BULETINUL INSTITUTULUI POLITEHNIC DIN IAI Publicat de Universitatea Tehnic Gh. Asachi, Iai Tomul LI (LV), Fasc.

5, 2005 Secia CONSTRUCII DE MAINI

RESEARCHES REGARDING THE WELDING VALUES OPTIMIZATION OF TWO DIFFERENT MATERIALS

BY

GHEORGHE LUNGU, IONEL SRBU and OCTAVIAN FRNCU

Abstract. The work presents the manual welding technology of the 20Mn12V and the OL52-3k steel types. It contains a study about the basis metal and the presentation of the weld metal and, also, some tests done on the 20Mn12 steel. The welding technological values are described for two experimenting stages. The first stage welding process needs stress-relief thermal treatment after the welding, whereas the second stage one doesnt need it. The described welding is for V joints splices. The work ends by presenting the welding technological instructions for butt-jointed cylinders of 10-20mm breadth of the 20Mn12V and OL52-3k steel. The basis metal used to manufacture the cylinders is the 20Mn12V and OL52-3K steel. Key words: welding technology, values optimization, different materials.

1. Introduction The work presents the manual welding technology of the 20Mn12V and the OL52-3k steel types. It contains a study about the basis metal and the presentation of the weld metal and, also, some tests done on the 20Mn12 steel, which is off-gauge and absent form any norm, the data on this material being given in the quality certificates done in the laboratory.

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The welding technological values are described for two experimenting stages. The first stage welding process needs stress-relief thermal treatment after the welding, whereas the second stage one doesnt need it. The described welding is for V joints splices. The work ends by presenting the welding technological instructions for butt-jointed cylinders of 10-20mm breadth of the 20Mn12V and OL52-3k steel. The basis metal used to manufacture the cylinders is the 20Mn12V and OL52-3K steel.
Table 1 The Chemical Composition of the OL 52-3k and 20Mn12V
No. Steel 1. 2. Steel Types. 20Mn12V OL52-3k C 0,21 0,22 Nn 1,14 1,6 Si 0,24 Chemical Composition P S V Ni 0,016 0,011 0,12 0,14 0,05 0,05 Cu 0,14 Gr 0,01 Ti 0,003 -

Table 2 The Mechanic Characteristics of the OL 52-3k and 20Mn12V

No. Steel 1. 2. Steel Types. 20Mn12V OL52-3k The Mechanic Characteristics Rp 0,2 Rm A5 [N/mm2] [N/mm2] [%] 701 828 24.4 440 611 16.4 Z [%] +200C KV [J] 0 -200C -

The E.51.5.B110.2.O.H super base welding electrode was used as a weld material. This electrode is often used for metallic constructions and is designed for highly stressed statically and dynamically structures, of low alloyed steel for up to 300C exploitation. When choosing the welding electrode, we took into account the mechanic rules and information about the chemical composition of the deposited metal THE WELDED JOINT DESIGN VALUES

Fig. 1 - Pipe-to-Pipe Joining Type

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Fig. 2 - Pipe-to-Cover Joining Type

THE WELDING TECHNOLOGICAL VALUES The preheating test: We used six calculation methods for the preheating test: The IIS Method The equivalent carbon is calculated using the following relation: (1)
Ce = C + Mn Cr + Mo + V Ni Si + + + 20 5 15 4

For the OL52-3k steel: C e = 0,35% and for the 20Mn12V steel: C e = 0,413 The welding type Ls in chosen from the method chart according to the Ce function and the hards type. For OL52-3k its Ls=C and for 20Mn12V Ls=F. The TCN thermal severity numbers are calculated according to the , the welding tests thickness and the nc cooling ways number. The preheating temperature depending on Ls, TCS and the electrode diameter result from the method chart. For OL52-3k Tpr=250C and for 20Mn12V Tpr= 1750C The Sfrian Method: The same Ce is calculated from the basis metal chemical analysis as in the IIS method. By using it, a Ce equivalent carbon is determined, taking into account the thickness of the welded pieces. (2)

C e/ = C e (1 + 0,005 )

/ / For OL52-3k: C e = 0,38 and 20Mn12V : Ce = 0,52

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For

the

OL52-3k

steel:

pr .1 = 126 0 C

and

for

20Mn12V:

pr .1 = 182 0 C
The Mrosko Method: The equivalent carbon is determined by using the following relation: (3)
Mo Ni Cr + + + 6 15 4 5 For OL52-3k: C e = 0,50 and 20Mn12V: C e = 0,55 Ce = C +

The following preheating values result from the method charts:

0 0 For the OL52-3k steel: pr .1 = 75 C and 20Mn12V: pr .1 = 150 C

The B.S. Kosetkin Method: (4)

