Search results for: weld penetration
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 258

Search results for: weld penetration

228 An Experimentally Validated Thermo- Mechanical Finite Element Model for Friction Stir Welding in Carbon Steels

Authors: A. H. Kheireddine, A. A. Khalil, A. H. Ammouri, G. T. Kridli, R. F. Hamade

Abstract:

Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.

Keywords: Carbon Steels, DEFORM 3D, FEM, Friction stir welding.

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227 Temperature Distribution in Friction Stir Welding Using Finite Element Method

Authors: Armansyah, I. P. Almanar, M. Saiful Bahari Shaari, M. Shamil Jaffarullah, Nur’amirah Busu, M. Arif Fadzleen Zainal Abidin, M. Amlie A. Kasim

Abstract:

During welding, the amount of heat present in weld zones determines the quality of weldment produced. Thus, the heat distribution characteristics and its magnitude in weld zones with respect to process variables such as tool pin-shoulder rotational and traveling speed during welding is analyzed using thermal finite element analyses method. For this purpose, transient thermal finite element analyses are performed to model the temperatures distribution and its quantities in weld-zones with respect to process variables such as rotational speed and traveling speed during welding. Commercially available software Altair HyperWork is used to model three-dimensional tool pin-shoulder vs. workpieces and to simulate the friction stir process. The results show that increasing tool rotational speed, at a constant traveling speed, will increase the amount of heat generated in weld-zones. In contrary, increasing traveling speed, at constant tool pin-shoulder rotational speeds, will reduce the amount of heat generated in weld zones.

Keywords: Frictions Stir Welding, Temperature Distribution, Finite Element Method, Altair Hyperwork.

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226 Quantitative Analysis of Weld Defect Images in Industrial Radiography Based Invariant Attributes

Authors: N. Nacereddine, M. Tridi, S. S. Belaïfa, M. Zelmat

Abstract:

For the characterization of the weld defect region in the radiographic image, looking for features which are invariant regarding the geometrical transformations (rotation, translation and scaling) proves to be necessary because the same defect can be seen from several angles according to the orientation and the distance from the welded framework to the radiation source. Thus, panoply of geometrical attributes satisfying the above conditions is proposed and which result from the calculation of the geometrical parameters (surface, perimeter, etc.) on the one hand and the calculation of the different order moments, on the other hand. Because the large range in values of the raw features and taking into account other considerations imposed by some classifiers, the scaling of these values to lie between 0 and 1 is indispensable. The principal component analysis technique is used in order to reduce the number of the attribute variables in the aim to give better performance to the further defect classification.

Keywords: Geometric parameters, invariant attributes, principal component analysis, weld defect image.

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225 Deformation and Crystallization in a 7075-T651 Friction Stir Weld

Authors: C. S. Paglia

Abstract:

The deformation and the crystallization in a 7075-T651 friction stir weld, in particular for regions directly in contact with the mechanical action of the rotating probe, have been investigated by means of optical microscopy. The investigation enabled to identify regions of the weld differently affected by the deformation caused by the welding process. The highly deformed grains in the horizontal direction close to the plate margin were indicative of shear movements along the horizontal plane, while highly deformed grains along the plate margin in the vertical direction were indicative of vertical shear movements of opposite directions, which superimposed the shear movement along the horizontal plane. The vertical shear movements were not homogeneous through the plate thickness. The microstructure indicated that after the probe passes, the grain growth may take place under static conditions. The small grains microstructure of the nugget region, formed after the main dynamic recrystallization process, develops to an equiaxed microstructure. A material transport influenced by the rotating shoulder was also observed from the trailing to the advancing side of the weld.

Keywords: AA7075-T651, friction stir welding, deformation, crystallization.

