Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Orbital hybrid laser arc welding using a high power fibre laser for pipeline construction
    ( 2018)
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    Recently developed fibre lasers provide multi-kilowatt beam power with high quality at impressive energy efficiency. Combined with gas metal arc welding (GMAW) equipment these lasers can be used in a hybrid process to weld thick-walled constructions single-pass, that are currently welded using multi-pass techniques. The main benefits are a reduction of heat induced distortions, due to the low heat input, as well as savings in filler material and process time. Probable applications can be found in power generation, ship building and pipeline constructions. An orbital (girth) laser-hybrid process using a 20 kW fibre laser and a GMAW torch is currently examined at the BAM, Berlin. The aim of this research is to obtain a stable and crack free girth welding process and to demonstrate its application in pipeline construction. The experiments are carried out on 16 mm thick plates as well pipe rings with 36" (914 mm) pipe diameter of X65. Particular welding parameters, such as welding speed, GMAW power, arc length are varied and their influence on the appearance of the weld in the different welding positions is analyzed. Even though issues remain that demand further research it could already be shown that the rings can be welded using a girth hybrid process that is divided into two half girth processes in downward direction.
  • Publication
    Hybrid laser arc welding of X80 and X120 steel grade
    ( 2017)
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    The aim of the present work was to investigate the possibilities of hybrid laser arc welding regarding reliable production of longitudinal welds of high strength pipe steels X80 and X120 and to evaluate achievable mechanical properties of laser hybrid welds. The study focused on weld toughness examination in low temperature range up to -60 °C. Suitable filler materials were identified in the context of this task. It could be shown that metal cored electrodes guaranteed sufficient Charpy impact toughness at low temperature for both investigated materials. Modern arc welding technologies such as modified pulsed spray arc were used to promote deeper penetration of the filler material into the narrow laser welding gap. Edge preparation with a 14 mm deep root face was considered as optimum, because no penetration of the filler material could be detected beyond this depth limit and therefore any metallurgical influences on the weld metal properties through the welding wire could be excluded.
  • Publication
    Hybrid laser arc welding of X80 and X120 steel grade
    ( 2014)
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    The aim of the present work was to investigate the possibilities of hybrid laser arc welding regarding reliable production of longitudinal welds of high strength pipe steels X80 and X120 and to evaluate achievable mechanical properties of laser hybrid welds. The study focused on weld toughness examination in low temperature range. Suitable filler materials were identified in the context of this task. It could be shown that metal cored electrodes guaranteed sufficient Charpy impact toughness at low temperature for both investigated materials. Modern arc welding technologies such as modified pulsed spray arc were used to promote deeper penetration of the filler material into the narrow laser welding gap. Edge preparation with a 14 mm deep root face was considered as optimum, because no penetration of the filler material could be detected beyond this depth limit, and therefore, any metallurgical influences on the weld metal properties through the welding wire could be excluded.
  • Publication
    Laser-hybrid welding for pipe production and pipe laying of thick large diameter pipes
    ( 2013)
    Rethmeier, Michael
    ;
    Gumenyuk, Andrey
    ;
    Gook, Sergej
    New brilliant high-power lasers such as disc laser and fibre laser open up new fields of applications for laser-hybrid welding, e.g. power generation, shipbuilding and pipeline construction. To a large extend, longitudinally welded large-diameter pipes are used for modern oil- und gas-pipelines. New material trends are high strength steel grades API-X80 or higher. For the production of such pipes a large plate is first formed to an open ring. Subsequent, it is continuously tacked by means of metal active gas (GMA) welding process. The remaining double-sided joint gaps are filled up by cost-intensive multiple-wire submerged arc welding (SAW) processes. For reasons of economy the GMA tackweld process can be replaced by the laser-GMA-hybrid welding process, whereby as primary objective sufficient weld metal toughness for low temperature applications down to 60C is pursued. Results are discussed in the light of achievable toughness of the welded joints and their accordance with the requirements demanded in the standards. It could be shown that the penetration depth of filler material is rather independent of the kind of arc used and does not exceed 13 mm. A second interesting aspect is the use of laser-hybrid welding in pipe laying, insensibility towards tolerances and the possibility of orbital welding are very important factors in addition to the weld seam quality. First promising results for laser-hybrid welding of thick materials could be demonstrated. Half-orbital welds could be demonstrated for a single pass weld in 16 mm thick large-diameter pipes.
  • Publication
    Prospects of application of laser-GMA hybrid welding for manufacturing of large diameter longitudinal welded high strength steel pipes
    ( 2013)
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    The aim of the present work was to investigate the possibilities of hybrid laser arc welding regarding reliable production of longitudinal welds of high strength pipe steels X80 and X120 and to evaluate achievable mechanical properties of laser hybrid welds. The study focused on weld toughness examination in low temperature range up to 260uC. Suitable filler materials were identified in the context of this task. It could be shown that metal cored electrodes guaranteed sufficient Charpy impact toughness at low temperature for both investigated materials. Modern arc welding technologies such as modified pulsed spray arc were used to promote deeper penetration of the filler material into the narrow laser welding gap. Edge preparation with a 14 mm deep root face was considered as optimum, because no penetration of the filler material could be detected beyond this depth limit, and therefore, any metallurgical influences on the weld metal properties through the welding wire could be excluded.
  • Publication
    High power laser beam welding
    ( 2013)
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    To a large extend, longitudinally welded large-diameter pipes are used for modern oil- und gas-pipelines. New material trends are high strength steel grades API-X80 or higher. For the production of such pipes a large plate is first formed to an open ring. Subsequent, it is continuously tacked by means of metal active gas (GMA) welding process. The remaining double-sided joint gaps are filled up by cost-intensive multiple-wire submerged arc welding (SAW) processes. For reasons of economy the GMA tackweld process can be replaced by the laser-GMA-hybrid welding process, whereby as primary objective sufficient weld metal toughness for low temperature applications down to -60°C is pursued. Results are discussed in the light of achievable toughness of the welded joints and their accordance with the requirements demanded in the standards. It could be shown that the penetration depth of filler material is rather independent of the kind of arc used and does not exceed 14 mm. A second interesting aspect is the use of laser-hybrid welding in pipe laying, insensibility towards tolerances and the possibility of orbital welding are very important factors in addition to the weld seamquality. First promising results for laser-hybrid welding of thick materials could be demonstrated. Half-orbital welds could be demonstrated for a single pass weld in 16 mm thick large-diameter pipes.