WO2008103122A1 - Method of manufacturing a component and use of said method - Google Patents

Method of manufacturing a component and use of said method Download PDF

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Publication number
WO2008103122A1
WO2008103122A1 PCT/SE2008/050183 SE2008050183W WO2008103122A1 WO 2008103122 A1 WO2008103122 A1 WO 2008103122A1 SE 2008050183 W SE2008050183 W SE 2008050183W WO 2008103122 A1 WO2008103122 A1 WO 2008103122A1
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WO
WIPO (PCT)
Prior art keywords
metal dusting
load
carrying member
component
weld
Prior art date
Application number
PCT/SE2008/050183
Other languages
French (fr)
Inventor
Mette Ramberg
Johan Hernblom
Original Assignee
Sandvik Intellectual Property Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sandvik Intellectual Property Ab filed Critical Sandvik Intellectual Property Ab
Publication of WO2008103122A1 publication Critical patent/WO2008103122A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/06Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of high energy impulses, e.g. magnetic energy
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • B23K2103/10Aluminium or alloys thereof

Definitions

  • the present invention relates to a method of manufacturing a component according to the preamble of claim 1 and the use of said method.
  • Metal dusting is a form of catastrophic carburization, where the metal disintegrates rapidly into coke and pure metal or other types of metal rich reaction products. Metal dusting typically occurs in gases that are initially supersaturated with respect to carbon, i.e. having a carbon activity greater than unity.
  • WO2005/021255 discloses a composite tube for use in environments where the risk of metal dusting is high.
  • the tube comprises a metal dusting resistant member of a copper-aluminum alloy and a load-carrying member of an alloy based on Fe, Ni or Co.
  • the tube may be produced by methods such as co- extrusion, overlay welding, explosion welding, dipping, co-drawing or shrinkage of one tube on another tube. According to this document, overlay welding is preferable.
  • overlay welding By utilizing overlay welding, a relatively high production rate can be accomplished at a low cost compared to other methods. However, this method may cause intermixture of the materials of the load-carrying member and the metal dusting resistant member. This in turn will lead to a premature decrease in corrosion resistance over time of use in the intended application. Moreover, overlay welding can in some cases cause cracking and/or penetration of melted metal from the welded material into the load-carrying member which in turn may lead to deteriorated mechanical properties of the load-carrying member. These problems are not necessarily severe if the component shall be processed further as in the case of WO2005/021255 but could be detrimental when producing component into the final shape directly.
  • US 6 737 175 discloses methods, such as CVD and sputtering, for production of this type of components. These two methods can only be used for deposition of relatively thin coatings, such as typically up to 100 ⁇ m. Consequently, there is a risk of a too low resistance to metal dusting, especially at high temperatures, since thin coatings will loose their corrosion resistance over time in the intended use.
  • the object of the invention is to provide a method of producing components with long service life, especially at high temperatures, to be used in environments with high carbon activity.
  • metal dusting is taken to mean the process whereby a metal or an alloy is attacked by a carbon rich gas and corroded into a mixture of coke/carbon and metallic or metal rich particles.
  • Manufacturing of a component comprising a load-carrying member and a material with high resistance to metal dusting is accomplished by utilizing Magnetic Pulse Welding (MPW).
  • MPW Magnetic Pulse Welding
  • the metal dusting resistant member is preferably only applied to the surfaces of said component, which are exposed to the environment where the risk of said corrosion type is high.
  • Figure 1 illustrates the principle of the MPW process wherein an outer tube is welded to an inner tube.
  • Figure 2 illustrates the principle of the MPW process wherein an inner tube is welded to an outer tube.
  • Figure 3 illustrates the principle of the MPW process when joining two corrosion resistant members to a load-carrying member.
  • Magnetic Pulse Welding is a cold welding process that is accomplished by a magnetic pulse causing a high-velocity impact between two materials resulting in a true metallurgical bond.
  • the technology of Magnetic Pulse Welding was developed more than 40 years ago, but new development of inductors and switchers raise the commercial implementations of the process.
  • the term welding in Magnetic Pulse Welding is some misleading as the method can be used for crimping, forming, cutting and perforating, and the process should therefore be addressed as Magnetic Pulse Technology.
  • the following parameters are of importance: magnetic pressure, mass of the accelerated part, material properties, gap between the two parts to be welded and the impact angle of the moving object.
