A PROJECT REPORT

ON

Door frame to shell welding using

MAG-SAW process

Submitted for the partial fulfillment of the

Requirement for the Alternative Route to Qualify as
International Welding Engineer
The Indian Institute of Welding ANB

By
ANILKUMAR GOPINATHAN NAIR
(R141700061)

14-05-2018
 DECLARATION

The Project entitled “Door frame to shell welding using MAG-SAW

process” is being submitted in fulfillment of the requirement for the
Qualification of International Welding Engineer of the “International
Institute of Welding” by the Alternative Route and conducted by the
“Authorised National Body” The Indian Institute of Welding-ANB.
I also confirm that the Project being submitted is the original work
personally undertaken by me and is not a copy of another person’s
work.

I take full responsibility in submitting this project and declare that

the same does not breach any confidentiality agreement with my
employer and The Indian Institute of Welding-ANB is indemnified by
me for any legal action/proceedings for intellectual right violation
from any organization or individual for publication of the contents of
the project in whole or in part

ANILKUMAR GOPINATHAN NAIR

Sreelakshmi,
Nechipuzhoor Post,
Pala, Kottayam Dist, Kerala, India

Contact: +91 9881016346

Email: akg.nitt@gmail.com

Page 1 of 36
 ABSTRACT
There is a part called door frame which is to be welded together with the shell plate
opening at the bottom section of a wind tower. The door frame is made up of material
S355 K2 and needs to be welded with a cut opening on the shell plate of material
S355 J0. The total weld length is 5.5m.

The existing process of doing manual MAG process is taking more man hours, upto
three shifts and the repair rate is also high due to various reason inherent with the
MAG process, thickness and joint configuration.

To minimize the defects and to reduce the cycle time, the existing MAG welding
process has been replaced with a MAG-SAW process. The straight portion of the door
frame to shell joint has been welded with MAG-SAW process and the curve portion
with MAG. A new welding procedure has been qualified. To achieve this joint, a tractor
SAW machine has been slightly modified to run over a track close to the joint to
achieve the joint.

The mechanization yield a defect free weld, whereas the welding process has been
completed in less than two shift time.

Page 2 of 36
 CONTENTS

SECTION TITLE PAGE NO.

DECLARATION i
ACKNOWLEDGMENT ii
ABSTRACT iii
CONTENTS iv

Chapter-1 INTRODUCTION 1-6

1.1 INTRODUCTION TO THE PROBLEM AREA 1
1.2 OTHER SUBSECTIONS 3
1.2.1 SUB-SUBSECTIONS 3
1.2.2 SUBSEQUENT SUB-SUBSECTION 5
1.3 OBJECTIVE OF THE PRESENT WORK
6

Chapter-2 ABOUT THE PROBLEM DEFINITION 7-24

2.1 INTRODUCTION AND BACKGROUND
7
2.2 OTHER SUBSECTIONS 9
2.2.1 SUB-SUBSECTIONS 15
2.2.2 SUBSEQUENT SUB-SUBSECTIONS
18

Chapter-3 EXPERIMENTAL INVESTIGATIONS 25-36

3.1 EXPERIMENTAL SET-UP AND CONDITION 25
3.2 OTHER SUBSECTIONS 28
3.2.1 SUB-SUBSECTIONS 30
3.3 DISCUSSION ON THE OBSERVATION MADE 33

Chapter-4 CONCLUSION 36

REFERENCE 37-42
Page Numbers are only as example and
actual numbers after the project is prepared to be given
CHAPTER-1

INTRODUCTION
1.1 INTRODUCTION TO A WINDMILL TOWER

A windmill tower is an important part of a windmill, which contributes to around 25%

equipment cost in wind power generation, using a windmill. The welded windmill
tower consists of cylinders called ‘shells’ made of steel plate rolled to a circular shape
and welded longitudinally. Circumferential welds connect several such shells to form a
tower section. Normally a tower consists of four such tower sections. Each section
ends with a steel flange in each end. The sections are bolted to each other. The
bottom flange is connected to the foundation and the top one to the nacelle.

