A resource-efficient process design for heavy fabrication: A case of single-pass-per-layer narrow gap welding

Mohanty, Uttam Kumar and Kapil, Angshuman and Abe, Yohei and et al, . (2022) A resource-efficient process design for heavy fabrication: A case of single-pass-per-layer narrow gap welding. Sustainable Materials and Technologies, 33. pp. 1-16. ISSN 2214-9937

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Abstract

The welding process, omnipresent in the heavy fabrication industry, is a potential source of hazardous emissions. The article is motivated by the need to improve the sustainability of the heavy fabrication processes. Single-pass-per-layer narrow gap welding (NGW) is a potential alternative for reducing carbon footprint in high-thickness joints conventionally fabricated using the multi-pass multi-layers, sometimes even 100 or more layers, which is time-, material-, and energy- consuming. A newly developed mathematical model allows process design based on resource-efficient bead-on-plate welds (i.e., one layer deposited on a substrate). The results of bead-on-plate experiments are firstly utilized to identify the process capabilities in terms of strength, process, and production measures and subsequently coupled with the NGW mathematical model to arrive at feasible process parameters for a given groove design. The proposed approach implemented for a candidate case reveals significant improvement in the utilization of process capabilities, i.e., increase in strength, melting efficiency, and deposition rate and reduction in energy and material consumption. This investigation brings out three fundamental design rules for single-pass-per-layer NGW, namely i) the corresponding width of the bead-on-plate weld should be >1.5 times the groove width, ii) an upper limit on the utilization of process capabilities exists beyond which the productivity goes down drastically, and iii) the upper limit can be realized only at critical layer thicknesses. The design approach can be implemented to achieve more productive, economical, and sustainable design for processes involving high energy and material consumption. © 2022 The Author(s)

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IITH Creators:

IITH Creators	ORCiD

Item Type:

Article

Additional Information:

The authors acknowledge the joint research agreement between KU Leuven, Belgium, and the Joining and Welding Research Institute (JWRI), Osaka University, Japan, that supported this work. The authors would like to thank Hitachi Zosen Corporation, Osaka, Japan, for providing experimental support under Globalizing Asian Networks Project (Ja19990018). We would like to sincerely thank Mr. Takahiro Fujimoto, Dr. Mitsuyoshi Nakatani and Dr. Akikazu Kitagawa, from Technical Research Institute, Hitachi Zosen Corporation, Osaka, Japan for their detailed technical inputs during the experimental stage of the work.

Uncontrolled Keywords:

Heat-resistant steel; Narrow gap; Process design; Single-pass-per-layer; Submerged arc welding; Sustainability

Subjects:

Physics > Mechanical and aerospace

Divisions:

Department of Mechanical & Aerospace Engineering

Depositing User:

. LibTrainee 2021

Date Deposited:

14 Sep 2022 13:14

Last Modified:

14 Sep 2022 13:15