  • One advantage of the process is the ability to join dissimilar materials. It may also be used for joining of difficult-to-weld materials, such as materials which may loose their mechanical or corrosion properties when welded. Since it is a cold welding process, a very narrow heat affected zone is accomplished due to a very low heat input. The utilization of said welding process results in high strength joints, high welding speed, high repeatability, and good process tolerances. Furthermore, there is no need for filler metal or shielding gases.
  • the present invention may suitably be used for joining tubular elements and the principle of the process for such elements is illustrated in Figure 1.
  • An outer tube 2 is welded to an inner tube 1 by usage of a coil 3 generating a magnetic force 4.
  • the load-carrying member can be either the inner or outer tube.
  • Figure 2 illustrates the same process for an inner tube 1 welded to an outer tube 2.
  • Figure 3 illustrates the utilization of the method according to the present invention for joining an inner metal dusting resistant member 5 and an outer metal dusting resistant member 6 to a tubular load-carrying member 7.
  • An inner coil 8 is used to provide an inner magnetic force 9
  • an outer coil 10 is used to provide an outer magnetic force 11.
  • the inner and outer magnetic forces can be generated simultaneously, or could be generated one at a time and thereby joining the two metal dusting resistant members with the load-carrying member in two separate steps.
  • the advantage of utilizing this embodiment with two steps, in comparison with first using the embodiment of Figure 1 followed by the embodiment of Figure 2, is that the component to be produced need not be moved from one manufacturing apparatus to another for joining the different members. Thereby, the manufacturing lead time is substantially reduced, and consequently, the manufacturing process is more cost effective.
  • the surface of the load-carrying member and/or metal dusting resistant member is cleaned in a proper way before welding. Suitable methods for cleaning are for example machining, pickling and shot peeing.
  • the metal dusting member suitably consists of a copper based alloy containing 2-20 % by weight of Al.
  • the alloy may also contain additions of up to 6 % Si, up to 1 % Fe, Ni and/or Co, and up to 1 % of rare earth metals (REM).
  • the composition of the alloy is (in percent by weight):
  • the component comprising the two different members may also comprise further members.
  • Examples of such members are diffusion barriers located between two other members, and surface coatings for enhanced heat transfer and/or electrical conductivity to and/or from the tube.
  • Suitable thickness of the metal dusting resistant member to be used in applications where the risk of metal dusting is high is usually 0,25-1 mm.
  • the lower limit is determined inter alia by the risk for reaction between the materials of the corrosion resistant member and the load-carrying member and/or the risk of evaporation of elements such as Cu when in service. Normally, the thickness of the metal dusting resistant member does not need to be more 2 mm.
  • Suitable materials for the load-carrying member are alloys based on Fe, Ni or Co which have good mechanical properties especially at high temperatures, such as austenitic alloys.
  • load-carrying materials are: - 18-25% Cr, 25-40% Ni, balance Fe and normally occurring additions like Al,
  • the thickness of the load-carrying member is suitably adjusted to the conditions in which the product will operate and to the selected composition. Suitable thicknesses are ranging from 1 mm to 15 mm. However, tubes with even thicker walls can be used if so required. Preferably the wall thickness of the tube is within the range 1 -10 mm, most preferably 2.5-5 mm.
  • the load-carrying member can be in any geometrical form, such as in the form of seamless or welded tube, sheet, plate or even complex geometrical forms.
  • the Magnetic Pulse Welding process is used for manufacturing components directly into their final dimension. It can also suitably be used for butt welding of the previously described component. Furthermore, it can be used for production of the different members before the actual joining of the members, for example for producing the load- carrying member and/or metal dusting resistant member in the form of a seam welded tubes. Moreover, it is possible to produce the component by means of MPW and thereafter use MPW to weld the component to the desired final geometrical shape, such as a seam welded tube.
  • the Magnetic Pulse Welding process is used for manufacturing a blank or billet which should be processed further, for example by means of extrusion or rolling.
  • the Magnetic Pulse Welding process is used for forming, such as bending or the like, of the previously described component.
  • the utilization of Magnetic Pulse Welding for joining the load-carrying member and the second member in accordance with the present invention is especially beneficial since the copper based alloy providing the resistance to metal dusting does not penetrate the load-carrying member. Consequently, the problems of deteriorated mechanical properties of the load-carrying member or deteriorated corrosion resistance of the component with the previously used methods are overcome. Furthermore, a cost effective method is accomplished as a result of the high welding speed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Magnetic Bearings And Hydrostatic Bearings (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Laminated Bodies (AREA)

