Stainless Steel Pipe TIG + MAG welding

 Case Study 1

0Cr18Ni9 bassoon φ530mm × 11mm stainless steel all position levels fixed butt joint oil pipeline is mainly used for power plants, welding more difficult, requiring high quality of welded joints, forming the inner surface required well, moderate bulge after welding requires PT , RT test. TIG welding are used in the past or manual arc welding, the former low efficiency, high cost, which is difficult to guarantee quality and low efficiency. To ensure both the quality and efficiency, the use of TIG, the outside bottom of filler wire welding method, MAG welding fill and cover surface, the quality and efficiency are guaranteed.

0Cr18Ni9 stainless steel thermal expansion, electrical conductivity and the rate of carbon steel and low alloy vary greatly, and the pool of liquidity is poor, poor shape, especially in the all-position welding is more prominent. In MAG welding process, the extended length of wire must be less than 10mm, torch oscillation amplitude, frequency, speed and dwell time with the right edge, concerted action, at any time adjust the torch angle to the surface of the edge of the weld fusion neat, beautiful shape, with ensure the quality of filling and cover the surface layer.
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2 welding methods and welding preparation

2.1 Soldering Methods

Material for the 0Cr18Ni9, pipe specifications for φ530mm × 11 mm, rendering the use of manual GTAW, gas mixture (CO2 + Ar) welding filling and capping, stand up to the level of fixed-position welding.

2.2 pre-welding

2.2.1 clean up the oil, rust and other dirt, the groove surface and within the repair 10mm milled around the metallic luster.

2.2.2 Check the water, electricity, gas and road is smooth, equipment and accessories should be in good condition.

2.2.3 according to size for assembly, tacking the use of rib plate (2:00, 7:00, 11:00 for the positioning block fixed), and points can be fixed within the groove, but must pay attention to positioning of welding quality.

2.2.4 tube filled with argon protection.
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New battery manufacture laser welding technology

Battery manufacturing industry is increasingly becoming the biggest 21st century challenges. Although the global annual production capacity battery has reached tens of billions of pieces, but the traditional battery manufacturing technology and cost effectiveness in the battery budget, can not meet the rapid growth of the battery applications. Most of us have been very clear, the battery used in hybrid vehicles, plug-in hybrid electric vehicles and all vehicles. Although the batteries in automotive applications mixed, but still can not stop the people in this industry to invest. "American Recovery and Reinvestment Act" (ARRA or AR2) mentioned to those in the U.S. investment company producing cells into the tens of millions of dollars. Borrow U.S. Energy Secretary Steven Chu (Steven Chu) as saying, "These are very effective investment in the future will bring us many times in return, mainly reflected in: the creation of employment opportunities, reduce dependence on foreign oil, we breathe air cleaner, and the impact the fight against climate change. "

In addition to applications in the automotive industry, the cost-effective, high-performance battery power and alternative energy industry in the application are also very attractive. Widespread installation of battery storage to provide residential power demand load levels, and emergency backup power. This distributed energy storage solutions can also improve the efficiency of electricity production base of production, to offset part of the demand for investment, to improve some of the large grid infrastructure. Moreover, the electrical energy storage will help give full play to the advantage of alternative energy sources of instability, such as solar and wind power. In addition, the economic and high-performance battery technology will also help reduce the cost of grid expansion.

Today, the "high performance and economy" should be used to clearly describe and approved batteries in helping us solve the energy challenge in playing the hero role. While so far a lot of development work focused on new battery technology developed and mature before the old technology (such as for flashlights, cameras and computer battery), compared also slightly tender. Because the application is now on the market for battery energy storage and battery life requirements are higher, the battery's weight and lower cost requirements, the challenges of the manufacturing process is still addressed. Many promising battery solutions exist only in theory, graphic design, CAD, and this approach has been designed and existing manufacturing capabilities and limitations faced by divorced. In other words, designers and manufacturing personnel to communicate between the need for more! We will help them.

Many applications in the industry in battery technology, has no recognized or obvious winner. Lithium ion, nickel metal hydride, zinc-air, sodium, sulfur, and many other battery chemistries competing with each other to meet the diverse needs of a variety of applications. And the battery for a given species, there are many different products will change shape, which may lead to different manufacturing methods. New batteries are mostly cylindrical or graphic design. Battery cells are stacked, packed up, or arrays, so that the separate units are combined in series and parallel circuits. The connection between unit and unit may involve similar or different metal materials, there are two or more different layers. Despite the diversity of design, but in all of these concepts in battery design have one thing in common emerging. The common challenge is the need to increasingly thin metal material at a faster speed link, which is laser applications.