Fig 1.1 A windmill tower

1.2 PARTS OF A TOWER SECTION

A tower section may have several parts other than the constituting shells as
attachments serving various purposes like climbing up, electrical cables routing etc.
Major such parts are lugs, supports and door frame.

1.3 DOOR FRAME

A door frame is an oval shaped structure welded together to one of the shells at
bottom tower section of a windmill tower. The door is hinged to this frame. The
purpose of this part is to allow access for humans to inside.

5
 Fig 1.2 Door at bottom of a windmill tower

Fig 1.3 A door frame being manually welded with shell

1.4 MATERIALS OF CONSTRUCTION

The materials used in construction of a windmill tower are as follow

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1.4.1 S355 Steel plates

These are general purpose steel plates with a minimum yield strength of 355N/mm 2
which is widely used in structural applications.

1.4.2 S275 Steel plates

These are general purpose steel plates with a minimum yield strength of 275N/mm 2
which is widely used in structural applications.

1.4.3 Chemical Compositions

Chemical composition of the various materials used in wind tower is as shown in table
1.1

Table 1.1 Chemical compositions

1.4.3 Mechanical Properties

Mechanical properties of different materials used in construction of wind tower has been
tabulated in table 1.2.

Table 1.2 Mechanical Properties

1.4.3 Sub-grades

Steel sub-grades indicate the Charpy impact value required to prevent brittle fracture.
JR – Longitudinal Charpy V-notch impacts 27J at Room temp
J0 – Longitudinal Charpy V-notch impacts 27J at 0°C
J2 – Longitudinal Charpy V-notch impacts 27J at -20°C
K2 – Longitudinal Charpy V-notch impacts 40J at -20°C

7
 NL – Longitudinal Charpy V-notch impacts 27J at -50°C

1.5 OBJECTIVE OF THE PRESENT WORK

The objective of the present work is to automate the door frame welding to shell
welding by using a combination of Metal Active Gas (MAG) welding and Submerged Arc
Welding (SAW) replacing currently using Metal Active Gas (MAG) welding alone.

8
 CHAPTER-2

PROBLEM DEFINITION

9
2.1 INTRODUCTION AND BACKGROUND

The door frame which is an opening on the bottom section of a wind tower. This
is made up of material S355 K2 and needs to be welded with a cut opening on the shell
plate of material S355J0. The total weld length is 5.5m and the details are as shown
below.

Fig 2.1 A door frame

Fig 2.2 Current Weld Details

The existing process of doing manual MAG process is taking more man hours and the
repair rate is also high due to various reason inherent with the MAG process,
thickness and joint configuration.

2.1.1 Problem Selection

A study has been conducted to observe the repair trend for a period of one month for
a bottom section. The areas which are found to contribute to repairs where identified
as

1
 a) Door welding (Volumetric defect)
b) Visual Defects – Bottom (Surface repair)

c) Circumferential seam repairs – Top section (Volumetric defect)

d) Circumferential seam repairs – Bottom section (Volumetric defect)

e) Visual Defects – Top (Surface repair)

A Pareto chart has been plot and it was evident that the door welding repair is
contributing more, as 37.56% of total repair length for the period of study.

Fig 2.3 Door Welding contributes to repairs

Also it was found that the length of repairs was at straight portion is 52% more than
that at curve area of the door frame. It was evident that the welding accessibility in
the weld groove contributes to the repairs.

1
2.2 INTRODUCTION OF SAW AS AN OPTION TO MECHANIZE THE
WELDING

Taking the above mentioned issues into considerations it was proposed to weld the
straight portion of the door frame-plate joints with Mechanized SAW process by slightly
modifying a tractor SAW machine and remaining curvy portion with manual MAG
process. It is expected to reduce the cycle time for completing the door frame welding
also.

