
1. analogue to the Almen test in shot peening, a test strip adapted to HFH procedures was to be developed. After HFH treatment of the test strip, it should be possible to determine or check the intensity of the …
P 872 - Development of a simple quality assurance test for the application of higher-frequency hammering processes The fatigue-strengthening effect of high-frequency hammering (HFH) has been demonstrated on a large number of construction details suitable for post-treatment. In addition to recognised rules for dimensioning and the qualification of users, the reliable use of HFH methods also requires the qualification and quality assurance of the device and its operating settings. In addition, proof of sufficient post-treatment quality on the component is required. Three different approaches initially appear possible here, which were investigated as part of this brief study and a parallel DASt research project.
In particular, the following approaches were tested for their effectiveness and ease of implementation: 1. analogue to the Almen test in shot peening, a test strip adapted to HFH procedures was to be developed. After HFH treatment of the test strip, it should be possible to determine or check the intensity of the post-treatment based on the deflection of this test strip. 2. determination of the penetration depth. The penetration depth can be determined by comparing a 3D laser measurement before and after post-treatment. The penetration depth should serve as a parameter for estimating the intensity of the post-treatment. 3. investigations with hardness measurements on post-treated and untreated weld seam transitions have shown differences in hardness. The quality of the post-treatment can possibly be assessed on the basis of the hardness comparison. The aim of this short study is to develop a simple and practical quality assurance procedure that can be used under normal manufacturing conditions. The effectiveness of the application of the HFH methods should also be guaranteed. As a result, a combination consisting of a simple visual inspection of the post-treatment track on the structure and a random sample with defined hardness testing is proposed for the quality assurance of the higher-frequency hammering processes. Appropriate gauges for measuring and documenting the indentation depths must then be used as part of the visual inspection. Further residual stress measurements could, if necessary, contribute to the verification of permissible hardness values and provide information on the residual compressive stresses introduced as a result of varying intensities.
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P 822 - Use of the laser beam-MSG hybrid welding process on longitudinally welded large-diameter pipes of grade API-X80/ -X100 to increase toughness and efficiency A significant proportion of modern oil and gas pipelines are made from longitudinally welded large-diameter pipes in API steel grades X65 (L450, 1.8726) and X70 (L485, 1.8727). Constantly increasing natural gas and crude oil production rates in conjunction with minimising wall thickness or increasing operating pressure will in future require corresponding material substitutions with modern higher-strength materials, such as API-X80 (L555, 1.xxxx), X100 (L690, 1-xxxx) and X120, with sufficient strength and toughness. The submerged arc welding process is used to weld these pipes. The entire pipe length is first welded with a continuous MSG tack weld. To increase economic efficiency, this process step is to be replaced by the laser beam-MSG hybrid welding process. For the safe operation of large-diameter pipes, the required impact strength of the welded joint must be observed in addition to the strength properties. Against this background, the primary research objective of this research project was to define and systematically investigate the achievement of sufficient toughness in the temperature range of -60°C and -40°C with economic process parameters. Suitable filler materials (solid wire and flux-cored wire electrodes) were identified for the laser-MSG hybrid welding of the aforementioned high-strength pipeline materials and systematic studies were carried out on the dependence of toughness on solidification behaviour and the achievable mixing depth. Increased economic efficiency when using laser hybrid technology is seen primarily in the modified seam preparation. A constructive change in the joint shape leads to a reduction in the seam volume and thus to a considerable reduction in production costs, because in this case the amount of filler material required to fill the seam is reduced. Based on demonstrators produced, an approx. 2.7-fold reduction in the seam cross-section and thus the required quantity of filler material is demonstrated. The IGF project 16415 N of FOSTA -Forschungsvereinigung Stahlanwendung e.V., Düsseldorf, was carried out at the Federal Institute for Materials Research and Testing (BAM), Department 9.3 "Welding Manufacturing Processes", Berlin, and funded by the Federal Ministry of Economics and Technology via the AiF as part of the programme for the promotion of joint industrial research and development (IGF) on the basis of a resolution of the German Bundestag. Authors: M. Rethmeier, S. Gook, A. Gumenyuk Publication: 2013
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