Influence of process energy on stress corrosion susceptibility of a friction hydro pillar repaired steam turbine rotor disc blade locating hole
- Authors: Pentz, Willem Gerhard
- Date: 2020
- Subjects: Friction welding , Mechanical engineering
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/47106 , vital:39810
- Description: Currently the power generation industry is struggling to keep older coal power plants running efficiently. One of the major hurdles is to keep repair and service cost low. Over time stress corrosion cracking (SCC) occurs in the locating pinholes of tier type rotors which locate the turbine blades. This is where this research aims to assist with an alternative repair technique, Friction Hydro Pillar Processing (FHPP) welding, to have longer service intervals thus saving cost and time. The same material can be used for welding and a new aligned hole can be drilled. FHPP welding is a solid state friction welding process. Four different FHPP axial forces were selected to compare their respective performance in subsequent tensile testing, impact testing and SCC testing. All the tensile samples extracted from preheated welds and post weld heat treated welds fracture in the parent material, which indicates good weld efficiency. The impact crack route from the weld nugget towards the parent material was identified in the energy and force graph. Axial force which promote impact toughness can be selected with this curve. SCC occurs when a tensile stress is applied to a susceptible material when in a conducive environment for cracking. A new SCC W-shape was designed and performed well during initial testing. With the SCC W-shape two specimens can be extracted opposite each other and tested. Both the preheated weld samples and the post weld heat treatment (PWHT) weld samples had improved SCC performance over their respective parent material samples. A high axial force, low process energy, and high process energy rate (low process energy and low weld time) produced a weld with improved SCC resistance. FHPP (with PWHT) is a promising repair technique as it improved on the SCC resistance and impact toughness as well as having 100% bond efficiency. More research is still required to identify the SCC mechanism of the FHPP weld.
- Full Text:
- Date Issued: 2020
- Authors: Pentz, Willem Gerhard
- Date: 2020
- Subjects: Friction welding , Mechanical engineering
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/47106 , vital:39810
- Description: Currently the power generation industry is struggling to keep older coal power plants running efficiently. One of the major hurdles is to keep repair and service cost low. Over time stress corrosion cracking (SCC) occurs in the locating pinholes of tier type rotors which locate the turbine blades. This is where this research aims to assist with an alternative repair technique, Friction Hydro Pillar Processing (FHPP) welding, to have longer service intervals thus saving cost and time. The same material can be used for welding and a new aligned hole can be drilled. FHPP welding is a solid state friction welding process. Four different FHPP axial forces were selected to compare their respective performance in subsequent tensile testing, impact testing and SCC testing. All the tensile samples extracted from preheated welds and post weld heat treated welds fracture in the parent material, which indicates good weld efficiency. The impact crack route from the weld nugget towards the parent material was identified in the energy and force graph. Axial force which promote impact toughness can be selected with this curve. SCC occurs when a tensile stress is applied to a susceptible material when in a conducive environment for cracking. A new SCC W-shape was designed and performed well during initial testing. With the SCC W-shape two specimens can be extracted opposite each other and tested. Both the preheated weld samples and the post weld heat treatment (PWHT) weld samples had improved SCC performance over their respective parent material samples. A high axial force, low process energy, and high process energy rate (low process energy and low weld time) produced a weld with improved SCC resistance. FHPP (with PWHT) is a promising repair technique as it improved on the SCC resistance and impact toughness as well as having 100% bond efficiency. More research is still required to identify the SCC mechanism of the FHPP weld.