Ce = C + Mn Si Ni Cr V + + + + + 6 24 10 5 4 14

For the OL52-3k steel we obtain: C e = 0,57 . 0 For flow limit = 736 N / mm 2 with pr .1 = 160 C resulting from the chart. The K.I. Lebedeva Method: The equivalent carbon is determined by using the following relation: Mn Cr Si Cu P Ni Mo V Ce = C + + + + + + + + (5) 6 6 5 7 2 12 4 5 For the OL52-3k steel: Ce = 0,56 and for the 20Mn12V steel we obtain: C e = 0,63 . The following preheating temperature result from the method charts: For the OL52-3k steel: pr .1 = 160 260 0 C
0 For the 20Mn12V steel: pr .2 = 190 310 C

The Tachenke and Killing Method: The equivalent carbon is calculated by using the relation: (6)
Ce = C +

For the OL52-3k steel: obtain: C e = 0,55 . For these equivalent carbon values, the authors take into consideration a preheating temperature of pr .2 = 100 200 0 C .

Mn Cr Ni Mo + + + 6 5 15 4 C e = 0,50 and for the 20Mn12V steel we

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The Estimated Preheating Temperature Determination: For the first stage of the tests, a temperature of 175-2000C, roughly chosen, considering the preheating temperatures got from the described calculation methods. A temperature of 200-2200C was used in the second stage in order to slow down the cooling speed. 2. The Welding Electrical Values A linear energy of 13 20KJ/cm, experimentally determined will be used in order to do the welded joining. We tested two welding methods, during two experimenting stages, with V joints for 18mm thickness. 2.1. First Stage Tests The welding is made with super base electrodes of 3,25 and 4 mm. The electrodes are calcinated at 250-3000C for 2 hours, before using them. The root layer is made with 3,25 electrodes and the rest with 4mm ones. The welding is made horizontally, by rotating the cylinder. Different technological methods were tested. These were: The welding without preheating and stress-relief The welding with preheating and stress-relief The welding with preheating and stress-relief (one test for 1 hour and one test for 2 hours). 2.2. Second Stage Tests The welding is made using super base 4mm electrodes for the root and 5mm for the other filling layers. The electrodes are calcinated at 250-3000C for 2 hours, before welding. The welding current for the 4mm electrodes is of 170180A, and for 5mm of 230-240A. The welding voltage is of 23-27V. The welding speed for 4mm electrodes is 7,5-7,9m/h and for 5mm ones is 7,6-7,8m/h, an experimentally determined speed. The linear energy of 1320kJ/cm, experimentally determined. 3. Technological Accounts When welding the last line, attention must be paid in order to weld it on the OL52-3k steel and, thus, the last line will be welded on the 20Mn12V steel. The technological welding lay out: the joints measuring check for the welding; the joints adjustment for the welding; the joints preheating for the temporary fixing; the temporary pipe welding to the cylinder cover; the temporary fixing cleaning for the welding;

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the welded temporary fixing checking; the root layer welding with _4mm electrodes; the after welding adjustment; the visual final welded areas checking with penetrating liquids; the mechanical processing of the increased height if the test method considers it necessary; the visual checking with penetrating liquids if there are any doubts. 4. Conclusions The first stage of the welding process has used 3, 25 mm superbase electrodes for the root layer and 4 mm for the filling layer. The welding linear energy was 13.000-18.000J/cm. One the thermal stress-relief treatment was done, all the mechanical tests results were appropriate. The second stage used 4 mm superbase electrodes for the root layer and 5 mm for the filling layers. The welding linear energy was of 27.000-30.000J/cm. The conclusion is that this method doesnt need thermal stress-relief treatment and is the optimal choice.
Received September 2005 Technical University Gh. Asachi, Jassy Department of Machine Tools REFERENCES 1. G e r k e n J. M., K o t e c k i D. J. Stainless Steels. Publication No.M250, The Lincoln Electric Company, 1990. 2. K o t e c k i D. J. Welding Parameter Effects on Open-arc stainless weld Metal Ferrite, Weld J., 57, 4 (1978). 3. M c C o w a n C. N., S i e w e r t T. A., O l s o n D. L. Stainless Steel Weld Metal Ferrite Content. Welding Research Council Bulletin 342, WRC, 1989. CERCETRI PRIVIND OPTIMIZAREA PARAMETRILOR DE SUDARE A DOU MATERIALE DIFERITE (Rezumat) Lucrarea prezint tehnologia de sudare manual a oelurilor 20Mn12V cu oelul OL523k. Lucrarea conine un studiu asupra metalului de baz i prezentarea metalului de adaos, conine ncercri efectuate pe oelul 20Mn12V. Parametrii tehnologici de sudare sunt prezentai pentru dou faze de experimentri. Tehnologia de sudare prezentat n prima faz necesit tratament termic de detensionare dup sudare, iar tehnologia de sudare din faza a II-a nu necesit tratament termic post sudare. Sudarea este prezentat pentru tipuri de mbinri cap la cap cu rostul n V. Lucrarea se ncheie cu instruciuni tehnologice de sudare pentru cilindrii cap la cap de grosimi cuprinse ntre 10-20mm a oelului 20Mn12V cu oelul OL52 -3k.