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224 Creep Constitutive Equation for 2- Materials of Weldment-304L Stainless Steel

Authors: Amir Hossein Daei Sorkhabi, Farid Vakili Tahami

Abstract:

In this paper, creep constitutive equations of base (Parent) and weld materials of the weldment for cold-drawn 304L stainless steel have been obtained experimentally. For this purpose, test samples have been generated from cold drawn bars and weld material according to the ASTM standard. The creep behavior and properties have been examined for these materials by conducting uniaxial creep tests. Constant temperatures and constant load uni-axial creep tests have been carried out at two high temperatures, 680 and 720 oC, subjected to constant loads, which produce initial stresses ranging from 240 to 360 MPa. The experimental data have been used to obtain the creep constitutive parameters using numerical optimization techniques.

Keywords: Creep, Constitutive equation, Cold-drawn 304L stainless steel, Weld, Base material

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223 Studies of Interfacial Microstructure and Mechanical Properties on Dissimilar Sheet Metal Combination Joints Using Laser Beam Welding

Authors: K. Kalaiselvan, A. Elango

Abstract:

Laser beam welding of dissimilar sheet metal combinations such as Ti/Al, SS/Al and Cu/Al are increasingly demanded due to high energy densities with less fusion and heat affected zones. A good weld joint strength involves combinations of dissimilar metals and the formation of solid solution in the weld pool. Many metal pairs suffer from significant intermetallic phase formation during welding which greatly reduces their strength. The three different sheet metal mentioned above is critically reviewed and phase diagram for the combinations are given. The aim of this study is to develop an efficient metal combinations and the influence on their interfacial characteristics. For that the following parameters such as weld geometry, residual distortion, micro hardness, microstructure and mechanical properties are analyzed systematically.

Keywords: Laser Beam Welding (LBW), dissimilar metals, Ti/Al, SS/Al and Cu/Al sheets.

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222 Experimental Estimation of Mixed-Mode Fracture Properties of Steel Weld

Authors: S. R. Hosseini, N. Choupani, A. R. M. Gharabaghi

Abstract:

The modified Arcan fixture was used in order to investigate the mixed mode fracture properties of high strength steel butt weld through experimental and numerical analysis. The fixture consisted of a central section with "butterfly-shaped" specimen that had central crack. The specimens were under pure mode I (opening), pure mode II (shearing) and all in plane mixed mode loading angles starting from 0 to 90 degrees. The geometric calibration factors were calculated with the aid of finite element analysis for various loading mode and different crack length (0.45≤ a/w ≤0.55) and the critical fracture loads obtained experimentally. The critical fracture toughness (KIC & KIIC) estimated with experimental and numerical analysis under mixed mode loading conditions.

Keywords: Arcan specimen, fracture toughness, mixed mode, steel weld.

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221 Artificial Neural Network Application on Ti/Al Joint Using Laser Beam Welding – A Review

Authors: K. Kalaiselvan, A. Elango, N. M. Nagarajan

Abstract:

Today automobile and aerospace industries realise Laser Beam Welding for a clean and non contact source of heating and fusion for joining of sheets. The welding performance is mainly based on by the laser welding parameters. Some concepts related to Artificial Neural Networks and how can be applied to model weld bead geometry and mechanical properties in terms of equipment parameters are reported in order to evaluate the accuracy and compare it with traditional modeling schemes. This review reveals the output features of Titanium and Aluminium weld bead geometry and mechanical properties such as ultimate tensile strength, yield strength, elongation and reduction of the area of the weld using Artificial Neural Network.

Keywords: Laser Beam Welding (LBW), Artificial Neural Networks (ANN), Optimization, Titanium and Aluminium sheets.

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220 Factors Affecting Weld Line Movement in Tailor Welded Blank

Authors: Shakil A. Kagzi, Sanjay Patil, Harit K. Raval

Abstract:

Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.

Keywords: ANOVA, Deep drawing, Tailor Welded Blank, TWB, Weld line movement.

