Sustainable Technologies for Thick Metal Plate Welding

Sproesser, Gunther; Chang, Ya-Ju; Pittner, Andreas; Finkbeiner, Matthias; Rethmeier, Michael

doi:10.1007/978-3-319-48514-0_5

Cited by 11 publications

(5 citation statements)

References 9 publications

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“…For example, a study has shown that laser hybrid welding has a better ecological balance sheet than arcbased welding processes. For this purpose, measurements were carried out in the categories of climate change, acidification, eutrophication as well as photochemical ozone formation, showing that the laser hybrid welding process performed better in all categories compared to the conventional processes [5,6]. Thus, it offers a high potential for sustainable manufacturing.…”

Section: Comparison Of Conventional Welding Processes With Alternativesmentioning

confidence: 99%

Process advantages of laser hybrid welding compared to conventional arc-based welding processes for joining thick steel structures of wind tower

Brunner-Schwer,

Üstündag,

Bakir

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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The most common welding processes when joining thick-walled steels in the industry are arc-based welding processes such as GMAW or SAW. For this purpose, the sheets are joined in multi-layer technique, which can lead to productivity losses due to high welding times. The process-specific challenges in welding thick steels using multi-layer technique relate to the high heat input from the process. Therefore, alternative welding processes are being actively sought. A suitable alternative is provided by beam-based welding processes such as the laser hybrid welding processes, which are characterized by deep penetration welds and lower heat input. With implementation of the laser hybrid welding process in the heavy industry, such as the wind tower industry, economic benefits can be reached such as the increase in productivity by reducing the layer number, and the lower consumption of filler material and energy. When comparing SAW welded 25 mm thick steels in five to six layers and single-pass laser hybrid welding, the welding time can be reduced more than 80 % and the costs of filler material, flux and energy can be saved up to 90 %. However, the industrial use of the laser hybrid welding process is still limited to applications, where the material thickness does not exceed 15 mm due to some process-specific challenges such as the sagging, sensitivity to manufacturing tolerances such as gaps and misalignment, limited filler wire mixing, and deteriorated mechanical properties resulting from high cooling rates. To overcome these challenges, a contactless electromagnetic backing based on an externally applied AC magnetic field was used. Eddy currents are induced due to the oscillating magnetic field, and an upward-oriented Lorentz force is generated to counteract the droplets formed due to gravitational forces. It allows to weld up to 30 mm thick structural steels in a single-pass with a 20-kW fiber laser system. Additionally, the gap bridgeability and the misalignment of edges were increased to 2 mm when welding 20 mm thick steels. With the aid of the AC magnetic field, a vortex was formed in the weld root, which had a positive effect on the filler wire mixing. A further significant advantage of the EM backing was the possibility to expand the process parameter window to maintain desired cooling times and mechanical properties, without suffering adverse effects concerning the root quality of the weld.

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Section: Comparison Of Conventional Welding Processes With Alternativesmentioning

confidence: 99%

Process advantages of laser hybrid welding compared to conventional arc-based welding processes for joining thick steel structures of wind tower

Brunner-Schwer,

Üstündag,

Bakir

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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“…In the impact assessment stage, some common social aspects around manufacturing processes are related to wages and compensation, safety, personal and technical growth, and social interaction [57]. For the robotic welding process transition in this study, social impact assessment primarily focuses on fair salaries and health and safety [58]. Fair salaries can be assessed by evaluating the difference between the local performance standard (P local ), e.g., average operator wage, and the work cell performance (P j ), e.g., wage for the operator position under study [3].…”

Section: Social Impact Assessmentmentioning

confidence: 99%

“…where E p is the emission factor of the specific substance per functional unit; W p is the potential effect of the specific substances in the fume (by comparison, it can be assumed as 1 if the deposition material is the same); L is the ventilation factor; R is the spatial factor (by comparison, it can be assumed as 1 if the location condition is the same); and K b is the factor of relative distance of head/body and fume source from 1 to 4, with 1 indicating far distance and 4 close distance [58,60].…”

Section: Social Impact Assessmentmentioning

confidence: 99%

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A Sustainable Decision-Making Framework for Transitioning to Robotic Welding for Small and Medium Manufacturers

Epping

Zhang

2018

Sustainability

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Small and medium-sized enterprises (SMEs) face challenges in implementing industrial robotics in their manufacturing due to limited resources and expertise. There is still good economic potential in using industrial robotics, however, due to manufacturers leaning toward newer technology and automated processes. The research on sustainability decision-making for transitioning a traditional process to a robotic process is limited for SMEs. This study presents a systemic framework for assessing the sustainability of implementing robotic techniques in key processes that would benefit SMEs. The framework identifies several key economic, technical, and managerial decision-making factors during the transition phase. Sustainability assessments, including cost, environmental impact, and social impact, are used in the framework for engineers and managers to evaluate the technical and sustainability trade-offs of the transition. A case study was conducted on a typical US metal fabrication SME focusing on transitioning a shielded metal arc welding (SMAW) process to a robotic gas metal arc welding (GMAW) process. A sustainability assessment was conducted following the framework. The results suggest that the transition phase involves numerous factors for engineers and managers to consider and the proposed framework will benefit SMEs by providing an analytical method for industrial robotics implementation decision-making.

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“…Welding is the main material joining technique for the production of construction machinery [3]. The quality of welding greatly determines the safety of the equipment, and the efficiency of welding is closely related to the processing cost of the equipment [4,5].…”

Section: Introductionmentioning

confidence: 99%

Prediction of HAZ Microstructure and Hardness for Q960E Joints Welded by Triple-Wire GMAW Based on Thermal and Numerical Simulation

Wang

Duan³

et al. 2021

Materials

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Since heat affected zone (HAZ) is the weak area of welded joints, this article proposes a method to predict the HAZ microstructure and hardness for the triple-wire gas metal arc welding (GMAW) process of Q960E high strength steel. This method combines welding thermal simulation and numerical simulation. The microstructures and hardness of Q960E steel under different cooling rates were obtained by thermal simulation and presented in a simulated HAZ continuous cooling transformation (SH-CCT) diagram. The cooling rate in HAZ were obtained by numerical simulation with ANSYS software for the triple-wire welding of Q960E thick plates. By comparing the cooling rate with the SH-CCT diagram, the microstructure and hardness of the HAZ coarse-grained region were accurately predicted for multiple heat input conditions. Further, an ideal heat input was chosen by checking the prediction results. This prediction method not only helps us to optimize the welding parameters, but also leads to an overall understanding of the process-microstructure-performance for a complex welding process.

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Sustainable Technologies for Thick Metal Plate Welding

Cited by 11 publications

References 9 publications

Process advantages of laser hybrid welding compared to conventional arc-based welding processes for joining thick steel structures of wind tower

Process advantages of laser hybrid welding compared to conventional arc-based welding processes for joining thick steel structures of wind tower

A Sustainable Decision-Making Framework for Transitioning to Robotic Welding for Small and Medium Manufacturers

Prediction of HAZ Microstructure and Hardness for Q960E Joints Welded by Triple-Wire GMAW Based on Thermal and Numerical Simulation

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