68 th IIW Annual Assem bly Helsinki FINLAND 28 th June – 3 rd July 20 15 68 th IIW Annual Assembly & International Conference 28 th June – 3 rd July 2015 Helsinki, Finland International Conference on High Strength Materials Challenges and Applications 2 nd – 3 rd July 2015 H E L SIN K I F I N L A N D IIW_2015_kooste.indd 2 4.5.2015 12.49 HT_2-3_15.indd 2 15.5.2015 15.59
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3/2015 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Antti Itävuo Outokumpu – High Performance Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Cavitar and Serimax Heatmasters – 40 Years of Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Mika Siren, Veli Kujanpää and Pekka Nevasmaa WSF Member Companies . . . . Lindgren, M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Hilkka Rissanen Aalto University: Research and Education in Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Finnish Technology Industry Current Situation and Outlook . . . . . . . . . . . . . . . . . . 66 Olli-Pekka Hämäläinen, Timo Björk, Matti Koskimäki and Antti Salminen High-Level Welding Research at the University of Oulu . . . . . . 14 Anna Fellman The Welding Society of Finland at Your Service . . . . 32 Ilkka Mujunen New Weld-Testing Methods in the Pipeline . . . . . . . . . 29 Seppo Mikkola Online Monitoring of Narrow-Gap Offshore Pipe-Welding . 81 THEME: Welding in Finland Photos on the cover page Tram Luxury cruiser Transtech Oy Meyer Turku Oy Harvester Car Ponsse Oy Valmet Automotive Oy Pressure vessel Steel bridge GaV Group Oy Ruukki Construction Oy Ge ne ra l Co m pa ni es Re se ar ch 68 th IIW Annual Assem bly Helsinki FINLAND 28 th June – 3 rd July 20 15 68 th IIW Annual Assembly & International Conference 28 th June – 3 rd July 2015 Helsinki, Finland International Conference on High Strength Materials Challenges and Applications 2 nd – 3 rd July 2015 H E L SIN K I F I N L A N D IIW_2015_kooste.indd 2 4.5.2015 12.49 HT_2-3_15.indd 1 15.5.2015 15.59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 M. . . . . . . . . Närhi Welding and Production Automation in the Heavy Fabrication Industry . . . . . . . . . . . . . . . . . . . . 18 Jouko Lassila Gary Marquis A Long International Walk through the Field of Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peltola and L. . . . . . . . . . . . . . 7 Ismo Meuronen and Juha Lukkari Laser and Laser Hybrid Welding in Finnish Industry . . . . 26 Niko Rautiainen and Eero Nykänen Caverion and LNG . . . . . . . . . 4 Petteri Rautaporras Welding in Finland Overview . . . . . . . . . . . . . . +358 500 414 045 e-mail: juha.lukkari@shy.inet.fi Toimitussihteeri Editorial Assistant Angelica Emeléus Tel. . . . The Welding Society of Finland Tel. . . . . Lehtonen, P. . . . . . . . . . . . . . . . . . . . . . . . 55 Timo Salonen Vahterus – Heat Exchangers with a Fully-Welded Heart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Paul Kah and Jukka Martikainen Structural Design and Laser Processing Research at Lappeenranta University of Technology . . . . . . . . . . . . . . . . . . 37 Kyösti Isosaari Kokkola LCC Oy Over 10 Years Experience in Laser Coating . . . . . . . . . . . +358 9 773 2199 www.hitsaus.net Toimitus Editorial Staff Päätoimittaja Editor-in-Chief Juha Lukkari Tel. . . . . . . . . . . 60 Heikki Remes, Pedro Vilaça, Jani Romanoff, Gary Marquis and Hannu Hänninen Welding Technology Laboratory at Lappeenranta University of Technology . . . . . . . . 70 David Porter, Kari Mäntyjärvi and Jouko Leinonen Education and Materials Joining Research Methods at Tampere University of Technology . . . . . . . . . . . 45 Hannu-Pekka Heikkinen, Stefan Lindner and Alexander Thulin Application-Oriented Welding Research for Demanding Process Conditions . . . . . . . . . . . . . . . . 23/ 20 15 1 WELDING IN FINLAND [ www.hitsaus.net ] 65th Volume ISSN 0437-6056 Julkaisija ja kustantaja Publisher Suomen Hitsausteknillinen Yhdistys r.y. +358 9 773 2199 e-mail: angelica.emeleus@shy.inet.fi Toimituskunta Editorial Board Jyrki Honkanen, Olli Kortelainen, Jouko Lassila, Eero Nykänen, Kristiina Pispala, Jukka Setälä, Mika Sirén, Juha Kauppila, Reetta Verho, Juha Lukkari, Angelica Emeléus Toimisto Office Mäkelänkatu 36 A 2 00510 HELSINKI Tel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Sepppo Heiskanen Meyer Turku Oy One of the Leading European Shipbuilding Companies . . . . . . 50 Kristiina Pispala Posiva and Final Disposal of Spent Nuclear Fuel in Finland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +358 3 358 9500 fax +358 3 358 9535 e-mail: tuotanto@orivedenkirjapaino.fi Levikki Circulation 4000 Member of The International Institute of Welding 1 Subscriptions (Finland) 80 . . . . . . . . . . . . . . . . . . . . . . . . 34 Tuomas Suominen and Thomas Freundlich From Chalk Markings to Barcodes . . . . . . . Subscriptions from abroad 140 . . . . . . . . . . . . . . . . . . . . . . . . . 23 Juha Kauppila, Pertti Lepola and Reijo Pettinen Arctech Helsinki Shipyard We Make You Break the Ice! . . Laihonen, H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finlands Svetstekniska Förening r.f. . . . . . . . . . . . . 20 Minttu Kauppila Qualification of Welding Personnel in Finland . . . . . . . . . . . . . . . . . . . . . . . . +358 9 773 2199 English editing and proofreading Colibri Communications e-mail: colibricomm@gmail.com Kirjapaino Printing House Oriveden Kirjapaino Oriveden Sanomalehti Osakeyhtiö PL 33 35301 Orivesi Tel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Pasi Peura, Petri Vuoristo and Jorma Vihinen Welding Research at VTT Ltd . . . . . . . . . . . . . .
Ismo Meuronen President of the Welding Society of Finland Chair of the IIW-2015 Organizing Committee CEO Meuro-Tech Prof. The Welding Society of Finland is truly privileged to have been afforded the oppor tunity to host the 68 th IIW Annual Assembly and accompanying International Conference on Challenges and Applications of High-Strength Materials, in Finland’s capital city of Helsinki, from June 28-July 3, 2015. The magazine was first issued in 1950, with two previous English language versions in 1989 and 1994, this current issue being N° 333. Gary B. Some 25 representative ar ticles have thus been compiled for this special publication. On behalf of the Welding Society of Finland, we would like to thank all of the companies, research institutes and individuals for their respective contributions towards making this magazine possible. We hope that this edition will provide a general overview of welding technology in Finland and will ser ve as a useful introduction to Finnish companies and their advanced manufacturing technology. During its 66-year membership of the IIW, only two previous IIW Annual Assemblies have been organized in Finland, in 1963 and 1989. Marquis IIW President (2014-2017) Chair of the IIW-2015 Scientific Committee Dean of the Aalto University School of Engineering Juha Lukkari Editor-in-Chief Welding Technology Magazine Welding Society of Finland HT_2-3_15.indd 2 15.5.2015 15.59. 23/ 20 15 2 WELDING IN FINLAND [ www .hitsaus .net ] 68 th IIW Annual Assem bly Helsinki FINLAND 28 th June – 3 rd July 20 15 H E L S I N K I F I N L A N D 68 th IIW Annual Assembly & International Conference IIW Annual Assembly & International Conference 28 th June – 3 rd July 2015 Helsinki, Finland International Conference on High Strength Materials Challenges and Applications | 2 nd – 3 rd July 2015 Further information and online registration at www.iiw2015.com IIW2015_183x45.indd 1 9.3.2015 15.01 Foreword It is our greatest pleasure to present this special issue, English-language edition of the welding technology magazine, Hitsaustekniikka. As proud hosts of the 2015 IIW Annual Assembly and International Conference, the focus of this special edition of Hitsaustekniikka has appropriately been centred around “Welding in Finland,” in order to place the spotlight on the Finnish welding industr y, products and related sectors, including the manufacture of welding equipment, filler metals and used steels, as well as welding research. This magazine is published by the Welding Society of Finland which was established in 1949 as the 14 th Member Countr y of the International Institute of Welding (IIW)
Visit www.cavitar.com Now you can. ller material. CAVILUX ® Welding monitoring solutions enable you to see the welding process as cold. You can monitor as well as adjust your process right away once a defect has been detected. › Want to see further. Get never-before-seen visual information on such things as seam position, melt pool behaviour and drop forming of . www.meyerturku.com InnovatIon and technology HT_2-3_15.indd 3 15.5.2015 15.59. [ www .hitsaus .net ] 68 th IIW Annual Assem bly Helsinki FINLAND 28 th June – 3 rd July 20 15 H E L S I N K I F I N L A N D 68 th IIW Annual Assembly & International Conference IIW Annual Assembly & International Conference 28 th June – 3 rd July 2015 Helsinki, Finland International Conference on High Strength Materials Challenges and Applications | 2 nd – 3 rd July 2015 Further information and online registration at www.iiw2015.com IIW2015_183x45.indd 1 9.3.2015 15.01 Want to see through heat and blinding brightness to the core of your welding process
HT_2-3_15.indd 4 15.5.2015 15.59. Indeed, the challenge for the years to come will be to considerably improve the competitiveness of the operational environment, in order to once again make Finland an interesting and attractive target for investment. During 2014, development nevertheless appeared to be headed in a positive direction, giving rise to the cautious optimism that is now in the air. Production volume of mechanical engineering branches in Finland. Nonetheless, when reviewing the production graphs for the mechanical engineering industry-related sub-sectors (Figure 1), it can be noted that the scenario is also quite challenging in the metals industry. However, it has since become increasingly clear that our country is besieged by fundamental infrastructural problems. Via the success of the export industry, it will also be possible to stimulate private demand and to steer Finland as a whole on to the fast track to growth. At first, the collapse seemed only to be a transitory downturn. The United States of America (USA) and the developing economies in Asia still continue to act as the global economic drivers. The technology industry accounts for about half of Finland’s total exports and the industry’s problems are reflected more and more clearly in the public economy and in private demand. 23/ 20 15 4 WELDING IN FINLAND [ www.hitsaus.net ] Finnish Technology Industry Current Situation and Outlook Petteri Rautaporras Finland’s technological industry has been faced with many challenges over the past six years, exacerbated by the fact that the continuous growth of preceding times hit a brick wall at the end of 2008. When the industry’s difficult situation is analysed, considerable weight is frequently attributed to the distress experienced by the electronics and electrical sectors (particularly, the halt in telecommunications equipment production). However, hopes of a quick recovery vanished completely in 2012 and 2013, whereupon production quantities fell back to the low levels seen in 2009. In the USA, the steady growth which has been ongoing for many years is anticipated Production Volume of Branches of the Mechanical Engineering in Finland Seasonally adjusted volume index Shares of turnover 2013: machinery 64 %, metal goods 25 %, transport equipment 11 % Source: Macrobond, Statistics Finland 17.3.2015 1 Fig. Progress to date After the collapse of 2009, production initially appeared to assume the same growth pattern it had followed prior to 2008. 1
Many of the companies that have transferred their production operations overseas have nonetheless maintained their product development base at least partially in Finland. With this operational model, companies face their own challenges. Like many of its competitors, Finland has lost its position and has yet failed to recover from the collapse of 2009. Will production return to Finland, at least to some extent. Previously, global corporations established themselves in lower productioncost countries and, simultaneously, closer to their final customers. 23/ 20 15 5 WELDING IN FINLAND [ www.hitsaus.net ] to continue. Cost competitiveness and the attractiveness of the operational environment carry considerable weight when solutions are sought in enterprises with respect to their operational reorganisation. It is nevertheless clear that the Russian economy will plunge, due in part to the international economic sanctions currently in place, but also to the downfall in the world’s oil prices. Nevertheless, the situation as a whole appears to be slightly better than in the last two years and, provided that no greater negative shocks impact the world, it may be that the slightly positive trend will continue during the latter part of 2015. Many of today’s successful mechanical engineering-based enterprises frequently offer their customers comprehensive solutions, instead of the old, more streamlined operational model. On a broader front, smaller companies also transferred their production operations to Estonia and to other Eastern European countries, to name a few. Petteri Rautaporras Economist Federation of Finnish Technology Industries www.teknologiateollisuus.fi Industrial Production Volume in USA, EU, Japan and Finland Seasonally adjusted volume index Source: Macrobond 17.3.2015 2 Fig. Changes in the production structure Global competition struck the mechanical engineering industry quite severely over the last six-year-period and companies reacted in many different ways to this new, challenging situation. If the matter is examined on a corporate level, a very large number of enterprises in possession of excellent competitive ability can still be found in our nation – companies that have the skills and the desire to invest in the expansion and improvement of their operations. At this juncture, it is very difficult to predict prospective developments in Russia. Outlook for 2015 On the basis of the Federation of Finnish Technology Industries’ order book survey, turnover for the start of 2015 in the mechanical engineering sector is anticipated to be slightly higher than for the corresponding period last year. It can be seen in Figure 2 that Finland’s industry has fared poorly by international comparison. On the national economic level, depreciation is currently greater than new investments. Conversely, other enterprises drastically reduced their business operations, retaining only the most profitable elements. From my viewpoint, this very clearly indicates that Finland has been encountering a major problem with its own competitiveness. Even at its best, however, growth is expected to be only rather modest and, from the perspective of the national economy, very little relief will be felt. From the sub-contractors’ perspective, at least part of the planning can be executed by the sub-contractors themselves, thereby optimising their own operations, as well as increasing productivity. A large number of companies have also been obliged to cease operations altogether. In this manner, many have embarked on the promotion of their own exports, thereby expanding their clientele and establishing a more regular order book. Sadly, these investments have frequently been directed in recent years to somewhere other than Finland. Numerous enterprises also currently function at a very low rate of profitability and, consequently, are struggling to survive: approximately 25% of the member companies of the Federation of Finnish Technology Industries were unprofitable in 2013. Even so, situations and approaches vary greatly from one enterprise to another and of course, there is no model that functions automatically to guarantee success. This provokes the concerns of both main contractors and sub-contractors. Longer-term predictions are still very difficult and prospects remain rather obscure. From Finland’s standpoint, there are two essential questions surrounding this issue: Will R&D activity also be transferred to foreign countries in pursuit of production. Our capital is thus being continuously eroded and, consequently, our potential production capacity is steadily becoming smaller. Western Europe, however, is projected to languish at around zero per cent growth for some time, so increased demand from that market is not realistically to be foreseen. The deterioration of its competitive edge has plunged Finland into a serious slump with regard to investment. Viewed from a global perspective, the situation with regard to demand is far from optimum, but its fragility only explains Finland’s industrial problems to a very minor degree. Volume of industrial production volume in USA, EU, Japan and Finland. 2. In China, growth is predicted in the range of about seven per cent in the immediate future. For many long-established sub-contractors, the road to new-found success has indeed been via the development of their own end products. It is nevertheless increasingly apparent that the majority of companies must bring about some measure of change to their operations, in order to successfully adapt to a changing world. Reasons for poor development Although multiple contributing factors may explain why Finland’s manufacturing industry is on such thin ice, I would suggest that the country’s weak competitiveness certainly plays a most significant role. The way forward Along with the rest of the world, the mechanical engineering sector has shifted towards being a provider of solutions in ever-increasing measures. In the best-case scenario, end products for sale or solution entities are self-generated, making it easier to adapt to rapid changes in subcontracting orders. HT_2-3_15.indd 5 15.5.2015 15.59. It is a fact that demand could be much better, but it nevertheless does exist. Finnish companies – or more precisely, those companies that operate in Finland – have lost their market shares appreciably over the last few years
€ 2 635 5 999 883 3 047 2 088 14 652 White collar workers, % of total 69,1 43,3 33,8 100,0 100,0 66,7 Enterprises 976 9 438 177 6 423 8 383 25 397 ECONOMIC BACKGROUND FINLAND 1990 1995 2000 2005 2009 2010 2011 2012 2013 GDP, Mill € 91 010 98 556 136 261 164 387 181 029 187 100 196 869 199 069 201 341 Real change, % 0,7 4,2 5,6 2,8 -8,3 3,0 2,6 -1,5 -1,2 Investments, Mill € 26 993 18 996 31 457 37 739 41 187 40 933 43 779 44 305 42 596 Real change, % -3,6 12,5 6,2 3,2 -12,5 1,1 4,1 -2,5 -4,9 Exports of goods and services, Mill € 20 144 35 246 57 348 66 175 65 661 72 366 77 093 78 881 76 866 Real change, % 1,4 8,8 16,1 6,9 -20,1 6,2 2,0 1,2 -1,7 Consumer prices, change % 6 1 3 1 1 3 3 2 Unemployment rate, % 3 15 10 8 8 8 8 8 8 Average exchange rates 1 Euro=USD *) 1,272 1,293 1,083 1,244 1,395 1,326 1,392 1,285 1,328 *) USD exchange rate prior to 1997 is based on corresponding Finnish markka rate converted at the avergae FIM/XEU (ECU) rate MECHANICAL ENGINEERING IN A NUTSHELL 1990 1995 2000 2005 2009 2010 2011 2012 2013 Output Turnover, Mill. € 4 557 8 785 1 735 4 578 2 845 22 500 Investments Fixed, Mill. € 2 031 620 50 279 55 3 035 Exports Export of goods, Mill. € 27 153 8 840 8 341 5 048 65 164 Value added, mill. € 4 436 4 813 6 421 7 846 8 557 8 627 9 363 9 448 8 785 Investments Fixed, Mill. The Finnish technology industry`s main sectors in a nut shell . 23/ 20 15 6 WELDING IN FINLAND [ www.hitsaus.net ] TECHNOLOGY INDUSTRIES’ MAIN BRACHES IN A NUTSHELL 2013 Electronics and electrotechnical industry Mechanical engineering Metals industry Information technology Consulting engineering Technology industries, total Output Turnover, Mill. HT_2-3_15.indd 6 15.5.2015 15.59. € 7 184 11 214 6 600 24 999 % of total Finnish export of goods 13 20 12 45 Employment Employees in Finland 43 200 125 500 15 800 54 500 46 300 285 300 Employees abroad 124 383 115 746 23 935 15 340 5 965 285 369 Total labour costs, Mill. Table 2 . € 316 625 435 468 130 1 974 Research and development, Mill. € 3 013 3 179 4 330 5 162 5 688 5 374 5 759 6 089 5 999 White collar workers, % of total 34,1 32,9 34,5 38,9 39,4 41,9 42,3 43,3 Exports Export of goods, mill. Mechanical engineering in a nut shell . € 142 210 323 361 458 462 528 615 620 Employment Employment, total 129 400 109 500 130 300 132 600 133 200 123 300 127 100 130 500 125 500 Total labour costs, mill. The sub-branches of the mechanical engineering sector are the manufacture of machines and transport equipment and the fabrication of metal products . Economic background . Table 3 . € 594 496 610 601 937 550 625 733 625 Research and development, Mill. € 5 904 8 636 10 476 10 699 10 986 11 172 11 451 11 214 % of total export of goods 19,9 17,5 20,0 23,7 21,0 19,7 20,1 20,0 Abroad Employees in foreign subsidiaries 62 536 74 035 99 061 100 718 106 789 112 575 115 746 Table 1 . € 10 509 12 939 18 573 22 462 25 142 24 755 28 027 28 593 27 153 Value added, Mill
In addition, the majority of existing welding robots are relatively old and operate mainly using 1-wire welding. In 2014, the average number of personnel employed by Finnish metals industry companies was 15,300; in 2008, the industry employed a total of 18,100 people in Finland (The Federation of Finnish Technology Industries). The total production of steel products, non-ferrous metals, castings and metallic minerals in Finland increased by some four per cent last year. 1. In comparison, in 2007, prior to the financial crisis, the corresponding revenue was EUR 11.2 billion. In 2014, the registered turnover by Finnish mechanical engineering companies (machinery, metal products and vehicles) was EUR 27.2 billion, remaining virtually unchanged from one year to the next. Generally speaking, the past six years have been anything but easy. With respect to the individual categories, while the production of steel products, castings and metallic ores was seen to have increased, the production of non-ferrous metals remained at 2013 levels. Since then, the recession impacted not only on production volumes and exports, but also affected a number of manufacturing enterprises, welders and welding experts. Further, many companies are suffering from a general lack of qualified welders. In the last four years, however, overall industrial production in Finland has been on the decrease, Fig. After 2008, companies’ order books were filled typically only for a period of 3-4 months, a factor which negatively impacted on profIndustrial Production Volume in EUCountries Seasonally adjusted volume index Source: Macrobond 28.4.2015 4 Fig. Some 70-75% of Finnish exports are destined for Europe, a clear indication that European customers and their local economies also play key roles in Finland. The turnover for companies involved in the metals industry in Finland (steel products, non-ferrous metals, castings and metallic minerals) was EUR 9.2 billion in 2014, an increase of some four per cent over 2013 figures. On average, the mechanical engineering industry employed some 118,900 people in 2014, as compared with figures for 2008, when the industry employed a total of 150,100 workers in Finland. The capacity utilisation rate in the steel industry is currently at its lowest level for the past 18 months. Notwithstanding, there are so many companies and product ranges which have actually managed to remain unscathed, resulting also in high production figures. 23/ 20 15 7 WELDING IN FINLAND [ www.hitsaus.net ] Welding in Finland Overview Ismo Meuronen and Juha Lukkari This article will provide you with good overview of welding technology in Finland and a useful introduction to Finnish engineering companies. Mechanical engineering and the metals industry Industrial growth in Finland was positive for a long time, up until the end of 2008. HT_2-3_15.indd 7 15.5.2015 15.59. 1. In 2008, prior to the financial crisis, the mechanical engineering sector in Finland had reported a total turnover of EUR 33.3 billion, over 22% higher, according to The Federation of Finnish Technology Industries. Overview of industrial welding production During the industry’s last “good” year in 2008, VTT Technical Research Centre of Finland Ltd. Today, the general unemployment rate in Finland is 10.3 % (as of 23.04.2015 / Statistics Finland). Only a few and selected examples are mentioned in this article. The level of welding automation is registered as less than 20%, production being generally low, with the added issue of a moderate melting rate. Presentations of examples of available services and products supplied by various companies in welding and related industry are presented later in this magazine. The major role of manual welding has resulted in project-oriented production, combined with small batches and non-modular design, as opposed to the more productive robot welding. Industrial production volumes in EU countries since 2008 (The Federation of Finnish Technology Industries). In summary, the main characteristics of Finnish welding production were noted: project-oriented and typically non-modular design, low automation and productivity levels, as well as a general lack of welders. published an investigative report about welding production, which featured 100 companies, including sub-contractors and main suppliers. Fig. 1. The Finnish engineering industry has produced several products that are well-know, such as ships, paper machines, offshore equipment, forest machines, boilers, diesel engines, elevators and products for mining industry
The many cases where production was outsourced to other countries bear testimony to the critical state of affairs. 23/ 20 15 8 WELDING IN FINLAND [ www.hitsaus.net ] itable investments. The bio-product mill’s annual output will include the production of softwood and hardwood pulp, the generation of electricity far in excess of its needs, as well as environmentally-clean oil and turpentine, amongst others. The Finnish shipbuilding industry has undergone several changes over the past few years, resulting today in the existence of only two shipyards in Finland. 3. The Finnish mechanical engineering industry has maintained consistent operations in the heavy machinery sector. Articles presented by both shipyards are featured in this magazine. Two large boiler manufacturing companies are Valmet Oyj and Warkaus Works Oy, Fig. Finnish industrial boiler production (Valmet Oyj). Containerboard machine (Valmet Oyj). Large cruise vessels are manufactured at the Meyer Turku shipyard, while icebreakers and arctic vessels are constructed in the Arctech Helsinki Shipyard. The key factors behind their continued successful existence are the very long experience in the construction of these types of ships, in addition to an exceptionally wellfunctioning, sub-contracting network. While pulp and paper machinery manufacturing are still strong production areas, though at the moment a lot of machines are being manufactured in the Far East. HT_2-3_15.indd 8 15.5.2015 15.59. In reality, in the near future, this will mean a mill of massive proportions, accompanied by boiler, pressure vessel, pipeline and steel construction projects for Finnish industry. Typical welded products Successful products emanating from the Finnish mechanical engineering industry include passenger ferries, cruise liners and ice breakers; engines for ships and power plants; pulp and paper machines; rock and mineral processing equipment; lifts; hoists and cranes; forestry and agricultural machinery etc. Fig. This new bio-product mill will be the largest investment to be made by the forest industry in Finland, with total investment expected to be in the vicinity of approximately EUR 1.2 billion. 3. Finland’s existing companies are producing highly-valuable and sought-after products, due mainly to their historically excellent knowledge of the processing and welding of stainless steels, Fig. Caverion Oy, GaV Group Oy, Sahala Works Oy, Savonlinnan Works Oy (Andritz Oy), Steris Finn-Aqua Oy, Technip Offshore Finland Oy, Vahterus Oy and Viafin Oy are well-known manufactures of pressure vessels. 2. As a result, industrial welding in Finland can be characterised by the considerable processing of heavy plates and heavy sections, in combination with rather low levels of mass production. On April 21, 2015, the Metsä Group announced the planned construction of the next-generation bio-product mill in Äänekoski, Finland. Fig. 2
23/ 20 15 9 WELDING IN FINLAND [ www .hitsaus .net ] vices and heavy industrial products, Fig. Bronto Skylift is the world’s market leader in truck mounted hydraulic platforms for rescue and fire fighting as well as for any construction work, Fig. 4 (right). Manufacturing of forest machines is also an important segment in the Finnish mechanical industry. Materials handler (Mantsinen Group Ltd Oy) and theater and concert hall Kilden (Ruukki Construction Oy). There are two internationally very well-known manufactures, Ponsse Oyj and John Deere Forestry Oy, in Finland, Fig. A considerable amount of production in the metals industry has been transferred to other countries where labour costs are lower. 8. Mercedes-Benz (Valmet Automotive Oy). Typical applications are beams in liftFig. mek Oy, among others steel bridges, steel structures and frames for public and industrial buildings as well as power plants, Fig. Mantsinen Group Ltd Oy manufactures a wide range of hydraulic materials handlers, well-known wordwide, Fig 4 (left). Manufacturing involves also robot welding of very heavy plates, and Fig. 12. 5. 6 and 7. The company has manufactured among others 15 hulls for Spar type production platforms worldwide. However, the partial return of manufacturing to Finland from countries in the Far East, for example, is a reflection of a positive trend. The Finland-based manufacture of some special products for certain industries (e.g., energy, mining, paper machine, marine and automotive) has even managed to withstand competition against low-cost countries. Even some long, vehicle container trucks are successfully manufactured using high-strength stainless steels. Technip Offshore Finland Oy is a world class offshore company, specializing in Spar hull and mooring systems, drilling rig conversions, offshore construction serHT_2-3_15.indd 9 15.5.2015 15.59. 5. Hull structure for Spar type platform ready for a transport (Technip Offshore Finland Oy). Tram (Transtech Oy). The leading companies in steel construction are Ruukki Construction Oy and NorFig. 4. The car (Valmet Automotive Oy) and transport equipment (e.g. Fig 6. Fig. 7. 9. The increasing tendency to use highstrength steels also has a direct impact on the carbon footprint of products and production. Transtech Oy) industries have increased their productivity by investing in robots, Fig
LNG (Liquefied natural gas) provides significant environmental benefits with low emissions compared to traditional maritime fuel. There is growing interest in the use of natural gas as a source of energy also in ships. A significant amount of industrial Fig. Use of ultra high-strength steels (Bronto Skylift Oy). Many LNG terminals will be built in the next few years around Finland´s coast. 8. LNG (Liquid natural gas) is one of today`s themes in Finland. 8. 1). 10. Arctech Helsinki Shipyard Oy is building a new icebreaker for the Finnish Transport Agency. 9. and Fig. MS Viking Grace (Meyer Turku Oy) the world`s first large LNG powered passenger ship and Seagas the world’s first fuelling vessel for LNG (Oy AGA Ab) in the Port of Stockholm. 9. This year AS Tallink Grupp and Meyer Turku Oy signed a contract for the construction of LNG powered fast ferry for Tallinn-Helsinki route shuttle operations. Harvester (Ponsse Oyj). [ www.hitsaus.net ] ing equipment and forest machines, Fig. Fig. Robot welding Although the level of robot welding in production has been nearly constant for the past several years, today’s significantly reduced new and renewed investments are alarming trends with respect to competitiveness. 10. The icebreaker will be the first LNG-powered icebreaker in the world. The delivery will be in the beginning of 2017. The icebreaker will be powered by both diesel and LNG. The new decisions and plans for the construction of several LNG terminals have been highly welcomed by the manufacturing industry. International statistics indicate a permanent reduction of production capacity in industry, equivalent to approximately -20% since 2008 (see Fig. HT_2-3_15.indd 10 15.5.2015 15.59. Fig. MS Viking Grace (the delivery year 2012) represents a complety new generation of passanger ferries with it`s revolutionary LNG fuel system built by Wärtsilä Oy, Fig. The wider distribution of LNG is encouraging a new type of production and manufacturing know-how in the context of the current economic situation
23/ 20 15 12 WELDING IN FINLAND [ www.hitsaus.net ] Qualification Most sub-contractors of steel constructions in Finland have qualified for the EN 10901 certification, with the accompanying CE stamp of approval, representing more than 500 companies. Table 5 . The steady increase was halted by the Finnish economic depression, with the largest drop taking place in 2009. The production and use of steel products . In the last few years, the decline seems to have stopped. 2011 8 927 . . Country Consumption (kg/person) Italy 30 South Korea 25 Finland 21 Germany 21 Japan 16 USA 15 China 6 India 1 World Average 9,4 though with a slight lag. 2012 8 551 8 256 295 Occupational classification: Welders and gas cutters (7212) Age group Male Female Total 18-24 709 21 730 25-34 1 969 69 2 038 35-44 1 866 94 1 960 45-54 2 047 58 2 105 55-64 1 619 53 1 672 65-74 46 46 Total 8 256 295 8 551 Table 3 . The Total Number of Welders (Statistics Finland) Year Total Male Female 1970 17 661 17 300 361 1980 20 783 19 841 942 1990 16 618 16 039 579 1995 13 640 13 301 339 2000 13 289 12 957 332 2005 10 491 . One likely reason for this fairly high consumption rate is a strong wood processing sector (cellulose and paper) which has been a backbone HT_2-3_15.indd 12 15.5.2015 15.59. Finland is “proudly” one of the top countries in the world in terms of consumption of stainless steel per capita, Table 5. Welding in numbers Welding can also be examined in terms of numbers: . The consumption of filler metals The number of welders has declined steadily over the last 30 years by about half. After increasing volumes, use has stayed in low levels. Steel Use, Production and Foreign Trade of Finished Steel Products in Finland 1975–2014 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 1975 1980 1985 1990 1995 2000 2005 2010 2014 Exports Imports Steel Use Production 04/2015 1000 t Sources: Customs, Metallinjalostajat Fig. A detailed article about qualification is also presented in this magazine. The number of IIW/EWF diplomas awarded annually has for several years been at the highest level in Finland, as opposed to other countries. Nevertheless, much work remains to be done regarding other enterprises and auditors. Age Distribution 2012 (Statistics Finland) . Stainless steel accounts for about five per cent of the country’s overall steel consumption. The production and use of steel products increased evenly from 1975 until about 2006/2007, Table 4 and Fig. Year Production (tn) Import (tn) Export (tn) Use (tn) 1970 798 844 208 1434 1975 1087 691 204 1574 1980 1976 607 824 1759 1985 2232 650 1161 1721 1990 2556 688 1508 1736 1995 3242 895 2170 1964 2000 3903 1147 2708 2342 2005 4072 1155 3124 2103 2010 3561 1482 3639 1404 2013 3238 1091 2611 1718 2014 3487 1091 2871 1707 Table 4. Production, use and export of steel products (rolled products and pipes) (Board of Customs and Association of Finnish Steel and Metal Producers). . In 2011, the use of steel products was in very low level. 14. The occupational classification code for welders by Statistics Finland is 7212, which also includes gas cutters. It is likely that the figures do not include all welders since, in the last few years, while the number of foreign welders has increased, they have not been included in the national statistics. Consumption of stainless steel per capita in 2008 in selected countries (CRU, Metal Bulletin). The average age and gender of welders . However, this trend promises to present challenges in the future. The average age may not be as advanced as previously believed, with half of the welders being under 45 years. Production, use and export of steel products (rolled products and pipes) (Board of Customs). It is clear that more young people are needed in the field. The total number of welders . Use followed production, alTable 2 . 2009 8 407 . During the same period, the number of female welders has slightly increased. 14. The number of cutters is estimated to be small.