- Full Text:
- Date Issued: 2020
Development of a creep sample retrieval technique and friction weld site repair procedure
- Authors: Wedderburn, Ian Norman
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: vital:9635 , http://hdl.handle.net/10948/d1020116
- Description: The remnant life monitoring of creep loaded high temperature and pressure components in power stations is critical to ensuring their safe and cost effective operation as failures can have severe consequences. Effective creep life condition monitoring allows for optimising component life predictions and subsequent plant maintenance decisions. In South Africa many power generation stations have been in operation well beyond their 30 year design service life, as such knowledge of the remnant creep life of high temperature and pressure components, such as steam pipelines, becomes of utmost importance. Techniques for the remnant creep life assessments of critical high temperature and pressure components must therefore be as effective as possible. The common and well accepted in-situ inspection technique for assessing creep damage in steam pipes is by the metallographic replication technique. The technique is however limited to the outer surface of the pipe, without information on damage within the wall. This research will illustrate a means of obtaining a sample for creep life analysis with depth through the wall of a pipe, as wells as an alternative technique for the repair of the sample retrieval site. A sample retrieval technique was developed that would retrieve a small diameter cylindrical sample from a cored blind hole for creep analysis by visual creep void assessment or by the small punch creep test. The small punch creep test requires only a small diameter thin disc of material for testing for which its results are comparable with conventional uniaxial creep testing which requires a much larger sample of material. The smaller sample requirement of the small punch creep test therefore allows for a vastly reduced invasive sample retrieval operation and consequently smaller repair size area. Also the fact that the sample is retrieved from a blind hole is advantageous since the pipe wall is not penetrated which would require full plant shutdown. A friction welding technique was identified as an alternative to traditional arc fusion welding for the repair of the sample retrieval site, this technique being the Friction Hydro Pillar Processing technique. Friction Hydro Pillar Processing is a solid-state welding technique and as such has a number of inherent benefits over arc fusion welding as the weld is performed below the melting temperature of the material. From a process point of view Friction Hydro Pillar Processing is ideally suited for automation, has virtually no fumes generated, minimal distortion is experienced and no spatter has to be removed afterwards. The technique has yet to see industrial application and as such development of suitable process parameters was undertaken. Finally, to apply the sample retrieval and repair operations in-situ to a steam pipe in a power plant suitable equipment was developed. Existing friction welding equipment is generally bulky workshop based equipment and is unsuitable for on-site work due to its size and weight. Therefore development of dedicated equipment was required to enable Friction Hydro Pillar Processing to be applied to steam pipes within a power plant environment.
- Full Text:
- Date Issued: 2013
- Authors: Wedderburn, Ian Norman
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: vital:9635 , http://hdl.handle.net/10948/d1020116
- Description: The remnant life monitoring of creep loaded high temperature and pressure components in power stations is critical to ensuring their safe and cost effective operation as failures can have severe consequences. Effective creep life condition monitoring allows for optimising component life predictions and subsequent plant maintenance decisions. In South Africa many power generation stations have been in operation well beyond their 30 year design service life, as such knowledge of the remnant creep life of high temperature and pressure components, such as steam pipelines, becomes of utmost importance. Techniques for the remnant creep life assessments of critical high temperature and pressure components must therefore be as effective as possible. The common and well accepted in-situ inspection technique for assessing creep damage in steam pipes is by the metallographic replication technique. The technique is however limited to the outer surface of the pipe, without information on damage within the wall. This research will illustrate a means of obtaining a sample for creep life analysis with depth through the wall of a pipe, as wells as an alternative technique for the repair of the sample retrieval site. A sample retrieval technique was developed that would retrieve a small diameter cylindrical sample from a cored blind hole for creep analysis by visual creep void assessment or by the small punch creep test. The small punch creep test requires only a small diameter thin disc of material for testing for which its results are comparable with conventional uniaxial creep testing which requires a much larger sample of material. The smaller sample requirement of the small punch creep test therefore allows for a vastly reduced invasive sample retrieval operation and consequently smaller repair size area. Also the fact that the sample is retrieved from a blind hole is advantageous since the pipe wall is not penetrated which would require full plant shutdown. A friction welding technique was identified as an alternative to traditional arc fusion welding for the repair of the sample retrieval site, this technique being the Friction Hydro Pillar Processing technique. Friction Hydro Pillar Processing is a solid-state welding technique and as such has a number of inherent benefits over arc fusion welding as the weld is performed below the melting temperature of the material. From a process point of view Friction Hydro Pillar Processing is ideally suited for automation, has virtually no fumes generated, minimal distortion is experienced and no spatter has to be removed afterwards. The technique has yet to see industrial application and as such development of suitable process parameters was undertaken. Finally, to apply the sample retrieval and repair operations in-situ to a steam pipe in a power plant suitable equipment was developed. Existing friction welding equipment is generally bulky workshop based equipment and is unsuitable for on-site work due to its size and weight. Therefore development of dedicated equipment was required to enable Friction Hydro Pillar Processing to be applied to steam pipes within a power plant environment.
