Hybrid friction diffusion bonding of 316L stainless steel tube-to-tube sheet joints for coil-wound heat exchangers

Haneklaus, Nils; Cionea, Cristian; Reuven, Rony; Frazer, D.; Hosemann, Peter; Peterson, Per F.

doi:10.1007/s12206-016-0832-z

Cited by 10 publications

(7 citation statements)

References 20 publications

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“…In UCB's previous studies [7][8][9][10] of DB joining of thin-walled tubes to tubesheets, the pull-out force during testing was limited, by the small tube cross-sectional area, to approximately 8.7 kN. In the present study, rods were used instead of tubes to allow higher force to be developed on the joint.…”

Section: Setup and Experimentsmentioning

confidence: 95%

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Ni Interlayer to Improve Low-Pressure Diffusion Bonding of 316L SS Press Fit Tube-to-Tubesheet Joints for Coiled Tube Gas Heaters

Reuven

Bolind

Haneklaus

et al. 2017

Journal of Nuclear Engineering and Radiation Science

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This study suggests a new approach to diffusion bonding (DB) 316L stainless steel: a low-pressure procedure that includes a nickel interlayer. In this approach, relatively lower pressure is applied to the sample before the DB process, in contrast to the usual approach in which higher pressure is applied during the DB process. This new procedure was tested on mock-up 316L stainless steel tube-to-tubesheet joints, which simulated similar joints in coiled-tube heat-exchanger applications. This study confirms that the new procedure meets the overall success criteria, namely, a pull-out force exceeding the force required for tube rupture. It also shows that the DB joint is improved by the use of a Ni interlayer; the joint strength increased by approximately 33% for a 0.25 μm Ni interlayer and by approximately 18% for a 5 μm Ni interlayer. The joint cross sections were qualitatively examined using optical microscopy (OM) and scanning electron microscopy (SEM); the observations suggest that only portions of the interface were diffusion bonded, as a result of the low-pressure procedure and the surface roughness (due to the sample fabrication). The portions that were diffusion bonded, though, were sound, as characterized by the fact that the steel grains grew through the interface line to create a continuous metallographic structure.

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Section: Setup and Experimentsmentioning

confidence: 95%

“…and ID: 4.57 mm (0.18 in.)) [7][8][9][10]. This paper specifically describes the experiments on the procedure of using commercial plating techniques to apply a nickel (Ni) interlayer of various thicknesses onto the tubes to support the tube-to-tubesheet tapered interference fits.…”

Section: Introductionmentioning

confidence: 99%

Ni Interlayer to Improve Low-Pressure Diffusion Bonding of 316L SS Press Fit Tube-to-Tubesheet Joints for Coiled Tube Gas Heaters

Reuven

Bolind

Haneklaus

et al. 2017

Journal of Nuclear Engineering and Radiation Science

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“…These WC-based composites can be applied at low cost in the FSW of high-softening-temperature material such as steel alloys and nickelbased alloys. In addition, they can be applied in other friction-based applications [58,59]. Figure 16.…”

Section: Fsw Tool For High-softening-temperature Materialsmentioning

confidence: 99%

The Development of WC-Based Composite Tools for Friction Stir Welding of High-Softening-Temperature Materials