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219 Penetration Analysis for Composites Applicable to Military Vehicle Armors, Aircraft Engines and Nuclear Power Plant Structures

Authors: Dong Wook Lee

Abstract:

This paper describes a method for analyzing penetration for composite material using an explicit nonlinear Finite Element Analysis (FEA). This method may be used in the early stage of design for the protection of military vehicles, aircraft engines and nuclear power plant structures made of composite materials. This paper deals with simple ballistic penetration tests for composite materials and the FEA modeling method and results. The FEA was performed to interpret the ballistic field test phenomenon regarding the damage propagation in the structure subjected to local foreign object impact.

Keywords: Computer Aided Engineering, CAE, Finite Element Analysis, FEA, impact analysis, penetration analysis, composite material.

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218 Analysis of Normal Penetration of Ogive -Nose Projectiles into Thin Metallic Plates

Authors: M. H. Pol, A. Bidi, A.V. Hoseini, G.H. Liaghat

Abstract:

In this note, a theoretical model for analyzing of normal penetration of the ogive – nose projectile into metallic targets is presented .The failure is assumed to be asymmetry petalling and the analysis is performed by using the energy balance and work done .The work done consist of the work required for plastic deformation Wp, the work for transferring the matter to new position Wd and the work for bending of the petals Wb. In several studies, it has been shown that we can neglect the loss of energy by temperature. In this present study, in first, by assuming the crater formation after perforation, the value of work done is calculated during the normal penetration of conical projectiles into thin metallic targets. Then the value of residual velocity and ballistic limit of the projectile is predicated by using the energy balance. In final, theoretical and experimental results is compared.

Keywords: Ogive Projectile, normal impact, penetration, thinmetallic target.

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217 Some Studies on Temperature Distribution Modeling of Laser Butt Welding of AISI 304 Stainless Steel Sheets

Authors: N. Siva Shanmugam, G. Buvanashekaran, K. Sankaranarayanasamy

Abstract:

In this research work, investigations are carried out on Continuous Wave (CW) Nd:YAG laser welding system after preliminary experimentation to understand the influencing parameters associated with laser welding of AISI 304. The experimental procedure involves a series of laser welding trials on AISI 304 stainless steel sheets with various combinations of process parameters like beam power, beam incident angle and beam incident angle. An industrial 2 kW CW Nd:YAG laser system, available at Welding Research Institute (WRI), BHEL Tiruchirappalli, is used for conducting the welding trials for this research. After proper tuning of laser beam, laser welding experiments are conducted on AISI 304 grade sheets to evaluate the influence of various input parameters on weld bead geometry i.e. bead width (BW) and depth of penetration (DOP). From the laser welding results, it is noticed that the beam power and welding speed are the two influencing parameters on depth and width of the bead. Three dimensional finite element simulation of high density heat source have been performed for laser welding technique using finite element code ANSYS for predicting the temperature profile of laser beam heat source on AISI 304 stainless steel sheets. The temperature dependent material properties for AISI 304 stainless steel are taken into account in the simulation, which has a great influence in computing the temperature profiles. The latent heat of fusion is considered by the thermal enthalpy of material for calculation of phase transition problem. A Gaussian distribution of heat flux using a moving heat source with a conical shape is used for analyzing the temperature profiles. Experimental and simulated values for weld bead profiles are analyzed for stainless steel material for different beam power, welding speed and beam incident angle. The results obtained from the simulation are compared with those from the experimental data and it is observed that the results of numerical analysis (FEM) are in good agreement with experimental results, with an overall percentage of error estimated to be within ±6%.

Keywords: Laser welding, Butt weld, 304 SS, FEM.