- Full Text:
- Date Issued: 2013
Monitoring and intelligent control for complex curvature friction stir welding
- Hua, Tao
- Authors: Hua, Tao
- Date: 2006
- Subjects: Friction welding , Fuzzy systems
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9612 , http://hdl.handle.net/10948/420 , Friction welding , Fuzzy systems
- Description: A multi-input multi-output system to implement on-line process monitoring and intelligent control of complex curvature friction stir welding was proposed. An extra rotation axis was added to the existing three translation axes to perform friction stir welding of complex curvature other than straight welding line. A clamping system was designed for locating and holding the workpieces to bear the large force involved in the process between the welding tool and workpieces. Process parameters (feed rate, spindle speed, tilt angle and plunge depth), and process conditions (parent material and curvature), were used as factors for the orthogonal array experiments to collect sensor data of force, torque and tool temperature using multiple sensors and telemetry system. Using statistic analysis of the experimental data, sensitive signal features were selected to train the feed-forward neural networks, which were used for mapping the relationships between process parameters, process conditions and sensor data. A fuzzy controller with initial input/output membership functions and fuzzy rules generated on-line from the trained neural network was applied to perceive process condition changes and make adjustment of process parameters to maintain tool/workpiece contact and energy input. Input/output scaling factors of the fuzzy controller were tuned on-line to improve output response to the amount and trend of control variable deviation from the reference value. Simulation results showed that the presented neuro-fuzzy control scheme has adaptability to process conditions such as parent material and curvature changes, and that the control variables were well regulated. The presented neuro-fuzzy control scheme can be also expected to be applied in other multi-input multi-output machining processes.
- Full Text:
- Date Issued: 2006
- Authors: Hua, Tao
- Date: 2006
- Subjects: Friction welding , Fuzzy systems
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9612 , http://hdl.handle.net/10948/420 , Friction welding , Fuzzy systems
- Description: A multi-input multi-output system to implement on-line process monitoring and intelligent control of complex curvature friction stir welding was proposed. An extra rotation axis was added to the existing three translation axes to perform friction stir welding of complex curvature other than straight welding line. A clamping system was designed for locating and holding the workpieces to bear the large force involved in the process between the welding tool and workpieces. Process parameters (feed rate, spindle speed, tilt angle and plunge depth), and process conditions (parent material and curvature), were used as factors for the orthogonal array experiments to collect sensor data of force, torque and tool temperature using multiple sensors and telemetry system. Using statistic analysis of the experimental data, sensitive signal features were selected to train the feed-forward neural networks, which were used for mapping the relationships between process parameters, process conditions and sensor data. A fuzzy controller with initial input/output membership functions and fuzzy rules generated on-line from the trained neural network was applied to perceive process condition changes and make adjustment of process parameters to maintain tool/workpiece contact and energy input. Input/output scaling factors of the fuzzy controller were tuned on-line to improve output response to the amount and trend of control variable deviation from the reference value. Simulation results showed that the presented neuro-fuzzy control scheme has adaptability to process conditions such as parent material and curvature changes, and that the control variables were well regulated. The presented neuro-fuzzy control scheme can be also expected to be applied in other multi-input multi-output machining processes.