Abstract

A component comprising a load-carrying member and a corrosion resistant member is manufactured by means of Magnetic Pulse Welding in order to avoid deteriorated properties of the component.

Description

METHOD OF MANUFACTURING A COMPONENT AND USE OF SAID METHOD
The present invention relates to a method of manufacturing a component according to the preamble of claim 1 and the use of said method.
Metal dusting is a form of catastrophic carburization, where the metal disintegrates rapidly into coke and pure metal or other types of metal rich reaction products. Metal dusting typically occurs in gases that are initially supersaturated with respect to carbon, i.e. having a carbon activity greater than unity.
WO2005/021255 discloses a composite tube for use in environments where the risk of metal dusting is high. The tube comprises a metal dusting resistant member of a copper-aluminum alloy and a load-carrying member of an alloy based on Fe, Ni or Co. The tube may be produced by methods such as co- extrusion, overlay welding, explosion welding, dipping, co-drawing or shrinkage of one tube on another tube. According to this document, overlay welding is preferable.
By utilizing overlay welding, a relatively high production rate can be accomplished at a low cost compared to other methods. However, this method may cause intermixture of the materials of the load-carrying member and the metal dusting resistant member. This in turn will lead to a premature decrease in corrosion resistance over time of use in the intended application. Moreover, overlay welding can in some cases cause cracking and/or penetration of melted metal from the welded material into the load-carrying member which in turn may lead to deteriorated mechanical properties of the load-carrying member. These problems are not necessarily severe if the component shall be processed further as in the case of WO2005/021255 but could be detrimental when producing component into the final shape directly. Furthermore, US 6 737 175 discloses methods, such as CVD and sputtering, for production of this type of components. These two methods can only be used for deposition of relatively thin coatings, such as typically up to 100 μm. Consequently, there is a risk of a too low resistance to metal dusting, especially at high temperatures, since thin coatings will loose their corrosion resistance over time in the intended use.
The methods given above all have at least one disadvantage when used as manufacturing method for components to be used in environments where there is a risk of metal dusting occurring, i.e. environments with high carbon activity, especially at high temperatures. Hence, there is a need of an alternative method for manufacturing these types of components.
Consequently, the object of the invention is to provide a method of producing components with long service life, especially at high temperatures, to be used in environments with high carbon activity.
Summary of the invention
The stated object in achieved by a method as initially defined and having the features of the characterizing portion of claim 1.
In this disclosure metal dusting is taken to mean the process whereby a metal or an alloy is attacked by a carbon rich gas and corroded into a mixture of coke/carbon and metallic or metal rich particles.
Manufacturing of a component comprising a load-carrying member and a material with high resistance to metal dusting is accomplished by utilizing Magnetic Pulse Welding (MPW). The metal dusting resistant member is preferably only applied to the surfaces of said component, which are exposed to the environment where the risk of said corrosion type is high.
Brief description of the drawings
Figure 1 illustrates the principle of the MPW process wherein an outer tube is welded to an inner tube. Figure 2 illustrates the principle of the MPW process wherein an inner tube is welded to an outer tube. Figure 3 illustrates the principle of the MPW process when joining two corrosion resistant members to a load-carrying member.
Detailed description of the invention
Magnetic Pulse Welding (MPW) is a cold welding process that is accomplished by a magnetic pulse causing a high-velocity impact between two materials resulting in a true metallurgical bond. The technology of Magnetic Pulse Welding was developed more than 40 years ago, but new development of inductors and switchers raise the commercial implementations of the process. The term welding in Magnetic Pulse Welding is some misleading as the method can be used for crimping, forming, cutting and perforating, and the process should therefore be addressed as Magnetic Pulse Technology.
To ensure a good weld the following parameters are of importance: magnetic pressure, mass of the accelerated part, material properties, gap between the two parts to be welded and the impact angle of the moving object.
One advantage of the process is the ability to join dissimilar materials. It may also be used for joining of difficult-to-weld materials, such as materials which may loose their mechanical or corrosion properties when welded. Since it is a cold welding process, a very narrow heat affected zone is accomplished due to a very low heat input. The utilization of said welding process results in high strength joints, high welding speed, high repeatability, and good process tolerances. Furthermore, there is no need for filler metal or shielding gases.