Table 2.1 Process comparison

Existing Proposal
Process MAG - Manual MAG in curve - Manual
SAW in straight portion -
Mechanized
Bevel preparation Double V on plate Single V (5mm depth to be back
ground and weld)
WPS Exists To be qualified
Time required for 8 hours 4 hours
bevel preparation
Time required for 10 hours 5-6hours (expected)
welding
Total time required 18 hours 9-10 hours
to complete the
process
Saving in Time NA 8-9 hours

2.3 PROJECT PLAN

In order to try the feasibility of welding the door frame with shell, a plan has been
made to weld on a test plate set up simulating the real welding at shop floor. The
activities included
1. Preparation of test pieces
2. Modification of the tractor SAW machine
3. Development of a track for tractor machine to move.
4. Trial welding
5. Preparation of WPS
6. Welder/Welding operator Qualification
7. Preparation of quality documents like weld map, WPS synopsis
8. Change QAP if required
9. Preparation of SOP
10. Job welding

1
CHAPTER-3

PRE-STUDY

1
3.1 WELDABILITY OF PARENT MATERIALS
The door frame material is S355K2 and shell material is S355J0. Hence the joint is to
be achieved between S355J0 and S355K2. These materials are covered under
standard EN 10025-2. Both these materials are identified as weldable materials. Since
the quality of weld is influenced by the welding conditions, the following factors has
been studied.
a) Joint Design
b) Susceptibility to hydrogen cracking
c) Toughness and hardness of heat affected zone (HAZ)
d) Susceptibility to solidification cracking

3.1.1 Joint Design

From the application point of view the joint has been designed as shown below.

3.1.2 Susceptibility to hydrogen cracking

Hydrogen cracking may also be called cold cracking or delayed cracking. The principal
distinguishing feature of this type of crack is that it occurs in ferritic steels, most often
immediately on welding or a short time after welding.

In C-Mn steels, the crack will normally originate in the heat affected zone (HAZ), but
may extend to the weld metal. Crack can also occur in the weld bead, normally
transverse to the welding direction at an angle of 45° to the weld surface. In low alloy
steels, the cracks can be transverse to the weld, perpendicular to the weld surface,
but are non-branching, and essentially planar..)

Cracks which originate in the HAZ are usually associated with the coarse grain region.
The cracks can be intergranular, transgranular or a mixture. Intergranular cracks are
more likely to occur in the harder HAZ structures formed in low alloy and high carbon
steels. Transgranular cracking is more often found in C-Mn steel structures.

In fillet welds, cracks in the HAZ are usually associated with the weld root and parallel
to the weld. In butt welds, the HAZ cracks are normally oriented parallel to the weld

bead.. 2
C
Cracking usually occurs at temperatures at or near normal ambient. It is caused by
the diffusion of hydrogen to the highly stressed, hardened part of the weldment. In C-

1
Mn steels, because there is a greater risk of forming a brittle microstructure in the
HAZ, most of the hydrogen cracks are to be found in the parent metal. With the
correct choice of electrodes, the weld metal will have a lower carbon content than the
parent metal and, hence, a lower carbon equivalent (CE). However, transverse weld
metal cracks can occur, especially when welding thick section components; the risk of
cracking is increased if the weld metal carbon content exceeds that of the parent
steel.

The occurrence of hydrogen cracking depends on a number of factors:

a) Composition of the steel,
b) The welding procedure,
c) Welding consumables and
d) The stress involved.

If the t8/5 time (cooling time from 800°C to 500°C) associated with welding is too
short, excessive hardening can occur in the heat affected zone. When the hydrogen in
the weld is above a critical level the hardened zone can crack spontaneously under
the influence of residual stress after the weld has cooled to near ambient
temperature.

3.1.2.1 Composition of steel

This will have a major influence on hardenability and, with high cooling rates, the risk
of forming a hard brittle structure in the HAZ. The hardenability of a material is
usually expressed in terms of its carbon content or, when other elements are taken
into account, its carbon equivalent (CE) value.