15. Since 2008, the levels have fallen by a few thousand tonnes and remained between 8,000 and 10,000. Oasis of The Seas – The world’s largest luxury cruise ship (Meyer Turku Oy). Consumption of filler metals in Finland, 1974-2014. In Italy, the situation is almost the same, but the share of solid wires is even higher. 16. When divided into sections, with respect to various filler metals, the overall consumption figures provide an idea of the prevalence and usage of different welding processes. 77%: Tubular-cored wires (FCAW) . The overall global consumption of filler metals aptly explains the trend in welding volume, Fig. The country-specific differences are significant, due to the industrial production structure, products and many other factors. In both countries, the automotive and other sheet metal industries reflect the overall national welding statistics, which of course include the consumption of solid wires. 15. The Finnish engineering industry has produced several products that are well-know, such as ships, paper machines, offshore equipment, forest machines, boilers, diesel engines, elevators and products for mining industry. 11%: Covered electrodes (MMA, SMAW) . However, this is a decreasing trend, since production has been shifted to countries with lower wage levels. This means that stainless steel-welding is also fairly common in Finland. The market for consumables has fluctuated yearly from 10,000 to 15,000 tonnes, during the period of 1970 and 2008. Even in an international context Finnish welding technology is relatively sophisticated, despite the scarcity of material resources compared with bigger industrialized countries. Ismo Meuronen President, The Welding Society of Finland Juha Lukkari Editor-in-Chief, Hitsaustekniikka Welding Magazine Fig. With Norway being an “offshore” country, this means that the quantity of tubularcored wires consumed is clearly very high and almost double the amount of solid wires. Germany is still a true “solid wire country,” where the use of tubular-cored wires is still relatively low. However, according to the latest information, based on new investment decisions and an increased number of orders, the entire manufacturing industry will soon be revitalised. The project involved almost 2,500 kilometres of welds, which consumed over 1,000 tonnes of filler metals: 75 % (FCAW), 15 % (SAW), 9 % (SMAW/MMA) and 1 % (other). 1%: Other The largest single product ever welded in Finland, as judged by the consumption of filler metals, is the world’s biggest cruise ship, Oasis of The Seas, constructed in 2009 by STX Europe Turku (trading today as Meyer Turku Oy), Fig. 16. The distribution of filler metals naturally varies according to the industrial production structure and welded products. Only a few and selected examples are mentioned in this article. 11%: Submerged arc welding consumables (SAW) 2000 4000 6000 8000 10000 12000 14000 16000 18000 19 74 19 76 19 78 19 80 19 82 19 84 19 86 19 88 19 90 19 92 19 94 19 96 19 98 20 00 20 02 20 04 20 06 20 07 20 08 20 09 20 10 20 11 20 12 20 13 20 14 C on su m pt io n in 10 00 kg Year Fig. . Summary Since 2008, the Finnish welding industry has undergone many changes which have greatly affected production volumes and exports. The use of MAG-tubular-cored wires started to increase at the beginning of the 1990s, eventually surpassing the use of covered electrodes around the mid-1990s. There has been, or currently exists, a worldwide change from manual metal arc welding to “wire welding processes.” Simply put, this trend means MIG/MAG-welding with solid wire (GMAW) and MAG-welding with tubularcored wire (FCAW). The biggest users of tubular-cored wires are the shipbuilding and offshore industries. As outlined in the article presented by Meyer Turku Oy, the use in this shipyard is as follows: . 23/ 20 15 13 WELDING IN FINLAND [ www.hitsaus.net ] of Finnish industry, although recently, its significance and volume have decreased sharply. In Finland, there is a considerable degree of “heavy” welding which results in a consumption of submerged arc welding consumables. In Finland, since the mid1980s, the quantity of solid wires consumed greatly surpassed the number of covered electrodes. HT_2-3_15.indd 13 15.5.2015 15.59
Most of the companies offer design services and some have their own products which confirm the possibilities of laser welding. These companies either have their own production machinery or use available sub-contractors to provide laser and laser hybrid welding services. 2 kW, 10 kW fiber lasers Robot station 10 x 2.5 x 1.5 m 2010 Laser hybrid welding, cladding, cutting, scanner for 2 kW laser University of Oulu, Nivala 3 kW and 4 kW disc lasers 2 robot stations with work spaces 2x2x1,5 m 2004 Laser welding research is focussed on ultra high strength, wear resistant and stainless steels Table 1 . Over the years, research activity has developed nationally and many of these institutes today present their achievements in the pages of this magazine. 23/ 20 15 14 WELDING IN FINLAND [ www.hitsaus.net ] Laser and Laser Hybrid Welding in Finnish Industry Anna Fellman Laser and laser hybrid welding processes are employed in the production process of innovative Finnish companies. Research center and location Welding lasers Workstation Year of establishment Notices Lappeenranta University of Technology, Lappeenranta 10 kW, 5 kW fiber lasers Gantry 11x4x1,5 m, robot station with KUKA 125 1985 Possibilities for laser hybrid welding, cladding, cutting and hardening Tampere University of Technology, Tampere 1, 2 and 8 kW fiber lasers Several different robot stations 1998 Heavy focus on laser cladding research WinNova, Laitila 12 kW disc laser, 4 kW Nd:YAG laser Robot station with KUKA 32 HA and 10 m linear track 2006 Laser hybrid welding, prototype production Machine Technology Center Turku Ltd. what is being welded and how the use of lasers in production has been of benefit. Large constructions with thick materials also mean that the accuracies required by laser welding cannot be easily reached. Introduction Laser welding has been studied in Finland since 1985, but the use of the process in the Finnish metal industry is still quite marginal, considering that there is a lot of welding done in Finland. Table 1 presents data about active Finnish research institutes and their machinery available for laser and laser hybrid welding research. However, there are some producers of mass products and large investment product manufacturing pioneers who have found significant competitive advantages from using laser or laser hybrid welding in their production process. There are also private specialists in laser and laser hybrid welding which offer research and development services for companies. HT_2-3_15.indd 14 15.5.2015 15.59. Laser and Laser Hybrid Welding Research Activities in Finland Laser welding research in Finland was introduced atLappeenranta University of Technology in 1985. One entity active in the research of laser and laser hybrid welding is VTT, which currently does not own its machinery, but co-operates with other institutes for the purpose of research. For this article, the author obtained permission from some Finnish companies so as to be able to publish facts about the use of laser and/or laser hybrid welding during production, ie. The author expresses her gratitude to the contact persons of the companies for the co-operation and permission to publish the facts and figures. Most of these companies started with the sub-contracting of laser cutting, bending, conventional welding and other sheet metal processing services but have since expanded their services to also offering laser welding. Some companies which are unwilling to invest in their own production machinery are in any case using laser or laser hybrid welding to produce some of their products or parts and are buying this service from sub-contractors who offer laser and laser hybrid welding services. Laser and Laser Hybrid Welding Sub-Contracting in Finland Laser and laser hybrid welding services for product manufacturing are offered by quite many sub-contractors, see Table 2. Universities and research institutes, as well as private sector specialists, provide research and development services for Finnish industry. Research institutes and universities offer many different kinds of lasers and workstations for testing laser and laser hybrid weldability of materials and products. One of the reasons for the quite limited use of laser welding is the fact that many Finnish companies produce large investment products which use thick materials. The Use of Laser and Laser Hybrid Welding in the Finnish Metal Industry Although laser welding is not so widely used in Finnish production, it is largely relied upon in many Finnish workshops and factories. The Finnish research institutes which offer laser and laser hybrid welding research services
Today, the laser welding of tubes is mainly conducted without filler metals, but some of the special grades such as duplex and highalloyed austenitic grades are welded using cold filler metal additions, Fig. Strength 1500 Mpa Train coach wall panels, tipper bodies, pallets, containers, sandwich steel panels High Metal Production Oy, Vantaa 4 kW CO 2 + hybrid welding equipment 3D gantry station 14 x 2 x 0.5/(1) m Stainless steels, duplex, SMO, heat resistant steels, 8 mm penetration Beam structures of pulp and paper machines, machinery for food industry, sandwich panels etc. (Picture: OSTP Finland Oy Ab) Fig. Details of Laser and Laser Hybrid Welding Sub-Contracting in Finland . 23/ 20 15 15 WELDING IN FINLAND [ www.hitsaus.net ] Since 1996, OSTP Finland Oy Ab (formerly, Ja-Ro Oy Ab and Outokumpu Stainless Tubular Products Oy Ab) has has used laser welding of longitudinal seams of stainless steel process tubes, Fig. 2. The outer diameter of tubes manufactured at Jakobstad are 21.3400 mm, with thicknesses of 1.2-6 mm. The use of laser welding in tube manufacturing has increased productivity and the quality of welds, as well as weld appearance and improved formability of the tube. 2. CO 2 -laser-welding of longitudinal tube seams at OSTP. Nowadays, laser welding is used in several tube manufacturing lines, the other lines use GTA + plasma welding. The production volume of the Jakobstad plant reached approximately 26, 000 tonnes for the year 2014. Table 2 . Rautatyö Kröger Oy, Jyväskylä 8 kW CO 2 + hybrid welding equipment Gantry, 13.5 x 2 x 1 m Stainless steels up to 10 mm Tubular beams and sandwich panels SSAB Steel Service Center, Uusikaupunki 5+8+8 kW CO 2 + hybrid welding equipment Gantry, 18 x 4.5 x 0.7 m Structural and mild steels up to 8 mm, max. Since 2003, Stalatube Oy in Lahti has used lasers for the continuous longitudinal welding of rectangular and square structural tubes. The tubes are of stainless steels (austenitic, ferritic and duplex steels) and laser welding is used for thicknesses of 1-6 mm. (Picture: OSTP Finland Oy Ab) HT_2-3_15.indd 15 15.5.2015 15.59. Laser-welded process tubes from OSTP. It has also been recorded that weldability of special grades and materials is better with laser welding than with conventional welding methods. At that time, JaRo Oy Ab participated in a project (funded by the Finnish Funding Agency for Technology and Innovation (TEKES) and The Federation of Finnish Technology Industries) in which laser welding was tested for the welding of tubes and laser welding proved to be a good process for the manufacturing of tubes. LCC does laser cladding Laserle Oy, Helsinki 1.75 kW and 2.5 kW CO 2 lasers 2D & 3D stations, 11.25 x 1.25 x 0.3 m & 3 x 1.5 x 0.6 m Stainless steels s=0.1-3 mm, aluminium s=1-2 mm Joints in cylindrical shaped products etc. In front of the laser optics, there is an optical seam-tracking device. 1. Laser welding is employed because it allows a high welding speed, as well as a good and constant weld quality. Also, the tube parts, such as elbows and T-pieces, are manufactured out of laser-welded tubes. Fig. There are approximately 25 qualified laser welding operators in the plant (according to SFS-EN ISO 14732). A typical cross-section of a laser weld in a tube and close-up picture of the welding process is presented in Figure 3. 1. Powerbeam Oy, Hanko 4 kW CO 2 + hybrid welding equipment 3D-Gantry 12 x 4,5 x 1m +A +C Stainless steels 10 mm and mild steels up to 8 mm, copper Telescopic booms, heat exchangers, welding of copper, 3D-cutting and welding Powerbeam does copper laser welding and 3D-laser cutting and welding Kenno Tech Oy, Riihimäki 4.5 kW CO 2 Gantry 12 x 3 m Stainless and mild steels, especially high strength steels, thicknesses 0.3-6 mm Shielding products, sandwich panels, large heat exchanger plates Produces own products such as Balpro Protector shield walls, gates, containers and so on. SSAB Steel Service Centre (formerly, Ruukki Metals Oy) in Uusikaupunki manufactures several tonnes of tailored steel plates per year using laser welding. Typically, two or more plates of similar or variable thicknesses are joined together a butt joint, to form an Company and location Welding laser Workstation Materials and thicknesses Typical applications Notices HT Laser Oy, Haapamäki 5 kW CO 2 Gantry 6 x 3 x 0.6 m Stainless and mild steels up to 10 mm Beams and sandwich panels Produces own products such as laser platforms, wood pellet heating systems, boats and so on. Kokkola LCC 4 kW & 6 kW diode lasers Workpiece max 3x25m Steels and nickel, cobolt, aluminum and copper based alloys Wear and corrosion resistant products, axles, sleeves, gear wheels etc
On the right, a comparison of decks welded by submerged arc (upper picture) and laser hybrid welding (lower picture) (Figures: Meyer Turku Oy) Fig. Rectangular tube and lifting lugs, laser-welded to a cathode plate. The material of the tube is mainly AISI 304 or AISI 316L and in sheets of AISI 316L, but duplex grades are also used. Since 2009, Outotec Turula Oy has welded cathode plates using CO 2 laser. 6. 4. If the monitoring system detects a deviation in the welding process, only then the operator visually inspects the weld qualFig. The cathode plates are used in copper electrolysis and the maximum annual output is approximately 100,000 pieces. (References:http://www.industrial-lasers.com/articles/print/volume-27/issue-02/features/laser-welding-train-coachwall-panels.html, refered 15.1.2015 and Siltanen, J., Maaranen, I., Nurmela, V-M, 2014, Guidelines for Profitable Laser Processing -A Perspective of Ruukki Metals Uusikaupunki Service Centre in Finland, ICALEO 2014) Meyer Turku Oy has used laser+GMA hybrid welding for butt-joint welding of thinsheet ship decks since 2006. (Figure: Outotec Turula Oy) HT_2-3_15.indd 16 15.5.2015 15.59. The quality of the laser weld is verified by using on-line quality monitoring. On the left, a laser hybrid welding station at the Meyer Turku shipyard. Cross-section of laser-weld in tube (material EN 1.4307, s= 2mm) and a close-up view of laser-welding process. The materials processed at the Uusikaupunki plant are almost 100% special grades, such as high-strength or wear-resistant steels up to the yield strength 1250 MPa. The operation and success of the Uusikaupunki plant has been the result of the contributions and investments of the entire workforce so as to ensure high quality. This has significantly reduced the need for straightening work and major savings have been made because of the diminished consumption of filler metal. 5. The train coach wall panel manufactured to Alstom using laser cutting and welding. In addition, it is obvious in terms of SSAB, that the demand for tailored sheet products is rising, meaning that the production capacity of the Uusikaupunki plant should be assured in the near future. Prior to the introduction of laser welding, the edges of sheets are laser-cut in order to ensure the straightness of grooves and the absence of an air-gap between the sheets being welded. The thicknesses welded by laser are 3-3.25 mm. The thickness of the weldable plates is 2-8 mm, with the typical thickness to be welded being 3-4 mm. By using laser welding, the straightness of steel sheets made by the SSAB steel mill can be maintained and almost the same properties as those of the base metal can be achieved into weld areas. 3. The use of laser welding has increased productivity and standardized weld quality, but the most significant advantage has been the improvement of the dimensional accuracy of plates. (Pictures: OSTP Finland Oy Ab) Fig. The advantages of laser welding include the maintenance of constant quality and the possibility of precisely adjusting heat input. 23/ 20 15 16 WELDING IN FINLAND [ www.hitsaus.net ] entity by which the customer or SSAB cuts the plate for desired dimensions. This effort has been worthwhile because at the moment the plant is working at a high capacity and customers are extremely satisfied with the quality of products. Controlled heat input is an advantage in the welding of special steel grades, a procedure which is normally quite precisely defined. 6. In the past, plates were welded with short GMA welds, resulting in many distortions due to high heat input. (Siltanen et al, 2011) Fig. 4. The groove preparation method used is mechanical precision cutting. With laser welding, heat input is so low that there are hardly any distortions. During the manufacture of cathode plates, a rectangular tube is laser-welded into a straight steel sheet (size 1,1 m x 1,3 m), Fig. The manufacturing procedures were developed according to the requirements of the standard EN 15085-2 and entailed a lot of work at SSAB Uusikaupunki Steel Service Center. The requirements for durability are stringent, due to the fact that in use the cathode plates will face strong harrowing loads and are considerably often lifted from one place to another. Amongst others, the applications include train coach wall panels, tipper bodies, pallets, containers and sandwich steel panels, Fig. 5. The low--heat input of laser hybrid welding produces diminished distortions when compared to the previously-used submerged arc welding, Fig
8. Essential advantages include the improvement of work ergonomics and the fact that work becomes physically easier for welders. They also offer “surfacing” solutions by the laser welding of thin metal sheets of desired steel grades on thicker and cheaper steel plates, for example, stainless steel sheets on mild steel plates. 23/ 20 15 17 WELDING IN FINLAND [ www.hitsaus.net ] ity. Kenno Tech Oy in Riihimäki manufactures sandwich panels, tailored sheets and special profiles using laser welding, Fig. (Picture: Valmet Automotive Oy) Fig. 5 mm and a sheet area of a maximum of 3000 x 12;000 mm. Kenno Tech also joins plates to form larger plate entities, with thicknesses of materials from . The use of laser welding and automatisation has increased the effectiveness of production by 80%. Remote laser welding and laser brazing are used in the production of doors and trunk lids of Mercedes-Benz A-class cars at Valmet Automotive in Uusikaupunki. The thicknesses of the structures have been between 15-35 mm and lasers are used for welding up to a penetration of 10 mm. The welding parameters used are also more traceable. The quality of the laser weld has been rated higher than that of resistance spot welds. Laser welding is also being used elsewhere in the production of A-class cars: molded zinc-coated sheets (s= 0.8 mm) of trunk lids are joined together with lap and fillet joints using laser brazing, Fig. 7. HT_2-3_15.indd 17 15.5.2015 15.59. Despite being a small country, it is clear that there are quite many facilities and sub-contractors in Finland, available to facilitate laser and laser hybrid welding research. Valmet Technologies Oy has used laser for the welding of tube-to-tube coupling joints in boiler structures since 2012. Anna Fellman Consultant, Specialist D.Sc. 8. Kenno Tech solutions utilising laser welding: On the left, Balpro Protector shield walls in the UN operation in Lebanon and, on the right, joined profiles increasing the application areas of tubes and profiles. Kenno Tech has created solutions consisting of sandwich panels in which ultra-high-strength steels are utilised to achieve bullet-proof solutions: transport containers, modular fortification systems, watch towers, splinter shields and road barriers. It can be concluded that they have significantly benefitted from the use of lasers in their production processes. 7. Laser welding has replaced resistance spot welding which could not be used in the present construction. (Tech), IWE, MBA Weldcon www.weldcon.fi Fig. Some Finnish companies which invested in their own laser or laser hybrid welding production lines were featured in this article. Since the welding process is more controlled, this leads to better weld quality. Nowadays, they are welded with laser and GMAW. 7. Valmet Automotive Oy in Uusikaupunki uses remote laser welding for the manufacture of the front and back doors of Mercedes-Benz A-class cars, Fig. The company also handles the joining of roll-shaped profiles and tubes with longitudinal joints, creating products with more diversity for use. These efforts have been worthwhile since these companies are highly competitive in international markets, due to their high productivity and innovative, high-quality products. The door parts, made of molded zinc-coated sheets (s = 0.75-1 mm), are welded with lap joints using remote laser welding. The customer then uses this sheet for producing its product, such as a container or truck platform. In the past, structures were welded with the root pass welded using GTAW and filling passes were conducted using SMAW or GMAW. With the use of automated on-line weld quality control, productivity is further improved. It is possible to introduce laser welding for even a small fraction of production with little investment, since there are many companies which offer laser welding sub-contracting services, with several offering even semi-fabricated products or complete, ready solutions. Companies which use laser welding admit that they have had to do a lot of work to get production running in a reliable manner and to convince customers about the high quality of laser-welded products. Additionally, laser welding does not form distortion and imprints to the joint area, which could not even be allowed in the target area. If no deviation is found by the monitoring system, the plates will move directly from production to packaging. The shape of the trunk lid is such that it cannot be manufactured out of one piece and is therefore made out of the brazing of two separate pieces. Conclusions This article has attempted to reflect the current situation in terms of laser and laser hybrid welding machinery available in Finnish research institutes and at the sub-contractor level. The laser-brazed joint surface is so clean that there is no need to grind it before painting
In-House Publishing The Welding Society of Finland also publishes the Hitsaustekniikka magazine, with a regular six issues per year and a circulation of 4,000. It is the only Finnish trade magazine in its field and features mainly technological articles written by volunteer authors. Welding Training and Qualification Since 1989, one of the WSF’s foremost activities has been the delivery of the EWF/IIW welding training and qualification schemes. The names of the respective clubs, committees and forums reveal the scope and nature of their interests: the European/ International Welding Qualification Club, the High-Energy Density Processing Club and the Non-Destructive Testing Committee all operate nationwide, whereas four regional Senior Clubs are present only in the country’s main cities. At present, the WSF comprises 2,700 individual members and 150 member companies and institutions. The main topics covered include various welding techniques, research and development, consumables, equipment and the weldability of diverse materials. Almost 9,000 diplomas have been issued over the past 25 years, with the highest recorded annual figure being 770. In addition to the regional chapters, another network of groups has been created, based mainly according to technological interests. The focus is on local activities which may include meetings, seminars, excursions and the exchange of ideas and best practices. Companies, universities and research centres can also avail of a platform for cooperation within the WSF, with participation in the Laser Forum, Design Forum and Production and Materials Forum. These three entities constitute the Welding and Joining Institute of Finland, the undertakings of which also include collective tasks and projects funded by the members. However, the magazine also often publishes papers on welding automation, productivity and expenses, quality control and testing, training and qualification, as well as health and safety in welding, cutting and surface treatment. There are currently over 50 Approved Training Bodies (ATBs) in Finland, geographically well-distributed across the entire country. In addition to the magazine, the WSF publishes books about welding and Finnish language CD-ROMs for use in welding training and education courses. The fundamental aims of the ATBs are to service the Finnish metals industry and to increase the know-how about welding. Some key figures include the 500 EWE/IWE diplomas issued before 2013 and the 2,000 EWS/IWS diplomas issued before 2014, not forgetting the 300 EWT/IWT diplomas awarded in the past. The most important committee, however, is the WSF Governing Board, which oversees welding training and qualification efforts in Finland. Nationwide Networking The WSF’s main organisational structure comprises a network of regional chapters in 13 of Finland’s major cities, all run by volunteers. 23/ 20 15 18 WELDING IN FINLAND [ www .hitsaus .net ] The Welding Society of Finland at Your Service 4/28/15 Jouko Lassila Magazine and Website Training and Quali?ca5on Nordic Welding Expo Membership Ac5vi5es Other <The WSF logo upper right corner> Jouko Lassila The primary objectives of the Welding Society of Finland are to promote development and to ensure the operational preconditions of Finnish welding enterprises. The ATBs include Technical Universities, Vocational Schools and Institutes, as well as Adult Education Centres, which all offer a full gamut of training courses: welders, welding coordinators, welded structure designers, inspectors, specialists for robot welding and for laser welding, heat treatment of welded joints, practitioners for reinforcing bars, etc. Member companies and institutions can be divided into three main categories: the first includes enterprises which supply welding machines, consumables, production automation and related services; another group utilizes welding as part of the manufacturing process of their products, or for production purposes; the third group incorporates entities which provide education and training for welding professionals, from the welding engineer to the welder levels. HT_2-3_15.indd 18 15.5.2015 15.59. The Welding Society of Finland share of activities. In order to facilitate this, the WSF provides information about welding, manages the IIW/EWF welding training and qualification programmes, publishes the Hitsaustekniikka magazine and hosts various platforms for networking. Membership is comprised of welding experts and activities range from meetings and seminars, to visits and excursions to places of common interest