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216 Real-Time Testing of Steel Strip Welds based on Bayesian Decision Theory

Authors: Julio Molleda, Daniel F. García, Juan C. Granda, Francisco J. Suárez

Abstract:

One of the main trouble in a steel strip manufacturing line is the breakage of whatever weld carried out between steel coils, that are used to produce the continuous strip to be processed. A weld breakage results in a several hours stop of the manufacturing line. In this process the damages caused by the breakage must be repaired. After the reparation and in order to go on with the production it will be necessary a restarting process of the line. For minimizing this problem, a human operator must inspect visually and manually each weld in order to avoid its breakage during the manufacturing process. The work presented in this paper is based on the Bayesian decision theory and it presents an approach to detect, on real-time, steel strip defective welds. This approach is based on quantifying the tradeoffs between various classification decisions using probability and the costs that accompany such decisions.

Keywords: Classification, Pattern Recognition, ProbabilisticReasoning, Statistical Data Analysis.

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215 Investigating the Impact of the Laundry and Sterilization Process on the Performance of Reusable Surgical Gowns

Authors: N. Khomarloo, F. Mousazadegan, M. Latifi, N. Hemmatinejad

Abstract:

Recently, the utilization of reusable surgical gowns in order to decrease costs, environmental protection and enhance surgeon’s comfort is considered. One of the concerns in applying this kind of medical protective clothing is reduction of their resistance to bacterial penetration especially in wet state, after repeated laundering and sterilizing process. The purpose of this study is to investigate the effect of the laundering and sterilizing process on the reusable surgical gown’s resistance against bacterial wet penetration. To this end, penetration of Staphylococcus aureus bacteria in wet state after 70 washing and sterilizing cycles was evaluated on the two single-layer and three-layer reusable gowns. The outcomes reveal that up to 20 laundering and sterilizing cycles, protective property of samples improves due to fabric shrinkage, after that because of the fabric’s construction opening, the bacterial penetration increase. However, the three-layer gown presents higher protective performance comparing to the single-layer one.

Keywords: Reusable surgical gown, laundry, sterilization, wet bacterial penetration.

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214 Application of GAMS and GA in the Location and Penetration of Distributed Generation

Authors: Alireza Dehghani Pilehvarani, Mojtaba Hakimzadeh, Mohammad Jafari Far, Reza Sedaghati

Abstract:

Distributed Generation (DG) can help in reducing the cost of electricity to the costumer, relieve network congestion and provide environmentally friendly energy close to load centers. Its capacity is also scalable and it provides voltage support at distribution level. Hence, DG placement and penetration level is an important problem for both the utility and DG owner. DG allocation and capacity determination is a nonlinear optimization problem. The objective function of this problem is the minimization of the total loss of the distribution system. Also high levels of penetration of DG are a new challenge for traditional electric power systems. This paper presents a new methodology for the optimal placement of DG and penetration level of DG in distribution system based on General Algebraic Modeling System (GAMS) and Genetic Algorithm (GA).

Keywords: Distributed Generation, Location, Loss Reduction, Distribution Network, GA, GAMS.

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213 Artificial Intelligence in Penetration Testing of a Connected and Autonomous Vehicle Network

Authors: Phillip Garrad, Saritha Unnikrishnan

Abstract:

The increase in connected and autonomous vehicles (CAV) creates more opportunities for cyber-attacks. Cyber-attacks can be performed with malicious intent or for research and testing purposes. As connected vehicles approach full autonomy, the possible impact of these cyber-attacks also grows. This review analyses the challenges faced in CAV cybersecurity testing. This includes access and cost of the representative test setup and lack of experts in the field A review of potential solutions to overcome these challenges is presented. Studies have demonstrated Artificial Intelligence (AI) as a promising technique to reduce runtime, enhance effectiveness and comprehensively cover all the standard test aspects in penetration testing in other industries. However, this review has identified a significant gap in the systematic implementation of AI for penetration testing in the CAV cybersecurity domain. The expectation from this review is to investigate potential AI algorithms, which can demonstrate similar improvements in runtime and efficiency for a CAV model. If proven to be an effective means of penetration test for CAV, this methodology may be used on a full CAV test network.

Keywords: Cybersecurity, connected vehicles, software simulation, artificial intelligence, penetration testing.