The higher the CE value, the greater the risk of hydrogen cracking. Generally, steels
with a CE value of <0.4 are not susceptible to HAZ hydrogen cracking, as long as low
hydrogen welding consumables or processes are used.

3.1.2.2 Weld metal hydrogen content

The principal source of hydrogen is moisture contained in the flux used in submerged
arc welding. It is important to note that there can be other significant sources of
hydrogen, e.g. from the material, where processing or service history has left the
steel with a significant level of hydrogen or moisture from the atmosphere. Hydrogen
may also be derived from the surface of the material or the consumable.
1
Sources of hydrogen will include:
a) Oil, grease and dirt
b) Rust
c) Paint and coatings
d) Cleaning fluids

3.1.2.3 Parent material thickness

Material thickness will influence the cooling rate and therefore the hardness level, the
microstructure produced in the HAZ and the level of hydrogen retained in the weld.
The 'combined thickness' of the joint, ie the sum of the thicknesses of material
meeting at the joint line, will determine, together with the joint geometry, the cooling
rate of the HAZ and its hardness.
Fig.3 Combined thickness measurements for butt and fillet joints
3.1.2.4 Stresses acting on the weld
Cracks are more likely to initiate at regions of stress concentration, particularly at the
toe and root of the weld.
The stresses generated across the welded joint as it contracts will be greatly
influenced by external restraint, material thickness, joint geometry and fit-up. Poor
fit-up (excessive root gap) in fillet welds markedly increases the risk of cracking. The
degree of restraint acting on a joint will generally increase as welding progresses, due
to the increase in stiffness of the fabrication.

3.1.2.5 Heat input

The heat input to the material from the welding process, together with the material
thickness and preheat temperature, will determine the thermal cycle and the resulting
microstructure and hardness of both the HAZ and the weld metal.
Increasing the heat input will reduce the hardness level, and therefore reduce the risk
of HAZ cracking. However, as the diffusion distance for the escape of hydrogen from a
weld bead increases with increasing heat input, the risk of weld metal cracking is
increased.
Heat input per unit length is calculated by multiplying the arc energy by a thermal
efficiency factor, according to the following formula:

V = arc voltage (V)

A = welding current (A)
S = welding speed (mm/min)
k = thermal efficiency factor

1
In calculating heat input, the thermal efficiency must be taken into consideration. The
thermal efficiency factors given in EN 1011-1: 2009 for the principal arc welding
processes, are shown in table 3.1.

Table 3.1 Thermal efficiency factors of processes

Submergedarc (single wire) 1.0
MMA 0.8
MIG/MAG and flux cored wire 0.8
TIG and plasma 0.6

3.1.2.6 Preheat Temperature

Preheat temperature is calculated using the method C.2 of EN1011-2.

Fig 3.1 Excerpt from EN1011-2

Thickness of door frame = ~150mm

Thickness of shell plate = 37mm
Hence the combined thickness = 187mm
Heat input for SAW process = 4kJ/mm
Scale = C
Carbon Equivalent shall not exceed 0.51

1
From the graph it is found that a minimum preheat of 100°C is required to avoid the
hydrogen cracking.

3.1.3 TOUGHNESS AND HARDNESS OF HEAT AFFECTED ZONE (HAZ)

The welding of ferritic steels produces a zone in which the original microstructure is
changed by the heat producing the weld. Depending on the microstructure, the
toughness and hardness will also be changed. The change of the microstructure in the
HAZ depends mainly on the chemical composition of the parent metal and on the
temperature/time cycles which occur during welding.

