Determination through the distortions analysis of the best welding sequence in longitudinal welds VATS electron beam welding FE simulation

This paper presents a detailed finite element simulation of the longitudinal rib welds of Vessel Advanced Technology Segment (VATS) by e-beam welding. Nine different simulation sequences were carried out to explain the different mechanisms that drive the distortions process during welding and to lead to an optimum sequence which minimizes the final distortions. The simulations were used to guide the manufacture of the final sequence of the VATS. Distortion measurements taken after welding compared very well with the simulated results.     

FEM simulation of a small EB welded mock-up and new sequence proposed to improve the final distortions

In this paper, an Electron Beam (EB) welded mock-up is used for the calibration of the finite element method welding simulation developed. Once the method is validated, a new simulation welding sequence is proposed with the objective to reduce the mock-up final distortions. The final distortions should be reduced from 7 mm to 1 mm.Distortion measures and final deformed shapes are compared between two simulation scenarios to establish the effects of the new provisions assumed. The new simulation scenario includes a balanced longitudinal weld sequence in order to minimize the effects of the accumulative angular distortion process. The power of the FE method developed is demonstrated and will allow the optimization of the welding sequences to carry out previous simulation in FEM in future applications of ITER.     

Use of a new methodology for prediction of weld distortion and residual stresses using FE simulation applied to ITER vacuum vessel manufacture

The ITER VV Sectors have to be manufactured to extremely tight tolerances, without the production of a prototype to establish the welding distortions. It is thus necessary to develop a (computationally) successful methodology for modelling weld process in order to predict welding distortion and residual stresses. Further, in order to optimise the manufacture sequence and method, the model should be able to rapidly assess the effect of using different sequences. Once the optimal sequence has been decided, then the method has also to be able to accurately predict the final shape.     

秦山核电二期扩建工程不锈钢厚壁管的焊接施工技术

从焊前准备、产品焊接以及焊接过程中焊接应力、焊接变形的控制等方面,系统地介绍了秦山核电二期扩建工程不锈钢厚壁管的焊接技术。针对安装过程中出现的各类影响焊接质量的主要因素进行了系统的分析,提出解决焊接变形、错边变形、加工坡口不均匀等质量问题的办法,采用合理的焊接顺序、焊接见证件管理技术及模拟焊接技术和局部挖补促进应力分布,可有效保证焊接质量,从而更好地促进厚壁管焊接技术的发展。     

Long-Term Integrity of Waste Package Final Closure for HLW Geological Disposal, (V) Applicability of MAG Welding Method to Overpack Final Closure

Overpack, a high-level radioactive waste package for Japan's geological disposal program, is required for preventing the sealed vitrified waste from contact with groundwater for 1,000 years. In this study, metal active gas (MAG) welding, a typical arc welding method, was evaluated for its applicability in sealing a carbon steel overpack lid with a thickness of 190 mm. Welding conditions and parameters were examined with multilayer welding for three different groove depths. Welded joint tests including the observation of macro- and microstructures were conducted, and mechanical properties were within tentatively applied criteria. Measurements and numerical calculations for residual stress were also conducted, and residual stress distribution tendencies were discussed. These test results were compared with those previously reported for tungsten inert gas welding (TIG) and electron beam welding (EBW). MAG welding possesses the potential to complete overpack lid closure with a maximum groove depth of 190 mm, but the applicability of MAG welding to overpack final closure should be discussed from the viewpoint of the presence of slag inclusions possibly induced in the weld metal.     

Multipurpose ANSYS FE procedure for welding processes simulation

ANSYS FE procedures and 3D models for thermal and mechanical simulation of both Laser and TIG welding processes are presented. The special features are the applicability to a non uniform gap and the use of a fast iterative procedure that assures the constancy of the fixed maximum temperature along the single pass and between each pass and the following, apart from their shapes and sizes. All the thermal and mechanical material properties of both INCONEL 625 and AISI 316 are described till to liquid phase; convection and radiation effects are considered. The 3D ANSYS models use both brick and non linear contact elements and elastic and elastic–plastic materials.Two full simulation are presented: a laser welding test (taken from ENEA) and a TIG welding one (source W7-X) with the root seam plus 14 passes; thermal and mechanical results are reported in the two cases and for the latter an extensive sensitivity analysis, changing mesh size of the filling material, welding speed and material properties, is explained with results and comparisons. This large sensitivity analysis has been executed for TIG welding because in this case (multi-pass welding) the reduction of CPU time is a strong requirement; but some conclusions are helpful for laser welding too. The mechanical calculation results very sensitive to the mesh shape: this fact implies very fine and regular meshes. The specimens are first restrained and then welded with the foreseen welding procedure; after that it is released and the final linear and angular shrinkages are calculated. The ANSYS birth and death procedure is used and the CPU time was strongly reduced.     