It is today one of the largest welding industry events in the Nordic countries, offering the industry an important forum for the introduction of new products and technological innovations. +358 40 589 7071 Juha Kauppila Manager, Training and Qualification juha.kauppila@shy.inet.fi tel. The Nordic Welding Expo and Conference The Nordic Welding Expo (NWE) is organised by Tampere Trade Fairs Ltd., in collaboration with the Welding Society of Finland. From the outset, the aims for international cooperation have been the development and exchange of the best joining and welding practices, technologies and applications. +358 50 414 045 persons. +358 50 373 9559 Juha Lukkari Editor-in-Chief, Hitsaustekniikka Magazine juha.lukkari@shy.inet.fi tel. Since 1948, the NWC has been arranged every two to three years in one of the Nordic Countries and was billed as an IIW-associated event for the first time in 2014. At Your Service HT_2-3_15.indd 19 15.5.2015 15.59. In the past 10 year-period, this premier event has been held on a bi-annual basis and was arranged in 2014 in conjunction with EuroSafety and Workplace Welfare Exhibitions. The Nordic Welding Conference (NWC) was arranged concomitantly with the NWE, with sessions covering the following topics: Global Welding Challenges; Welding in the Future; High-Strength Steels and Applications; Robot Welding and Automation; Laser Welding; and the Design of Welded Structures. +358 40 557 2939 Angelica Emeléus Office Secretary, Editorial Assistant angelica.emeleus@shy.inet.fi tel. Finland has hosted the IIW Annual Assembly and International Conference on two previous occasions, in 1963 and 1989. Last year’s event involved over 200 exhibitors, almost 60 of whom participated in the Nordic Welding Expo. 23/ 20 15 19 WELDING IN FINLAND [ www.hitsaus.net ] Committed to the IIW from the Beginning Only one year after the International Institute of Welding (IIW) was founded in Brussels in 1948, the Welding Society of Finland was established in spring 1949 and was accepted shortly thereafter as Finland’s Responsible Member Society at the IIW’s meeting in the Netherlands. The Conference featured more than 30 presentations and attracted about 60 participants from Finland, Sweden, Norway, Denmark, Germany, France and Israel. The number of Finnish welding experts interested in IIW activities has been relatively and steadily high throughout the years; in recent times, the Finnish delegation has numbered between 20 and 30 delegates, experts, observers and accompanying Jouko Lassila Executive Director jouko.lassila@shy.inet.fi tel. Of the total 8,000 visitors who attended the three-day event, some 2,500 were primarily interested in the NWE
Subsequently, he moved to Lappeenranta and began his employment at the Lappeenranta University of Technology (LUT) as a Professor of Steel Structures, working out of the laboratory established by internationally-renowned Professor, Erkki Niemi. This was Professor Marquis’ first job in Finland, at VTT, the Nordic region’s largest research and technology institution, involved in much international cooperation. Since 2013, he has occupied the position of Dean of Aalto University’s School of Engineering, while simultaneously attending to diverse responsibilities in his new role as IIW President (2014-2017). One of my priorities is also the hiring of new professors. ”At Lappeenranta University of Technology, everything is located under the same roof. We conducted different kinds of research for the Finnish metals industry, the energy sector, the machine building and process industries. Gary Marquis A Long International Walk through the Field of Engineering Minttu Kauppila Professor Gary Marquis’ entire career has been focused on the field of engineering. These key actions have a major impact on the long-term future of Aalto University.” HT_2-3_15.indd 20 15.5.2015 15.59. Engineering is such a very international discipline that the topics tend to be globally quite similar. After accepting the position, his work responsibilities were those of a typical professor: teaching, research and service functions. Regarding Finland, Professor Marquis appreciates the high level of focus on engineering and the Finnish education system itself. Professor Marquis believes that LUT’s relatively small size is one of its main advantages. ”I studied at the University of Illinois. 23/ 20 15 20 WELDING IN FINLAND [ www .hitsaus .net ] Professor Marquis was born in the USA, but has lived for the past 27 years in Finland. There was a really strong engineering programme. ”As a Dean, my primary role is academic leadership. It wasn’t really difficult to fit into work life in Finland, even though I arrived from the USA. I am not currently teaching regularly, nor leading any research projects, but I still supervise some Master’s and doctoral degree studies. In Finland, he completed his doctoral studies at the Helsinki University of Technology, employed at the same time as a Research Scientist at VTT (Technical Research Centre of Finland). I was good in Mathematics and Science so basically, the choices for me were to study Engineering, or to do something in the Business and/or Accounting fields. The job of the Dean is to help other people to succeed and to help in the establishment of a new generation of engineers and researchers. One of his favourite pastimes in Finland has also been taking long walks outside in nature. He has lived almost half of his life in the USA and the other half in Finland. ”I was employed as a Research Engineer at VTT and I worked essentially in the Metals laboratory. It was a very large and multidisciplinary facility. The choice of Engineering wasn’t really a major decision for me, but it turned out to be a good option.” Going overseas Professor Marquis received a good university background and continued his further studies abroad. In this regard, I recruit almost one professor per month. Nevertheless, LUT enjoys a good reputation as a student-friendly university.” The job of being a dean at Aalto University While Professor Marquis enjoyed life in the city of Lappeenranta, after working there for seven years, he received a job offer from Aalto University School of Engineering, for a position in its Department of Applied Mechanics. This means that you can realistically visit every single classroom, office or laboratory, without ever going outside. In 2013, he was appointed Dean of Aalto University School of Engineering. Professor Gary Marquis was born and raised in the USA and spent his childhood years in Chicago, Illinois. Also, I quickly realised that the way in which work was conducted in Finland wasn’t so different than in the USA.” The small and pleasant city of Lappeenranta Professor Marquis’ tenure at VTT lasted for almost 13 years
This is one of the many reasons which convinced Marquis to accept employment there. ”Aalto has been encountering many opportunities to develop as a fully-international university. There is occasionally a spirit of trying to “impress” one’s colleagues. At a typical professional conference or symposium, individuals usually present details of their current research interests, without always relating the work to that of their colleagues. In some Commissions, the average age for regular members is fairly high. He subsequently served as Chair for a consecutive 8-year period, generally receiving excellent feedback about the way in which Commission XIII was operated. ”Industry derives huge advantages when it is able to present its challenges to researchers. To some degree, the things I handle as a Dean and as the IIW President are quite similar. ”Within the IIW, we need to start thinking about our long-term vision. My experience at universities in the USA proves that students at the MSc level can and will make intelligent and informed choices. In the IIW context, members don’t serve the organisation, but the association serves the members.” As Dean of Engineering at Aalto University, Professor Marquis is motivated to help students to succeed. The TMB also manages the IIW prizes scheme and reviews technical aspects of all IIW International Conferences and Congresses. Nevertheless, everyone is able to bring their questions to the IIW table because there exists such little formality.” Professsor Marquis really appreciates the multi-cultural, multi-lingual and multi-dimensional aspects of the IIW. The university system in Finland traditionally incorporates a very rigid set of courses which a student is obliged to take, in order to hope to become a certain type of engineer. For information, the TMB Chair is also a sitting member of the IIW Board of Directors. Also, communicating our work to industry and involving more young people in the organisation are high priorities. The difference lies in how students are given a certain measure of authority with regard to how their studies are effected. However, in the IIW context, there exists much more of a spirit of working together. The difference lies in the fact that Aalto University has employees and students, whereas the IIW is a non-profit association which regroups hundreds of individuals who willingly volunteer their time and efforts.” The IIW collaborates really well with the industrial and research communities. There are no bad choices, there are just choices. ”In 2008, I started a 3-year term as a member of the Technical Management Board (TMB), the entity which oversees the research, technological development and standardisation activities of the IIW. In this regard, Professor Marquis welcomes any and all input, feedback or new ideas from the IIW’s Member Countries, about any subject. Afterwards, in 2011, the IIW Board of Directors confirmed my nomination to the post of Chair of the TMB. If one were to compare the engineering education in Finland and the USA, one would discover that the course content is quite similar, as well as many of the challenges faced in both educational contexts. Colleagues from around the world regularly meet two or more times per year, for a period of several years, or even decades. Marquis’ advance in the IIW hierarchy began with his nomination as Delegate for Finland to Commission XIII Fatigue of Welded Components and Structures, followed by the advent of the retirement in 2006 of long-standing Chair, Professor Steve Maddox, which resulted in Marquis succeeding to the post. One example of this is the burning issue of good governance and how decisions in an internationally-oriented organisation should be made. HT_2-3_15.indd 21 15.5.2015 15.59. It was during this 3-year-period that I became more broadly familiar with the issues and challenges facing the IIW.” The first IIW President from Finland At the 2014 IIW Annual Assembly in Seoul, Professor Gary Marquis was appointed the first ever IIW President from Finland. ”When I attended my first IIW Working Unit meetings, I was instantly attracted to the way in which the IIW works. Over such a period of time, a great deal of trust is developed and common research and development goals of the individual IIW Working Unit are thus defined.” The humble beginnings of Prof. 23/ 20 15 21 WELDING IN FINLAND [ www.hitsaus.net ] Education in Finland and in the USA Aalto University has defined a very clear mission of becoming an internationally-recognised university. “I like the global atmosphere in the IIW and the ways in which we work together to develop something truly significant. The network and balance between science and engineering provide enormous potential for both industry and the research community. According to Professor Marquis, the Technical Commissions work especially well when questions and challenges arise from practical contexts. At such a level, students are definitely motivated and possess clear career goals. This is something that has been slowly changing at Aalto.” Progress in the IIW Professor Marquis has worked within the IIW (International Institute of Welding) for more than 15 years; the first IIW event he ever attended was while in service at VTT. The teaching cultures in the two countries remain quite different, as are the relationships between student and faculty. In the IIW context, there is a very low threshold between the leading experts in certain fields and those who have little or no experience, such as new students, for example. There has been a tendency to assume that, if students are offered choices, they will then only opt for the “easy” classes, or else randomly sign up for courses which do not properly prepare them for a bonafide professional career. As IIW President, the focus now needs to be placed on how the IIW is governed and how it should develop in the future
He nevertheless admits that certain aspects of life in Finland are not always easy to deal with, but he feels that it has overall been a good choice to move here and to raise a family. The communication culture is also quite different. Most colleagues compliment the fact that he has learnt Finnish so well and it remains his primary work language at Aalto University. For this reason, different kinds of activities will be arranged during the period of the 2015 IIW Annual Assembly. This is one thing that I miss about being in the USA. It is also a really clean country and very environmentally-conscious. As the IIW President, there are numerous official duties to be fulfilled by Professor Marquis during the IIW Annual Assembly week. ”When people are making jokes, for example, it can be really hard for me to understand. HT_2-3_15.indd 22 15.5.2015 15.59. ”I will have many small tasks. It’s so nice when you can go outdoors and experience nature so close-by.” Different communication culture Mastery of the Finnish language has been one of the principal challenges for Professor Marquis. The mere fact that Finland was approved as host to this year’s event is symbolic confirmation that Finland is held in high regard. There are many representatives from Finland involved in the different IIW Working Groups and who occupy leadership positions within the IIW. In Finland, so many things are taken for granted, basic amenities like electronic banking, which works so extremely well. The most critical roles will involve chairing the respective Board of Directors and General Assembly meetings.” Finland has enjoyed an extremely high profile in the IIW in recent decades. In general, people enjoy a healthy lifestyle and seek outdoor exercise. For example, as the IIW President, I will have to officially declare the week-long event open. Furthermore, there are a few meetings which I must imperatively attend to “interview” and discuss with some new potential Member Countries. Finns don’t often tend to be very open to meeting new people. Professor Marquis believes that the key lies in cultivating a society of highlyeducated people. ”We need people who can solve new challenges as part of their routine job descriptions. “Finland has very good education and health systems. Professor Marquis has worked within the IIW for more than 15 years. In the USA, one can go to a restaurant and land up having a conversation with a waitress, or having a talk with a stranger, while you are standing in a line.” The Key to Finland’s success Since Finland is a small country, it needs to do some things better than others in order to succeed. Last summer, he was confirmed as IIW President. Foreigners are also very much interested in visiting Finland as well. ”Considering the size of the country, Finland has a large and active delegation. They are commonly-known as social tours, but can take the form of sports-related, cultural or nature-inspired activities.” Good education, beautiful nature Professsor Marquis himself has liked Finland enough to have lived here for 27 years. Finland has been especially active in the areas of education and certification. Nevertheless, he still sometimes finds certain social situations difficult because the Finnish language is not his native tongue. Finland already has wonderful infrastructures in place, such as a good road system, internet and banking facilities. I don’t visit there so often, but when I am there, I so enjoy just having natural contact with normal people. Professor Marquis intimates that the IIW’s upcoming summer gathering means a lot for Finland. There are also a number of awards which I must distribute during the week. We have to now concentrate on giving opportunities to people and to nurturing higher education in Finland.” Minttu Kauppila Freelance journalist Pictures: Minttu Kauppila Professor Marquis believes that higher education is the key to helping Finland succeed on a global scale. 23/ 20 15 22 WELDING IN FINLAND [ www.hitsaus.net ] The IIW Annual Assembly and International Conference in Helsinki The 68 th IIW Annual Assembly and International Conference will be held in Helsinki this summer and a record attendance by delegates and accompanying persons is expected
Expansion on such a major scale has been the fruit of a clear vision and a mission to fully and effectively establish the training programmes here in Finland. Since the WSF is not itself directly involved in training, it relies on its Approved Training Bodies (ATBs) and their key role and contributions within the overall qualification system. Since the humble beginnings of welding qualification and education in Finland during 1989-1990, the Welding Society of Finland is now proud to report that 8,920 diplomas were issued at the end of 2014 (EWE-IIW/ IAB). All national training efforts undertaken by the Welding Society of Finland have also been a part of the “bigger picture” of linking the international education and qualification systems. As of the end of 2014, Finland counted a total of 52 ATBs, geographically, evenlydistributed across the country, as presented in Figure 2. The main purpose of providing such training is to serve the Finnish metals industry by increasing the national know-how and knowledgebase in welding and allied techniques. 1. Workers at all levels of the welding profession “speak the same language ” in Finland, as do their counterparts in Germany, Portugal, or the P.R. 23/ 20 15 23 WELDING IN FINLAND [ www .hitsaus .net ] Qualification of Welding Personnel in Finland Status of ATB’s in Finland 2014 Juha Kauppila, Pertti Lepola and Reijo Pettinen The Welding Society of Finland (WSF) is the designated Authorised National Body (ANB) for welding education and training in Finland and, for many years, has been active in both the European Welding Federation (EWF) and International Institute of Welding/International Authorisation Board (IIW/IAB) welding education and qualification systems. 2. The very first EWE-course was introduced some 25 years ago during the period 19891990 and, since that time, an impressive 28 other courses have been organised throughout the country. These diplomas represent training carried out for Welders, Welding Coordinators, Welded Structure Designers, Inspectors, Robot-welding/Laser welding/Welded joint Heat Treatment Specialists and Practitioners for Reinforcing Bars, as detailed in Figure 1. However, it will be a major challenge in the future to keep education dynamic and relevant, as reflected in the content of the respective courses. By the end of December 2014, 903 EWE/ IWE and EWT/IWT diplomas has been issued Fig. Fig. Several of the courses were developed in very close collaboration with partners in the EWF and the IIW/IAB and working so closely together has truly been symbolic of “welding” within the international “welding family.” At present, the Welding Society of Finland is authorised to deliver the following education and qualification levels: EWE/IWE, EWT/ IWT, EWIP/IWIP, EWS/IWS, EWP/IWP, EWI/ IWI, EW/IW, IWSD, IMORW and ELP, RIB and Heat Treatment of Welded Joints. of China. New computer-based, training methods such as distance learning or the use of video meetings will complement traditional educational techniques. Most of the ATBs offer IW-training, with some 18 ATBs having also implemented IWS/IWP-training. We need to seize the courage to foresee and to fully embrace the changing context and challenges of the future. HT_2-3_15.indd 23 15.5.2015 15.59. This harmonisation of knowledge and qualifications has contributed largely to the tremendous strides made in the field on an international level. Implementation year of cource. ATBs in Finland 2014
These measures have served to increase the teachers’ knowledge base and to harmonise training. During this project, approximately 20 secondary level students started IW-training at the ATB. Reijo Pettinen also serves as Chairman of the Governing Board. The 2000 th EWS/IWS diploma was issued in November 2014. To date, approximately 1,100 diplomas have been awarded by Lappeenranta University. The adults enrolled in such centres usually only possess knowledge gained from their work lives and experiences, and their educational focus is therefore geared mainly towards accruing additional training and qualifications. The Kopar Group is an engineering and manufacturing corporation, with longstanding experience in bulk material handling, particularly in non-ferrous smelter industries, as well as in the power and energy sectors. Maria Lammentausta will soon be employed as a Welding Coordinator at Kopar Oy. Maria is already well-armed with IWS, IWI-S and Visual inspection Level 2 diplomas. In comparison, the numbers enrolled in the International Welder courses have remained fairly stable in recent years, with a marginal decrease in young student participation. 3. Students on degree objective training. Pettinen also informed that the latest developments involved the IMORW and ELP programmes which were finally approved in 2012. He is currently working on the ELSO Guideline, which involves a special course for Laser Safety Officers, the first of which will be offered during autumn 2015. Her responsibilities will include in-house company training, as well as inspection and the qualification Guidelines/Special Courses Number of Diplomas EWE/IWE 539 EWT/IWT 364 EWS/IWS 2009 IWI-C 272 IWI-S 64 EWP/IWP 117 EFW/IFW 2834 EPW/IPW 1169 ETW/ITW 1289 IWSD-C 49 IWSD-S 3 ETS 33 Robot Welding S 47 IRW-C 6 Laser Welding S 81 Welding for Reinforcing Bars -S 19 EWCP1090-2-S 14 Heat Treatment of Welded Joints 11 Total 8920 Table 1: Number of diplomas as of the end of 2014 . According to Lepola, it will be very important in future to stimulate industry interest and participation so as to convey the importance of IW-training to the sector. Pettinen recalls that the guideline for the International Welded Structure Designers (IWSD) education and qualification programme was accepted in 2006. With respect to adults, relevant qualifications are obtained via adult education centres. Pertti Lepola (IWE, IWI-C)) is a very experienced trainer at the SEDU-ATB in Seinäjoki and has worked with IW-certification since the outset of the first IW-welding project in 2006 (International Welding Project). 23/ 20 15 24 WELDING IN FINLAND [ www .hitsaus .net ] nationwide. Along with its IIW/IAB and EWF partners, Lappeenranta University has been focused on the development of education and active training centres in Finland. LUT had played an important role in its development, with Professor Gary Marquis, then affiliated with LUT, succeeding in receiving final approval during IIW-2006 Québec. Herein lies the great challenge for the future – how to attract young, secondary level students to careers in welding. At present, there are 50 ATBs which operate according to the IW-Guideline, with support material for IW-training for both teachers and students (2 CDs, based on the Guideline). The experience and results of the welding training were so positive that Teknologiateollisuus agreed to finance the continuation of the project. HT_2-3_15.indd 24 15.5.2015 15.59. Each ATB is subjected to a renewal audit which is conducted every 4 years, with a follow-up audit performed at the middle of the 4 year-period. A true investment in the future, similar to IWStraining, see Figure 4. ATBs are required to closely follow quality training manuals, which naturally correspond to the rules of the IW-Guideline. As Training Manager at the Centre for Training and Development of Lappeenranta University of Technology (LUT), Reijo Pettinen has longstanding experience in the development of training programmes for EWE/IWE, EWT/IW, IWSD, IMORW, ELP and ELSO, in collaboration with LUT’s professors, Jukka Martikainen, Veli Kujanpää, Antti Salminen and Timo Björk. 1 Grammar school High School and Voca3onal School (secondary level) University of Applied Sciences and University Number of the students on degree objective training Fig. Many of the personnel active in the field of metal construction, as defined by the European Standard, EN 1090-2, enrolled in the IWE, IWT and IWS courses during 2013 and 2014, which resulted in a higher than average number of registered students. In Finland, basic level, young students of welding receive qualifications at the secondary level, commonly-known as vocational schools or institutes. Although the total number of students at the secondary level of studies increased during 2013, as seen in Figure 3, the indication from the ATBs is that the industry definitely needs more young welders. LUT has awarded over 900 EWE/IWE and EWT/ IWT diplomas in Finland during the past 25 year-period and the University recently celebrated a quarter-century of involvement in education in March 2015. Subsequently, the number of ATBs expanded to nearly 35. The next course is scheduled during spring 2015. Pertti Lepola is an ATB auditor, with longterm experience in the implementation of IW-training. Teachers must also satisfy certain requirements: Qualification for Materials and Processes, Qualification to Control Welder Qualification Tests and Requirements for Visual Inspection