- Full Text:
- Date Issued: 2006
Characterization of friction hydro pillar process weld properties as applied to 10CrMo910 creep resistant steel for application in the power generation Industry
- Authors: Bulbring, Daniel Louis Hans
- Subjects: Materials -- Creep , Friction welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: vital:9636 , http://hdl.handle.net/10948/d1020586
- Description: Creep degradation of steam carrying vessels in the power generation industry is a concern that needs to be constantly monitored. The Weldcore® process has been earmarked as a potential method of creep sampling which will allow for thick-walled sections to be analysed. A component of the process involves plugging the resultant hole after removing a creep sample using a novel welding technique called friction hydro pillar processing. At the commencement of this study, insufficient data was available to warrant safe industrial application of the process. This research was conducted to evaluate the performance of 10CrMo910 friction hydro pillar process welds. The effects of downward force, stud taper angle, hole taper angle and hole base diameter on process response, defect population, static properties and dynamic performance were evaluated. The variation of downward force showed that higher forces produce significantly smaller defects and higher fatigue life. The occurrence of defects was linked to process parameters and geometry thereby identifying the correct parameters for safe use in the power generation industry. Flash formation was identified as an early indicator of weld defects and can assist with quality control in industrial applications. Methods of standardising the plunge depth and forge force were developed to identify the correct magnitudes for different geometries, without the need for testing. Defects were shown to populate specific regions of the weld and produce variations in fatigue life. Crack initiation sites were detected which will aid in identifying areas of focus in further research and development. Temperature measurements were linked to the occurrence of defects and crack initiation sites and have been identified as a method of identifying defective welds. The effects of process parameters and stud and hole taper angles on energy inputs and near interface temperatures were statistically evaluated. Downward force was shown to have the largest effect on energy input rates, total energy input and temperatures at the 11.5mm and 20.5mm positions. Smaller hole and stud taper angles produced lower energy inputs and were identified as more energy efficient than the larger taper angles. A regression model was also developed to predict the fatigue life of welds and can assist with critical process related decision making. A range of hole base diameters were identified which produced welds with low defect populations and fatigue performance similar to that of the parent plate. Larger hole base diameters were shown to produce significant defects along the hole bottom fillet, in the weld nugget and along the bond line. Temperature measurements of the larger diameter welds showed a delay in response and are attributed to a delayed contact of plasticised stud material with the sidewall. Welds with hole base diameters larger than 11mm produced unrepeatable and defective welds, and also required higher energy inputs making smaller diameters more desirable. Analysis of all welds in this study revealed that clearance and interfacial pressures characterise the quality of friction hydro pillar process welds, therefore models were developed to aid in critical decision making with respect to downward force and geometry. This study has successfully evaluated the effects of process parameters and geometry on the properties of friction hydro pillar process welds and thereby has increased understanding of the process.
- Full Text:
- Authors: Bulbring, Daniel Louis Hans
- Subjects: Materials -- Creep , Friction welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: vital:9636 , http://hdl.handle.net/10948/d1020586
- Description: Creep degradation of steam carrying vessels in the power generation industry is a concern that needs to be constantly monitored. The Weldcore® process has been earmarked as a potential method of creep sampling which will allow for thick-walled sections to be analysed. A component of the process involves plugging the resultant hole after removing a creep sample using a novel welding technique called friction hydro pillar processing. At the commencement of this study, insufficient data was available to warrant safe industrial application of the process. This research was conducted to evaluate the performance of 10CrMo910 friction hydro pillar process welds. The effects of downward force, stud taper angle, hole taper angle and hole base diameter on process response, defect population, static properties and dynamic performance were evaluated. The variation of downward force showed that higher forces produce significantly smaller defects and higher fatigue life. The occurrence of defects was linked to process parameters and geometry thereby identifying the correct parameters for safe use in the power generation industry. Flash formation was identified as an early indicator of weld defects and can assist with quality control in industrial applications. Methods of standardising the plunge depth and forge force were developed to identify the correct magnitudes for different geometries, without the need for testing. Defects were shown to populate specific regions of the weld and produce variations in fatigue life. Crack initiation sites were detected which will aid in identifying areas of focus in further research and development. Temperature measurements were linked to the occurrence of defects and crack initiation sites and have been identified as a method of identifying defective welds. The effects of process parameters and stud and hole taper angles on energy inputs and near interface temperatures were statistically evaluated. Downward force was shown to have the largest effect on energy input rates, total energy input and temperatures at the 11.5mm and 20.5mm positions. Smaller hole and stud taper angles produced lower energy inputs and were identified as more energy efficient than the larger taper angles. A regression model was also developed to predict the fatigue life of welds and can assist with critical process related decision making. A range of hole base diameters were identified which produced welds with low defect populations and fatigue performance similar to that of the parent plate. Larger hole base diameters were shown to produce significant defects along the hole bottom fillet, in the weld nugget and along the bond line. Temperature measurements of the larger diameter welds showed a delay in response and are attributed to a delayed contact of plasticised stud material with the sidewall. Welds with hole base diameters larger than 11mm produced unrepeatable and defective welds, and also required higher energy inputs making smaller diameters more desirable. Analysis of all welds in this study revealed that clearance and interfacial pressures characterise the quality of friction hydro pillar process welds, therefore models were developed to aid in critical decision making with respect to downward force and geometry. This study has successfully evaluated the effects of process parameters and geometry on the properties of friction hydro pillar process welds and thereby has increased understanding of the process.
- Full Text:
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