海阳AP1000核电工程安全壳电气贯穿件焊缝缺陷分析

海阳AP1000核电工程安全壳电气贯穿件套筒与补强板焊缝,焊接完成后经UT检验,发现存在大量危险性Ⅰ类缺陷,主要为裂纹、未融合、条渣、气孔等类型.通过统计分析,焊接缺陷主要集中在内侧焊缝套筒母材侧融合区,偏向于仰焊位置.本文主要从焊接工艺、施工作业条件等方面对缺陷产生的原因进行分析,得出通过对焊材选用、焊前预热方式、坡口设计、焊接工艺、电气贯穿件安装次序等方面的改进,可以很好的改善电气贯穿件焊接质量,这对后期核电建设具有一定的借鉴意义.     

Fundamental welding R&D results for manufacturing vacuum vessel of JT-60SA

The real vacuum vessel (VV) manufacturing of JT-60SA has started since November 2009 at Toshiba. Prior to starting manufacturing, fundamental welding R&Ds had been performed by three stages. In the first stage, primary tests for screening welding method were performed. In the second stage, the trial welding for 1 m-long straight and curved double shell samples were conducted. The dependences of welding quality and distortion on the welding conditions, such as arc voltage and current, setting accuracy, welding sequence, and the shape of grooves were studied. In addition, welding condition with low heat input was explored. In the last stage, fabrication sequence was confirmed and established by the trial manufacturing of the 20° upper half mock-up [1]. This paper presents the R&D results obtained in the first and second stages.     

A new method to estimate heat source parameters in gas metal arc welding simulation process

Heat source parameters were usually recommended by experience in welding simulation process, which induced error in simulation results (e.g. temperature distribution and residual stress). In this paper, a new method was developed to accurately estimate heat source parameters in welding simulation. In order to reduce the simulation complexity, a sensitivity analysis of heat source parameters was carried out. The relationships between heat source parameters and welding pool characteristics (fusion width (W), penetration depth (D) and peak temperature (T_p)) were obtained with both the multiple regression analysis (MRA) and the partial least-squares regression analysis (PLSRA). Different regression models were employed in each regression method. Comparisons of both methods were performed. A welding experiment was carried out to verify the method. The results showed that both the MRA and the PLSRA were feasible and accurate for prediction of heat source parameters in welding simulation. However, the PLSRA was recommended for its advantages of requiring less simulation data.     

Remove Welding Residual Stress for CFETR Vacuum Vessel by Trailing Ultrasonic Impact Treatment

The China fusion engineering test reactor (CFETR) vacuum vessel is welded by narrow gap TIG (NG-TIG) welding, and the welding residual stress of the CFETR vacuum vessel can be redistributed by trailing welding ultrasonic impact treatment. In order to investigate the feasibility of the residual stress removing scheme, and to obtain the optimal trailing ultrasonic impact treatment technological parameters in the process of removing welding residual stress, a welding model that similar to vacuum vessel welding seam is established by using ABAQUS software, a NG-TIG welding heat source subroutine which is written in FORTRAN language used to simulate NG-TIG welding. According to the welding simulation results, a trailing welding ultrasonic impact treatment model is established, and the effects of the impact pin number, the impact method, the impact pin diameter and the impact frequency on welding residual stress are studied. The results show that the longitudinal residual stress in welding seam and its adjacent area and the lateral residual stress in the whole region have been obviously decreased by different trailing welding ultrasonic impact processes, and have made the tensile stress in the welding seam and its adjacent area has been changed into compressive stress, which can provide theoretical guidance and reference for actual production.     

Design and Analysis of the Laser Robotic Welding System for ITER Correction Coil Case

ITER correction coil (CC) cases have characteristics of small cross section, large dimensions, and complex structure. The cases are made of heavy thick (20 mm), high strength and high toughness 316LN austenitic stainless steel. The laser welding is used for the case closure welding, due to its low heat input and deformation. According to the structural size and feature of the two types of cases, a set of laser welding workstation for the ITER CC case closure welding is designed. A slip plate module for the welding robot is designed to increase its workspace. According to the result of the movement simulation of the welding robots, the workstation is successful to cover all weld seams on the cases. Also, the welding platform and fixtures (includes the special welding tilter of the SCC) of the BTCC case and the SCC cases are designed. To verify the design structural feasibility of the welding tilter of SCC, the structural analysis for the rotating process has been formed in detail by using ANSYS. The simulating results show that the stress of the welding tilter can meet both static and fatigue criteria, and thus the basic structure is valid.     

