Development of an economic process variant for under-powder welding in transversely position (PC) on high plate thicknesses for the implementation on Off-Shore structures and in shipbuilding industries (UP- transversely) [AVIF-No. A273]

Responsible research centre: SLV Mecklenburg-Vorpommern (Dr. Peters),  FhG AGP Rostock (Prof. Wanner)

Time period: 01.02.2012 bis 31.01.2014

Final report: CMT 31/2015


Motivation / Background

The rising political pressure to develop renewable energies for the sake of climate protection and security of supplies is evidenced inter alia by the objective to install wind turbines with a power of 25.000 MW in the North Sea Region till 2030.

Due to the high building speed and the resulting logistical problems, there are new joining processes that have to be found. In this regard, the UP- welding of transverse seams can be a solution for the placing-on of tube exits or for the connection between finished tubes and the foundation in all ranges of vertical manufacture. Compared to the MSG-welding procedure that previously and almost exclusively has been used, a greater repeatability and economic efficiency for the imperative small batch production can be achievable through successful development work.

Summary of planned objectives and actions

The objective of the project is to develop an economic technology for the one-sided under-powder welding in transverse position for plate thicknesses from 13 mm to 80 mm. In this regard, known economic advantages of flat-position welding should be transferred to the welding in transverse position, especially through the development/adaptation of appropriate tools and their control technology as well as through the development of a multi-wire technology. In cooperation with producers of the tool technologies and end-users, the first main emphasis will be processed, which is a prerequisite for the usage of a further developed technology referring the UP-transversely welding. In this connection it is important to develop the tool technology in such a way that welding on the actual steel structure for fastening guide rails and such can be avoided or at least minimized. For the simultaneous starting development efforts regarding the second main emphasis, power sources of the type “Power Wave AC/DC 1000” by the company Lincoln Electrics will be engaged. The power source is equipped with a “Waveform Control Technology” which allows the user to selectively influence the amplitudes- and time balances, to modify the penetration of the weld and further to increase the rate of deposition. These characteristic curves of the Waveform Control technology are currently used in PA-position. For this reason, this technology offers optimal conditions for the development of appropriate operating points for a transverse position in cooperation with producers of welding equipment, considering to increase the rate of deposition, which is to be integrated. Beyond that an appropriate combination of wire and powder should be ascertained, that possesses optimized supporting effects for the slag, increase of the welding speed and mechanical-technological properties. In conclusion, the results of the activities will be presented using the example of an original size Demonstrator at the site of an involved end-user.

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