Battery usually contains many kinds of materials, such as zinc, steel, aluminum, copper, titanium and nickel. These may be made of metal electrodes, wire, or just a shell. They may be or not be a metal or other material covering the battery. However, no matter by what their composition, based on weight and cost minimization considerations, they should be as thin as possible. Many new battery design material thickness in the range 25 to 250 microns. Welding of these metals are two main requirements include creating a current conduction path and / or electrolyte can be stored, but the design and application of each battery, the battery's full performance specifications welding is unique. Conductivity, strength, hermetic, metal fatigue and corrosion resistance is typical of the welding quality evaluation criteria. Then, all of these criteria have been identified and achieved, the key determining factor is whether the economic cost.

Battery welding design for the success of the manufacturing process plays a key role. Fillet welding and butt welding is often attractive to the designer, but take the welding is by far the most likely to succeed. Lap welding welding compared to the other two methods, can provide more flexibility, thanks to its need to implement other means of welding required precision alignment of the node to the end of the beam. Lap welding but also for the final task of providing integrated multi-cell module of the possibility of welding (see Figure 1), this process may involve one or more material types. For example, a same type of metal may need to be accurately welded to another type of conductor. Welding methods can be used now there are many kinds, and is rapidly developing.

Bath series electrical connection and (BUSS) connections are usually required to connect non-similar metals. It is in this area, the unique high-speed laser welding (100-1000 mm / sec) is the other welding technology can not match. High-brightness fiber laser further promote high-speed welding, the weld can be achieved at low heat input and high solidification rate. This high cooling rate can effectively control the mixture of metal welded in place in the coagulation defects. Most likely to crack a combination of weld metal is copper and aluminum, which also happen to be in the lithium-ion battery in one of the most commonly used combinations of metals. High-speed fiber-optic laser welding of metal welding in this important process, showing a crack-free welding characteristics. Need to use or some other unusual combinations of metals can also use laser welding to complete, especially when the solidification rate is high time (see Figure 2). Finally, as long as the weld metal combinations can be achieved, it is vital that they are expected to assess the performance of the battery capacity of the application (especially strength, toughness, fatigue and corrosion in the metal).

Some people may think, this attractive advantages and opportunities of the manufacturing process must be accompanied by a combination of negative factors. The first factor is the negative of these unique application of laser welding cell designers is relatively unfamiliar. Thus, the "laser friendly" design is not often as the preferred welding. In addition, if we consider the use of laser welding technology, which often occurs, the outstanding issues will emerge - the performance of the weld how? Battery industry seem to be more willing to quickly put into reliable manufacturing capacity, the simple point of view, society in no time, resources or patience to evaluate, develop and implement new alternative solutions.

There is a recognized, are frequently used for laser welding solution is based on the galvanometer scanning laser welding. This "remote welding" technology in the vast world of laser welding is not particularly novel, but in the scan head and laser performance improvements, is it more and more attention. The increasing power of high-power fiber laser beam emitted almost perfect, now in the welding process is completely within the speed limit full use of, and limits the movement of other welding systems to accelerate the problem did not affect it. The beam quality is also guaranteed a greater visual range, a longer run time and greater angle of incidence, can be configured in a number of batteries used to weld multiple joints simultaneously welding (see Figure 3).

Other high-speed galvanometer scanning laser welding advances include the new "flying optics" welding technique. In this case, the need to achieve broad coverage, high welding speed and acceleration are all very high precision of synchronization through the scanning axis (A, B) and perpendicular direction of mechanical motion (X, Y) to achieve. EWI company uses a standard scan head and Aerotech Scanlab produced by the beta CNC software and hardware to develop and prove the feasibility of this technology. This high-performance solution for laser welding (see Figure 4) is currently used for battery and fuel cell welding welding challenges in the development.
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The last problem is the process of laser welding cell stability and quality assurance. Based on the speed and flexibility of laser welding, the manufacturing process also depends on the success of other mechanical parts in the whole system performance, to quickly achieve a good weld. This is a very difficult task, especially considering the small size and high speed welding, and battery manufacturing large quantities required to complete the weld. At the same time, taking into account in the final welding of the battery package requires the number of Six Sigma quality level of welding is not enough, need to achieve higher quality levels. For these key challenges (and welding quality assurance process route) solutions, mostly through high-speed image acquisition and analysis available. Some of these methods have in some lower-speed laser welding applications try, but need to further improve the speed and accuracy, which is in the battery manufacturing industry in the potential of laser welding full assurance.

Welding speed, mixed-metal performance and quality control has had the chance, only due to the further development and widespread use. Laser welding may only capture this round of new battery development boom in a small, but it may become the next most dominant cell materials selection connectivity applications.
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Welding technology's role in earthquake relief

First to the "5.12" earthquake victims of fellow citizens expressed deep condolences! Relief to the fighting in the first line of the majority of the PLA officers and soldiers, police officers, the majority of the cadres and the masses of volunteers and disaster paid tribute!

