Technological windows for MIAB welding of tubes featuring original longitudinal magnetization system with peripheral solenoids

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Characterization of magnetically impelled arc butt welded T11 tubes for high pressure applications

Magnetically impelled arc butt (MIAB) welding is a unique forge welding process in which an arc is drawn in the gap between the two tubes to be welded in order to raise them to a high temperature to allow forging to form a solid-state weld In this case, the arc is rotated with a high speed around the weld line by an electromagnetic force resulting from the interaction of the magnetic field and the arc current This paper presents the details of the results and the conclusions of the experimental trials conducted on the MIAB module designed and developed based on the principle Further, nonlinear electromagnetic analysis has been performed to determine the magnetic field and electromagnetic force distribution in MIAB process using finite element package ANSYS Typical results of this analysis pertaining to magnetic field are compared with the experimental data for steel tubes (outer diameter 47 mm and thickness of 2 mm) It is observed that the results from finite element analysis and the experimental trials are in excellent agreement The proposed three-dimensional finite element method model for electromagnetic force distribution facilitates comprehensive understanding of the arc rotation process in MIAB welding

Development of a MIAB welding module and experimental analysis of rotational behavior of arc—simulation of electromagnetic force distribution during MIAB welding of steel pipes using finite element analysis

Magnetically impelled arc butt (MIAB) welding is a pressure welding process used for joining of pipes and tubes with an external magnetic field affecting arc rotation along the tube circumference. Past studies based on experiments and finite element analysis (FEA) suggested that the weld quality can be significantly improved by proper adjustment of its input parameters such as current, voltage, flux density, etc. Experiments are useful for understanding the physics behind the process, but the quantification and optimization of the MIAB process needs a thorough numerical investigation. Therefore, the present work presents a combined experimental and numerical study for investigating the arc speed indicator of the T11 grade chromium alloy tubes of the MIAB process. Firstly, experiments on the MIAB process are conducted, and the arc speed is measured based on the four inputs (welding current, welding voltage, magnetic coil current, and voltage). This is followed by introduction of a numerical approach of multi-gene genetic programming (MGGP) to formulate a functional relationship between arc speed and the four design variables. The statistical error metrics based on the square of correlation coefficient, relative error (%), and root mean square were used to validate the model performance against the experimental data. The proposed model can be utilized to select the best combination of input variables to optimize the arc speed, which has a vital role in governing the weld quality. In addition, 2-D analysis conducted reveals that the welding current influence the arc speed of the clay the most followed by coil current and coil voltage.

Experimental- and numerical-based studies for magnetically impelled arc butt welding of T11 chromium alloy tubes

Magnetically impelled arc butt (MIAB) welding is a solid phase pressure welding process similar to flash-butt welding, but it uses a magnetic field to rapidly spin the arc. The spinning arc provides a more consistent interior and exterior weld flash than typically seen on the flash-butt upset areas. MIAB welding process is presently being employed for welding tubular sections in automobile industries in various parts of United Kingdom and Germany. However, there are no details reported in available literatures on application of MIAB welding process for pressure parts. Hence, in this study, a pivotal attempt is being made to employ MIAB welding process to weld carbon steel tubes (51 mm and 44 mm outer diameter) and (5-6 mm thick) in economizer coils of pressure vessel. Several trials are conducted to create an optimal parameter window for MIAB welding process by varying the different input parameters. Further, mechanical testing and metallurgical characterization are carried out on the MIAB-welded specimen...

Feasibility of Magnetically Impelled Arc Butt (MIAB) Welding of High-Thickness Tubes for Pressure Parts

Magnetically Impelled Arc Butt (MIAB) welding is mainly used in the automotive industry for butt welding of tubes and tubular parts 8–100mm in diameter and 0.8–6mm wall thickness. To extend the range of MIAB welding applications research work was conducted on different hollow and solid parts, special attention being given to welding of parts, the cross section of which is commensurable with of the active spot diameter of the rotating arc.

Magnetically Impelled Arc Butt Welding of Hollow and Solid Parts

The E. O. Paton Welding Institute has developed a new technology of resistance flash butt welding of pipes of various diamaters and has designed welding machines providing pipe welding within the range of 114 − 325 mm and 720 − 1420 mm diameter. For welding of 720 −1420 mm diameter pipes the internal pipe welding machines are used which move inside the pipe by means of the drive built-in into the welding machine. This type of the machines is equipped with a flash remover which cuts the internal flash in a hot state. The E.O. Paton Welding Institute conducted a wide scope of investigations and tests of welded joints of the pipes welded by resistance flash butt welding machines. The tests covered the X52 through X70 grades of pipe steels and 12.5 mm to 25.4 mm wall thicknesses. The tests were performed to reveal a correspondence of the welded joint quality obtained to the requirements of the codes used (API 1104 and oth.). The results of the mechanical tests, X-ray and ultrasonic inspections, the data of metallographic examinations accomplished in accordance with the requirements of code API 1104 and also the results of the additional Charpy and COD strength tests confirmed a high quality of welded joints.

Krivenko Valerij G

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