3.1.4 SOLIDIFICATION CRACKING

Solidification cracking of the weld metal is usually found as centreline cracking. It is
more often found in root runs and, although frequently open at the surface and visible
after deslagging, can be just below the surface and covered by up to 0,5 mm of sound
metal. Solidification cracks can be deep and can seriously reduce the efficiency of a
joint. When welding carbon manganese steels, this type of cracking is most commonly
found in submerged-arc welds, and sometimes be a problem with gas-shielded
process. Solidification cracking is associated with impurities, particularly sulphur and
phosphorus, and is promoted by carbon picked up from the parent metal at high
dilution levels while manganese reduces the risk of cracking. Impurity levels and
crack susceptibilities are usually greatest in weld runs of high dilution, e.g. root runs
of butt welds. To minimize the risk of cracking, consumables are preferred with low
carbon and impurity levels and relatively high manganese contents. A reduction in
welding speed can be helpful in overcoming cracking.

The solidification crack susceptibility of weld metal is affected by both its composition
and weld run geometry (depth/width ratio). The chemical composition of weld metal
is determined by the composition of the filler material and the parent metal and the
degree of dilution. The degree of dilution, as well as weld run geometry, both depend
on the joint geometry (angle of bevel, root face and gap) and the welding parameters
(current and voltage).

For submerged-arc welds a formula has been developed for carbon and carbon
manganese steels in which the solidification crack susceptibility in arbitrary units
known as units of crack susceptibility (UCS) has been related to the composition of
the weld metal [in % (m/m)]. Although developed for submerged-arc welding,
the use of the formula can be helpful in assessing the risk of solidification cracking for
other welding processes and other ferritic steels.

1
The formula is as follows:
UCS = 230 C + 190 S + 75 P + 45 Nb − 12.3 Si − 5.4 Mn − 1

Using this formula it is found that UCS value can be as high as 36.22, which indicates
that the steel is highly prone to solidification cracking especially in weld runs with high
depth/width ratio.

3.2 WELDING CONSUMABLES

The welding consumables selected for the submerged arc welding confirms to AWS
5.17 F7A4-EM12K classification. Also AWS 5.18 ER70S-6 is selected for MAG process.
The chemical composition of these consumables is (as %ge weight) given in table 3.2.

Table 3.2 Chemical compositions of consumables

Based upon the Welding consumables specifications, the following welding

consumables brand has been selected to be procured.

Table 3.3 Consumables brand selected

3.3 MODIFICATION OF TRACTOR WELDING MACHINE

3.3.1 TRACTOR WELDING MACHINE

1
The machine we used is a Lincoln Electric make LT-7 model as shown in the fig. This
is a self propelled mechanized wire feeder designed for submerged arc welding
process with a track guiding capability.

Fig 3.2 Lincoln Electric LT-7 Machine

Fig 3.3 Door frame template

2
 CHAPTER-4

QUALIFICATION OF WELDING
PROCEDURE SPECIFICATION

2
4.1 PREPARATION FOR WELDING PROCEDURE SPECIFICATION

4.1.1 Customer Specification

The joint is a dissimilar thickness weld. As per customer specification as shown in (Fig
4.1), the joint has to be qualified as T joint in accordance with ISO 15614-1.

2
 Fig 4.1 Customer specification

4.1.2 Development of Welding Procedure Specification

ISO 15607, table 2 gives general guidelines towards development of a welding
procedure specification.

2
 Fig 4.1 Excerpt from ISO 15608

Method based on a welding procedure test can always be applied, unless the
procedure test does not adequately corresponds to the joint geometry, restraint,
acceptability of the actual welds. This method specifies how a welding procedure can
be developed based on the welding on a standardized test coupon and testing
methods specified according to the standard ISO 15614-1. Since the customer
specification specifies the standard ISO 15614-1, the particular method based on
welding procedure test has been selected to qualify this joint.

3.1.3 Parent Materials

The material of construction of the parts are as below.

Door frame : EN 10025-2 S355 K2
Shell plate : EN 10025-2 S355 J0

In order to minimize the number of welding procedures tests, steels are grouped
according to ISO 15608. Referring to the international standard, ISO 15608 it is found
that both materials EN 10025-2 S355 J0 and EN 10025-2 S355 K2 belong to the
group 1 and sub group 1.2 due to the materials high yield strength of approximately
355 Joules.