    Since the "5.12" earthquake happened all the time since my interest relief in the process of looking at a scene depicting shocking that a rate touching the lens, I feel very excited.

    Both rushed to the disaster, Premier Wen directing disaster relief, or command to mobilize the PLA and armed police hit the branches of the military advance of General Secretary Hu Jintao. Whether fighting in the first line of the PLA and rescue, armed police officers and soldiers, volunteers and the disaster area or the majority of cadres and the masses. They kind of afraid of difficulties and heroic fighting spirit of all that I moved.

    32 years ago, as a People's Liberation Army soldiers, who have personally experienced the Tangshan earthquake and the earthquake relief work. At that time, I Luan County forces in Tangshan region of the repair service, is a welder. I survived the earthquake. However, our barracks and the surrounding houses have suffered devastating damage, the people suffered heavy casualties.

    I would say is as a welding worker, we should be in relief for what?

    Welding - The technology in relief of early, mid, late has its irreplaceable role in other types of work. His main advantages are: 1, both gas welding or welding. The equipment is simple, use common, easy to carry operation, particularly in the current urgent circumstances, to facilitate the collection and transport. Oxygen cutting welding is the collapse of steel structures in one of the best tools. Small welding machine can dig survivors in the current emergency rapid welding shaped components, as a kind of rescue and support tools to quickly put into use.
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    In my experience the following welding of the majority of relief workers, introduced a few of the early, mid, post more applicable technologies and tools.

    First, the current is a pre-earthquake relief, should organize the collection and procurement of gas welding equipment, welding machines, welding technology, the organization quickly rushed to the hardest hit, with the majority of the PLA and armed police emergency rescue. The main task is to use the equipment for concrete reinforcement in cut and shaped components to prevent the rapid welding secondary damage caused by the collapse rubble.

    Second, the pre-earthquake relief, 167 hours of basic search and rescue mission is completed. Both the medium stage. Middle stage of the main task is to clean up the remains of dead compatriots, while the ruins of the demolished. At this time requires a lot of basic tools. Such as: Wadao, big shovel, small carts, chisel, pry bar, winch and other tools. These tools can be used welding equipment and welding machines manufactured and put into use quickly.

    Third, the relief continues to move forward, will enter the stage of life to settle the victims, both advanced stage. This stage the majority of our welding and machining factory workers should be made simple cooking equipment, such as: small diesel furnace, steam cooker, semi-permanent seismic room. Enable victims to eat the hot meals drink water, live on the warm room. Prepare for post-disaster reconstruction.

    In the above three stages, the majority of welding technology and welding of the technical staff in the relief work of this great play an irreplaceable role.

    Because of my work, I can not personally to the first line of relief, only in this way express my support for the earthquake relief work.
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Shenzhen, a breakthrough in the quality of welded steel construction

Recently, the country's first LNG import terminal project - came news of the Shenzhen LNG project, the construction of Sinopec four built in 9% Ni (nickel) steel welded construction of a new high, a welding pass rate for the first time more than 99 %, and achieved a record high.

The project as the first domestic installation of a large LNG storage tanks, the unique nature of their construction methods and welding materials, special construction company once to four Department of the Shenzhen project technical staff has become more difficult. To overcome this difficulty, the four construction companies since 2004 successfully completed up to 21 9% Ni steel welding procedure, which makes the original assessment of need to get outside for hands in the four successful completion of the construction and subsequent T-1101 and No. T-1102 tank construction to maintain more than 98% of the welding pass rate, get a foreign project supervision and the owner of the high degree of recognition.
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Currently, the key to the construction phase of the T-1103 in the number of LNG tank construction, four technical quality of the construction company staff of "quality first, continuous improvement." The quality, strictly in the construction process, layers of control site construction quality, especially in the 9% Ni steel welding process, the strict control of welding parameters and welding process discipline to ensure the progress of construction under the premise of making a welding pass rising, now 9% Ni steel welding passing rate reached 99.13% of the best in history, and therefore subject to the total package, the owners and foreign experts alike, the continuous improvement of welding pass rate also shows that China has fully mastered the 9% Ni steel welding, as in China construction industry overall open foreign LNG tank construction market has far-reaching significance.
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Petrochemical construction and efficient welding technology and the current situation

Visit to China National Petroleum Offshore Engineering Company Zhijian Senior Engineer