The present invention may suitably be used for joining tubular elements and the principle of the process for such elements is illustrated in Figure 1. An outer tube 2 is welded to an inner tube 1 by usage of a coil 3 generating a magnetic force 4. The load-carrying member can be either the inner or outer tube. Figure 2 illustrates the same process for an inner tube 1 welded to an outer tube 2.
Figure 3 illustrates the utilization of the method according to the present invention for joining an inner metal dusting resistant member 5 and an outer metal dusting resistant member 6 to a tubular load-carrying member 7. An inner coil 8 is used to provide an inner magnetic force 9 and an outer coil 10 is used to provide an outer magnetic force 11. The inner and outer magnetic forces can be generated simultaneously, or could be generated one at a time and thereby joining the two metal dusting resistant members with the load-carrying member in two separate steps. The advantage of utilizing this embodiment with two steps, in comparison with first using the embodiment of Figure 1 followed by the embodiment of Figure 2, is that the component to be produced need not be moved from one manufacturing apparatus to another for joining the different members. Thereby, the manufacturing lead time is substantially reduced, and consequently, the manufacturing process is more cost effective.
According to one embodiment the surface of the load-carrying member and/or metal dusting resistant member is cleaned in a proper way before welding. Suitable methods for cleaning are for example machining, pickling and shot peeing.
The metal dusting member suitably consists of a copper based alloy containing 2-20 % by weight of Al. The alloy may also contain additions of up to 6 % Si, up to 1 % Fe, Ni and/or Co, and up to 1 % of rare earth metals (REM). According to a preferred embodiment, the composition of the alloy is (in percent by weight):
4-10 % Al
>0-3 % Si 0-1 % REM balance Cu and normally occurring impurities.
The effect of the different elements of the alloy above is comprehensively described in WO2005/021255 and will therefore not be described further in the present disclosure. The effect of the different alloying elements as described in WO2005/021255 is hereby incorporated in its entirety.
The component comprising the two different members may also comprise further members. Examples of such members are diffusion barriers located between two other members, and surface coatings for enhanced heat transfer and/or electrical conductivity to and/or from the tube.
Suitable thickness of the metal dusting resistant member to be used in applications where the risk of metal dusting is high is usually 0,25-1 mm. The lower limit is determined inter alia by the risk for reaction between the materials of the corrosion resistant member and the load-carrying member and/or the risk of evaporation of elements such as Cu when in service. Normally, the thickness of the metal dusting resistant member does not need to be more 2 mm.
Suitable materials for the load-carrying member are alloys based on Fe, Ni or Co which have good mechanical properties especially at high temperatures, such as austenitic alloys. Examples of load-carrying materials are: - 18-25% Cr, 25-40% Ni, balance Fe and normally occurring additions like Al,
C, N, Ti, Nb, Mo etc. - 16-35% Cr, 50-75% Ni, , balance Fe and normally occurring additions like Al, C, N, Ti, Nb, Mo etc. - 7-13% Cr, 0-0.2% C, 0-0.2 % N (min 0.05% C+N) balance Fe and additions of Nb, Ti, V, Mo and/or W etc.
- 16-22% Cr, 8-20% Ni, balance Fe and additions of for example Mn, Nb, C
The thickness of the load-carrying member is suitably adjusted to the conditions in which the product will operate and to the selected composition. Suitable thicknesses are ranging from 1 mm to 15 mm. However, tubes with even thicker walls can be used if so required. Preferably the wall thickness of the tube is within the range 1 -10 mm, most preferably 2.5-5 mm. The load-carrying member can be in any geometrical form, such as in the form of seamless or welded tube, sheet, plate or even complex geometrical forms.
According to an embodiment of the invention, the Magnetic Pulse Welding process is used for manufacturing components directly into their final dimension. It can also suitably be used for butt welding of the previously described component. Furthermore, it can be used for production of the different members before the actual joining of the members, for example for producing the load- carrying member and/or metal dusting resistant member in the form of a seam welded tubes. Moreover, it is possible to produce the component by means of MPW and thereafter use MPW to weld the component to the desired final geometrical shape, such as a seam welded tube.
According to another embodiment of the invention, the Magnetic Pulse Welding process is used for manufacturing a blank or billet which should be processed further, for example by means of extrusion or rolling.
According to a further embodiment of the invention, the Magnetic Pulse Welding process is used for forming, such as bending or the like, of the previously described component. The utilization of Magnetic Pulse Welding for joining the load-carrying member and the second member in accordance with the present invention is especially beneficial since the copper based alloy providing the resistance to metal dusting does not penetrate the load-carrying member. Consequently, the problems of deteriorated mechanical properties of the load-carrying member or deteriorated corrosion resistance of the component with the previously used methods are overcome. Furthermore, a cost effective method is accomplished as a result of the high welding speed.