Ahmed

Barakat

Mohamed

et al. 2021

Metals

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This work presents a detailed investigation for the effect of Y2O3 and Ni additions on the densification behavior, microstructural evolution and mechanical properties of a WC-Co-TaC-NbC composite. With the aim of obtaining WC-based composites with improved fracture toughness, to be used in severe conditions of high-temperature deformation, different concentrations of Y2O3 were incorporated with and without 5 wt% Ni addition. The consolidated composites were characterized using density measurement, XRD, SEM, hardness, fracture toughness, transverse rupture strength and compression testing. Fully dense composites were obtained through the applied consolidation regime of cold compaction and sintering at 1450 °C for 1.5 h under vacuum with a relative density up to 97%. The addition of 2.5 wt% Y2O3 to the base WC composite increased the relative density and then slightly decreased with the increase of the Y2O3 content. The addition of 5 wt% Ni to the base composites significantly increased the relative density to 97%. The XRD results indicated the existence of the Co3W3C η-phase after sintering, and the intensity of its peaks was reduced with the addition of 5 wt% Ni. The microstructure of the consolidated composites consisted of three phases: WC, Co3W3C and Y2O3. The area fraction of the Y2O3 phase increased as its weight fraction increased. In terms of the fracture toughness, the transverse-rupture strength (TRS) and the compressive strength were significantly improved by the addition of 5 wt% Ni with the 2.5 wt% Y2O3. Accordingly, this composition was used to manufacture the tools for the friction stir welding of the high-softening-temperature materials, which was successfully used for 25 plunges and about 500 cm of butt joints in nickel-based and carbon–steel alloys.

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“…Under these conditions, thermal shock and creep deformation can become an issue. Proposed methods of tube-to-tube sheet connections include different methods of diffusion bonding, including simple diffusion bonding, tube expansion followed by diffusion bonding, and hybrid friction diffusion bonding [38,39]. Further material analysis and creep deformation studies of different tube-to-tube sheet connections will need to be done to determine the best bonding method.…”

Section: Tube Bundle Fabricationmentioning

confidence: 99%

Coiled Tube Gas Heaters For Nuclear Gas-Brayton Power Conversion

Peterson

2018

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Additionally, THERMOFLEX has the capability of estimating sizes of shell-and-tube heat exchangers, which although are not anticipated for use in our reference design, give an upper bound on component sizes, and are presented in Table 2. The high temperature recuperator requires approximately 14,000 m 2 of surface area given an overall heat transfer coefficient of 500 W/°C•m², which translates to a size of 4.9 by 23.6 m. As mentioned earlier this is about twice or more the size of the other heat exchangers, and also points to the need for a more compact design due to the low overall heat transfer coefficient. Spiral wound heat exchangers have overall heat transfer coefficients in the range of 700-2500 W/°C•m² [3], implying that the calculated volumes (lengths) in Table 2 can be reduced by a factor of 2 to 5. Component HT Recoup LT Recoup Water Cooler U 500.1 525.6 889.7 W/°C•m² A 13,859 6,387 4,299 m² D 4.864 4.22 3.183 m L 23.6 18.28 13.56 m V 438.5 255.7 107.9 m³ A/V 31.6 25.0 39.8 m²/m³ The development of a "high temperature" (700°C) CTGH design was deemed to be impractical due to the low allowable stresses of current code qualified materials at the anticipated operating point conditions. As such, a CTGH design and component sizing for the "medium-high temperature" (550°C) operating conditions appropriate for application to SFR's is being pursued. An "unconstrained" CAD model of the integral power conversion unit (PCU) was created, allowing for design flexibility based on estimated sizes of components. The major constraints imposed are simply the outer diameter of the vessel to maintain rail transportability. Figure 3 depicts the initial PCU design, including the turbomachinery, generator, external ducting with flow paths, recuperators and cooler. More detail will be added, including appropriate sizes for the heat exchangers, flow paths, insulation, etc. during the coming quarter.

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Hybrid friction diffusion bonding of 316L stainless steel tube-to-tube sheet joints for coil-wound heat exchangers

Cited by 10 publications

References 20 publications

Ni Interlayer to Improve Low-Pressure Diffusion Bonding of 316L SS Press Fit Tube-to-Tubesheet Joints for Coiled Tube Gas Heaters

Ni Interlayer to Improve Low-Pressure Diffusion Bonding of 316L SS Press Fit Tube-to-Tubesheet Joints for Coiled Tube Gas Heaters

The Development of WC-Based Composite Tools for Friction Stir Welding of High-Softening-Temperature Materials

Coiled Tube Gas Heaters For Nuclear Gas-Brayton Power Conversion

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