As competition intensifies, the prices of petroleum, petrochemical construction cycle is short and efficient welding technology, equipment and materials applications is the trend. But efficient welding technology, equipment and materials in petroleum, chemical construction applications, there are still many problems. The following combination of specific projects to talk about the efficient application of welding technology and practical needs, necessity and importance.
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    First, the offshore oil project in the construction of large marine structures. The weight of large offshore oil steel, structure and size of offshore oil development with increasing water depth, marine structures has been increasing, the volume of structures and the use of the plate thickness is increasing. With the rise in steel prices and offshore structures, offshore installation capacity requirements, the application of high strength steel is also a large area using, so that you can reduce the amount of steel. Small marine structures using materials mostly 355MPa even lower intensity level of the material, large-scale structure of 420MPa steel for offshore platforms is increasing the use of proportion. In addition, with the plate thickness increases, bringing a large number of post weld heat treatment of the workload. For example, the offshore platform jacket of a 95mm, φ3750mm ring weld, using double-sided groove (groove depth of 1 / 3, outside the groove depth of 2 / 3), weld metal weight of nearly 271kg, so the use of efficient welding technology, equipment, welding technology and high-performance materials (eliminating weld annealing treatment) is inevitable. Solve the above problem, from two aspects: First, the use of efficient submerged arc welding, the waveform control technology, dual-wire submerged arc welding system (U.S. Lincoln's products); the other hand, high strength, high toughness welding material through the evaluation of weld toughness CTOD test, the abolition of annealing after welding, thus shortening the construction cycle of marine structures.

    Secondly, a large LNG storage tank construction. Large LNG storage tank for the 9Ni steel base metal. The material in the welding parameters welding requires very strict, welding heat input is small, low-temperature layer, which doomed the welding of low efficiency. Therefore, LNG girth welding using submerged arc welding in the horizontal welding, and welding and the use of both sides of the same side welding backing forming welding submerged arc process, using AC square-wave high-efficiency submerged arc welding machine and other new technologies, can effectively improve the welding efficiency.

    At present, China Petroleum and Chemical efficient welding technology gap with foreign countries than not, the new welding equipment, welding and welding materials in the same starting line. Because the current structure in the marine LNG storage projects and large-scale projects using welding equipment and welding materials are mostly imported, welding technology and welding auxiliary facilities with foreign companies is not much difference. But the most crucial question is: those in the field of welding equipment and welding materials and more dependent on imports, our own production equipment and welding materials can not meet the industry's production requirements, but also our welding equipment and welding materials businesses to work together.

    Our company is an offshore steel construction companies, hope that China's welding business with foreign companies to develop a very technical level, even higher level of technology of welding equipment and welding materials, welding technology reduces the high dependence on foreign .
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New welding technology to help the Central Asian Pipeline "accelerate"

 Central Asian natural gas pipeline project pipeline up to 1801 km, since August 8 this year, sparking open welding has, in Kazakhstan has been rapidly advancing the construction of 500 km. Yesterday morning, in Almaty, Kazakhstan, Central Asia, China Petroleum Pipeline Bureau, the total pipeline welding division Jin Red Star introduced to ensure that this pipeline for 30 years safe in the pipeline's construction of the building, they are in the traditional "semi-automatic welding cellulosic electrodes plus" technology, the innovation of "semi-automatic welding in welding plus" technology, welding is 1.5 times the original schedule, while reducing the labor intensity of 1.5 times and construction costs.

   Uniform welding standards

     Central Asian natural gas pipeline from Turkmenistan and Uzbekistan from the border of Baghdad Naim, via Uzbekistan, Kazakhstan, and finally to our country's Horgos connected with the Second West-East. Transit countries of Kazakhstan and Uzbekistan are involved in this long-distance pipeline construction.

     Early in the project, the first star placed in front of Jin's contradiction is that the Kazakh state with two black state in welding and welding inspection personnel to follow the standard construction is still in Russia in 1989 to develop standards, and the present welding and global testing standards is the latest version of the American Petroleum Institute API1104 welding specifications, has achieved great technical leap.

     To ensure quality, increase weld schedule, repeated and Kazakh star Jin, Wu countries one by one against the standard of welding experts to communicate, and ultimately make them acceptable to use the latest version of the global welding and testing standards.
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   Accelerate the progress of welding

    With the unification of welding technology and testing standards, but more fully in the project to promote efficient welding technology. After several experiments, the technical staff from the traditional "semi-automatic welding cellulosic electrodes plus" technology, and innovation and a "semi-automatic welding in welding plus" technology. The process by China Petroleum Pipeline Bureau expert seminar.

    Pipeline construction in Central Asia came in handy in the process, the progress of welding proven traditional technology is 1.5 times the original. Central Asia pipeline diameter of 1067 mm, 1 km long pipeline with 85 pipe to be welded, just 10 hours to complete, fully automated welding machine with similar speed, but an automatic welding machine than 1 year unit to save $ 22 million; and the original old technology can only be done half a kilometer, while saving 30% than the traditional craft of welding consumables, which means savings of 30% of the equipment and human resources.
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