Claims

1. Method of manufacturing a component with high resistance to metal dusting wherein said component comprises a load-carrying member of a first material and a second member of a metal dusting resistant material characterized i n that the metal dusting resistant material is applied to the load-carrying member by means of Magnetic Pulse Welding.
2. Method according to claim 1 characterized i n that the load-carrying member is provided with a third member by means of magnetic welding wherein said third member preferably consists of a metal dusting resistant material.
3. Method according to claims 1 or 2 characterized in that the metal dusting resistant material is a copper based alloy comprising 2-20 % by weight of aluminum.
4. Method according to claim 3 characterized i n that the metal dusting resistant material has the following composition in percent by weight:
4-10 % Al >0-3 % Si 0-1 % REM balance Cu and normally occurring impurities.
5. Use of the method according to any of the preceding claims for manufacturing of components to be exposed to environments wherein there is risk of metal dusting occurring.
6. Use according to claim 5 wherein the component is in the form of a tube, sheet, strip or bar.
7. Use according to claim 5 wherein the load carrying member has at least one weld other than the weld accomplished when joining of the load- carrying member and the other member of a material resistant to metal dusting.
8. Use according to claim 7 wherein the one weld other than the weld accomplished when joining of the load-carrying member and the other member of a material resistant to metal dusting is a butt weld.
9. Use according to claim 7 wherein the one weld other than the weld accomplished when joining of the load-carrying member and the other member of a material resistant to metal dusting is a seam weld produced when manufacturing the load-carrying member, the member of a material resistant to metal dusting or the final component of claim 1.
10. Use according to claim 5 wherein the component has a complex geometry.
PCT/SE2008/050183 2007-02-20 2008-02-15 Method of manufacturing a component and use of said method WO2008103122A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0700418-7 2007-02-20
SE0700418A SE530890C2 (en) 2007-02-20 2007-02-20 Method of manufacturing a component and use of said method