According to Lammentausta, training serves to provide theoretical knowledge for working and a comprehensive new approach to work methods. Pertti Lepola and other referees in WorldSkill competition in London 2011. mote the critical importance of education to Finnish industry. She will therefore need a lot of perseverance and willpower to successfully complete this final phase. The owners and managers of Kopar Oy have understood the important role of expertise in relation to welded structures. At present, Maria Lammentausta is in the final stretch of her IWE-course at LUT. nance of training in all tasks related to the welding and joining sectors. A common “welding-language” must therefore be defined so as to facilitate discussion of key issues and to hope for eventual international agreement, rendered that much more realisable and easy because of ease of communication and similar methods. We extend our heartfelt best wishes for good luck and success to her, see Figure 5. With only eight weeks of theory left before completion of her studies, for Lammentausta, the most challenging hurdle remains the study of materials and their behaviour during welding. At least she recognises that it is a win-win situation for everyone concerned. It is then that the company considers the actual work to be completed and its cost. Currently, there are numerous open employment possibilities at Kopar Oy for student internships and summer vacation work, since the company is committed to employing young locals. 4. 23/ 20 15 25 WELDING IN FINLAND [ www.hitsaus.net ] of welders. She readily acknowledges that there is a major challenge encountered in attracting young people to potential careers in welding. The EWF and IIW/IAB fulfil important roles with regard to the development and mainteFig. Juha Kauppila, The Welding Society of Finland Pertti Lepola, Vocational Adult Education Sedu Reijo Pettinen, Lappeenranta University of Technology HT_2-3_15.indd 25 15.5.2015 15.59. While rules and standards will eventually change and the work itself will be modified on a multi-national scale, it is clear that Finland will need to seriously focus on its various educational challenges. The role of the Welding Coordinator is important during the contract negotiation phase, as well as during the process of evaluation of quality requirements. The new Guidelines for training and qualification focus on rules to be followed, as well as the need for common approaches, in order to make action possible on a global scale. The role of the Welding Society of Finland is to actively proFig. Her studies were undertaken so as to be able to help to support her family and, concomitantly, as a result of an employer’s incentive. Despite her relatively young age, she has developed the skills necessary for conducting her work. Maria Lammentausta by the side of the cooling screw conveyor to Poland. 5
ing methods have always been characteristics of Helsinki Shipyard. Innovative products and workFig. DAS During extensive, common ice-test trials with Finnish Neste Shipping tankers, it was discovered that vessels with azimuthal propulsion were able to navigate through ice far easier by advancing stern ahead. Vitus Bering and Alexey Chirikov (2012). The shipyard has since delivered about 60 percent of all the icebreakers currently in operation around the world. Established under the name Arctech Helsinki Shipyard in April 2011 . Key figures in a nutshell . Our mission is to develop and to deliver the best solutions for arctic ship operations. Mercator (1910). 150 years of experience in shipbuilding Icebreaking innovations The Helsinki shipyard has an impressive track record of various special vessels and is also a forerunner in the development and application of technological innovations. The product range has varied from harbour tug boats to panamax-size cruise liners. The following are a few of the icebreaking advances that have been developed and utilized at Helsinki Shipyard. New Pioneering concepts, reliable and high-quality products are the amongst the success factors required to maintain the good market share that Helsinki Shipyard has enjoyed in the Arctic vessel industry. The special JV-company, Nemark, was formed in the 1990s between Helsinki shipyard, Neste Shipping, two Russian shipping companies and the Transport Ministry of the Russian Federation, in order to also be able to test this concept along the Russian North Sea Route. Oblique icebreaker An oblique icebreaker is a special type of iceHT_2-3_15.indd 26 15.5.2015 15.59. Arctech has a long history and experience in the building of arctic vessels and ships have been built for 150 years in the same location at the Helsinki Shipyard.The first icebreaking vessel, Mercator, was delivered from the Helsinki Shipyard in 1910. 23/ 20 15 26 WELDING IN FINLAND [ www.hitsaus.net ] Arctech Helsinki Shipyard We Make You Break the Ice! Niko Rautiainen and Eero Nykänen Arctech Helsinki Shipyard Inc. Fig. Today Azipod ® is registred trademark of ABB. 2. 1. Today the abbreviation “DAS” is registred trademark of Aker Arctic Technology Inc. During its 150 years of operations, the Helsinki Shipyard has seen the construction of over 500 vessels and has conducted enormous amounts of ship repair and conversion projects. It also serves to unite the marine industry clusters of both the Russian Federation and Finland. Azipods The electrical, podded propulsion system was developed in cooperation with the Finnish Maritime Administration and ABB. Owned by the Russian United Shipbuilding Corporation . Main products: icebreakers and arctic offshore and special purpose vessels . These tests were carried out with excellent results. specializes in Arctic shipbuilding technology, including the construction of icebreakers and other Arctic offshore and special vessels. Approximately 500 employees . The vessel that was optimised to operate bow first in open water and stern first under heavy ice conditions was named the Double Acting Ship. Our vision is to be the leading brand in arctic shipbuilding
3. The use of flux-cored arc welding is also constantly increasing in outfitting works. The mechanization of welding and other production phases. The ship is now in operation. The icebreaker will be delivered to the customer by winter 2016. One of the development areas for Arctech is to further improve the block outfitting and painting processes at the supplying shipyards, to optimise the production chain already at the the block fabrication stage. The tendency has been to increase the use of prefabricated modules. The improvement of safety by transferring the fire works and difficult work positions to a shop floor environment. The reduction of costs by manufacturing the modules in more efficient production facilities with efficient processes. Dimensional accuracy Dimensional accuracy is being developed and improved by better control, in co-operation with the block sub-contractors. 4. The icebreaker will be the first LNG-powered icebreaker in the world. The minimization of the lead time from hull erection to the delivery of the ship. Building Indoors To save costs, ensure quality and improve the work environment, production is executed as much as possible indoors. In open water, the service speed will be a minimum of 16 knots. In special cases, acid-resistant compound steel is used in the ice belt to reduce friction between the hull and the ice. The only phase which cannot be completed indoors is the final commissioning of the ships. Manual metal arc welding is used only in outfitting. The vessel MS Baltika was built in co-operation with Arctech Helsinki Shipyard and Yantar Shipyard. LNG-powered ice breaker The shipyard is building new icebreaker for the Finnish Transport Agency. . The enhancement of quality by working with partners that are global players, manufacturing the modules in industrial facilities with advanced processes. The first vessel of this kind was ordered by the Russian Ministry of Transport on the 8 th of December, 2011. At the Arctech Helsinki Shipyard, it is possible to complete all of the production phases inside covered production facilities. Thermo-mechanically-rolled, extra-high-strength, shipbuilding steels have excellent properties. . The vessel will be able to move continuously through about 1.6 m-thick level ice, to break a 25-m-wide channel in 1.2 m--thick ice at a speed of 6 knots, as well as to reach 9-11 knots of average assistance speed in the Baltic Sea. The hull erection phase starts with outfitted and painted blocks. Oblique icebreaker MS Baltika. The low amount of alloying elements ensures good weldability and a low amount of preheating. 23/ 20 15 27 WELDING IN FINLAND [ www.hitsaus.net ] breaker designed to operate not only ahead and astern, but also obliquely (sideways). Pipe welding is performed with orbital welding devices. The impact strength test temperature requirement can be as low as -60°C and steels with a yield strength class of up to 500 MPa are used. Fig. Measurement analysis of the block interface. The outer hull block limits are welded with mechanization devices, and block limits on decks are welded with submerged arc welding, whenever possible. Focus areas in production development Selected suppliers Block manufacturing for Arctech Helsinki Shipyard is handled by selected suppliers. This icebreaker of the future will be powered by both diesel and LNG, i.e., liquefied natural gas, which will result in the reduction of both emissions and fuel costs. In this way, a relatively small icebreaker is capable of opening a wide channel in ice to facilitate the passage of large merchant ships. HT_2-3_15.indd 27 15.5.2015 15.59. Steel materials Steels used in icebreaker hull blocks are low-temperature, high-strength or extra highstrength shipbuilding steels. The vessel has been designed to operate in temperatures as extreme as -30°C. . The oblique icebreaker concept was developed in the late 1990s. The main objectives for the afore-mentioned development have been: . The design of MS Baltika is based on ARC 100 concept, which has been developed by Aker Arctic Technology for Arctech Helsinki Shipyard. The new icebreaker features the highest technology and has been designed especially for the demanding icebreaking operations in the Baltic Sea. . Selected Turn-key and System Suppliers The global turn-key suppliers and system suppliers are playing a major role in the modularization and industrialisation of ship production. Welding Processes The main welding process used in hull assembly is flux-cored arc welding with ceramic backing. Fig
Shell plates consisting of 500 MPa TMCP-steels. SCF Sakhalin. HT_2-3_15.indd 28 15.5.2015 15.59. The development of new concepts, as well as development projects in production, are part of the daily operations. The next icebreaking innovation is in the pipeline, waiting to be launched as part of some upcoming projects. Niko Rautiainen, Manager, Hull Production Eero Nykänen, Welding Engineer Arctech Helsinki Shipyard Inc. OHSAS 18001: Occupational health and safety management standard What next. Innovations are often conceived as solutions to customer needs. Picture 6. 5. 23/ 20 15 28 WELDING IN FINLAND [ www.hitsaus.net ] Quality system Quality management of Arctech Helsinki Shipyard is certified to the following standards: . ISO 3834-2: Comprehensive quality requirements for welding . ISO 9001: Quality management standard . ISO 14001: Environmental management standard . Helsinki www.arctech.fi Fig. Mechanized welding in hull assembly
They are usually supplied in the quenched and tempered condition (austenitizing at 770 to 830 ° C, with cooling in water or oil, and tempering at 540 to 600 ° C, with cooling in air or water). Caverion – New Company, Long History The Caverion Group designs, builds, operates and maintains user-friendly and energy-efficient technical solutions for buildings and industries in Northern, Central and Eastern Europe. In addition, the steel must contain a very low content of impure elements such as sulphur and phosphorous. Our strengths include technological competence and comprehensive services, covering all technical systems throughout the life-cycles of properties and industrial plants. These steels are also referred to as cryogenic nickel steels. Caverion Oy delivers technical systems and processes to all branches of industry for the design and manufacture of industrial components, including piping, pressure vessels, process equipment, columns, mass towers, tanks and boilers. Unless constructions are very heavily-restrained, there is no need for pre-heating, usually recommended only for materials in excess of 50 mm in plate thickness. Elongation A: min 18 % . Caverion is one of the largest players in the realm of mechanical projects in Europe, also known for its FOB deliveries all around the world. Mn: 0,30-0,80 % . Caverion’s know-how has been applied in offices, retail properties, housing, public premises, industrial plants and infrastructure, amongst other places. Postweld heat-treatment (PWHT) is normally not necessary, unless mandated by regulations. This leads to a need for the transportation and storage of gas. Small amounts of stable, remaining austenite also improve impact toughness and weldability. Impact energy KV (X7Ni9): min 100 J @ -196 ° C (longitudinal) The chemical composition of X8Ni9 (X7Ni9) is as follows: . 9 % nickel steels are normally not susceptible to hydrogencracking because of quite low hardness and the remaining austenite in the HAZ. As an example, Caverion had already been involved in LNG-projects during the period 1993-1997, with the delivery of four LNG-carriers to AbuDhabi (ADNOC). Caverion is positioned to act as an EPCcontractor, using its own engineering resources as well as its international sub-contractors, international supply chain, large fabrication yards with modern work methods, in addition to its large erection (site supervision) team. With a head office in Helsinki, Finland, the company employs approximately 17,000 persons in 12 countries within Northern, Central and Eastern Europe. LNG – Highly-efficient and Low-emission Fuel Liquefied natural gas is commonly known as LNG. A large number of projects has been completed in recent years and very many more new projects are currently underway and will soon be realised. Offering a good combination of strength and toughness at a reasonable price, 9 % nickel steel is fully-ductile down to -196 ° C, well below the boiling point (-163 °C) of natural gas. Caverion Industria Oy manages two production workshops in Finland, in Ylivieska and Leppävirta, where much of the pre-fabrication work is handled. We also offer a wide range of industrial maintenance ser vices from individual assignments to comprehensive maintenance of production processes, maintenance cooperation and outsourcing ser vices. Much of the world`s natural gas resources are, however, generally located far from the areas of consumption. The normal fabrication sequence for very large storage tanks is first the welding of the horizontal seams (PC, 2G), using the subHT_2-3_15.indd 29 15.5.2015 15.59. Impact energy KV (X8Ni9): min 70 J @ -196 ° C (longitudinal) . The materials also need to have highstrength in order to reduce the wall thickness of the vessels and must facilitate easy welding, without any risk of brittle fracture and cracking. P: max 0,020 % (X7Ni9: max 0,015 %) . The materials used in the vessels and tanks which keep the gas at liquefaction temperatures (-163 °C) need to remain ductile and crack-resistant, with a high level of safety. This martensite is quite special in the sense that it is neither hard nor brittle, due to a very low carbon content, but is instead strong and tough. S: max 0,010 % (X7Ni9: max 0,005 %) . Recommended heat input is restricted to below a maximum of 2-3 kJ/mm, depending on the source. C: max 0,10 % . Many standards have qualified 9 % nickel steels. For these temperature applications, special high-strength, high-toughness, nickelbased filler metals and rarely, special, austenitic, high-alloy, stainless filler metals are to be used in order to comply with the high ductility, impact toughness and strength requirements. MIG-welding with solid wires (gas metal arc weldingGMAW) is used to a quite limited degree. The mechanical properties of the EN steel grades, X8Ni9 (QT680) and X7Ni9, are specified as follows: . Natural gas can be considered the most environmentally-friendly fossil fuel, because it has the lowest CO 2 emissions per unit of energy and contains little or no sulphur. The excellent low temperature impact properties are the result of a fine-grained microstructure of tough nickel-ferrite (tempered martensite) in the quenched and tempered condition. Si: max 0,35 % . V: max 0,05 % (X7Ni9: max 0,01 %) The 9 % nickel steels have very good weldability and are welded with shielded metal arc welding (SMAW)/manual metal arc welding (MMA), flux-cored arc welding (FCAW) and submerged arc welding (SAW). Some advantages of pre-fabrication include a reduction in the total duration of project work, better logistics, optimisation of project lead-time and reduced erection capacity as well as improved work safety. 9 % nickel steel belongs to a larger family of nickel steels with varying nickel contents ranging from 0,5-9 %. Natural gas replaces oil and gas as fuel for industry and shipping and, from the point of view of energy, is the same as biogas. Yield strength: R eH : min 585 MPa . Listed on the Helsinki Stock Exchange (NASDAQ Helsinki), revenue for Caverion was approximately EUR 2.4 billion in 2014. Ni: 8,50-10,00 % . At -163 °C, natural gas is condensed to liquid, when the volume becomes 600 times smaller. EN 10028-4 specifies the grades, X8Ni9 (1.5662) and X7Ni9 (1.5663), which correspond to ASTM A553 Type I. Tensile strength: R m : 680-820 MPa . The inter-pass temperature should be kept below 150 ° C. This simplifies the storage and transportation of the gas and thus makes its use very economical. 23/ 20 15 29 WELDING IN FINLAND [ www.hitsaus.net ] Caverion and LNG Seppo Mikkola There has been growing interest in the use of natural gas as a source of energy, driven by both economic and ecological advantages
Optimised planning of material flow helped the company to keep the small on-site stocking area tidy and facilitated easy feeding to erection levels. . Inside an LNG terminal, there can naturally be found much piping and welded pipes, typically composed of austenitic stainless steels. Nynäshamn LNG terminal. The project involved a tight schedule. Solutions: . Dimensions: 36 m (dia)/34 m (height) . Welding procedure (WPS) for FCAW. Increase and modifications in the scope of work was handled with Caverion’s large group of white and blue collar personnel. 500 .. Fabrication in indoor facilities enabled effective and safe working conditions. Work scope was increased. Cryo AB is one of the world’s leading manufacturers of cryogenic equipment for the storage, transportation and handling of liquefied natural gases. Manual metal arc welding (SMAW) is then used for all vertical welding of the shell plates (PF, 3G) to the X groove (double V preparation). and Plate Distance contact work piece Suutinetäisyys (mm) 15..17 WPS approved by Hyväksyntä Polartest Oy NB 0875 Approval date Hyväksymispäivä 08.06.2009 Welding data / Hitsausarvot Layer Palkokerros Process Prosessi Filler diameter(s) Lisäaine (mm) Current range Hitsausvirta (A) Voltage range Hitsausjännite (V) Speed range Kuljetus (mm/s) Welding energy range Hitsausenergia (MJ/m) 1...4 PF 136 1,2 145...155 21,6...22,6 2,5...3, 6 0,9...1,2 1 PC 136 1,2 135...145 21...23 3,6 0,8...0,9 2...10 136 1,2 150...160 21...23 5,8...9,8 04...0,5 Additions and notes / Lisätiedot ja huomautukset 1 This WPS is a printout from a Database kept up by the Welding Engineer of the Company Caverion Industria Oy www.caverion.fi 1295 Printed: 05.04.2015 Welding Procedure Specification ISO 15609-1 Nr. to procedure V15B Groove preparation Railon valmistelu Machining or grinding Groove/Railo Ref. Lysekil: ~ 80.000 hours . The company’s expertise extends across the entire handling chain – from certified tanks to storage stations to full-blown LNG terminals. Total delivery in metres: . 500 .. Weather conditions near the seaside were difficult. Caverion Industria Oy www.caverion.fi 1295 Printed: 05.04.2015 Welding Procedure Specification ISO 15609-1 Nr. Work was conducted in Lysekil with zero days lost to accidents. Details and range of qualification / Muuttujat ja niiden vaihtelualueet Welding process(es) Hitsausprosessi(t) 136 FCAW MAG-Täytelanka Joint type(s) Liitosmuodot BW bs,nb, mb Päittäisja pienahitsit Parent material group(s) Peusaineryhmät 9.3 ISO/TR 15608 Position(s) Asennot All, except PG Kaikki, ei alasmäkeä Typical material grade(s) Tyypilliset laadut X7Ni9 Typical material standard(s) Tyypilliset ainesstandardit EN10028-4 (ASTM 553 Typel) Consumable (Trade mark) Lisäaineiden kauppanimet Böhler Nibas 625 PW-FD Classification / Luokittelumerkintä Current type(s) / Virtalajit EN ISO 14172-Ni 6625 +DC Shielding gas(es) Flow rate Suojakaasut ja virtausmäärät Mison 25 Mison 25 15l/min Backing or Backing gas(es) Juurikaasut ja puhtausvaatimus Preheat..Interpass T(oC) Työlämpöalue 20..300 PWHT range (oC) / Dwell (min) Jälkilämpökäsittely / Nozzle diameter (mm) Suutinhalkaisija 15..17 Qualified thickness range (mm) Paksuusalue (mm) Qualified diameter range (mm) Halkaisija-alue (ISO 15614-1) 10.. and Plate Distance contact work piece Suutinetäisyys (mm) 15..17 WPS approved by Hyväksyntä Polartest Oy NB 0875 Approval date Hyväksymispäivä 08.06.2009 Welding data / Hitsausarvot Layer Palkokerros Process Prosessi Filler diameter(s) Lisäaine (mm) Current range Hitsausvirta (A) Voltage range Hitsausjännite (V) Speed range Kuljetus (mm/s) Welding energy range Hitsausenergia (MJ/m) 1...4 PF 136 1,2 145...155 21,6...22,6 2,5...3, 6 0,9...1,2 1 PC 136 1,2 135...145 21...23 3,6 0,8...0,9 2...10 136 1,2 150...160 21...23 5,8...9,8 04...0,5 Additions and notes / Lisätiedot ja huomautukset 1 This WPS is a printout from a Database kept up by the Welding Engineer of the Company Challenges: . . 2. Total man-hours: . View to inside of a tank. 3. Nynäshamn: ~ 5 km . 1295 T10 Seppo Mikkola 28.08.2009 / Seppo Mikkola 28.08.2009 Procedure description / Menetelmän kuvaus Manufacturer Valmistaja Caverion Industria Adress Osoite ja yhteystiedot www.caverion.fi Qualification standard Pätevöintistandardi ISO15614-1 Supporting PQR's Menetelmäkokeet 1295 Filler and flux handling Lisäaineen käsittely Acc. Welding The plates were delivered ready-bended and bevelled for welding. . . Nynäshamn’s LNG-tank was Caverion’s first storage tank over 10,000 m³. . . Fig. Details and range of qualification / Muuttujat ja niiden vaihtelualueet Welding process(es) Hitsausprosessi(t) 136 FCAW MAG-Täytelanka Joint type(s) Liitosmuodot BW bs,nb, mb Päittäisja pienahitsit Parent material group(s) Peusaineryhmät 9.3 ISO/TR 15608 Position(s) Asennot All, except PG Kaikki, ei alasmäkeä Typical material grade(s) Tyypilliset laadut X7Ni9 Typical material standard(s) Tyypilliset ainesstandardit EN10028-4 (ASTM 553 Typel) Consumable (Trade mark) Lisäaineiden kauppanimet Böhler Nibas 625 PW-FD Classification / Luokittelumerkintä Current type(s) / Virtalajit EN ISO 14172-Ni 6625 +DC Shielding gas(es) Flow rate Suojakaasut ja virtausmäärät Mison 25 Mison 25 15l/min Backing or Backing gas(es) Juurikaasut ja puhtausvaatimus Preheat..Interpass T(oC) Työlämpöalue 20..300 PWHT range (oC) / Dwell (min) Jälkilämpökäsittely / Nozzle diameter (mm) Suutinhalkaisija 15..17 Qualified thickness range (mm) Paksuusalue (mm) Qualified diameter range (mm) Halkaisija-alue (ISO 15614-1) 10.. Nynäshamn: ~ 45.500 hours . Dimension of the tank in Nynäshamn: . Caverion Involvement in Swedish LNG Projects In recent years, Caverion has been awarded two contracts as the main sub-contractor in LNG projects for the Swedish company, Cryo AB. The facility’s newest terminal, Lysekil, was added during the period 2013-2014. 1295 T10 Seppo Mikkola 28.08.2009 / Seppo Mikkola 28.08.2009 Procedure description / Menetelmän kuvaus Manufacturer Valmistaja Caverion Industria Adress Osoite ja yhteystiedot www.caverion.fi Qualification standard Pätevöintistandardi ISO15614-1 Supporting PQR's Menetelmäkokeet 1295 Filler and flux handling Lisäaineen käsittely Acc. 1. Fig. Seppo Mikkola Welding Supervisor, IWS Caverion Industria Oy Helsinki, Finland www.caverion.com Fig. Lysekil: ~ 8 km . 23/ 20 15 30 WELDING IN FINLAND [ www.hitsaus.net ] merged arc welding process (SAW) from both sides of the K-groove (double bevel preparation). . The welding processes employed were SMAW and FCAW, using nickel-chromium-molybdenum of the AWS classification ENiCrMo-3 (SMAW) and ENiCrMo3T1-4 (FCAW), so-called alloy 625 as filler metal. In recent years, mechanised FCAW using new, rutile, all-position, flux-cored wires has been used more and more frequently for vertical welds, with the help of light rail carriages. to drawing/ Piirustuksen mukaan. On smaller tanks, welds are most often made using the MMA and FCAW processes. The facility consists of a jetty, a 22,000 m³ of storage tank, process equipment and loading areas for trucks, all constructed between 20092010. to drawing/ Piirustuksen mukaan. Pre-fabrication was maximised in order to save work-load on-site. Volume: 22,000 m 3 . Sweden’s first LNG terminal is located in Nynäshamn, near to Nynas AB’s refinery. Forming part of the German company, Linde Engineering Division, Cryo AB combines over 50 years’ experience with advanced technologies for the benefit of its customers. Height: 29 m (dia)/27 m (height) HT_2-3_15.indd 30 15.5.2015 15.59. to procedure V15B Groove preparation Railon valmistelu Machining or grinding Groove/Railo Ref.