2
 Fig 4.2 Excerpt from ISO 15608
According to the Table 5, ISO 15614-1:2017, when the test piece materials are
selected from group 1.2, the procedure is qualified to weld between group 1.2 to
group 1.2 or 1.1. Since both the materials belong to to group 1.2, S355J0 materials
are selected for procedure qualification. The material selection is approved from
customer.

The range of qualification of steel groups and subgroups are specified as below
according to ISO 15614-1:2017, fig 4.3.

2
 Fig 4.3 Excerpt from ISO 15614-1

3.2 PRELIMINARY WELDING PROCEDURE SPECIFICATION

3.2.1 Number of procedures required

Qualifying two welding procedures can cover the entire thickness of the joint
according to ISO 15614-1. Another WPS required to cover the fillet weld, which is not
covered as part of this work. Preliminary welding procedures are prepared and are
shown Annexure A.

3.2.2 pWPS for MAG

As per the customer specification two separate preliminary WPSes were made to weld
two test coupon for WPS test coupons. The two tests will together constitute a WPS to
weld the door curve portion using MAG. The pWPSes were named as
AEPPL/pWPS/269 and AEPPL/pWPS/270. The pWPS is shown in Annexture A.

3.2.2 pWPS for MAG and SAW

To weld the straight portion of the door frame using MAG and SAW, a pWPS is
prepared which has named AEPPL/pWPS/280. The pWPS is shown in Annexture A.

2
 CHAPTER-4

WELDER/WELDING OPERATOR
QUALIFICATION

2
4.1 Plan
Since the joint has to be welded using the processes MAG and SAW, the process
invoves MAG welder and SAW welding operator. Hence the welder has to be qualified
according to the requirements of ISO 9606-1 and welding operator as ISO 14732.

4.2 Selection of Test Coupons

The performance qualification test coupons are selected based upon section 6.2 of
ISO 9606-1.

4.3 Welding and Testing of Test Coupons

When qualifying welders, the emphasis is placed on the welder's ability manually to
manipulate the electrode, welding torch or welding blowpipe, thereby producing a
weld of acceptable quality. While when qualifying welding operators, emphasis is
placed on welding operator’s ability to use the machine to produce the welds with
acceptable quality.
Below table shows the requirements of the standards.

Test Methods for Welder/Welding operator Qualification

As per foot note “c”, the butt joints made by welder and welding operator had been
tested with ultrasonic testing method as well as visual testing.

2
4.4 Performance Qualification Records

2
CHAPTER-5

JOB WELDING

3
5.1 Process Flow
 Cutting the door opening using oxy fuel cutting
 Bevel preparation
 Door frame fit up
 Root welding using MAG processes
 Welding straight portion with SAW on both sides
 Smoothening the weld edges
 Welding the curvy portion using MAG
 Back gouging
 Fill the groove with MAG

5.2 Quality Assurance plan

Quality assurance plan is in as shown.

5.3 Preparation of Weld Map

A weld map has been prepared and issued to communicate the shop floor regarding
welding details.

5.4 Preparation of WPS Synopsis

3
A welding synopsis has been prepared and issued to communicate the shop floor
regarding WPS parameters. This document is a work instruction to be used as an
alternative to WPS.

Conclusion

From the experimental results as discussed in the

previous chapter, following conclusions may be drawn;

* Please list the conclusions drawn

3
3
 REFERENCE

[1] L.K. Gillespie and P.T. Blotter, The formation and properties of
machining burrs, ASME, Journal for Engineering for Industry,
vol.98, No.1, pp. 66-74, 1976. (A journal paper referencing style)
[2] P.N. RAO, Manufacturing Technology: Forming and Welding,
Publisher, place and year of publication. (A book/ handbook
referencing style)
[3] www.mfg.mtu.edu/.../trad/drilling/nomen.html/drilpt.gif (A web page
referencing style)