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212 A Review on Process Parameters of Ti/Al Dissimilar Joint Using Laser Beam Welding

Authors: K. Kalaiselvan, K. Sekar, S. Elavarasi

Abstract:

The use of laser beam welding for joining titanium and aluminum offers more advantages compared with conventional joining processes. Dissimilar metal combination is very much needed for aircraft structural industries and research activities. The quality of a weld joint is directly influenced by the welding input parameters. The common problem that is faced by the manufactures is the control of the process parameters to obtain a good weld joint with minimal detrimental. To overcome this issue, various parameters can be preferred to obtain quality of weld joint. In this present study an overall literature review on processing parameters such as offset distance, welding speed, laser power, shielding gas and filler metals are discussed with the effects on quality weldment. Additionally, mechanical properties of welds joint are discussed. The aim of the report is to review the recent progress in the welding of dissimilar titanium (Ti) and aluminum (Al) alloys to provide a basis for follow up research.

Keywords: Laser beam welding, titanium, aluminum, process parameters.

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211 Real-Time Identification of Media in a Laboratory-Scaled Penetrating Process

Authors: Sheng-Hong Pong, Herng-Yu Huang, Yi-Ju Lee, Shih-Hsuan Chiu

Abstract:

In this paper, a neural network technique is applied to real-time classifying media while a projectile is penetrating through them. A laboratory-scaled penetrating setup was built for the experiment. Features used as the network inputs were extracted from the acceleration of penetrator. 6000 set of features from a single penetration with known media and status were used to train the neural network. The trained system was tested on 30 different penetration experiments. The system produced an accuracy of 100% on the training data set. And, their precision could be 99% for the test data from 30 tests.

Keywords: back-propagation, identification, neural network, penetration.

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210 Effects of Turbulence Penetration on Valve Leakage in Nuclear Reactor Coolant System

Authors: Gupta Rajesh, Paudel Sagar, Sharma Utkarsh, Singh Amit Kumar

Abstract:

Thermal stratification has drawn much attention because of the malfunctions at various nuclear plants in U.S.A that raised significant safety concerns. The concerns due to this phenomenon relate to thermal stresses in branch pipes connected to the reactor coolant system piping. This stress limits the lifetime of the piping system, and even leading to penetrating cracks. To assess origin of valve damage in the pipeline, it is essential to determine the effect of turbulence penetration on valve leakage; since stratified flow is generally generated by turbulent penetration or valve leakage. As a result, we concluded with the help of coupled fluent-structural analysis that the pipe with less turbulence has less chance of failure there by requiring less maintenance.

Keywords: Reactor coolant system, thermal stratification, turbulent penetration, coupled fluent-structural analysis, Von Mises stress.

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209 Effect of Welding Parameters on Penetration and Bead Width for Variable Plate Thickness in Submerged Arc Welding

Authors: Harish K. Arya, Kulwant Singh, R. K. Saxena

Abstract:

The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on penetration and bead width. The penetration reduces with increase in plate thickness due to heat loss in thickness direction for same heat input, while bead width increases for thicker plate due to faster cooling.

Keywords: Submerged arc welding, plate thickness, bead geometry, cooling rate.

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208 Determination of the Optimal DG PV Interconnection Location Using Losses and Voltage Regulation as Assessment Indicators Case Study: ECG 33 kV Sub-Transmission Network

Authors: Ekow A. Kwofie, Emmanuel K. Anto, Godfred Mensah

Abstract:

In this paper, CYME Distribution software has been used to assess the impacts of solar Photovoltaic (PV) distributed generation (DG) plant on the Electricity Company of Ghana (ECG) 33 kV sub-transmission network at different PV penetration levels. As ECG begins to encourage DG PV interconnections within its network, there has been the need to assess the impacts on the sub-transmission losses and voltage contribution. In Tema, a city in Accra - Ghana, ECG has a 33 kV sub-transmission network made up of 20 No. 33 kV buses that was modeled. Three different locations were chosen: The source bus, a bus along the sub-transmission radial network and a bus at the tail end to determine the optimal location for DG PV interconnection. The optimal location was determined based on sub-transmission technical losses and voltage impact. PV capacities at different penetration levels were modeled at each location and simulations performed to determine the optimal PV penetration level. Interconnection at a bus along (or in the middle of) the sub-transmission network offered the highest benefits at an optimal PV penetration level of 80%. At that location, the maximum voltage improvement of 0.789% on the neighboring 33 kV buses and maximum loss reduction of 6.033% over the base case scenario were recorded. Hence, the optimal location for DG PV integration within the 33 kV sub-transmission utility network is at a bus along the sub-transmission radial network.

Keywords: Distributed generation photovoltaic, DG PV, optimal location, penetration level, sub-transmission network.

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207 Studies on Microstructure and Mechanical Properties of Simulated Heat Affected Zone in a Micro Alloyed Steel

Authors: Sanjeev Kumar, S. K. Nath

Abstract:

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, and Weldability.

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206 The Effect of the Weld Current Types on Microstructure and Hardness in Tungsten Inert Gas Welding of the AZ31 Magnesium Alloy Sheet

Authors: Bilge Demir, Ahmet Durgutlu, Mustafa Acarer

Abstract:

In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.

Keywords: AZ31 magnesium alloy, microstructures, micro hardness TIG welding.

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205 Effects of Asphalt Modification with Nanomaterials on Fresh and Stored Bitumen

Authors: Ahmed W. Oda, Ahmed El-Desouky, Hassan Mahdy, Osama M. Moussa

Abstract:

Nanomaterials have many applications in the field of asphalt paving. Two locally produced nanomaterials were used in the asphalt binder modification. The nanomaterials used are Nanosilica (NS), and Nanoclay (NC). The virgin asphalt binder was characterized by the conventional tests. The bitumen was modified by 3%, 5% and 7% of NS and NC. The penetration index (PI), and the retaining penetration (RP) was calculated based on the results of the penetration and the softening point tests. The results show that the RP becomes 95.35% at 5% NS modified bitumen and reaches 97.56% when bitumen is modified with 3% NC. The results show significant improvement in the bitumen stiffness when modified by the two types of nanomaterials, either fresh or aged (stored).

Keywords: Bitumen, modified bitumen, aged, stored, nanomaterials.

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204 Failure Analysis of Pipe System at a Hydroelectric Power Plant

Authors: Ali Göksenli, Barlas Eryürek

Abstract:

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, water-hammer, crack, welding seam.

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203 Fatigue Behavior of Friction Stir Welded EN AW 5754 Aluminum Alloy Using Load Increase Procedure

Authors: A. B. Chehreh, M. Grätzel, M. Klein, J. P. Bergmann, F. Walther

Abstract:

Friction stir welding (FSW) is an advantageous method in the thermal joining processes, featuring the welding of various dissimilar and similar material combinations, joining temperatures below the melting point which prevents irregularities such as pores and hot cracks as well as high strengths mechanical joints near the base material. The FSW process consists of a rotating tool which is made of a shoulder and a probe. The welding process is based on a rotating tool which plunges in the workpiece under axial pressure. As a result, the material is plasticized by frictional heat which leads to a decrease in the flow stress. During the welding procedure, the material is continuously displaced by the tool, creating a firmly bonded weld seam behind the tool. However, the mechanical properties of the weld seam are affected by the design and geometry of the tool. These include in particular microstructural and surface properties which can favor crack initiation. Following investigation compares the dynamic properties of FSW weld seams with conventional and stationary shoulder geometry based on load increase test (LIT). Compared to classical Woehler tests, it is possible to determine the fatigue strength of the specimens after a short amount of time. The investigations were carried out on a robotized welding setup on 2 mm thick EN AW 5754 aluminum alloy sheets. It was shown that an increased tensile and fatigue strength can be achieved by using the stationary shoulder concept. Furthermore, it could be demonstrated that the LIT is a valid method to describe the fatigue behavior of FSW weld seams.