SERIMAX SAS is a specialist in pipe-joining projects in the offshore oil and gas pipeline industry. Welding process remote control became mandatory. 2. Also torch and wire position with respect to the gap can be checked and adjusted accordingly. SERIMAX uses orbital MIG/MAG welding to join the pipes of various diameters and wall thicknesses together and has developed its own solutions for each application. Each sensor unit contains camera with integrated laser illumination. CAVILUX Welding Monitoring solutions from CAVITAR Ltd, the Finnish specialist in diode laser based illumination and monitoring systems for industrial and scientific applications, have been successfully implemented in EXTERNAX production environment for over a year. Based on these excellent results, SERIMAX and CAVITAR have started long-term collaboration in 2014 in order to enable the utilization of CAVILUX Welding Monitoring technology in SERIMAX’s future orbital welding equipment. 3. The last 20 years have seen a significant increase in pipeline installation complexity and associated acceptance criteria of them. The expertise of welders is absolutely crucial for obtaining high-quality welds. Figure 1: Remote control of the EXTERNAX welding equipment made possible with CAVILUX Welding Monitoring system. By having two sensor units (Fig. 23/ 20 15 31 WELDING IN FINLAND [ www.hitsaus.net ] Jean-François DAGENAIS www.serimax.com Jean-françois.dagenais@serimax.com Cavitar Ltd www.cavitar.com info@cavitar.com Online Monitoring of NarrowGap Offshore Pipe-Welding Narrow-gap offshore pipe-welding is typically performed in challenging environment and with exceptionally high quality requirements. Customer projects typically include phases such as the qualification of the applied welding process, custom development of the welding equipment and on site offshore or on-shore welding. According to SERIMAX, this collaboration has been successful and results beyond expectations. CAVILUX Welding Monitoring solution is based on active high-power pulsed diode laser illumination at the visible wavelength. Sensor unit. The co-operation aims to further develop visual welding monitoring to improve welders’ HSE (Health & Safety Executive) and orbital welding process control. The CAVILUX Welding Monitoring solution consists of two sensor units, control unit, panel PC, software and flexible industrial grade cables. As can be seen, it is possible to have a clear view from the process. EXTERNAX, the latest welding equipment developed by SERIMAX, had to integrate a very compact welding carriage. Since the arc brightness is greatly suppressed, exceptional image quality of the welding process can be obtained. Figure 2 shows an example image from the narrow gap MIG/MAG arc welding process. The robust industrial welding monitoring solutions developed by CAVITAR provide the welder with a clear view to the orbital MIG/ MAG arc process. The essentially monochromatic light of the laser enables to see the welding process in detail without the blinding brightness of the arc. The volume of the sensor unit is approximately 0,5 l and the weight is approximately 0,5 kg. An additional key benefit of the monitoring system is that the entire process can be recorded in the form of high-quality videos. 3.), it is possible to see both front and back side of the welding process simultaneously. At the same time the monitor screen can be placed in a remote location from the radiation and process fumes. This data can be added to the weld quality supervisor files, Quality Control and traceability are therefore improved. Image taken from the narrow-gap welding process with CAVILUX Welding Monitoring system Fig. However, working positions can often be uncomfortable and the exposure to welding fumes must be avoided. Pipe-laying industry’s zero tolerance for welding defaults is understandable since even one non compliant weld could have major ecological and economic consequences. HT_2-3_15.indd 31 15.5.2015 15.59. Fig. All these benefits allow the welder to fully concentrate on the welding process itself in order to achieve best possible weld quality
Other founding shareholders included the major welding equipment manufacturer, Kemppi Oy, and its management. Today, the company is certified by the ISO 9001 quality system and the ISO EN 17663 standard, “Guidelines for quality requirements for heat treatment in connection with welding and allied processes.” In addition, the company is committed to following international health and safety standards and environmental management systems. Quality, safety and competence Heatmasters has always been driven to operate with the highest level of expertise, in respect of the industry’s best practices and standards. Thus, Mr Eero Jääskeläinen and his brothers landed in Gothenburg, Sweden, where they found employment at the heat treatment company, Svenska Cooperheat AB. The course in Finland has been audited and was approved by the EWF in September 2013. Starting point During the 1970s, it was not uncommon for Finns to emigrate in search of better work opportunities. Thus, 1995 saw the acquisition of Svenska Värmebehandling Ab, based in Gothenburg, Sweden, followed shortly afterwards by a vast subcontracting agreement with Fakop in Poland (now part of Amec Foster Wheeler). Targeting the highest level of technology Quite soon after the start of operations, it became clear that the company needed to develop its own equipment. After learning the secrets of preand postwelding heat treatment for a few years, they returned to Lahti, Finland, where Eero established the country’s first commercial heat treatment company in 1974. The firm’s six-channel, microprocessor-controlled transformer was introduced in 1982 and truly revolutionised the market. Along with Heatmasters’ own heat treatment wizards, many customers, distributors, suppliers and financing partners from several countries participated in the festivities. Its advent meant that a technician could manage to heat several joints simultaneously, using only one transformer. In 1995, production and sales of the equipment were finally directed to a new subsidiary, Heatmasters Oy. Since its humble beginnings as a small provincial player, the company has grown considerably over the past 40 years, cementing its position today as one of the leading heat treatment services and technology providers in Europe and further afield. Today, the entity in Estonia, Heatmasters Baltic, operates actively in Estonia, Latvia, Lithuania and Belarus. In order to provide uniform and top-quality heat treatment services to its customers, Heatmasters embarked upon the training of its personnel and sub-contracting partners with the EWF special course, “The European System for Heat Treatment of Welded Joints,” in accordance with EWF-628r1-10. Between 2002 and 2007, the company established joint ventures in Estonia, the Ukraine and Saudi Arabia. Upon completion of the course, competence is evaluated via both a theoryoriented examination and a practical test, during which local heat treatment is performed using reFurnace heat treatment HT_2-3_15.indd 32 15.5.2015 15.59. Expansion and internationalisation Up until the beginning of the 1990s, the company operated from a single location in Lahti, Finland. It provides students with essential knowledge about metallurgy and the basics of heat treatment of welded joints, as well as the theory and practice of heat treatment. In 1993, a co-operation agreement was signed with the A. 23/ 20 15 32 WELDING IN FINLAND [ www.hitsaus.net ] Heatmasters – 40 Years of Heat Treatment Ilkka Mujunen In June 2014, Heatmasters celebrated its 40 th anniversary of operations in Lahti, Finland. Ambitions were quite high the company wanted to develop the most modern equipment in the world and eventually succeeded in realising this objective. Ahlström boiler plant (currently part of the Andritz Group), situated some 200 kilometres north of Lahti in Varkaus, a site at which heavy investments were made into furnaces. Despite the ongoing recession in Finland, the investments paid off and the company was then ready to exploit potential opportunities abroad
On-site services also include the heating of customers’ products in temporary, gasfired furnaces, assembled out of modular panels at the clients’ production facilities. Heat treatment services today Heatmasters is actively involved in on-site and in-house heat treatment services. Furthermore, we will officially certify additional quality systems, namely, the OHSAS 18001 health and safety system and the ISO 14001 environmental management system. It is of the utmost importance for customers to be able to rely on our experience and competence. As we have been strictly ensuring the expertise of our heat treatment technicians and sub-contractors, EWF-certified training will be ongoing. On average, the highest score (3.8) has been awarded for “keeping promises,” considered by customers to be the most important criterion (39% of respondents). We know that we are on the right track, since our customer feedback system provides a continuous measurement of client satisfaction. Furnaces are developed for stress relieving, normalising, pre-heating, austenitizing, pearliting, ferriting and softening. (Tech.), Business Manager of Heatmasters. All services are provided using the state-of-the-art equipment developed inhouse by Heatmasters. Heatmasters will also continue to expand geographically, by establishing operations in new countries, as well as through the strengthening of relationships with international customers and the provision of services currently outside of our geographical range. We are continuing to measure our performance with SMEs and with world-leading groups such as ABB, Aker Solutions, Alstom, Andritz, Babcock & Wilcox, Bilfinger, Caverion, ExxonMobil, Foster Wheeler, Metso, Rolls Royce, Siemens and Valmet, to name a few. This is undertaken in cases where the transportation of large objects is deemed to be either too difficult or costly. Heating is provided using either electricity or gas. Ilkka Mujunen CEO Contact person: Jukka Sirviö Business Manager, Heat treatment services Heatmasters Group Oy Koneharjunkatu 6 FI-15850 Lahti Finland www.heatmasters.net Gas heating from inside. Inductive preheating. This controller enables not only automated and accurate process control, but also facilitates an effective and integrated process, from heat treatment instruction to ready certificate. Heat treatment technology today Heatmasters supplies a wide range of products to professional heat treatment companies and manufacturing workshops and, through a network of 25 distributors, our high-quality products are shipped to over 30 countries worldwide. The most commonly-sought treatments include stress relieving and normalising. The temperature range is up to 1200 degrees Celsius and the sizes of the objects to be heat-treated may vary from a few kilogrammes, to some 30-40 tonnes. Typical on-site PWHT (Post-Welding Heat Treatment) services are provided for assembly and maintenance companies which operate in nuclear power plants, power plants, oil refineries, pulp and paper mills, and chemical plants. There are several gas and electric furnaces at each Heatmasters location, since flexibility and fast response times to customer requirements can only be possible by maintaining a very high level of capacity. HT_2-3_15.indd 33 15.5.2015 15.59. Strategic steps to move forward Heatmasters has been continuously developing new processes and products so as to help its customers to improve their businesses, a trend which will certainly endure. 23/ 20 15 33 WELDING IN FINLAND [ www.hitsaus.net ] sistance heating. Both the heat treatment machines and the furnaces are computer-controlled using a Heatmasters controller. Typical products to be heat-treated include pressure vessels, heat exchangers and large welded constructions (common in the offshore industry). Our product range includes various types of furnaces, threeand six-channel, heat treatment machines for pre-heating and PWHT, as well as several tools and accessories geared for professional heat treatment. With our 40 years of experience, we are positioned to provide an expert and costefficient service in close proximity to our customers: our Finnish and Estonian units support clients mainly in the Baltic countries, the Swedish unit operates throughout Scandinavia and the Polish unit covers Central Europe. The principal trainer for the course is Jukka Sirviö, M.Sc. The main types of furnaces include fixed, moveable and temporary modular units. Many different constructions are available, e.g., top-hat furnaces, furnaces with pivot doors, chamber furnaces, forced-air circulation furnaces and car bottom/bogie furnaces. Over the past six months alone, satisfaction levels have measured an average of 3.7 points on a scale of 1-4
One of the greatest features of array methods is that test results are more easily stored. 23/ 20 15 34 WELDING IN FINLAND [ www.hitsaus.net ] New Weld-Testing Methods in the Pipeline Tuomas Suominen and Thomas Freundlich With over 300 services to more than 75,000 customers, operating from offices in eight countries, Inspecta supports companies as they expand their operations around the world. HT_2-3_15.indd 34 15.5.2015 15.59. For example, thickness measurements can be presented in colour charts, whereby one can really see the scale of possible corrosion damage. Phased array ultrasonic testing. “We have been going upstream, investing in equipment and in the intellectual capital of our specialists, making it possible for us to deliver better, smarter and more cost-effective services to our clients.” Faster, sharper and easier testing methods Advanced non-destructive testing (NDT) methods are developing rapidly. In phased ultrasonic testing, the same defect can be shown as an image and the reflector can be located three-dimensionally inside the weld,” explains Matti Ruha. A phased array ultrasonic probe consists of several transducer elements that operate independently. “After a job well done, a satisfied customer is our best business card. “You no longer have to be an expert in ultrasonic techniques to understand the test results,” according to Inspecta Finland’s NDT specialist, Ari Kaarnalehto. Array applications are also becoming common in eddy current applications. Better visuals A major benefit of phased array ultrasonic and eddy current array is that they produce easily-understandable, visual test results. “In traditional ultrasonic testing, the customer is notified only when we have identified a possible defect. The new methods are also faster to use and offer visually clearer, and more easily comparable, test results. The method pinpoints the exact location and size of any defects, using graphic colour images. Nowadays, it is much easier to determine if the signal response has identified an actual defect, or if it is merely characteristic to the shape of the object. Computer technology helps tremendously in the analysis of test results. Using new technology, we can now inspect objects that have been out of reach in the past. “The customer receives test data files to help observe the condition of the system,” reveals Matti Ruha. Inspecta uses the new technology at nuclear power plants, for example, when inspecting pipe welds. “We are still more or less a local company, but Inspecta’s international assignments are growing in fields where we have special expertise,” explains Mats Bergman, Manager of Advanced Testing in Sweden. Array techniques are faster than traditional ultrasonic and eddy current testing and, today, one can inspect objects that were previously unreachable. The key to Inspecta’s success has been to follow Nordic companies as they develop globally. At a good phase with phased array ultrasonic testing One of the newest, advanced NDT testing methods is by phased array ultrasonic. TOFD ultrasonic testing. By controlling the timing of the ultrasonic pulses from each element, the direction of the sound wave emitted by the probe can be steered electronically. Multi-metal welds can also be inspected with the phased ultrasonic. According to Matti Ruha, NDT Branch Manager for Inspecta in Finland, most new, advanced NDT techniques in this country are first adopted at challenging nuclear applications, then offered to traditional power plants and other industries. A good word and a great reputation spread rapidly within our industry,” remarks Jouni Koivumäki, Regional Director in Finland
HT_2-3_15.indd 35 15.5.2015 15.59. At best, it can take several days before one could see the film. “The testing can be complex, as installations typically include both new and older equipment,” says Runar Meland, Regional Manager, Inspecta Norway. With the new digital x-ray, it is possible to scan multiple sections of the same 200 x 200 mm area, with different radiation outputs, and to receive different material thicknesses in the same image. On the go One of the newest technologies in NDT testing is digital radiography, a.k.a. Up until now, phased array ultrasonic testing had not been used on the existing sub-sea equipment welds found on much of the undersea equipment currently in service in the North Sea,” notes Runar Meland. We can see precisely which x-rayed objects are used in which machines.” All Ponsse’s new products are tested at the factory’s premises. The critical components are scanned with digital x-ray, both before the usage test and after. TOFD ultrasonic testing detects and calculates the depth of sub-surface weld cracks, using the diffraction patterns of ultrasonic waves from the weld joint. digital x-ray. “New digital x-ray methods have served us well, as we can instantly see defects. “If we see read-outs that are within limits, we can x-ray the components and check to see whether the material has undergone any changes.” Ponsse invests heavily in advanced NDTtesting. “Every scan is documented. It is easy to rely on the company’s expertise and experience and, as a third party, they help us to make our production top quality in the future.” Advanced ultrasonic in sub-sea applications In Norway, much of Inspecta’s non-destructive testing work is carried out for a particularly tough environment – on undersea equipment. One of the world’s leading forest machine producers, Ponsse, has worked with Inspecta for several years. This guarantees that the product can withstand the working hours for which it has been designed. “Furthermore, the welds can be combined with up to three different materials.” For these demanding applications, Inspecta has had excellent results with advanced NDT methods used alongside standard testing services. The quality of the image is better than was the case with film. Also, with traditional x-ray, only one substance material thickness can be scanned at a time. These methods include phased array ultrasonic testing, as well as TOFD (time-of-flight diffraction) ultrasonics. The amount of radiation is only fractional, when compared with traditional radiography with film, rendering testing much easier and safer. “We will continue working with Inspecta. “We can drive three years of full-day work use with the machine in only one and a half months,” declares Jarmo Kortelainen. “This is quite a new way of thinking. It makes testing much faster and data analysis much quicker than with traditional radiography using film. “Casting and plate weld inspection with the digital x-ray is overwhelmingly more efficient, but we still also rely on visual evaluation, penetrant, magnetic and ultrasonic inspections,” says Kortelainen. We get confirmation of product quality much faster than before,” asserts Kortelainen. 23/ 20 15 35 WELDING IN FINLAND [ www.hitsaus.net ] Digital X-ray ensures top quality . “We have been able to do a lot of testing at our premises at Vieremä,” says Ponsse’s Welding Coordinator, Jarmo Kortelainen. “In addition, we have digitally x-rayed the casting quality at the foundry we are using.” The Ponsse Scorpion represents today’s most advanced forest harvester technology. With our new digital xray testing, it has been possible to inspect the new Scorpion harvester’s lift gate, steel welded joints. We still continue to test random samples during production.” The challenge encountered with the traditional testing method was that the results were received slowly. “These advanced techniques have generated a lot of interest with some of our major customers.” Meland predicts that, in the next five to ten years, phased array ultrasonics may reScorpion Harvester (Ponsse). According to Jarmo Kortelainen, “at the beginning of our production run, we xrayed products to make sure that the quality of castings and welding joints was adequate. With the new digital x-ray, Ponsse was able to verify product quality before launching regular production
Things tend to be easier when you work with the client, not for the client,” says Inspecta’s Regional Director, Jouni Koivumäki. Poland’s central location in Europe and the fact that it is the EU’s sixth largest economy, create significant growth opportunities for Inspecta and its customers. By choosing Inspecta, our clients not only gain access to the latest testing methods, but also benefit from our extensive knowledge base of similar projects. “Clients do appreciate our efforts to put new technologies into use. Inspecta International but local The same technologies, test methods and best practices can be utilized in each country in which Inspecta works, but the specific needs of companies will also vary, depending on the industrial base in each country. When we are looking for a solution to a problem, it’s a joint venture. Tuomas Suominen and Thomas Freundlich www.inspecta.com Scorpion Harvester (Ponsse). As part of the Inspecta family, the Polish team acquired a workplace that is safe, stable and rewarding, with access to advanced technology and training. “Sweden and Finland, meanwhile, are distinguished by large pulp, paper and nuclear sectors.” In July 2014, Inspecta acquired the Polish testing and diagnostics company, EPTSiL, from the Polinex-Mostostal SA Group. “In Norway and Denmark, we have large offshore and shipping industries, but not in the other Inspecta countries,” explains Mats Bergman. Kokkola LCC Oy, Ahjokuja 8, FI-67800 Kokkola, +358 44 262 6860, www.lcc.fi Laser Coatings Laser Hardenings SUPERB COATINGS WITH LASER HT_2-3_15.indd 36 15.5.2015 15.59. “This will bring clear benefits and will also reduce the radiological impact of these essential testing procedures,” he concludes. 23/ 20 15 36 WELDING IN FINLAND [ www .hitsaus .net ] place much of the testing that is currently being performed with radiography
When driving a car, riding a bike, or even just getting a good night’s sleep, we must be able to rely on a welder’s handiwork being able to withstand close scrutiny. Traditionally, the welder has adjusted these parameters manually. In welding projects performed in compliance with industry standards or other specific requirements, the Welding Procedure Specifications are based on thorough investigations of weld properties, including mechanical durability. If the current is too low, the penetration of the filler material remains too shallow, while too high a current results in the metal surrounding the weld seam becoming brittle. Quality is, of course, monitored. HT_2-3_15.indd 37 15.5.2015 15.59. In addition, it is essential to set the rate of flow of the shielding gas correctly; this protects the weld seam against oxidation. In MIG/MAG welding, the parameters that need to be adjusted include the feeding speed of filler wire and the voltage and current of the arc. The WPSs have often been available only in paper format and the responsibility for adherence to the correct parameters has rested on the welder’s shoulders. Writing things down by hand always introduces the possibility of human error to the process. In addition, transferring the notes scribbled next to the welds into the company’s qualitycontrol records is a time-consuming exercise. On top of this, finding deviations within a large quantity of data is a laborious process. After completion of a weld, the welder details and necessary data have traditionally been marked next to the weld seam with a piece of chalk. 23/ 20 15 37 WELDING IN FINLAND [ www.hitsaus.net ] From Chalk Markings to Barcodes Kyösti Isosaari Most people would be surprised to learn how much our day-to-day lives depend on welds. These days, a considerable proportion of industrial welding is performed with the MIG/ MAG-technique. Before the WPS for a certain special weld is completed, the test pieces may have undergone several rounds of breakingstrength tests. Quality requires work Until recently, in many companies, recording Welding Procedure Specifications and documenting compliance with them have involved plenty of manual work. Adjusting the welding parameters on the basis of a guesstimate is now the stuff of only smallscale non-professional welding. In light of this, it’s surprising that real-time quality control is only now making its presence felt in the welding industry. An inspector in a white helmet approaching the work site to measure the voltage and current with a clamp-on meter is a familiar sight for many a welder. These days, structurally important industrial seams are welded only under the guidance of appropriate specifications. The welding parameters are an essential factor in the durability of a weld seam. The weld turns out just right when all the welding parameters have been set correctly and the welder’s work practices are appropriate. Meanwhile, the office personnel strive to maintain up-to-date records of the numerous qualifications that welders may have and track their continuing validity. Welding Procedure Specifications (WPSs) offer necessary welding information, including the appropriate welding parameters for each material, material thickness, and type of weld. Also, Welding Procedure Specifications and other requirements often specify the qualification the welder must possess. In this process, the welding machine feeds filler material to the arc at the desired speed via a welding gun
And, of course, mistakes may occur without anyone ever being the wiser. Because of this, there is a real risk of some deviations going unreported. The system has met with a warm reception even though the initial reaction may have involved slight concern over having to learn to use a new tool. This means that only those welds actually featuring the faulty filler material have to be repaired. ArcQuality may prevent many mistakes from occurring even before a single seam is welded. 23/ 20 15 38 WELDING IN FINLAND [ www .hitsaus .net ] Regrettably, it is natural for humans to try to cover up their mistakes. This does not lead to any problems related to warranties. If the welder does not take steps to rectify the situation, the notification is automatically forwarded to the supervisor. Also, the number of welds that need to be repaired has decreased. In the future, the system will be made available for submerged arc welding machines. All welding information and any deviations from the pre-set values are recorded, so they can be traced and analyzed later. Fig. Managing Director Kimmo Liljamaa explains that the system shifts some of the responsibility for the work to the welder. ArcQuality can be retrofitted to older models of Kemppi machines and even to devices from other manufacturers, via an external adapter. The first challenger is likely to emerge from China. 3. Its four-gigabyte memory has sufficient capacity to record information collected over a month of three-shift production. If a command fails to meet this criterion, it is rejected. Now all the welds are of uniform quality and the appearance of a welded piece no longer reveals who performed the work. That early solution consisted primarily of a system for recording welding parameters, but the years since have added functionality for project planning and management. Many weld passes make up the whole Launched by Kemppi Oy in last June, the Kemppi ARC System 3 control system has been refined ever since the first commercial version’s release, in 2008. The system comes complete with anti-virus software, and the Linux operating system installed on the welding machine accepts verified commands only in the programming language used by the server. 2. It comes as an added bonus that the system has improved the quality of the welds. Lahti-based Kemppi Oy set its sights on solving the problem once and for all. Besides MIG/MAG machines, the ArcQuality system is compatible with TIG and MMA welding products. According to Kari Kemppi, Vice-President for Welding Management Solutions and ICT, other companies will launch systems of this type in the not-too-distant future. This has boosted productivity. HT_2-3_15.indd 38 15.5.2015 15.59. The parameter data recorded by the ArcQuality system are transferred to off-site storage in XML format via a wireless connection. With deviations from set parameters being noticed while the work is still in progress, welders have to hone their technique. Thanks to its quick response, the company has gained a couple years’ head start over its competitors in this field. In recent years, many companies operating in the welding industry have started to wonder whether welding quality could be monitored more efficiently. The information may also be stored on the company’s own server. If the welder fails to react to the notification, the site supervisor may intervene. Should any deviations occur, the system provides notification. Kemppi Arc System 3 comprises various modules, but the tool that is of key relevance for an individual welder is ArcQuality. Fig. Real-time monitoring of welding parameters does not have any real impact on a welder’s work as long as work practices are in order. It issues an alert if the welder does not have all of the qualifications required for the work. The system also monitors the servicing interval for welding equipment. In the event that, for example, the filler material supplier announces that a particular batch suffers from quality deviations, all pieces welded with this material can be identified. The Kemppi ArcQuality system’s weldingmachine-specific intelligence is found in the reader with its Linux operating system. Even if the device is unable to connect to the company’s wireless network, the reader has the capacity to store data for a month’s worth of welding work. Technology adds flexibility The main purpose of ArcQuality, however, is to notify the welder if the welding parameters fail to remain within the limits set in the WPS. For the welder, ArcQuality does not bring great changes to the work process. The main difference is that information on the welder, the filler material, and the relevant WPS is recorded in the system, which identifies the welder via a barcode on an identification card. It also provides notification if the filler material selected is not suitable for the weld. Indeed, several systems that record welding parameters already exist. Get at the roots of deviations Kavamet-Konepaja Oy, a Tornio-based steelstructure and engineeringproduct supplier, has been testing Kemppi Arc System 3 for around a year now. The main reason for the acquisition of the system was the desire to bring the company’s documentation practices into line with the requirements for a CE marking. This intelligent device features a barcode reader and user interface that simplify the process dramatically. If the system fails to connect to the Internet, the reader of the welding machine steps in, retaining all the necessary information. The information on the WPS and filler material is processed in a similar manner, speeding up the initial phase of welding work. If the need arises, the data can be accessed by means of any device with an Internet connection, even a smartphone. The most visible part of this module is an electronic reader device connected to the welding machine. The next step will be to introduce features that offer assistance with productivity questions. All the information collected is archived and copied to a secure server run by Kemppi’s reliable partner in Finland
The requirements for the marking have been set forth in the standard SFS-EN 1090. Because of this, one of the rig’s legs was torn off. Kemppi has production units in Lahti and Asikkala, Finland, and in Chennai, India. The cost of the additional work ran into the tens of millions of dollars. It has operations in 16 countries and regularly exports to more than 70. The company employs over 600 workers. Under this reform, a higher standard is expected of welding quality control systems. Kemppi Kemppi Group’s subsidiary Kemppi Oy is a family business, founded in 1949, and one of the leading manufacturers of arc welding equipment and suppliers of software and service solutions for welding. Without real-time monitoring of deviations, the welder may end up shouldering the responsibility for delays. Further information can be found at www.kemppi.com. Of the 212 employees on board the platform at the time, 123 died. In addition to loss of lives, failures in weld seams may lead to environmental disasters or financial harm. Thanks to the system, supervisors can verify a report that it was for unavoidable reasons that the arc has not been ignited. As of the beginning of July year 2014, all commercial loadbearing steel structures and their parts must carry a CE marking. A fracture originating in this weld in a non-load-bearing structure started to spread, and in the end it resulted in the collapse of a bracing that connected the platform’s legs. In the challenging conditions prevailing in the offshore industry, a failure in a weld can have disastrous consequences. It ended up upside down when the last remaining anchor cable snapped. This is just what happened in connection with the Trans-Alaska Pipeline, which was laid in the 1970s and required extensive repair work when investigations performed later led to discovery of a number of quality issues. The listing continued to increase until the rig finally capsized. Productivity does not depend solely on the individual welder’s performance. 5. +358442899573, mika.neffling(et)kemppi.com HT_2-3_15.indd 39 15.5.2015 16.00. One of the most tragic disasters related to a problem in welding quality ever to take place is the capsizing of the drilling rig Alexander L. The system may also provide information on other bottlenecks in the production chain. If the filler wire is not suitable for the weld, the system does not allow the welder to start the work. Kyösti Isosaari Journalist Note: The article was published first in Tekniikan Maailma No 20/2014 Fig. As necessary, work may be monitored even from a smartphone in projectsite conditions. The delay might be a result of a wait for necessary components or the crane required for the next work phase still being at the other end of the factory hall. In 2013, its net sales came to about 111 million euros, with international markets accounting for 90% of that sum. 23/ 20 15 39 WELDING IN FINLAND [ www .hitsaus .net ] Fig. 4. Lessons learned from maritime accidents Additional tools too, improving other aspects of productivity, are available for the system. On March 27, 1980, the rig, anchored in the Ekofisk oil field and converted to accommodation, was destroyed in stormy conditions with winds gusting to more than 70 km/h and waves up to 12 meters high. In a chain of events that took less than 20 minutes, the platform first leaned to one side and then capsized. An investigation into the accident revealed that one of the main factors in the disaster was a 6 mm weld seam of inferior quality. Progress on an individual weld can be monitored and notifications pertaining to deviations can be received via any computer with a login to the system. For further information, please contact: Mika Neffling, Global Solution Manager, tel. The maritime industry, offshore work in particular, is partly behind the stricter requirements set for the quality of welding work. Kielland, named after the Norwegian poet. Over the years, the stricter quality requirements set for welds have been extended to cover steel structures used in more everyday settings. The ArcQuality reader conveys information on the welder, WPS, and filler material to the system via a barcode