热处理对含Nb锆合金焊接试样显微组织和耐腐蚀性能的影响

用真空电子束焊接方法将Zr-1.88Sn-0.35Fe-0.52Nb合金板与Zr-4板对接焊的样品,在400C、10.3MPa过热水蒸汽中腐蚀165d后,用光学显微镜从样品横截面上测量了焊接面和其背面不同部位的氧化膜厚度,并用透射电镜观察了不同部位锆合金的显微组织。结果表明:焊接样品经过500C退火处理,耐腐蚀性能明显提高,在相同的熔区和热影响区(含Nb侧)内,经过退火和未经退火的样品表面氧化膜的厚度相差10-20倍;焊接冷却时形成的bZr在退火时分解为aZr bNb是提高耐腐蚀性能的主要原因;焊接样品经过500C-1.5h退火处理后,熔区的耐腐蚀性能非常优良,在400C过热蒸汽中腐蚀165d后,氧化膜厚度未超过2mm,折算为腐蚀增重只有30mg·dm-2。根据电子探针的分析结果,熔区中的成分大约是Zr-1.2Sn-0.25Nb-0.25Fe-0.02Cr。     

Feasibility Study on Welding Structure of the HT-7U Toroidal Field Coil Case

1. IntroductionThe TF magnet system of HT-7U consists of 16coils arrayed toroidally and spaced 22.5" apart oneanother. The designed TF coils provide a magneticfield, which is necessary to maintain plasma in atokamak configuration with a current up to I MA.The TF coils have a D--shaped geometry of 3.5 meters high and 2.5 meters wide, producing a magneticfield of 3.5 T on 1.7 m of main radius. The TF coilcases, enclosing the TF winding packs, are the mainstructural components of the magn…     

Predicting welding residual stresses in a dissimilar metal girth welded pipe using 3D finite element model with a simplified heat source

Dissimilar metal welds are commonly used in nuclear power plants to connect low alloy steel components and austenitic stainless steel piping systems. The integrity assessment and life estimation for such welded structures require consideration of residual stresses induced by manufacturing processes. Because the fabrication process of dissimilar metal weld joints is considerably complex, it is very difficult to accurately predict residual stresses. In this study, both numerical simulation technology and experimental method were used to investigate welding residual stress distribution in a dissimilar metal pipe joint with a medium diameter, which were performed by a multi-pass welding process. Firstly, an experimental mock-up was fabricated to measure the residual stress distributions on the inside and the outside surfaces. Then, a time-effective 3-D finite element model was developed to simulate welding residual stresses through using a simplified moving heat source. The simplified heat source method could complete the thermo-mechanical analysis in an acceptable time, and the simulation results generally matched the measured data near the weld zone. Through comparing the simulation results and the experimental measurements, we can infer that besides the multi-pass welding process other key manufacturing processes such as cladding, buttering and heat treatment should also be taken into account to accurately predict residual stresses in the whole range of the dissimilar metal pipe.     

0Cr18Ni10Ti不锈钢源壳TIG焊接温度场数值模拟及试验验证

针对0Cr18Ni10Ti不锈钢放射源源壳钨极氩弧焊(TIG)焊接过程,采用ANSYS有限元软件对焊接温度场进行数值模拟分析,建立了非稳态TIG焊接熔池形态的数值分析模型,分析中引入了热焓和表面分布高斯电弧热源模型,初步计算了焊接电流和焊接速度对焊接温度场分布的影响。通过比较焊缝有效熔深的测量结果和计算结果,验证了所建模型的正确性和可靠性。以计算结果为基础,对焊接工艺参数进行优化,建立了0Cr18Ni10Ti不锈钢放射源源壳的焊接工艺路线。     

Effects of thermal load and cooling condition on weld residual stress in a core shroud with numerical simulation