Keywords: Aluminum alloy, fatigue performance, fracture, friction stir welding.

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202 Containment/Penetration Analysis for the Protection of Aircraft Engine External Configuration and Nuclear Power Plant Structures

Authors: Dong Wook Lee, Adrian Mistreanu

Abstract:

The authors have studied a method for analyzing containment and penetration using an explicit nonlinear Finite Element Analysis. This method may be used in the stage of concept design for the protection of external configurations or components of aircraft engines and nuclear power plant structures. This paper consists of the modeling method, the results obtained from the method and the comparison of the results with those calculated from simple analytical method. It shows that the containment capability obtained by proposed method matches well with analytically calculated containment capability.

Keywords: Computer Aided Engineering, CAE, containment analysis, Finite Element Analysis, FEA, impact analysis, penetration analysis.

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201 Factors Influencing B2c eCommerce Diffusion

Authors: R. Mangiaracina, A. Perego, F. Campari

Abstract:

Despite the fact that B2c eCommerce has become important in numerous economies, its adoption varies from country to country. This paper aims to identify the factors affecting (enabling or inhibiting) B2c eCommerce and to determine their quantitative impact on the diffusion of online sales across countries. A dynamic panel model analyzing the relationship between 13 factors (Macroeconomic, Demographic, Socio-Cultural, Infrastructural and Offer related) stemming from a complete literature analysis and the B2c eCommerce value in 45 countries over 9 years has been developed. Having a positive correlation coefficient, GDP, mobile penetration, Internet user penetration and credit card penetration resulted as enabling drivers of the B2c eCommerce value across countries, whereas, having a negative correlation coefficient,equal distribution of income and the development of traditional retailing network act as inhibiting factors.

Keywords: B2c eCommerce diffusion, influencing factors, dynamic panel model

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200 Assessment of Using Wastage Steel as Welded Reinforcement

Authors: Muhammad Murtaza Nasir, Safdar Abbas Zaidi, Kamran Khan

Abstract:

This work is carried out to evaluate the possibility of using to-be-wasted steel as reinforcement after welding together pieces of reinforcing steel bars, left over during construction activities. Tests were performed on a total of nine samples. These were made by welding pieces of reinforcing steel bars purchased from the local scrap steel market. The samples were tested in uniaxial tension using a universal testing machine (UTM). It was found that the failure of the welded bars is governed by the thickness of the weld. It is concluded that suitable design of the weld is essential for achieving the desired level of ductility/elongation of these bars, if they are to be used as conventional reinforcement in reinforced concrete members.

Keywords: Ductility/elongation, low cost housing, reinforced concrete, welding, welded reinforcement, wastage steel.

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199 Evaluation of Iranian Standard for Assessment of Liquefaction Potential of Cohesionless Soils Based on Standard Penetration Test

Authors: Reza Ziaie Moayad, Azam Kouhpeyma

Abstract:

In-situ testing is preferred to evaluate the liquefaction potential in cohesionless soils due to high disturbance during sampling. Although new in-situ methods with high accuracy have been developed, standard penetration test, the simplest and the oldest in-situ test, is still used due to the profusion of the recorded data. This paper reviews the Iranian standard of evaluating liquefaction potential in soils (codes 525) and compares the liquefaction assessment methods based on standard penetration test (SPT) results on cohesionless soil in this standard with the international standards. To this, methods for assessing liquefaction potential are compared with what is presented in standard 525. It is found that although the procedure used in Iranian standard of evaluating the potential of liquefaction has not been updated according to the new findings, it is a conservative procedure.

Keywords: cohesionless soil, liquefaction, SPT, Iranian liquefaction standard

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