In most cases where laser coating has been used, the lifetime of the customer’s components has been considerably extended. 23/ 20 15 40 WELDING IN FINLAND [ www.hitsaus.net ] Kokkola LCC Oy Over 10 Years Experience in Laser Coating Sepppo Heiskanen For more than 10 years, Kokkola LCC Oy (LCC) has been a pioneer in laser coating in Finland. The surface to be coated may be either round or flat and different dimensions may be coated as a result of NC-control. Components are usually coated to improve their corrosion resistance and friction properties, so as to protect against wear and tear. Although the company was founded only in 2004, its personnel have accumulated experience in laser coating since the year 2000, during which time LCC has paved the way for laser coating in Finnish industry. LCC’s principal customer base lies within the processing industry (including steel, paper and chemical factories), as well as the marine, off-shore and on-shore industries and power plants. LCC employs two NC-controlled work stations for the laser coating of components which may measure up to 25 m in length, with a diameter of up to 3 m and a maximum weight of 20 tonnes. Typical applications can be used to laser coat different kinds of shafts, piston rods, gear wheels, wear plates, nozzles, fittings, valves and many other components. It is possible to apply an interior coating to a minimum of Ø70mm and to a depth of one metre. In recent times, the mining industry, especially in the north of FinLaser coating of piston rod to oil rig, North Sea Laser coating of sealing surface of steering tube HT_2-3_15.indd 40 15.5.2015 16.00. This is due primarily to the fact that the coating of components has been proven to be more viable by laser coating than by other conventional methods
Laser coating is an advanced coating technology used for the improvement of the surface properties of various components and equipment. Metallurgical bonding (welding bond) between base material and coating. Environmentally-friendly and economical. Some of the major benefits of laser coating include: . Conventional welding coating requires an additional two or three layers in order to obtain pure weld metal on top of the coating layer. . Further, the maintenance and repair of worn components often result in a performance superior to that of uncoated components. With respect to the components themselves, laser coating also produces very low dilution and low heat input, rendering the surfaces of new components highly resistant to wear, corrosion and high temperatures. . Seppo Heiskanen Managing Director Kokkola LCC Oy Ahjokuja 8 FI-67800 KOKKOLA www.lcc.fi Example of low heat input, coating of piston rod HT_2-3_15.indd 41 15.5.2015 16.00. Laser coatings are surface coatings with an extremely dense, crack-free and non-porous structure. 23/ 20 15 41 WELDING IN FINLAND [ www.hitsaus.net ] Inside coating of clutch Big roll laser coating against wear land and in Sweden, has become a growing business sector. The company’s main markets are Finland and Europe, including the Russian Federation. They demonstrate excellent metallurgical bonding to the base materials and have both a uniform composition and coating thickness. This ensures the formation of real metallurgical bonding between the coating and the base material, resulting in excellent bonding strength, high density and low dilution. Low heat input, as compared to conventional welding coats, resulting in minimal deformation and changes in the features of the base materials. Some 50% of LCC’s turnover originates from the coating of new components, with the remaining earnings derived from reconditioning activities. The powder absorbs energy from the laser beam, starts heating and melting in-flight, later depositing itself on the surface of the base material. Low dilution rate, normally rendering one layer of coating sufficient for obtaining good corrosion and/or wear resistance. Part of the energy is also absorbed by the surface, causing the controlled melting of a thin layer of the base material. . During the laser coating process, a powder is injected by the carrier gas into the laser beam
Part fabrication and sub-assemblies For every “Mein Schiff” vessel, more than 20,000 tons of plates and profiles are transported to the shipyard on trains and trucks. Production of hull structures Ship hulls are mainly produced by using different grades of shipbuilding steels. Profiles are mounted and welded to the deck panel by using eight tandem MAG welding heads. A highly-effective steel production process is used to create the 250,000 parts needed to construct one floating hull, using CNC-controlled cutting machines, profile cutting lines, a t-girder manufacturing line, welding robot gantries, panel lines and bending machinery. The hull production process is divided into 5 stages: part fabrication, sub-assemblies, block assembly, grand block assembly and hull assembly. Block assembly Deck plates are lengthened in the main panel line with a one-sided, butt welding station, using two tandem SAW welding heads. “Mein Schiff 3”, the first vessel in the series, was delivered to the German TUI Cruises during spring 2014, to be followed by delivery of “Mein Schiff 4” in spring 2015, “Mein Schiff 5” in 2016 and “Mein Schiff 6” in 2017. The company’s shipyard in Turku employs 1,350 people and specialises in the construction of cruise ships, car-passenger ferries and special vessels. Plates and profiles are then cut into smaller pieces, lengthened, bent, or used in their original form, in order to create stiffeners, sub-assemblies, bulkheads, side shells or panels. Hulls are constructed from big grand blocks which are further divided into blocks, sub-assemblies and parts. The welding speed can be 200 cm/min for a single welding head and 1,600 cm/min for the HT_2-3_15.indd 42 15.5.2015 16.00. “Mein Schiff” vessels A sophisticated and highly-innovative cruise ship is currently under construction at the Meyer Turku shipyard, the successful building site for cruise ships and technically-demanding special vessels for decades. The subsidiaries of Meyer Turku are Piikkio Works Oy (Cabin Factory in Piikkiö), Shipbuilding Completion Oy (Provider of turn-key solutions to public spaces in ships) and ENG´nD Oy (Engineering company offering services to the shipbuilding and offshore industries). The Turku Shipyard has produced two of the world’s largest cruise vessels, “Allure” and “Oasis of the Seas”. Plates and profiles are blasted and painted with primer in pre-treatment lines. “Mein Schiff 4” will be the first delivery under the company’s new owners. 23/ 20 15 42 WELDING IN FINLAND [ www.hitsaus.net ] Meyer Turku Oy One of the Leading European Shipbuilding Companies Antti Itävuo Meyer Turku Oy is one of the leading European shipbuilding companies, owned by Meyer Werft. Aluminium is used only in limited and special locations
The trail electrode is in a modified short arc mode to fill the groove. Robotic welding of bulkheads using MAG welding with metal-cored wire. In CMT Twin, the lead electrode is in a pulse mode so as to maximize penetration without excessive heat input. Butt welds can also be welded using a tandem MAG process known as CMT Twin. Deck girders, webs, bulkhead girders and side shells are then installed and welded to the deck panel. whole station. The heat Hull production stages and product groups. Fore and aft bottom Mid-bottom Public areas Cabin areas Superstructures Bottom Machinery area roof Public areas Cabin areas Fore/aft, special Superstructures Deck panels Bulkheads Side shell structures Tgirders Floors and keels "Egg box" structures Other assemblies Plates Pro?les Hull assembly Grand block assembly Block assembly Sub-assemblies Part fabrication HT_2-3_15.indd 43 15.5.2015 16.00. Deck plates can also be lengthened in a 12 m-panel line using a laser hybrid MAGwelding station. A 6kW fibre laser can be used to weld butt joints with lower heat input and with less deformation than with traditional SAW. CMT Twin involves a much lower heat input than with SAW and a lower heat input than in traditional tandem MAG welding. 23/ 20 15 43 WELDING IN FINLAND [ www .hitsaus .net ] Technical specifications Length 294 m Breadth 36 m Draught 8 m Speed 21 knots Gross tonnage 99,436 Passenger cabins 1,254 Passengers 2,790 Crew 1,030 Classification Det Norske Veritas Flag Malta “Mein Schiff 3”
Grand block and hull assembly stages “Mein Schiff” vessels are manufactured in segments in order to simplify the final assembly. Grand blocks are painted in painting halls prior to being lifted into the dry dock. Welding figures Each “Mein Schiff” vessel contains more than 1,000 kilometres of welds and about 500 tons (500,000 kg) worth of welding conTandem MAG welding of stiffeners in the main panel line. With rutile wires, argon/CO 2 mixed gas or pure CO 2 is used as the shielding gas, while metal-cored wires are welded using argon/CO 2 mixed gas. Blocks are lifted on top of each other and welded together to form grand blocks. Manual, metal arc welding electrodes are mainly used for welding during outfitting, as well as TIG welding rods and stainless steel electrodes. Grand blocks are typically made out of three to five 22 mlong and 35 m-wide blocks. The usual deck plate thickness in the hotel area is 5.5 mm and 12 mm for the shell plates. be fully operational, the air conditioning must function perfectly and restaurants need to be ready to serve the many thousands of meals needed to satisfy passenger requirements. Swimming pools, auditoriums, basketball courts, staircases, pipes, doors, pipe supports, cable trays and interiors are just but a few examples of areas which undergo welding during outfitting. The thickness of the bottom plates starts at 16 mm. Box 666 FI-20101Turku Finland www.meyerturku.com HT_2-3_15.indd 44 15.5.2015 16.00. After a hull has been completed and its float-out conducted, only about six months remain before the scheduled delivery of the vessel. Each hull consists of about 70 grand blocks weighing 200-600 tons. Most of the steels are either NVA or NVA36 ship steels with strengths of 235 or 355 MPa. Even though most of the welding consumables are used during the construction of the hulls, numerous welding consumables are used during outfitting operations as well. 11%: Submerged arc welding (SAW) . Finished grand blocks are later lifted into the dry dock and welded together to create a watertight hull. Most of the flux-cored arc wires are of the rutile type, those which are multi-purpose and allposition wires, followed by metal-cored wires which are used especially for productivity reasons. The minimum material thickness used for a hull is 4 mm. Antti Itävuo Welding Engineer Meyer Turku Oy P.O. 23/ 20 15 44 WELDING IN FINLAND [ www.hitsaus.net ] input using CMT Twin is slightly higher than in laser welding, but it is not as strict with respect to groove preparation tolerances as is the case for laser hybrid welding. “Mein Schiff 4” ready for its float-out. It is used for manual, robotic and mechanised welding. 1%: Other Flux-cored arc welding (MAG welding with cored wire) is the most common welding technique employed. sumables, used in the following categories: . All of the hull materials for the “Mein Schiff” vessels are approved by Det Norske Veritas. Absolutely everything has to be finished before passengers can be allowed on board: swimming pools must be filled up with warm water, stores need to be stocked with goods ready for purchase, elevators need to Butt welds welded with different processes: CMT Twin, laser hybrid welding and SAW. Steels used in the construction of hulls are approved by classification societies. 11%: Manual metal arc welding (MMA) . 77%: Flux-cored arc welding (FCAW)
In the transport and automotive sector there are high demands on oxidation in exhaust systems and mechanical strength in car frames and bodies can be utilized so that the added material also has a use and does not only add weight. HT_2-3_15.indd 45 15.5.2015 16.00. As with any other choice, selecting the correct grade is a balance between many factors and requirements. Outokumpu employs more than 12,000 professionals in more than 30 countries, with headquarters in Espoo, Finland and shares listed on the Nasdaq Helsinki. Different strength-strain combinations of stainless steel families are presented in Fig. Less used strengthening methods are bake hardening or reversion annealing to achieve a fine grain structure. The strength properties achieved depend on the steel grade and actual degree of cold deformation. We create advanced materials that are efficient, long lasting and recyclable – thus building a world that lasts forever. Increasing the energy efficiency of car engines leads to higher operating pressures and temperatures, which increase material demands. By alloying with nitrogen (EN 1.4318) or by a alloying to a duplex microstructure, values of R p0.2 350 N/mm 2 and higher can be achieved. The demand for corrosion resistance is not so high in many cases due to frequent and thorough cleaning. High-strength stainless steels Stainless steel is an ideal material to create lasting solutions in demanding applications from cutlery to bridges, energy to medical equipment. Certain stainless steel grades offer good mechanical properties to use on structural body parts. Mechanical strength is rarely utilized in such applications. 23/ 20 15 45 WELDING IN FINLAND [ www.hitsaus.net ] Outokumpu – High Performance Stainless Steel Hannu-Pekka Heikkinen, Stefan Lindner and Alexander Thulin Outokumpu is a global leader in stainless steel. The strength of stainless steel can be increased in many different ways. Another way to increase material strength is by cold working. 1. There are many different grades of stainless steel. The most widely used stainless steels like EN 1.4301 (ASTM 304) and EN 1.4401 (ASTM 316) have an austenitic microstructure. At the same time, the growing demands for improved safety force the industry to search for any possibilities for weight reduction. Stainless steel as a material . Features like heat resistance and high strength should not be forgotten either. The strength of stainless steel is typically standardized to R p0.2 230 N/mm 2 . Stainless steel, invented a century ago, is an ideal material to create lasting solutions in demanding applications from cutlery to bridges, energy and medical equipment: it is 100% recyclable, corrosion-resistant, maintenance-free, durable and hygienic. In many pressure vessels and large storage tanks, high strength grades can be utilized to save weight. Also familiarity of the material, environmental impacts and benefits, legislation, standards and approvals may have an effect on material selection. In the chemical, petrochemical, and energy sector, material requirements are not particularly demanding when it comes to surface finishes, but there are often high demands on corrosion resistance. This article is focused on high-strength stainless steels. High-strength stainless steels can be made by controlled cold rolling, or it can, in addition to this, also be hardened during the forming process of the product. In the catering and appliances sector surface appearance and cleanability are important. The material selection criteria differ between industrial segments. The specific requirements vary, depending on the application, in areas such as corrosion resistance, operating temperature, mechanical strength (which influences thickness and weight), surface cleanability and appearance. Stainless steel as a material is 100% recyclable, corrosion-resistant, maintenance-free, durable and hygienic
2. A very interesting application for stainless steel is fuel tanks for cars. Tram line in Krefeld, Germany, Ferritic stainless steel grade 1.4003 / S40977 used as painted (Source: Krefeld Stadwerke AG). 3. The Finnish Langh Group Cargo Solutions has chosen 316 plusTM in the cold-worked condition for their special transportation containers. Underride guards and roll formed and laser welded profile made of temper rolled 1.4310. Metastable austenitic stainless steels offer interesting properties, like high strength (over 1.000 N/mm 2 ) with a coexistent good ductility of over 20% A 80 for the construction parts in mobility applications. Grade 1.4310 in thicknesses of 2 3 mm is used as the material of underride guards on truck trailers, Fig. 4. 316 plus enables transportation of aggressive and sharp bulk raw materials. Samples of stainless steel parts from automotive segment. These parts have a protective function and are also design elements. These CrMn steels are called the 200-series. Better corrosion resistance reduces painting on the inner side of the car body, and that way makes cost reductions possible. Because of the substitution of nickel to manganese, a new steel category with an austenitic microstructure, chromium-manganese steels, without volatile and cost-intensive nickel were developed. 6. 4. 3. For many years, stainless steels have represented a standardized group of materials established under application conditions in railway vehicle manufacturing. Another grade for same applications is the 4589, which has a higher strength (R p0.2 > 420 N/ mm 2 ) than 4003 and offers weight reduction when compared to S355 carbon steel. 316 plus contains less nickel and molybdenum, and the grade has higher strength than 316(L), even in the annealed condition, due to its higher nitrogen alloying. The manufacturer, Bombardier Transportation GmbH, Fig. Fig. Grade 316 plus is a unique product developed by Outokumpu that provides a competitive alternative to 316(L). The container’s floors and walls are made of temper-rolled 316 plusTM due to strict wearand corrosion resistance requirements. Extremely difficult cross section profiles can be made by cold rolling forming by using a 1200 N/ mm 2 tensile strength material. Plastic materials Fig. Graph of strain-tensile strength combination of stainless steels. 23/ 20 15 46 WELDING IN FINLAND [ www.hitsaus.net ] Examples of stainless steel applications Stainless steels are widely used in car exhaust systems and for automobile parts, such as hose clamps and seatbelt components, decorative trims and head gaskets to name a few, Fig. 1. The properties of 316 plus allow thinner wall thickness in comparison to the standard 316(L) resulting in lower overall weight of the container, Fig. 7. CrNiMn steel H400 (also known as 1.4376) has been used in many automotive applications where excellent formability, aesthetic outlook and strength, and/or crashworthiness are required, Fig. 2. Temper-rolled austenitic applications Cold working of stainless steel offers a way of increasing strength. It is coming into use in chassis, suspension, body, fuel tank, and catalytic converter applications. It is also a candidate for structural applications. One example of using stainless steels in railway vehicles in recent years was the tram line in Krefeld, Germany, Fig. HT_2-3_15.indd 46 15.5.2015 16.00. 5 and Fig. applied the ferritic grade 4003 in a painted condition for its “Flexity” model range. Fig. Outokumpu introduced the high-chromium austenitic Outokumpu 316 plusTM (Outokumpu 4420) at the end of 2013
8. Fig. Fig. Summary For most applications, there are several stainless steel grades which could do the job. The capacity of a steel tank can also be larger than a plastic tank when an external carrier is not needed. Fuel tank made of stainless steel. 6. However, with increasing concerns regarding the permeability of the plastic and evaporative emissions, the weight of plastic tanks has increased due to the addition of many different layers of material. 5. It offers a lighter structure than a conventional stainless steel structure. Different groups of stainless steel have different properties. Apron of Mercedes Benz Actros made of H400 (t=3.0mm). R&D can provide support with more detailed information. 23/ 20 15 47 WELDING IN FINLAND [ www.hitsaus.net ] Fig. Outokumpu provides good aids for material selection. 8. 9. Using stainless steel instead of aluminum as a tank material avoids clogging of the fuel filter. HT_2-3_15.indd 47 15.5.2015 16.00. To work out together with the customer the most appropriate solution, we need to understand the application. AdBlue-additive tank made of LDX 2101 ® . Cross member beam made of H400 tube by hydro forming. The car had an innovative stainless steel fuel tank made of 1.4301 HyTens® grade, Fig. In March 2011, the Saab Phoenix concept car was shown at the 81 st Geneva International Motor Show. Hannu-Pekka Heikkinen 1 , Stefan Lindner 2 and Alexander Thulin 3 1 Tornio Research Center, Outokumpu Stainless Oy, Tornio, Finland 2 Krefeld Research Center, Outokumpu Nirosta GmbH, Krefeld, Germany 3 Avesta Research Center, Outokumpu Stainless AB, Avesta, Sweden www.outokumpu.com Fig. Special container made of Temper rolled 316 plus . B-pillar made of tailoredwelded blanks. 7. 9. The tank for AdBlue-additive is made of LDX 2101® duplex grade, Fig. An aqueous urea additive, AdBlue, is used in selective catalytic reduction (SCR) in order to lower the NO x emissions in diesel emissions. have been used for a long time, largely because of the weight advantage. Fig
Fabrication of welded oxygen tubes for pressureoxidizing autoclaves Refractory gold ores refer to ore bodies that require high temperature pressure oxidation before gold can be extracted via the conventional cyanide process. Lindgren, M. The belt is fabricated by the welding of numerous stainless steel sheets, with the conventional belt material being of the ferritic grade, 3Cr12 [5]. Recently, owing to the increased number of impurities in raw materials, reduced belt life was experienced at some sites. Fig. Fig. This situation emphasizes the need for the assessment of the reliability of both construction materials and fabrication techniques. 23/ 20 15 48 WELDING IN FINLAND [ www.hitsaus.net ] Application-Oriented Welding Research for Demanding Process Conditions M. The Outotec Ferrochrome Process has become an industrial benchmark and is acknowledged as the Best Available Technology (BAT) with respect to the environment, according to European Union criteria. 1a shows the microstructure of a hyper-duplex weld with precipitates. Consequently, Outotec embarked upon an extensive research project so as to evaluate alternate a b Material Uniform corrosion rate [mm/y] Super-duplex EN 1.4410 1.4 Hyper-duplex UNS S32707 0.2 Table 1 . 1b shows a precipitation-free weld. In order to overcome these challenges, Outotec has designed oxygen tubes made of a novel hyper-duplex material. Furthermore, the cost pressures experienced by end-users of processing equipment have promoted the use of leaner stainless steel grades and have also given rise to more cost-efficient fabrication techniques constantly being sought. Several recent cases are discussed below. Outotec is able to supply process solutions and equipment for such challenging environments. Microstructural study of the hyper-duplex welds demonstrated that the material was susceptible to secondary phase precipitation if cooling of the welds was not sufficiently controlled. Temperatures can attain 250°C and oxygen pressure can be as much as 40 bars [1]. Peltola and L. Optical micrograph of a) a hyperduplex weld showing a significant quantity of precipitates in the heat-affected zone b) a precipitation-free weld obtained after enhanced cooling. In order to determine the performance of welded structures, various types of characterization work and testing are conducted in Outotec’s research facilities, or via its external research network. While titanium is corrosion-resistant under such conditions, it cannot be used in oxygen tubes, due to the risk of titanium fire. The improved uniform corrosion resistance of the material has been verified via immersion tests in a simulated process environment [2]. Therefore, various cooling procedures were evaluated to generate a precipitation-free weld for optimum performance. Welding represents an important aspect of the fabrication process of oxygen tubes. Laihonen, H. The belt rotates at 300°C and is subjected to a corrosive environment. Pressure oxidation is conducted in an autoclave in an acidic environment at high temperatures. As a direct result of this belt, the Fig. The process includes a sintering stage in which raw pellets are sintered in a steel belt sintering (SBS) furnace. Consequently, material degradation, e.g., in the form of corrosion, has become more relevant. Welding is a critical joining technique in the fabrication of process equipment. Construction materials are subjected to high demands in this type of aggressive environment. Uniform corrosion rates measured in an acidic environment at 230°C, 35 bars [2]. While super-duplex stainless steels are not susceptible to burning, their corrosion resistance in this environment remains limited. At this stage, pellets are conveyed on a perforated steel belt through a multi-compartmental furnace. The trend of declining ore grades has led to more demanding conditions in the processing stage and an increased number of harmful impurities in the processing environment. Improvements in steel belt fatigue strength Ferrochrome is an essential raw material in the production of stainless steel. HT_2-3_15.indd 48 15.5.2015 16.00. Närhi Outotec provides cutting-edge solutions and process equipment for the mining and metallurgical industries. The presence of precipitates is known to reduce the corrosion resistance of a material [3] as well as its mechanical properties [4]. The uniform corrosion rates obtained for superduplex (EN 1.4410) and hyper-duplex (UNS S32707) materials are detailed in Table 1. furnace is able to operate on a continuous basis. 1. Lehtonen, P
Shneerson, V. The cycles to failure for EN 1.4521 are presentedin Fig. 23/ 20 15 49 WELDING IN FINLAND [ www.hitsaus.net ] stainless steel grades, with a view to prolonging the lifetime of the belts. P. Several test panels were fabricated using plasma arc welding with filler wire at the Outotec Turula workshop, using two different sheet thicknesses (2.5 and 3 mm) and three different filler metals (ESAB 309 MoL (main alloy: 23%Cr13%Ni-3%Mo), Avesta 904L (main alloy: 20%Cr-25%Ni-4,5%Mo-1,5%Cu), and Avesta P12 (main alloy: 64%Ni-22%Cr-9%Mo)). These are achieved by a combination of the experience of several decades of knowledge of processes and equipment design, as well as the latest achievements in scientific research at Outotec’s own topnotch research facilities. 2. Suter, C. Perren, T. 2. The joints were later characterized with an optical and scanning electron microscope. Fedorov, J. The effect of several fillers on the bending fatigue resistance of the grade was investigated. Laihonen, Steel belt development, 7 th Outotec Steel Belt Conference, 16-18.10.2012, Pretoria, South Africa 6. It is clearly evident that, even in the gaseous phase, the CuSi3 alloy suffered from extensive corrosion and therefore, is not suitable for such a service environment. One candidate was the more-alloyed ferritic grade, EN 1.4521. Gallo, P.J. Welding will remain an important fabrication method for Outotec Fig. The leaching equipment may contain secondary joints that do not bear loads. 43 (2001), 727-745 4. During a two-week period, one panel was immersed at 95°C in a liquid which simulated a leaching solution (75 g/l H 2 SO 4 + 650 mg/l Cl + 40 g/l Fe and 15 g/l Cu). Society for Mining, Metallurgy, and Exploration Inc., 2006, 561 2. J.C. Free, Hydrometallurgy: Fundamentals and Applications, Wiley, 2013, 444 p M. Iain House, The chemistry of gold extraction, 2 nd Ed. Lindgren, M. 74, 2015, 81-87 5. Uggowitzer, H. Lehtonen, P. Processing typically involves leaching, purification and metal recovery stages. Godefroid, Effects of volume fractions of phases and precipitates on the mechanical behaviour of UNS S31380 duplex stainless steel, International Journal of Fatigue, Vol. Lindgren, P. Brazing for cost-effective joints in leaching environments Hydrometallurgical processing is a versatile technique for the treatment of low-grade ores. equipment and, as a result, application-oriented studies of various aspects of welding and the use of welded structures will definitely continue. Sample thickness can be observed to have a greater influence on fatigue life than different filler metals. Närhi, M. Outotec supplies reactors and related equipment which are tailored to perform various leaching duties. Another panel was also exposed to the gaseous phase, above the liquid inside the test reactor. Haakana, A. O’Callaghan, T. T-joints of 2205 duplex stainless steel were fabricated using the brazing alloy, SGCuSi3 (DIN 1733). Närhi Outotec (Finland) Oy P.O.Box 69 FI8101 Pori Finland www.outotec.com Fig. 3. Influence of precipitates, Corrosion Science, Vol. L. Corrosion tests were thus performed on these joints in order to evaluate the possibility of reducing costs by using brazing instead of welding. Candida, L.B. Zaytsev, Y. References 1. J.O. In each individual case, however, the optimal grade depended upon the actual site conditions [6]. During the leaching stage, the ore or concentrate is leached, using a combination of sulfuric acid-based solution at elevated temperatures [7]. Solenthaler, G. Cycles to failure in bending fatigue tests for two sheet thicknesses and three different filler metals. Laihonen, Steel belt: development & effect of operation, 8 th Outotec Steel Belt Conference, 2023.10.2014, Sabie, South Africa 7. a b HT_2-3_15.indd 49 15.5.2015 16.00. Närhi, M. The microstructures of the welds were observed with an optical microscope, the hardness profiles were measured, and the welded materials were subjected to bending tests with a strain amplitude of 0-2400 mStrain. 3 presents the sample before and after its exposure. Peltola, L. Böhmi, M.O. M.L. Summary In order to provide real benefits to its customers, Outotec is committed to high quality research, where improved process equipment reliability and capex/opex cost reductions for equipment and process solutions are concerned. Lindgren, P. Several potential stainless steel grades were identified with varying corrosion resistance and mechanical properties. Kaartti, Pokrovskiy pressure oxidation (POX) hub, Proceedings of ALTA 2013 Gold Conference, 25.5-1.6.2013, Perth Australia, 33-71 3. L. A test panel a) before and b) after corrosion testing. Fig. Speidel, Corrosion resistance of super duplex stainless steels in chloride ion containing environments: investigations by means of a new microelectrochemical method II. Laihonen, H. de Lacerda, L.C. Mearsden, C. R.A
Robotized welding in crane boom production enables constant quality and a higher quality for critical welds. Pemamek designs and manufactures turn-key solutions that are customized to the clients’ specific needs and requirements. With the introduction of automated solutions, wasted costs associated with machine downtime, excessive scrap and redundant job functions can be easily and radically decreased, or even eliminated. The key elements for the improvement of productivity are the maximization of outputs and the minimization of input parameters, using advanced technology solutions and automated welding systems. The company has been deemed to be financially solid, with the highest possible Dun & Bradstreet Credit Worthiness Certification. 23/ 20 15 50 WELDING IN FINLAND [ www.hitsaus.net ] Welding and Production Automation in the Heavy Fabrication Industry Kristiina Pispala The welding industry is at a stage where methods for improvement and the maximization of operational performance via automated welding solutions are continuously being sought. There is a need for the definition of a production concept and for decisions about the optimum cost vs produced unit ratio. Pemamek company profile Pemamek is a world-leading specialist in automated welding solutions and an experienced supplier for over 40 years. Experienced suppliers like Pemamek can help to identify technical solutions and to choose the ideal equipment for a specific production concept. The technology is extremely advanced, yet very simFig.1. PEMA ® WeldControl user interface The solutions offered by PEMA ® have been designed by welders for welders. Pemamek’s markets are truly global, with exports to both North and South America, Europe, Russia and as far as Asia and Australia. The Finnish company, Pemamek, is a world-leading specialist in automated welding solutions for the heavy fabrication sector. Pemamek is active in heavy fabrication automated solutions for different sectors: Shipbuilding and Offshore, Industrial Boilers, Wind Energy, Mobile Machinery Heavy Fabrication, Steel Construction, Process and Nuclear industries, etc. Roadmap towards successful investments Any successful revamp of production starts with the elaboration of a manufacturing strategy that will support a company’s business plan, as well as the long-term development of production. The company has delivered comprehensive welding automation solutions in over 50 countries and over 15,000 different tailor-made equipment systems. Depending on a company’s level of automation and efficiency, a fabrication operation can either be a competitive advantage or a money pit. Welding automation for more productivity In order to improve the efficiency of an individual company’s welding operations, it is critical to first determine precisely what actually needs to be changed, to ensure that goals are realized. Having a dedicated partner is an asset when it comes to getting the best possible value and the fastest return on investment in welding automation. HT_2-3_15.indd 50 15.5.2015 16.00
