Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process
The P91 martensitic steel and 304L austenitic stainless steels are two mainly used structural steels in power plants. The major problem in conventional multipass tungsten inert gas (TIG) welding of P91/304L steel is high heat input and joint distortion, increased cost and time associated with V groo...
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2024-12-01
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| author | Tushar Sonar Mikhail Ivanov Igor Shcherbakov Evgeny Trofimov Emiliya Khasanova Muralimohan Cheepu Kun Liu |
| author_facet | Tushar Sonar Mikhail Ivanov Igor Shcherbakov Evgeny Trofimov Emiliya Khasanova Muralimohan Cheepu Kun Liu |
| author_sort | Tushar Sonar |
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| description | The P91 martensitic steel and 304L austenitic stainless steels are two mainly used structural steels in power plants. The major problem in conventional multipass tungsten inert gas (TIG) welding of P91/304L steel is high heat input and joint distortion, increased cost and time associated with V groove preparation, filler rod requirement, preheating and welding in multiple passes, and labor efforts. Hence, in this study, a novel approach of robotically operated activated flux TIG (A-TIG) welding process and thin AlCoCrFeNi<sub>2.1</sub> eutectic high entropy alloy (EHEA) sheet as the interlayer was used to weld 6.14 mm thick P91 and 304L steel plates with 02 passes in butt joint configuration. The joints were qualified using visual examination, macro-etching, X-ray radiography testing and angular distortion measurement. The angular distortion of the joints was measured using a coordinate measuring machine (CMM) integrated with Samiso 7.5 software. The quality of the A-TIG welded joints was compared to the joints made employing multipass-TIG welding process and Inconel 82 filler rod in 07 passes. The A-TIG welded joints showed significant reduction in angular distortion and higher productivity. It showed a 55% reduction in angular distortion and 80% reduction in welding cost and time compared to the multipass-TIG welded joints. |
| format | Article |
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| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-7cda8164a5524c2d8a83ffb38cb5d1f12024-12-27T14:32:53ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-12-018628310.3390/jmmp8060283Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding ProcessTushar Sonar0Mikhail Ivanov1Igor Shcherbakov2Evgeny Trofimov3Emiliya Khasanova4Muralimohan Cheepu5Kun Liu6Department of Welding Equipment and Technology, Institution of Engineering and Technology, South Ural State University (National Research University), Chelyabinsk 454080, RussiaDepartment of Welding Equipment and Technology, Institution of Engineering and Technology, South Ural State University (National Research University), Chelyabinsk 454080, RussiaDepartment of Welding Equipment and Technology, Institution of Engineering and Technology, South Ural State University (National Research University), Chelyabinsk 454080, RussiaDepartment of Materials Science, Physical and Chemical Properties of Materials, Institution of Engineering and Technology, South Ural State University (National Research University), Chelyabinsk 454080, RussiaDepartment of Welding Equipment and Technology, Institution of Engineering and Technology, South Ural State University (National Research University), Chelyabinsk 454080, RussiaResearch and Development, Vitzronextech Co., Ltd., Ansan 15603, Republic of KoreaSchool of Materials Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang 212100, ChinaThe P91 martensitic steel and 304L austenitic stainless steels are two mainly used structural steels in power plants. The major problem in conventional multipass tungsten inert gas (TIG) welding of P91/304L steel is high heat input and joint distortion, increased cost and time associated with V groove preparation, filler rod requirement, preheating and welding in multiple passes, and labor efforts. Hence, in this study, a novel approach of robotically operated activated flux TIG (A-TIG) welding process and thin AlCoCrFeNi<sub>2.1</sub> eutectic high entropy alloy (EHEA) sheet as the interlayer was used to weld 6.14 mm thick P91 and 304L steel plates with 02 passes in butt joint configuration. The joints were qualified using visual examination, macro-etching, X-ray radiography testing and angular distortion measurement. The angular distortion of the joints was measured using a coordinate measuring machine (CMM) integrated with Samiso 7.5 software. The quality of the A-TIG welded joints was compared to the joints made employing multipass-TIG welding process and Inconel 82 filler rod in 07 passes. The A-TIG welded joints showed significant reduction in angular distortion and higher productivity. It showed a 55% reduction in angular distortion and 80% reduction in welding cost and time compared to the multipass-TIG welded joints.https://www.mdpi.com/2504-4494/8/6/283ferritic-martensitic steelaustenitic stainless-steelhigh entropy alloyrobotA-TIG weldingX-ray radiography |
| spellingShingle | Tushar Sonar Mikhail Ivanov Igor Shcherbakov Evgeny Trofimov Emiliya Khasanova Muralimohan Cheepu Kun Liu Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process Journal of Manufacturing and Materials Processing ferritic-martensitic steel austenitic stainless-steel high entropy alloy robot A-TIG welding X-ray radiography |
| title | Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process |
| title_full | Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process |
| title_fullStr | Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process |
| title_full_unstemmed | Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process |
| title_short | Enhancing Welding Productivity and Mitigation of Distortion in Dissimilar Welding of Ferritic-Martensitic Steel and Austenitic Stainless Steel Using Robotic A-TIG Welding Process |
| title_sort | enhancing welding productivity and mitigation of distortion in dissimilar welding of ferritic martensitic steel and austenitic stainless steel using robotic a tig welding process |
| topic | ferritic-martensitic steel austenitic stainless-steel high entropy alloy robot A-TIG welding X-ray radiography |
| url | https://www.mdpi.com/2504-4494/8/6/283 |
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