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WO2008103122A1 true WO2008103122A1 (en) 2008-08-28

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013163972A1 (en) * 2012-05-04 2013-11-07 Universität Kassel Method for applying a corrosion and/or wear-inhibiting metallic coating onto the inner lateral surface of a metallic tubular body by means of magnetic impulse welding; and a welding jig comprising a blade-type coil
FR2993946A1 (en) * 2012-07-26 2014-01-31 Peugeot Citroen Automobiles Sa Joining two coaxial tubes in a cylinder barrel casing of a combustion engine of an automobile, comprises welding the tubes when inserted one into the other, and deforming outer wall of outer tube during the welding
AT522611A1 (en) * 2019-05-29 2020-12-15 Miba Gleitlager Austria Gmbh Method for manufacturing a multilayer plain bearing
CN112997349A (en) * 2018-11-07 2021-06-18 拉特格斯,新泽西州立大学 Closure for electrochemical cell
US12135061B2 (en) 2019-05-29 2024-11-05 Miba Gleitlager Austria Gmbh Multilayer slide bearing and method for producing a multilayer slide bearing

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1387721A (en) * 1972-02-18 1975-03-19 Andrianov A M Demichev V F Method of magnetic pulse welding metals and a device for carrying out the method
US4150274A (en) * 1975-11-10 1979-04-17 Minin Vladilen E Method for lap welding of skelps and device for effecting same
US6234375B1 (en) * 1995-06-16 2001-05-22 Dana Corporation Molecular bonding of vehicle frame components using magnetic impulse welding techniques
US20030127453A1 (en) * 2001-05-31 2003-07-10 Kichline John L. Method for performing a magnetic pulse welding operation

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1387721A (en) * 1972-02-18 1975-03-19 Andrianov A M Demichev V F Method of magnetic pulse welding metals and a device for carrying out the method
US4150274A (en) * 1975-11-10 1979-04-17 Minin Vladilen E Method for lap welding of skelps and device for effecting same
US6234375B1 (en) * 1995-06-16 2001-05-22 Dana Corporation Molecular bonding of vehicle frame components using magnetic impulse welding techniques
US20030127453A1 (en) * 2001-05-31 2003-07-10 Kichline John L. Method for performing a magnetic pulse welding operation

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013163972A1 (en) * 2012-05-04 2013-11-07 Universität Kassel Method for applying a corrosion and/or wear-inhibiting metallic coating onto the inner lateral surface of a metallic tubular body by means of magnetic impulse welding; and a welding jig comprising a blade-type coil
FR2993946A1 (en) * 2012-07-26 2014-01-31 Peugeot Citroen Automobiles Sa Joining two coaxial tubes in a cylinder barrel casing of a combustion engine of an automobile, comprises welding the tubes when inserted one into the other, and deforming outer wall of outer tube during the welding
CN112997349A (en) * 2018-11-07 2021-06-18 拉特格斯,新泽西州立大学 Closure for electrochemical cell
EP3878023A4 (en) * 2018-11-07 2022-08-17 Rutgers, the State University of New Jersey Enclosures for electrochemical cells
CN112997349B (en) * 2018-11-07 2024-05-14 拉特格斯,新泽西州立大学 Closure for electrochemical cells
AT522611A1 (en) * 2019-05-29 2020-12-15 Miba Gleitlager Austria Gmbh Method for manufacturing a multilayer plain bearing
US12135061B2 (en) 2019-05-29 2024-11-05 Miba Gleitlager Austria Gmbh Multilayer slide bearing and method for producing a multilayer slide bearing

Also Published As

Publication number Publication date
SE0700418L (en) 2008-08-21
SE530890C2 (en) 2008-10-07

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