles is one of the principal causes of ignition hazards. Indeed, gas can sweep away particles, generated by corrosion inside the pipes or during maintenance operations (welding residues, careless disassembly, etc.) and produce accumulations at places where the gas velocity decrease. Moreover, in such an environment rich in oxygen (oxidant), particles are highly reactive and can ignite system walls more actively and at higher temperatures. Oxidation based thermal effects are responsible for mechanical properties lost, leading to the destruction of the pressure equipment wall. To deal with this problem, a numerical analysis is done regarding a sample representative of a wall subjected to pressure and temperature. The validation and analysis are done comparing the numerical simulations results to experimental measurements. More precisely, in this work, we propose a numerical model that describes the thermomechanical behavior of thin metal disks under pressure and subjected to laser heating. This model takes into account the geometric and material nonlinearity and has been validated by the comparison of simulation results with experimental measurements.

Keywords: ignition, oxygen, numerical simulation, thermomechanical behavior

Procedia PDF Downloads 87

Authors: H. Shokouhmand, A. Ghanami

Abstract:

Heat pipe is simple heat transfer device which combines the conduction and phase change phenomena to control the heat transfer without any need for external power source. At hot surface of heat pipe, the liquid phase absorbs heat and changes to vapor phase. The vapor phase flows to condenser region and with the loss of heat changes to liquid phase. Due to gravitational force the liquid phase flows to evaporator section.In HVAC systems the working fluid is chosen based on the operating temperature. The heat pipe has significant capability to reduce the humidity in HVAC systems. Each HVAC system which uses heater, humidifier or dryer is a suitable nominate for the utilization of heat pipes. Generally heat pipes have three main sections: condenser, adiabatic region and evaporator.Performance investigation and optimization of heat pipes operation in order to increase their efficiency is crucial. In present article, a parametric study is performed to improve the heat pipe performance. Therefore, the heat capacity of heat pipe with respect to geometrical and confining parameters is investigated. For the better observation of heat pipe operation in HVAC systems, a CFD simulation in Eulerian- Eulerian multiphase approach is also performed. The results show that heat pipe heat transfer capacity is higher for water as working fluid with the operating temperature of 340 K. It is also observed that the vertical orientation of heat pipe enhances it’s heat transfer capacity.

Keywords: heat pipe, HVAC system, grooved heat pipe, heat pipe limits

Procedia PDF Downloads 344

Authors: H. Shokouhmand, A. Ghanami

Abstract:

Heat pipe is a simple heat transfer device which combines the conduction and phase change phenomena to control the heat transfer without any need for external power source. At hot surface of the heat pipe, the liquid phase absorbs heat and changes to vapor phase. The vapor phase flows to condenser region and with the loss of heat changes to liquid phase. Due to gravitational force, the liquid phase flows to evaporator section. In HVAC systems, the working fluid is chosen based on the operating temperature. The heat pipe has significant capability to reduce the humidity in HVAC systems. Each HVAC system which uses heater, humidifier or dryer is a suitable nominate for the utilization of heat pipes. Generally, heat pipes have three main sections: condenser, adiabatic region, and evaporator.Performance investigation and optimization of heat pipes operation in order to increase their efficiency is crucial. In the present article, a parametric study is performed to improve the heat pipe performance. Therefore, the heat capacity of the heat pipe with respect to geometrical and confining parameters is investigated. For the better observation of heat pipe operation in HVAC systems, a CFD simulation in Eulerian- Eulerian multiphase approach is also performed. The results show that heat pipe heat transfer capacity is higher for water as working fluid with the operating temperature of 340 K. It is also showed that the vertical orientation of heat pipe enhances its heat transfer capacity.

Keywords: heat pipe, HVAC system, grooved heat pipe, CFD simulation

Procedia PDF Downloads 467