It facilitates the integration of production systems and is easy to learn. Advanced control systems PEMA ® WeldControl product series PEMA ® WeldControl systems are designed with a simple, one-panel control system, thereby eliminating the complexity of multiple controllers. 23/ 20 15 51 WELDING IN FINLAND [ www.hitsaus.net ] the right controls for every user from the operator to the welding engineerand service as a real management tool. The PEMA ® operational interface favours the use of numbers and symbols, rendering the system quick and it is easy to adopt. WeldControl 100 and 500 are true management tools. PEMA ® WeldControl 100 . PEMA ® WeldControl’s efficient user interface is ideal for integrated machine and welding process control. The large touch-screen is specifically designed for use while wearing gloves. The welding platform is a solution for the simultaneous welding of multiple joints. Integrated power source and movement control . Easy to switch from one operating machine to another, because user interfaces look the same and machine controls are alike. When compared with lighter applications, it is clear that a new era in robot welding automation has begun. 3. Fig. It provides guaranteed extended performance with all technologies. ple and easy to use. Mainly used for multi-pass welding with a laser seam tracking system . The same control system for many types of machines . There is an intuitive menu system that can be tailor-made for each case, if required. Possibility for creation of programs e.g., automatic wire cutting, automatic welding and back-home positioning, automated calculation for welding start and end points. PEMA ® WeldControl 500 Adaptive . Complete boom fabrication plant. Fig. All the same features as PEMA ® WeldControl 100, plus the following: . 2. The innovative touchscreen control panels help users to make the most out of the automatic welding features, such as columns and booms, and to boost the efficiency of both the welding process and the handling of workpieces. Regardless of the level of automation, integration is possible with different PEMA ® products. Its operator-friendly user interface eliminates non-value-added work and minimizes the possibility of human errors. Adaptive welding for control of the welding process . The WeldControl interface features three levels of operation, providing HT_2-3_15.indd 51 15.5.2015 16.00. All power sources can be incorporated into a single system. Product identification and flow are controlled by PEMA ® material handling – a new boom is delivered every 15 minutes. Weld work tracking is also a good tool for effective quality control. PLC-controlled welding machines can be operated with this system . Production monitoring for engineering departments and data collection provide valuable information for production management, particularly with regard to efficiency and development. Renewed PEMA ® control devices and graphic user interfaces are features included in all PEMA ® welding applications. The fabrication of even the heaviest offshore structures becomes possible in reasonable timeframes. Robotized welding stations in automated welding PEMA ® robotized welding stations and production lines are designed for use in extra heavy-duty production environments. All basic functions can be ready-programmed at start-up, thus limiting the potential risk of a human error
The use of external axes and the creation of diverse shapes . Offline programming for workpieces that are quite similar, yet still unique . Fig. Much easier and faster to program than with regular offline programming . 6. These include robotized Fig. The program automatically creates a workpiece and welds according to the operator’s parameters . The fastest and most flexible offline software on the market. 5. Programming is carried out by drawing lines over the welded shapes on screen. Faster than regular offline programming (70%). Solutions for stiffener mounting and welding guarantee excellent performance. Offline programming of robots . The program itself also automatically detects corners. 23/ 20 15 52 WELDING IN FINLAND [ www.hitsaus.net ] PEMA ® WeldControl 200 Vision . The operator can create a program for the robot in a few minutes . 4. Automated and PEMA ® WeldControl-operated welding stations increase manufacturing flexibility flexible manufacturing systems and units promote high levels of profitability in one-off, small-series and product familybased production. An 8-hour welding program can be created in less than 10 minutes. PEMA ® WeldControl 400 Integro . Robotized welding for heavy performance two robots operating simultaneously in narrow spaces during winch flange welding. PEMA ® WeldControl 300 Offline . Potential for much faster programming than with a robot pendant (90%). Possibility for easy programming of straight fillet welds and vertical welds on corners . The lines are automatically generated to welds by the PEMA ® WeldControl 200 program. HT_2-3_15.indd 52 15.5.2015 16.00. Fig. Offline programming for integration e.g., TEKLA design software-created workpieces . Allows robots to continue welding while the next workpiece is programmed . Modern flat panel line is a simple, flexible and lasting solution for ship and offshore panels. More welds can be added than with regular offline programming. Very efficient programming and workpiece calibration system for open-top workpieces . Camera for workpiece calibration by robot . Work can also be divided into tasks, allowing for the possibility of program editing during welding. More flexibility for production Regardless of the types of metal structures to be manufactured, their structural integrity will certainly depend on the quality of welding. Welds are automatically read from TEKLA models and converted to robot language . PEMA ® WeldControl 300 Create . Fully automatic program creation
In co-operation with its customers, PEMA ® has the unparalleled ability to develop solutions for the handling of large, heavy parts, while ensuring top quality welding and exceptionally-high arc-time. The flexible robot solutions with the offline PEMA ® WeldControl system are ideal for one-off production. Stable quality with automation When welding thick materials in the heavy engineering industry, stable quality is a must. Safety in the workplace is therefore raised to a higher level with production and welding automation. If the parameter falls out of the tolerance range, production can be immediately stopped and no defects will slip through the system. Among other benefits, robotized welding has proven to be faster and more productive than manual welding, also resulting in savings on material costs. Fully-integrated column and boom and special rollers for efficient long-seam and flange welding in wind tower production. Among the major manufacturers, feedback on the PEMA ® robotized welding stations has been positive. Kristiina Pispala Marketing Manager Pemamek Oy Ltd Lamminkatu 47 FI-32200 Loimaa Finland www.pemamek.com Fig. Fig. 23/ 20 15 53 WELDING IN FINLAND [ www.hitsaus.net ] welding stations, automated and robotized welding production lines, and materialand workpiece-handling equipment. 10. Fig. 8. With tightening competition, there is a constant need to accelerate production through-put times. Advanced pipe welding solutions are also trusted products in the offshore industry. 7. The PEMA ® solutions are equipped for the detection of fumes, noise, open arcs, sparks and hazards associated with the lifting and moving of heavy workpieces. Constant, on-line, parameter monitoring is also possible with PEMA ® solutions. Further and faster with robotic welding PEMA ® is a trusted partner for the engineering and manufacturing industries. Fig. Drawing from its long experience in heavy engineering automation and its collaboration with Yaskawa, the strong PEMA® know-how about welding, robotics and automation will take Overall improvements in safety Every company wishes to provide a safe working environment for its employees. PEMA ® WeldControl software solutions link seamlessly design data with production equipment on the shop floor. manufacturing productivity to new heights. 9. PEMA ® automation repeats the pre-set process parameters time after time, and without errors. HT_2-3_15.indd 53 15.5.2015 16.00. The introduction of PEMA ® automation will result in a reduction in quality costs and in lower inspection and repair expenses
At present, TVO Oyj operates two 880 MW nuclear power units (NPUs), with one EPR NPU currently under construction in Olkiluoto Eurajoki. Introduction Posiva Oy has been established in 1995, but final disposal has been developed earlier by TVO Oyj and Fortum Oy (former IVO). Olkiluoto was selected as the final disposal site after detailed site evaluations of four prospective locations across Finland. 1. In May 2001, the Government’s positive “decision-in-principle” was finally ratified. SNF will be packed in copper canisters and embedded in Olkiluoto crystalline bedrock at a depth of 400-450 meters, Fig. 1. A deficiency of a single barrier or a predictable geological or other change will not endanger the performance of the insulation. The release barriers include the physical state of the fuel, the disposal canister, the bentonite buffer, the backfilling of the tunnels and the surrounding rock. As part of the decision-making process, the Government required statements from the Eurajoki municipality and from the Radiation and Nuclear Safety Authority. Fortum Oy operates two 440 MW VVER NPUs in Loviisa. Final disposal and encapsulation facility. In 1999, Posiva submitted an application to the Finnish Government for a “decision-inprinciple,” in which Olkiluoto in Eurajoki was proposed as the repository site and KBS-3 as the chosen method for execution of final disposal. With no identifiable obstacle to a positive “decision-in-principle,” this was granted by the Government in December 2000, after which the proposal was further discussed by the Finnish Parliament. 23/ 20 15 55 WELDING IN FINLAND [ www.hitsaus.net ] Posiva and Final Disposal of Spent Nuclear Fuel in Finland Timo Salonen Posiva Oy handles the final disposal of the spent nuclear fuel (SNF) produced by its owners, TVO Oyj and Fortum Oy. Studies of the final disposal have started 1978 and the schedule for the final disposal was set in 1983, when the Government decided on the objectives and programme for nuclear waste management. The final disposal of SPF is based on the use of multiple release barriers, which ensure that the nuclear waste cannot be released into organic nature or become accessible to humans. HT_2-3_15.indd 55 15.5.2015 16.00. The disposal of SNF must be organised in a way that is not harmful to organic nature. Following the registration of Posiva’s application for a construction licence for the repository in 2012, the Finnish Radiation and Nuclear Safety Authority, STUK, submitted its statement to the Ministry of Employment and the Economy in February 2015. In this statement, STUK noted that “the SNF enFig
Funds for nuclear waste management are collected in advance, forming part of the price of nuclear energy in Finland. While EBW has been used for a rather longer period as a production tool and is a more mature technique than FSW, a weld obtained via FSW demonstrates better corrosion and creep ductility against requirements. During the glacial period, the 2.5 km-thick ice sheet will increase pressure to about 25 MPa. A preliminary proposal for a welding machine has been submitted, while the design and development of the welding process continue, Fig. The overall figure covers the disposal of 5.500 tonnes of uranium in about 2,800 canisters. The total cost of final disposal is 3.300 M€, of which 700 M€ is directed towards investments in encapsulation and disposal plants, 2.400 M€ towards operational costs and 200 M€ towards the decommissioning of plants. The interior (insert) or disposal canister is fabricated from nodular, graphite cast iron, with the exterior made of hot-formed copper. Under high-pressure, copper will creep, therefore copper and weld creep ductility must both be sufficiently high. One demanding task involves the qualification of welding personnel; in parallel to the development of welding, NDT for welding is also advanced, including NDT qualification. 2. Creep and corrosion testing have been performed for both methods and NDT and destructive testing have been carried out on a large number of welds. Three different copper canisters are planned for different fuel types: VVER (Lo1-2), BWR (Ol 1-2) and PWR (OL3). Results revealed that both the methods and the welds fulfilled the long-term safety and implementation requirements established for encapsulation plants. Groundwater pressure will be at 4 MPa after the closure of the disposal tunnel. Visual, eddy current, phased-array ultrasonic and radiographic testing will be used for the testing of welds at the encapsulation plant. It is worthwhile to mention here that SKB in Sweden will use the same concept as Posiva Oy, i.e., the Swedish KBS-3V concept. Similar geological disposal concepts, concerning different materials, are also under development in Canada, the United Kingdom, Belgium, France, Germany, Japan, Switzerland and Japan, for example. While the company will submit its operational licence application around 2020, Posiva Oy will be ready to begin final disposal operations at the end of 2022. The height of the canisters ranges from 3.55 to 5.22 m. Canisters also have to withstand a 5 cm-rock shear load. 23/ 20 15 56 WELDING IN FINLAND [ www.hitsaus.net ] capsulation plant and final disposal facility designed by Posiva can be built to be safe.” Prior to any Government decision about the grant of construction licences, as prepared by the Ministry of Employment and the Economy, a safety assessment conducted by STUK is required. The swelling pressure of the bentonite will be at a maximum of 15 MPa. The hotformed weld material has almost the same material properties as the hot-formed base material of the copper canister. Conclusive reports about these evaluations were prepared during 2013-2014 (Salonen 2014, Purhonen 2014). Comprehensive residual stress measurements (RS) have been taken, using all conventional measurement methods and, for EBW, the deep-hole drilling method was also used. 2. The total isostatic pressure during the glacial period will be 44 MPa. This analysis incorporates major climate changes and different scenarios, e.g., likely and unlikely events. All variants of the canisters have the same outer diameter of 1.05 m. FEM analysis and destructive testing, using electron backscattering diffraction (EBSD) measurements, were used to confirm RS results. 3. Comparisons between EBW and FSW were also performed during 2013-2014. The copper canister will be sealed by welding after loading the SNF. Anaerobic conditions will be present after a few hundred years, at which time the risk of copper corrosion will be negligible. In this regard, extensive R&D work related to corrosion and mechanical testing for canister materials has been conducted in various R&D institutes, under similar conditions as would obtain during final disposal. Canisters will be disposed at a depth of about 420 m in the bedrock of Olkiluoto, located on the west coast of Finland. There remain some outstanding questions related to residual stresses and long-term properties of welds, as well as the need for an update of creep FEM-modelling. Since long-term safety is of the highest priority, the FSW method was eventually selected as the canister sealing method during spring 2014. Copper will protect the insert and SNF elements from the corrosive effects of groundwater. For example, mock-ups of short canisters have been pressure-tested and the collapse pressure was measured to be 138 MPa. Copper canisters will be surrounded by a bentonite buffer which will swell once groundwater diffuses into the bentonite. Evaluation has also shown that the FSW method can be further developed and that machines can be designed within the established timetable. The canister length will be about 5 m and diameter, 1,050 mm, with the wall thickness of the copper part measuring 50 mm. According to this timetable, Posiva Oy will be the first in the world to start final disposal of SNF. Posiva Oy is involved with ongoing R&D work into FSW, in co-operation with SKB. The design of the insert will depend on the fuel type, Fig. The hot-formed weld material is the main reason for the higher margins of the FSW weld, when compared to an EBW weld, which is like a cast material. Extensive R&D work has been conducted, including weld properties, process development and the implementation of welding methods in encapsulation plants. From left to right, copper-iron canisters for the SNF from the Loviisa 1-2 (VVER-440), Olkiluoto 1-2 (BWR) and Olkiluoto-3 (EPR/PWR) reactors. A nodular cast iron insert is a load-bearing component. While the diameters remain the same for each canister, canister lengths will differ. Disposal Canisters Safety requirements are very stringent and, for example, the reference period for the long-term safety analysis spans hundreds of thousands of years. Conclusions Posiva Oy has been developing the final geological disposal of spent nuclear fuel, based on the Swedish KBS-3V concept, involving the use of copper-cast iron canisters, to be sealed using FSW. HT_2-3_15.indd 56 15.5.2015 16.00. Sealing of the Canisters Posiva Oy’s long involvement in the welding of copper dates to the 1990s, back to the early days of the development of electron beam welding (EBW) for sealing purposes. Some corrosion will occur at the beginning of the disposal period during the aerobic phase in bedrock, but corrosion has been estimated to be only 2 mm. SKB in Sweden developed friction stir welding for sealing canisters, also tested in conjunction with Posiva Oy. According to the current timetable, disFig
Raiko H. Posiva has also evaluated the long-term durability and chemical resistance of canisters and, as a result, with great confidence, it can therefore attest that canisters and welds will fulfil set requirements, although some open questions remain unevaluated. 3. Posiva Oy, p. p. 155 (ISBN 978-951-652-194-0) Nolvi L. Posiva Oy. 76 (ISBN 978-951-652-171-1) Raiko et al., Canister Production Line 2012, Report Posiva 2012-16, p. Report POSIVA 201213. 90 (ISBN 978-951-652-176-6) Pitkänen J., Inspection of Bottom and Lid Welds for Disposal Canisters, Report POSIVA 2010-4. 2009, Manufacture of Disposal Canisters, Report POSIVA 2009-03. HT_2-3_15.indd 57 15.5.2015 16.00. p. Posiva Oy, p. p. net Professional heat treatment services and equipment Near You, Expertly and Costeffectively! posal will start in 2022; Posiva Oy will therefore be the first to handle the disposal of SNF. Posiva Oy. Posiva Oy, p. Posiva Oy. The design of the FSW machine and process development are both ongoing. 23/ 20 15 57 WELDING IN FINLAND [ www .hitsaus .net ] www.heatmasters. p. 96 (ISBN 978-951652-216-9) Salonen, T. 2010, Welding of the Lid and the Bottom of the Disposal Canister, Report POSIVA 2010-5. 188 Purhonen, T. 174, (ISBN 978-951-652-197-1) Meuronen, I. 98 Timo Salonen Development Engineer Posiva Oy www.posiva.fi Fig. 98 (ISBN 978-951-652-175-9) Pitkänen J., Inspection of Disposal Canisters Components, Report POSIVA 2012-35. 2014, State of the Art of the Welding Method for Sealing Spent Nuclear Fuel Canister Made of Copper: Part 2 EBW, Posiva WR-2014-21. 2014, State of the Art of the Welding Method for Sealing Spent Nuclear Fuel Canister Made of Copper: Part 1 FSW, Posiva WR-2014-22. NDT for welding is also under development, but its readiness is at a very promising level. Posiva Oy. & Salonen, T. FSW machine at the encapsulation plant. 2012, Canister Design 2012. References http://www.posiva.fi/en under databank
Fig. This innovation, developed by Vahterus, combines the best qualities of two more traditional heat exchanger types: shell and tube heat exchangers, and plate and frame heat exchangers. At the heart of each heat exchanger is a fully-welded pack of plates – the innovation that originally launched Vahterus’ success. “Growth is our driving force and remaining local is our strength. According to Paavo Pitkänen, Technology Director at Vahterus, this phenomenon is due to the safety of Vahterus’ products. We strive to maintain an extremely high standard of quality, and our customers are aware of this.” More power and less space The flagship Vahterus product is its plate and shell heat exchanger (PSHE). Shell and tube heat exchangers can also be fully-welded, but they require up to five times more space than plate and shell heat exchangers. Originally operating out of an old sheep house on the family farm, over the past 25 years, Vahterus has evolved into an important international player in its field, now boasting subsidiaries in Germany, the UK, China and the United States. Vahterus, however, uses fully-welded packs of circular plates, which make our product much more durable,” according to Pitkänen. The refrigeration industry, in particular, has sought out Vahterus’ products and this sector has proven to be its largest client base. “Safety and environmental issues are extremely important to our customers. A family-owned company founded in 1990 by its CEO, Mauri Kontu, this year Vahterus celebrates its 25 th year in business. Fig. Nevertheless, the original family company values still apply – people and co-operative partners are highly-valued at Vahterus and the drive for innovation and development has never waned. Welder at work. The majority of our employees are from around Uusikaupunki, a fact which is important to us,” declares Mauri Kontu, company CEO. When dealing with substances like ammonium and carbon dioxide, there is no room for mistakes and leakages. – Heat Exchangers with a Fully-Welded Heart HT_2-3_15.indd 58 15.5.2015 16.00. Plate and shell heat exchangers also need less maintenance than tube heat exchangers. Vahterus operates within three main business areas: chemical and process, energy and refrigeration. “Traditionally, plate heat exchangers use rubber seals or copper soldering. “We are and will remain a Finnish company.” Around 90 per cent of Vahterus products are exported. 23/ 20 15 58 WELDING IN FINLAND [ www .hitsaus .net ] Vahterus Hilkka Rissanen Vahterus is a manufacturer of plate and shell heat exchangers, based in Kalanti, South-west Finland. With its workforce of 250 people based in five countries, Vahterus produces heat exchangers for over 50 nations, serving the needs of customers in demanding circumstances. Vahterus still manufactures its products at its birthplace in Kalanti and certainly has no intentions of moving elsewhere. By using fully-welded circular plates inside a shell structure, the Vahterus PSHE combines the best of both worlds: the product endures high pressure and temperatures, but still remains very space-efficient. Plate and shell exchanger (PSHE). 2. Due to the tubular flow between the plates, the heat exchanger is able to keep itself clean. 1
Welders can monitor their work in real time online, which leads to an improvement in quality. Laser cutting. As a solution, for the past 25 years, Vahterus has co-operated with a neighbouring adult education centre, WinNova. Each product is manufactured according to the pressure vessel regulations of the destination country of export. Each product also undergoes a pressure test before it is even allowed to leave Vahterus. This is also apparent in the composition of Vahterus’ workforce. One thing in which Vahterus is currently investing is the digital quality control of welding, with digitalisation becoming increasingly important, especially in demanding areas of welding such as for pressure vessels. HT_2-3_15.indd 59 15.5.2015 16.00. Strict quality controls The circumstances in which Vahterus heat exchangers are used allow for no mistakes whatsoever. Finding a professional welding workforce is not always easy, especially in a field where such a high demand exists. It is no wonder that professional welders are in such high demand in Kalanti. According to Kontu, both Vahterus’ possibilities and challenges lie in thin-plate welding. Success requires constant development R&D form a very important part of Vahterus’ daily work, as illustrated by the fact that the company owns numerous patents for its products and applications. A large part of the research and development work is conducted with suppliers, partners and customers. “It may seem like a simple product, but it really isn’t. The advent of more challenging conditions has increased the importance of R&D and engineering work. Each welder must possess at least 5 EN standard qualifications and approximately two ASME qualifications. Right now, we are taking that leap with regard to high-pressure environments,” declares Pitkänen. Rather the contrary. Out of 250 employees, approximately 80 are involved in sales, engineering, quality control and R&D. “The technology and welding equipment are of our own design, with the help of our co-operation partners, of course. Welding at the core of quality After the conceptualisation of the idea for the product, quality welding represents perhaps the most critical part of PSHE. Recovering heat energy has become increasingly important for Vahterus’ customers, an issue which certainly shows no signs of diminishing in importance in the future. 23/ 20 15 59 WELDING IN FINLAND [ www.hitsaus.net ] The advantages of the system have resulted in a high demand, as PSHEs can be used in situations which are too challenging for traditional heat exchangers. Vahterus employs over 90 proficient welders and welding operators. “We want to be the forerunner in the heat exchanger market. The consequences of a heat exchanger breaking in a high-pressure environment, such as on an oil rig, would be catastrophic. Due to the technology it has developed, Vahterus is now the market leader of plate and shell heat exchangers. At present, Vahterus heat exchangers can be used in environments with pressures up to 250 bars, but the company still continues to aim higher. But we possess the technological know-how and we assemble the equipment here,” explains Pitkänen. Via this method, Vahterus has managed to sign up more than 20 employees. We are strongly headed in that direction now,” declares Pitkänen. We have approximately 250 welding procedure specifications,” reveals Pitkänen. In order to find the required workforce, Vahterus has recruited and re-educated employees with various backgrounds. “This requires research and experiments. This partly explains Vahterus’ rapid and impressive growth, in the vicinity of 25 per cent annually. Another reason for Vahterus’ progress has been the global trend of focusing on energy efficiency and environment-friendliness. Materials which are particularly more demanding, such as super duplex stainless steel, require further experiments in order to determine the appropriate filler metals, shielding gases and welding parameters. The modern methods speed up the process significantly. “Much of the development work involves fine-tuning, but at times, one needs to take big leaps forward in order to succeed. Secondly, we need to manufacture products that utilize this information and comply with all regulations in the field,” adds Pitkänen. Vahterus aims to build long-lasting partnerships based on trust and the reaping of mutual benefit. “One of the most important advances in the field in the last ten years has been the development of MAG-welding. This s a very demanding field and thus it is also highly regulated. “Our employees need to constantly confirm their expertise through production welding tests. To ensure the absolute faultlessness of all their products, Vahterus exercises strict quality controls. To ensure the best quality for their products, Vahterus developed its own methods of thin-plate welding, in association with its suppliers and co-operation partners. Everything is subject to a licence,” declares Pitkänen. 3. First of all, we need to understand everything about heat exchange. The regulations encompass every single aspect, from materials to manufacturing processes, to welding and methods of quality control. This means that continuous product development and the generation of innovative ideas are vital for us,” comments Kontu. These experiments are conducted in Vahterus’ own laboratory. Vahterus Oy Pruukintie 7 23600 Kalanti FINLAND www.vahterus.com Fig
A change in structural topology is often the result, even after the inclusion of thinner materials. This research field involves internationally-recognised, Professor Gary Marquis, two new Tenure Track Professors, Heikki Remes and Jani Fig. Aalto University School of Engineering has systematically carried out research on the behaviour of advanced welded structures, with a view to providing a design basis for advanced high-performing welded structures. 1. Welding technology Research conducted by the Engineering Materials group within Aalto University’s School of Engineering aims to provide reliable, sustainable and cost-effective solutions in various fields of mechanical engineering. The optimum solution is significantly affected by the selected manufacturing process since this demands specific application conditions and delivers a characteristic joint geometry with metallurgical impact in the weld zone that may greatly affects the strength of the structure. However, the full adoption of new materials is limited since the advanced structural solutions go beyond current design recommendations and rules. HT_2-3_15.indd 60 15.5.2015 16.00. For instance, while advanced production technology increases fatigue strength, thinner and more slender structures reduce the ultimate strength behaviour of the structure, unless low initial imperfections and residual stresses are obtained. New ESAB LEGIO 5UT FSW equipment installed at Aalto University’s welding laboratory. The group’s main activity is dedicated to narrow gap welding, friction stir welding and weld overlay coating. 23/ 20 15 60 WELDING IN FINLAND [ www.hitsaus.net ] Aalto University: Research and Education in Welded Structures Heikki Remes, Pedro Vilaça, Jani Romanoff, Gary Marquis and Hannu Hänninen Aalto University School of Engineering has been dedicated to research and education in welding technology and the design of advanced welded structures. The research is concentrated primarily on strengthening mechanisms, in addition to the effects of fatigue, fracture and hydrogen on materials. In 2014, a new powerful FSW equipment with dedicated control features for laboratorial research (Figure 1) was installed in the welding laboratory enabling high quality research in the fields of solid state welding and processing of advanced engineering materials (Vilaça & Thomas 2012). The main research areas in welded structures are advanced welding techniques and nondestructive testing (NDT). The new FSW equipment also envisages to supports the development of know-how and training specialists in the production of joints for demanding applications, such as the nuclear fuel containers in Finland. In addition, other FSW-related processes, such as Friction Surfacing (Vilaça et al., 2014) are under development. The research on welding methods includes the demanding dissimilar metal welds of nickel-based alloys, copper and advanced ultra-high-strength steels. Ongoing research is targeting an advanced recently patented control system for FSW of special steels. The demand for advanced lightweight solutions has increased significantly in recent years, due to the need for improvement of the energy efficiency and load-carrying capacity of final products. Investigations into arc welding techniques are also performed at the welding laboratory facilities, which also feature a modern robotized welding cell, allowing for rapid prototyping and complementing the thorough 3D print capabilities of the Aalto University Digital Design Laboratory. In practice, this involves weight optimisation with the help of new materials and advanced production processes. This research is supported by a fully-equipped welding laboratory, outfitted with material testing and characterisation equipment, as well as residual stress measurement capabilities including X-ray diffraction, hole-drilling, ring core and contour methods. Design of advanced welded structures The methods for structural design are among the most basic requirements for the efficient use of new materials and for the modern manufacturing of final products. The Engineering Materials group focuses on, inter alia, the development of highstrength steel materials in demanding applications, their characterisation, testing and modelling. The research is led by Professor Hannu Hänninen and Professor Pedro Vilaça, the latter of whom was nominated as a tenure track professor in joining of materials and NDT in 2013
Reddy, from Texas University (USA), Aalto University is developing a computationally-efficient numerical approach which includes coupling between microand macro-structural scales. Vilaça, P., Thomas, W. Recently, the most significant outcome has been the new fatigue design recommendations for HFMI treatment, allowing for the improved use of high-strength steels in welded structures (Marquis et al., 2013). Furthermore, a significant increase in fatigue strength has been obtained for the yield strength of 690 MPa steel, in comparison to normal-strength steels (Remes et al., 2013). Journal of Constructional Steel Research, 89:21-29. Heikki Remes, Pedro Vilaça, Jani Romanoff, Gary Marquis, Hannu Hänninen Aalto University School of Engineering www.aalto.fi Fig. Welding in the World, 58: 661671. (2013) Influence of surface integrity on the fatigue strength of high strength steels. In collaboration with Finland Distinguished Professor, J.N. The aim of the research is to develop reliable fatigue life modelling methods and new S-N curves for the design of high-performing structures. (2012) State-of-theart in FSW technology. The Aalto research in this field is regularly published in various international journals and forums such as the International Institute of Welding (IIW). Remes, H.; Korhonen, E.; Lehto, P.; Romanoff, J.; Niemelä, A.; Hiltunen, P.; Kontkanen, T. This enhances the analysis of large and complex thin-walled structures, with the aim of promoting the design of innovative structural concepts that exploit new materials. 23/ 20 15 61 WELDING IN FINLAND [ www.hitsaus.net ] Romanoff, and a total of 10 doctoral students and post-doctoral researchers. In association with its industrial partners, this science-based approach to physical understanding, underscored by scientific evidence from full-scale experiments, has made it possible for Aalto University to create new design recommendations and successful applications for new steel materials. Aalto University has developed a micro-structure and strain-based approach for fatigue strength modelling, as well as the generic stress intensity factor for small and planar cracks, while also considering crack interaction. References Marquis, G.; Mikkola, E.; Yildirim, H.C.; Barsoum, Z. Springer. Chapter 4 of book: Structural Connections for Lightweight Metallic Structures. 2. The research is focused mainly on fatigue and the ultimate strength of complex structures, considering different scales ranging from micro-structures to full-scale structures, Fig. 2. A science-based approach for the development of a design basis for advanced welded structures at Aalto University School of Engineering. (2014) Differences between secondary and primary flash formation on coating of HSS with AISI 316 using friction surfacing. However, since these effects are often omitted in design due to significant computational efforts, investigations into new, interesting and potential structural concepts are thus often avoided. Traditionally, the fatigue crack initiation phase is neglected, due to crack-like flaws. Therefore, a fundamental understanding of material behaviour in relation to material microstructure, mechanical properties and geometrical features is a key element in the development of a new design basis. (2013) Fatigue Strength Improvement of Steel Structures by HFMI: Proposed Fatigue Assessment Guidelines, Welding in the World, 57:803-822. However, this leads to conservative structural design in the case of high-performing joints with superior geometrical properties. This work has been carried out in cooperation with Finland Distinguished Professor, Grzegorz Glinka, from the University of Waterloo (Canada), and Professor Yukitaka Murakami from Kyushu University (Japan). In addition to strength modelling, the utilisation of new materials and advanced structures requires knowledge of the structural response of large and thin-walled structures, where both geometrical and material non-linearity exist. HT_2-3_15.indd 61 15.5.2015 16.00. Vilaça, P., Hänninen, H., Saukkonen, T., Miranda, R., M. 85-124