Stress corrosion cracking (SCC) in the heat affected zone is the primary damage form due to weld residual stress, corrosion and neutron irradiation environment in the core shroud of a boiling water reactor. The distribution of weld residual stress around a weld is necessary to be clarified to evaluate the structural integrity of core shroud for SCC. Moreover, studying the effects of welding parameters on residual stress on reducing the residual stress is very important to suppress the initiation and propagation of SCC.In this paper, we used a finite element method (FEM) to clarify the distribution of weld residual stress around the sixth horizontal weld (H6a) between the lower ring and the cylinder in the core shroud. The simulation results of axial stress were consistent with the experimental results at the inside and outside surfaces of the core shroud, respectively. The effects of thermal loads and cooling conditions were also investigated with the same model. We simulated the welding progress with water cooling on the inside and outside surfaces of the core shroud in order to study the influence of cooling conditions on the residual axial stress around the weld. The simulation results indicated that water cooling decreased the residual axial stress at the same side due to changing the temperature-affected fields. Moreover, with fixing the peak temperatures of weld passes, the simulation results of the distribution of residual axial stress by the thermal loads with different heating time were compared. The simulation results suggested that the heating time was expected to be longer and the heat flux to be smaller for reaching the small tension residual axial stress or even compression stress around the H6a weld.     

Numerical simulation of the transient temperature distribution inside a close-packed array of cylindrical tubes during heating and cooling under high vacuum

The metallurgical processing of zircaloy for reactor fuel pin cladding requires the annealing of loads, each consisting of an array of tubes in a high-vacuum furnace. A knowledge of the transient temperature distribution in the load during the heating and cooling periods is of interest for the design of the furnace, the design of each load on account of the final yield of the furnace, and the metallurgical control of the process. A general mathematical model was devised, and is presented here, for the numerical simulation of heat transfer by radiation and conduction. The model was used to simulate the behaviour of loads consisting of a close-packed array of cylindrical tubes of two different diameters and wall thicknesses, and in one case with two different surface emissivities. The following processes were simulated: heating from an initial to a final temperature; pre-heating from an initial to an intermediate temperature; final heating from the intermediate to the final temperature, and cooling of the load. Numerous numerical results are presented and discussed in depth in order to get physical insight into the problem, and rules are formulated which are of great value to the engineer and the metallurgist.     

Evaluation of the electromagnetic characteristics of type 316L stainless steel welds from the viewpoint of eddy current inspections

This study evaluated the electromagnetic characteristics of austenitic stainless steel welds from the viewpoint of eddy current testing. Seven welded plate specimens, which were welded using JIS Z3221:2010 YS316L welding metals, were prepared. Two welding metals and several welding conditions were adopted to discuss the generality. The results of eddy current examination of the specimens using three different types of eddy current probes, that is, an absolute pancake probe, a differential plus-point probe, and a uniform eddy current probe, confirmed that the welds cause a large noise especially when the absolute pancake probe was used. The analysis of the signals through finite element simulations revealed that the magnetic property of the welds is not negligible from the viewpoint of eddy current testing. Complementary experiments were conducted using a vibrating sample magnetometer to validate the results.     

Prediction of residual stress distributions due to surface machining and welding and crack growth simulation under residual stress distribution

In nuclear power plants, stress corrosion cracking (SCC) has been observed near the weld zone of the core shroud and primary loop recirculation (PLR) pipes made of low-carbon austenitic stainless steel Type 316L. The joining process of pipes usually includes surface machining and welding. Both processes induce residual stresses, and residual stresses are thus important factors in the occurrence and propagation of SCC. In this study, the finite element method (FEM) was used to estimate residual stress distributions generated by butt welding and surface machining. The thermoelastic-plastic analysis was performed for the welding simulation, and the thermo-mechanical coupled analysis based on the Johnson-Cook material model was performed for the surface machining simulation. In addition, a crack growth analysis based on the stress intensity factor (SIF) calculation was performed using the calculated residual stress distributions that are generated by welding and surface machining. The surface machining analysis showed that tensile residual stress due to surface machining only exists approximately 0.2 mm from the machined surface, and the surface residual stress increases with cutting speed. The crack growth analysis showed that the crack depth is affected by both surface machining and welding, and the crack length is more affected by surface machining than by welding.     

核电站反应堆冷却剂系统主管道安装焊接

以秦山核电二期工程为例,论述了核电站反应堆冷却剂系统主管道安装焊接技术及质量控制要点,并对反应堆冷却剂系统主管道的安装顺序、安装技术要求、焊接质量检验方法以及焊接变形的控制等方面给予了详细的阐述,对核电站反应堆冷却剂系统主管道安装焊接及质量控制具有借鉴作用。