Research Research activities are mostly project-based. The welding technology laboratory offers more than 10 courses on welding-related topics, in both English and Finnish, a significantly greater choice than found in other Finnish universities. Over the past decades, welding technology engineers have completed more than 200 research projects and, since the start of the millennium, an average of one PhD per year has been awarded by the welding technology laboratory. 23/ 20 15 62 WELDING IN FINLAND [ www.hitsaus.net ] Welding Technology Laboratory at Lappeenranta University of Technology Paul Kah and Jukka Martikainen Lappeenranta University of Technology (LUT) was established in the late 1960s to meet the rapidly evolving demands of Finnish industry and business. The number of welding-related theses produced has increased significantly in recent years to a steady level of 15–20 theses per year, with almost all Master’s theses involving participation by industrial companies. Teaching Students of Mechanical Engineering choose a major subject based on either design or manufacturing technology. Supported by active industrial collaboration, mechanical engineering teaching and research at LUT are offered in an excellent environment for the development and dissemination of the latest know-how and expertise. The welding technology laboratory is the leading unit in Finland in its area of expertise. A robotic welding system makes it possible to evaluate robot weldability and response via the thorough testing of products, and specialised simulation software is available for process modelling and evaluation. Courses are offered at both the undergraduate and postgraduate levels in conventional welding technology, modern welding technology, welding metallurgy, laser materials processing, material science, virtual welding, in addition to a laboratory course on welding production. The welding technology laboratory enjoys very good R&D cooperation with universities and research institutions in the Russian Federation, Norway, Sweden, Germany, Denmark, Estonia, Portugal, Lithuania, the United Kingdom and the United States. Major research areas within LUT’s School of Mechanical Engineering include welding technology and steel structure fabrication. Research is focused on the productivity of welding and metallurgical and mechanical testing of welded structures. The courses address topics such as welding processes, welding mechanisation, automation of welding quality and the use of simulation software. The welding technology laboratory also plays an important role within the national training programme for the international welding diplomas, IWT and IWE. Small-scale assignments generally involve bilateral agreements with partner institutions and companies and may comprise a variety of professional services or short developmental HT_2-3_15.indd 62 15.5.2015 16.00. Recent doctoral dissertations include: The effect of welding heat inputs on the usability of high strength steels in welded structures (Pirinen Markku, 2012), Usability of laser–arc hybrid welding processes in industrial applications (Kah Paul, 2011), Optimizing of intelligence level in welding (Salkinoja Heikki, 2009), The effects of some variables on CO 2 laser-MAG hybrid welding (Fellman Anna 2008) and, Fusion weld metal solidification: Continuum from weld interface to centerline (Rajamäki Pekka, 2008). Modern welding machines are used to test various processes for different industrial applications and to optimise their productivity through enhanced weld quality and advanced mechanisation levels
The welding network research project addresses the needs of industrial engineering, business and management. Therefore, part of the research focuses on the control of metal transfer during the MIG/MAG process, as well as the optimisation of the selection of welding parameters to eliminate defects and to increase productivity. Petersburg State University of Technology. More extensive, multi-year, research projects typically involve the EU, EAKR or TEKES, with the laboratory then acting as project coordinator. If any misalignment is detected, the system is able to correct itself during the welding process and can also calculate any other faults which may arise. Welding processes are becoming more efficient as a result of increased mechanisation and greater use of robotization. The Boat program of the Finnish Funding Agency for Technology and Innovation, Tekes, examined robot welding in the manufacture of aluminium boats and the subsequent Moduva project examined modularization and the use of flexible jig technology, as well as the advantages offered by robotic applications in the construction of aluminium boats. Recent years have witnessed interest in modified MAG-welding processes. With the help of the neural network, a regulating window can be set for system variables, which can then be controlled so that they remain within certain limits, ensuring that the final product is as required. The LUT welding technology laboratory has recently completed a three-year research project on the welding of steels and the behaviour of welded steel structures in Arctic conditions. The welding technology laboratory is specialised in the quality assurance of welded products. In contrast, larger projects are usually part of companies’ own research and development work, assisted by the Finnish Funding Agency for Technology and Innovation, TEKES, and make use of the professional services of the laboratory. Control of the microstructure of the weld is critical to the quality of welded joints and the research results are expected to address major problems in the industry. These include efficient control, real-time welding parameter adjustment and welding quality control, as well as the provision of benefits including reduced fume emission, the elimination of the need for cleaning and the reduction in shielding gas consumption, thus providing a significant gain in productivity and quality. For example, research projects and theses have focused on brazing, tandem MAG-welding, as well as plasma and flashbutt welding. However, if the method of production is unknown and is not taken into account during the welding process, the mechanical properties of the resulting welded structures (especially toughness) can vary significantly. Since the 1990s, a significant number of the welding research projects has dealt with welding processes and their efficiency, as well as new, advanced welding process modifications. With thicker sections, it is essential to produce a root pass, but here too, burn-through risk is very high. Steels of the same strength class can be used with a number of alternative manufacturing technologies. The new system offers exciting possibilities for the welding of high-strength steels, since the parameter windows for the high-strength construction steels are narrow. The development of welding manufacturing is not only about the welding process, but also involves the understanding of the accompanying dynamics. Research is based on numerous different research approaches which exploit HT_2-3_15.indd 63 15.5.2015 16.00. The system is self-adjusting, flexible and adaptable, such that it can be integrated into different robotic systems and different manufacturers’ power supplies. Consequently, research projects have intensely studied robotic processes and products. Its self-adjusting properties are based on a new type of sensor system, controlled by a neural network program. In recent years, research has particularly been concentrated on the weldability of high-strength and ultra-high-strength steels. These projects demonstrate that a modular structure makes it techno-economically feasible to employ robot welding in device construction in small companies. The new LUT system can also be used in the manufacture and quality verification of pressure vessels, in addition to different types of containers, pipes and pipe systems, booms and beam structures. However, their sensitivity to heat is great, not only in their cross-sections, but also in their zinc-coated layers, and very strict control of heat input is required. Another research interest of the welding technology laboratory is the improvement of welding efficiency via industrial networking. A recent Tekes project was dedicated to the development of a novel welding system for mass-welding operations that addresses quality and productivity problems related to automated and mechanised welding. The EU-funded ENPI project included two research partners, the Central Research Institute of Stuctural Materials (CRISM), “Prometey,” and the St. The LUT system incorporates additional monitoring sensors for the thermal and weld profiles. The use of high-strength metals means that sheet sections are becoming increasingly thin. Welding technology laboratory research projects are in line with select priority areas. 23/ 20 15 63 WELDING IN FINLAND [ www.hitsaus.net ] tasks
The offshore environment is nowadays experiencing increased activity, due to the tremendous amount of resources available. Oil and gas companies use installations such as jack-ups, rigs, pipelines and platforms and these structures require much welding activity during their fabrication and installation. The DFMA method can considerably shorten the decision-making process and at the same time, also reduce the risk of defective materials and process selection. Improving efficiency necessitates the development of new engineering solutions that address incompatibilities by considering joint design, materials, welding processes, process parameters and consumables simultaneously, and equally importantly, in correlation with each other. This new welding management system is suitable for use by European companies, to be utilised in their factories and with partners or sub-contractors. HSA alloys, however, are challenging to welds, due to the presence of copper, in addition to the aluminium oxide layer. Narrowgroove welding allows for a significant reduction in welding time, involves a reduced consumption of filler materials and results in better weld properties. 23/ 20 15 64 WELDING IN FINLAND [ www.hitsaus.net ] empirical data from the welding industry and analyse network structures and dynamics from the perspective of welding quality and requirements. Research is ongoing, with regard to the design of new groove types for the shipbuilding steels, E500 TMCP and F500W, in order to minimise the cost of welding by the use of welding parameters for narrow-groove welds and conventional welding processes. The weldability of HSA alloys is being examined experimentally, with critical analyses of the weld macrostructure, microstructure and crack susceptibility (or sensitivity), with hardness profiles and tensile tests being carried out, in addition to chemical analysis of the Al 2 O 3 layer. Design for manufacturing and assembly (DFMA) methodology can be adopted for this purpose and the development of rules and guidelines for DMW applications can lead designers towards functional, fabrication-friendly and cost-effective weldments. During underwater welding, the water environment increases the cooling rate, which affects the final microstructure of the weld. Welding processes that are carried out underwater face challenges of reduced strength, toughness and ductility. Addressing these challenges has become an important research topic in the laboratory. Another ongoing research project is dedicated to the design and creation of a new welding, manufacturing quality control management system for countries such as the P.R. Traditional design processes burden welding engineers with issues related to metallurgical properties and incompatibilities, often after the detailed design has been completed, which can lead to costly re-work and delays. This research is related to the fields of management science, welding technology and training expertise and methodology. The new system will help, for example, Chinese welding manufacturing enterprises to maintain their welding production quality at high levels, while at the same time, enable management to develop culturally-appropriate training approaches that improve the co-operation and work efficiency of welding manufacturing personnel. of China, Russian Federation, Cameroon, Ghana and Kenya. Dissimilar metal welding (DMW) is widely used in industry for weight reduction and reinforcement (e.g., in the automotive industry), as well as for the reduction of manufacturing costs (e.g., in offshore constructions and power plants). Offshore welding processes demand a high level of quality due to the nature of the marine environment. The welding laboratory is also involved in research which focuses on how to improve the quality of welds created underwater and how to achieve a desirable weld bead geometry, essential for the achievement of a sound weld. High-strength aluminium alloys (HSA) have tensile strength comparable to mild steel. The research uses new and existing theories and tools to build an integrated system which incorporates modular design, LEAN, TWM and ISO 3834. HT_2-3_15.indd 64 15.5.2015 16.00. However, in many cases, DMW is associated with challenges which arise from physical-metallurgical discrepancies between the associated parts. Lighter than steel, aluminium also has a lower dead-load than steel
Simulation and remote offline programming software visual components . Adaptive welding equipment . BUG-O conveyor . 23/ 20 15 65 WELDING IN FINLAND [ www.hitsaus.net ] Equipment . Scanning Electron Microscope (SEM) analysis . The welding laboratory has also recently been able to show a remarkable improvement in the number and quality its scientific publications. Markku Pirinen, Dr, Project Controller markku.pirinen@lut.fi . We are open to many levels of co-operation, including the exchange of researchers and teachers and the provision of distance learning and supervision services. Heat treatment equipment: hardening, quenching and tempering, stress relieving techniques. Macrostructure and microstructure analysis . Destructive testing: . Associate Professor Paul Kah paul.kah@lut.fi, +358 40 832 5061 Professor Jukka Martikainen jukka.martikainen@lut.fi, +358 40 545 7367 Department of Mechanical Engineering, PO Box 20, 53851 Lappeenranta, Finland. Equipment for mechanised welding: . Joshua Omajene, thesis by publication: Underwater welding in offshore operation Jenni Toivanen: thesis by publication: Networks in welding Hamed Tasalloti, thesis by publication: Design and manufacturing of dissimilar materials welding Hamidreza Latifi: thesis by publication: Advanced adaptive arc welding Aderinola Oluwasanmi: thesis by publication: Efficient welding technologies applicable to HSS Arctic offshore structures Co-operation Opportunities The welding technology laboratory is interested in joining HORIZON 2020 research platforms and other international project platforms for research and development. Crack-Tip Opening Displacement (CTOD) testing . Energy Dispersive X-ray spectroscopy (EDX) . Non-destructive testing: . Ultra-sound testing and X-ray radiography . Paul Kah, Dr, Associate Professor paul.kah@lut.fi . Jukka Martikainen, Dr, Professor, Head of Laboratory jukka.martikainen@lut.fi . The welding technology laboratory is also interested in joint experiment arrangements and monitoring. Material testing equipment: . HT_2-3_15.indd 65 15.5.2015 16.00. Muyiwa Olabode, thesis by publication: High strength aluminum alloys welding Xiaochen Yang, thesis by publication: Development research of welding production quality control and a maintenance system model in China Pavel Layus, thesis by publication: Welding for Arctic shipbuilding applications Eric Mvola Belinga, thesis by publication: Adaptive controllability effects on gas metal arc welding processes: Performances and dissimilar welds qualities Ming Li Sun, monographic thesis: Welding quality transplantation and globalization by total quality management system procedure in outsourcing: Case study in China Emmanuel Gyasi: thesis by publication: Design applicability of GMAW in industrial applications Martin Kesse: thesis by publication: Enhanced TIG welding processes for welding of metals. Versatile and modern welding machines: . ABB Robotic welding station (Robot studios simulation and offline programming) . Raimo Suoranta, Lic, Lecturer raimo.suoranta@lut.fi . MIG/MAG, tandem, TIG, Plasma, SAW, Friction Welding, Resistance Welding, Thermite welding stations . Esa Hiltunen, MSc, Laboratory Engineer esa.hiltunen@lut.fi Laboratory Doctoral Researchers: The number and details about LUT’s scientific publications are illustrated below. 2-axis manipulator . Robotic welding station (Motoman EA1900N, robot carriage, 2-axis positioner, welding head) . Tensile, bending, impact and hardness testing equipment . Staff and Researchers Senior Researchers: . Welding boom PEMA 3x3 . Kari Lahti: thesis by publication: Submerged arc welding of Arctic high strength steel
Main Research Areas The main “stress” (pun intended) of the research still remains the fatigue analysis of welded structures and especially, joints. The materials currently being investigated are mainly highand ultra-highstrength structural and stainless steels, using several sub-variations of MAG processes, laser and laser-hybrid, and the improvement methods including optimal welding parameters, waving, HFMI, TIG-dressing, MIG-brazing and LTT-fillers. HT_2-3_15.indd 66 15.5.2015 16.00. 1 illustrates a highquality weld, based on waving technology in robotic welding. Mission The laboratory is creating new purposeful knowledge for the design and fabrication of steel structures for demanding applications, which means that the structures are typically made of highor ultra-high-strength steels (UHSS), are subjected to dynamic loading (fatigue) and can also be used at low ambient temperatures. Since such an exceptional task required an exceptional person to take the lead, the very first professorship was granted to Erkki Niemi. This research work has been the basis for current IIW (International Institute of Welding) recommendations concerning this method. Laboratory of Steel Structures Introduction The laboratory was founded in 1974, in response to an increasing industrial need for knowledge about advanced welded structures. 2, a novel local stress approach for the determination of the design curve for the fatigue assessment of welded structures. The method is a combination of the effective notch stress method (ENS), the SWT approach and the local strain method, and takes into account the residual stress effect, sres (welding, peening, etc.), the applied stress ratio effect, R, and the effect of (ultimate) material strength, Rm. Another important element of success has been the close cooperation with LUT’s Laboratory of Welding Technology; this perpetual symbiosis between the two neighbouring laboratories has been advantageous for both parties. Both laboratories form part of the Lappeenranta University of Technology (LUT) School of Mechanical Engineering. The current emphasis in this field can be subdivided into four focus areas: the effect of different weld processes, the effect of posttreatments (vs as-welded), the development of a general S-N master curve, and the design of details. In the past, special emphasis was placed on the fatigue analysis of welded joints and on the development of advanced analysis tools, resulting in important contributions to the formulation of the structural hot-spot stress method, for example. 1. The combination of Professor Niemi’s theoretical scientist’s mind and his practical reasoning abilities as an engineer proved to be fruitful, serving the needs of the Finnish machine and construction industries. The goal of education is primarily to encourage the design of innovative and competitive welded structures, but also to provide the tools for this task via the development of analytical skills. Fig. From the very beginning, one of the most important research areas has been laser welding and its various different processes. The latest remarkable achievement has been the master curve analysis, presented in Fig. Investigation of the fatigue strength of a high-quality fillet weld joint made of S960 QC steel. The importance of international collaboration in research has also increased remarkably during the years. Throughout the laboratory’s 40-year history, this particularly close relationship with industry has been a distinguishing factor that has been carefully cherished. The primary focus of studies is on structures which are subjected to dynamic loading. Fig. 23/ 20 15 66 WELDING IN FINLAND [ www.hitsaus.net ] Structural Design and Laser Processing Research at Lappeenranta University of Technology Olli-Pekka Hämäläinen, Timo Björk, Matti Koskimäki and Antti Salminen The Laboratory of Steel Structures is an internationally-appreciated facility involved in the design of welded structures for demanding applications. The Laboratory of Laser Materials Processing has been conducting laser processing research and development since 1985
ARAMIS optical 3D deformation measurement and analysis system . 23/ 20 15 67 WELDING IN FINLAND [ www.hitsaus.net ] In accordance with the increasing use of highand ultra-high-strength steels, interest in the strength of welded joints is growing, with regard to their load-carrying and deformation capacities. This field involves strong collaboration with CIDECT. One of the Welding Society of Finland’s national forums, HRO aims to solve problems related to the design of welded structures, common to all industrial partners. Laser shape measuring system (for determining the local weld geometry) Fig. The laboratory is also active in the education of International Welding Engineers (IWE) and International Welded Structure Designers (IWSD). 5 MN “MEGA” testing rig. Laboratory The research methods are based on theoretical models, FEA-based simulations and laboratory tests. 5 MN test rig “MEGA” for static/dynamic loading (designed and fabricated by LUT) . 3. From the outset, one of the most important research areas has been laser welding, using the various different processes possible with lasers. HT_2-3_15.indd 67 15.5.2015 16.00. This research is focused on the phenomenon of fretting and the ways in which it can be avoided. All research work is generally performed in collaboration with several international universities, with the IIW playing an important role as a general research forum. Over 150 m 2 of T-slot floor area . 2. At present, the second important focus area is laser additive manufacturing which is also, in fact, a very advanced weldFig. Stresstech residual stress measurement system . Due to the laboratory’s longstanding cooperation with the Finnish steel manufacturer, Ruukki (currently SSAB Europe), and its strong investments in tubular products, tubular structures also constitute an important area of research. This involves buckling tests of the capacities of welded RHS joints, with the aim of developing a design guide for joints made of high-strength steels. The goal of this research field is the identification of alternatives through the study of the behaviour of bolted joints in fatigue conditions. 3. The test rigs and other laboratory equipment include the following: . Their study includes the definition of the throat thicknesses and the softening effect on the joint capacities at room and low ambient temperatures. Novel master curve analysis of a butt-joint developed by Timo Nykänen at LUT. Contact Persons: Timo Björk, Professor of Steel Structures, +358 400 553508, timo.bjork@lut.fi Matti Koskimäki, Laboratory Manager, + 358 400729731, matti.koskimaki@lut.fi Laboratory of Laser Materials Processing Lappeenranta University of Technology has been conducting laser processing research and development since 1985. Other Activities The laboratory coordinates the Design Forum of Optimised Welded Structures (HRO) which includes about 35 Finnish companies involved in the design or fabrication of welded structures, many of whom are world market leaders in their own business areas. 4. Since welding is not the world’s only technique for joining steel structures, there must be a spot reserved for mechanical connections. The sensitivity analysis of the joints is performed by FEA, using material models developed based on the considerable collection of test results for RHS joints. All test rigs are naturally apt for standard test specimens. 800 kN, 400 kN, 3 x 150 kN and 25 kN test rigs for static/dynamic loading . 4) and a well-trained and imaginative staff. The Laboratory of Steel Structures possesses a wide array of test rigs, many of which are well-suited for performing what constitutes the laboratory’s main expertise, i.e., full-scale experimental tests. Full scale fatigue test. Fig. This is made possible by heavy-duty test rigs (of which the largest is able to exert forces of up to 5 MN, Fig. In 2014, the Laboratory of Steel Structures was granted an award as a “Centre of Excellence in Welding” by the Welding Society of Finland, in acknowledgement of its remarkable research and teaching work in the field of welded structures. However, the key factor that sets this laboratory apart from all others is its ability to perform fatigue tests on prototypes that can weigh several tonnes, as illustrated in Fig. Other topics have ranged from metal and paper cutting, to surface engineering and drilling. Current LUT professor, Timo Björk, is the designated Finnish delegate to IIW Commission XV Design, Analysis and Fabrication of Welded Structures, and a Finnish expert in Commission XIII Fatigue of Welded Components and Structures. K-joint test rig for RHS-truss members . 1 MN static compression test rig (up to 7 m in total length)
The variation of weld profile can be addressed by changes in the welding parameters, the important parameters to be changed especially for this purpose being the beam properties. 5. Laser Keyhole Welding Autogenous laser welding is a very suitable process for various applications. Welding of Ultra-High-Strength Steels Modern steels, such as ultra-high-strength steels, are among the key topics of current research. Studies undertaken with modern lasers (fibre and disk lasers) have shown that the keyhole behaves differently than with the traditional CO 2 laser, or with the former Nd:YAG laser. In the past, due to the lack of laser power, research was often concentrated on the weldability of thinner sections, product design and process monitoring. Due to the low carbon content of the steel, the average hardness in the FZ was significantly lower than the critical hardness value, barely reaching 400 HV in the case of the lowest line energy welds. 23/ 20 15 68 WELDING IN FINLAND [ www .hitsaus .net ] ing technology. This result is quite good, particularly when compared to results in existing literature. Additive Manufacturing Similarly, research in additive manufacturing has been concentrated on the R&D&I of various topics, in order to improve efficiency and decrease production through-put time. The research carried out in the field of welding is concentrated on studies of keyhole behaviour, as well as the welding of thick sections, fillet joints and modern steels. In addition to high-power lasers, there are gantry and robotic workstations outfitted with various quality assurance equipment and hybrid welding system configurations, as well as different systems related to additive manufacturing (AM). Autogenous welding is a very simple and fast process which affords several new opportunities for the design of welded structures. LUT has been performing research on laser additive manufacturing for several years, incorporating the AM of metals into the welding process. This provides excellent properties to the weld and enables the use of several different joint types. It has been utilised for the welding of different components for mechanical engineering products all over the world, the car manufacturing industry being the most advanced user. Further, the in-situ x-ray experiments, performed in collaboration with Stuttgart University, have revealed a difference between various parameter combinations during disk laser welding. the effect of welding speed and focal point position on the keyhole formation. Notwithstanding, the focus for R&D&I remains on product design, process monitoring, the weldability of thick sections and modern steels. The distortion is low and single-sided, full-penetration welds have exFig. The differences lead to different process modes that correlate directly with the weld shape and quality. In fact, in many cases, the design of parts can be evolutionally quite different. 6 a) The effect of the welding position on the weld profile at different welding speeds. Laser power is 6 kW, focal point position is -2 mm. (Kaplan et al., 2015) The heat is introduced evenly to the whole cross-section or penetration depth. (Unt et al., 2015) and b) the effect of a sealing run on T-joint root quality. Typically, one cubic millimetre of AM-produced material consists of 1 m of weld. This results in considerable improvement to this critical point of the weld. Research has been concentrated on the weldability and achievable properties of the weld metal, with autogenous laser keyhole welding typically being used. In hybrid processes, an arc welding process (MIG/ MAG, TIG, SAW) is typically combined with a laser welding process. Another option for the enhancement of weld quality is the performance of a fast sealing run with low power to melt the root side. Process development has been carried out both in powder bead fusion and directed energy deposition techniques (Pekkarinen et al., 2014 and 2015). Traditionally, laser welding is a very suitable method for welding direct-quenched, ultra-high-strength steels, for example. (Vänskä et al., 2013, Salminen et al., 2014, Sokolov et Fig. The only drawbacks of the process are the quality of the part manufacture and, in some cases, their metallurgy. During laser keyhole welding, the energy of the actual heat source laser beam is transferred to the workpiece via a hole that attains a specific pre-set depth. cellent productivity. (Vänskä, 2104) al., 2014) These recent studies have highlighted the differences between the CO 2 -laser keyhole welding and fibre/disk laser keyhole welding processes. Traditionally, pre-conceived ideas about keyhole welding maintained that, in all cases, the keyhole behaves in a similar manner with respect to certain materials. One topic in this field is the welding of AM metal material to equivalent metallic materials. For instance, process efficiency is one of the major areas where the heat input of the process should be studied, in order to be able to specify the HT_2-3_15.indd 68 15.5.2015 16.00. Figure 6 b) demonstrates how the root can be formed to improve the fatigue life cycle and visual quality of the weld. (Vänskä, 2014) Fillet Welding Lasers are also excellent tools for the welding of fillet joints. Today, the laser power available is more than 10kW, capable of welding low-alloyed steels of up to 15 mm in thickness with a single pass at a speed of 1 m/min. As is shown in Figure 9, despite the very high cooling rates of the autogenous fibre laser welding process, hardness in the FZ was increased only slightly, compared with the hardness of the base metal. Figure 6 a) shows some of the effects of optical parameters on the weld dimensions. Those cases are usually resolved either by adding some filler material, or by also increasing the heat input by using so-called hybrid processes
Journal of Materials Processing Technology. Journal of Laser Applications, August 2014, Volume 26, No 3, pp. The width of the weld increased as a function of the line energy. Physics Procedia 41 (2013) 199 – 208. (Farrokhi et al., 2015) of Process Efficiency Improvement in Laser Additive Manufacturing. Volume 219, May 2015, Pages 278–285. Vänskä, M., Abt, F., Weber, R., Salminen, A. pp. Sokolov, M. 27, S29002 (2015). and Shen, Z., Monitoring of temperature profiles and surface morphologies during laser sintering of alumina ceramics, Journal of Asian Ceramic Societies 01/2014 Salminen, A., Lappalainen, E. 289-302 Unt, A., Poutiainen, P. 361-375 Scotti, G., Kanninen, P., Matilainen, V-P., Piili, H., Salminen, A., Kallio, T. Physics Procedia 56 (2014) 317 – 326. (Farrokhi et al., 2015) Fig. Pekkarinen, J., Salminen, A. 23/ 20 15 69 WELDING IN FINLAND [ www.hitsaus.net ] expected metal microstructure and properties (Stepanov et al. Visual comparison of cross-sections of the welds, welded with the highest and lowest welding speeds. Journal of Laser Applications. In conjunction with the monitoring of welding, the monitoring of AM processes has been a real focus throughout the entire history of AM research (Qian et al. 2014). Vänskä, M., Defining the keyhole modes – the effects on the molten pool behaviour and the weld geometry in high power laser welding of austenitic stainless steels. Accepted for publication in the Journal of Manufacturing Science and Engineering 2015. (Farrokhi et al., 2015) HT_2-3_15.indd 69 15.5.2015 16.00. Box 20, 53851 Lappeenranta, Finland. and Salminen, A., Effect of Welding Parameters and the Heat Input on Weld Bead Profile of a Laser Welded T-joint in Structural Steel. Journal of Power Sources, Vol. and Purtonen T., A Study of the Basic Phenomena During the High Power Fiber Laser Welding of Thick Section Low Alloyed Steel. www.lut.fi Fig. Physics Procedia 56 (2014) 497 – 506. Average hardness in the FZ (hf) with a standard deviation varying between 5 and 10 HV. and Franssila, S., Laser additive manufacturing of Stainless Steel Micro Fuel Cells. Matilainen, V-P., Piili, H., Salminen, A., Syvänen, T. 8. and Nyrhilä, O., Characterization Fig. kW represents the laser power and m/min, the welding speed. thesis, Lappeenranta University of Technology 2014. and Kawahito, Y., Reduced Pressure Laser Welding of Structural Steel: Influence of Edge Morphology and Weld Hardness Analysis. and Salminen, A., Effects of sealing run welding with defocused laser beam on the quality of T-joint fillet weld. and Kujanpää, V., Laser cladding with scanning optics: Effect of scanning frequency and laser beam power density on cladding process. Unt, A., Poutiainen, I. and Graf, T., Effects of welding parameters onto keyhole geometry for partial penetration laser welding. 9. Optics & Laser Technology. and Salminen, A., Katayama, S. Product design has proceeded with various industrial cases, but also via academic studies of the optimisation of products by means of additive manufacturing, the so-called manufacturing for design (Scotti et al., 2014). Volume 69, June 2015, Pages 104–112. Lasers in Engineering. Kaplan, A., Torkamany, M., Ghaini, F., Vänskä, M., Salminen, A., Fahlström, K., Hedegård, J., Wire deposition by a laser-induced boiling front. Mechanical properties are tested using both visual and destructive testing equipment for different applications of various alloys and components. 7. 272, 25 December 2014, Pages 356–361. D.Sc. List of References: Farrokhi F.K., Siltanen, J., Salminen, A., High Power Fiber Laser Welding of DirectQuenched Ultra High Strength Steels Evaluation of Hardness, Tensile Strength, and Toughness Properties at Subzero Temperatures. Stepanov, A., Islam, M.E., Taimisto, L., Piili, H., Nyrhilä, O., Salminen, A., Comparison of Theoretical and Practical Studies of Energy Input in Laser Additive Manufacturing (LAM) Using Stainless Steel. Lasers in Engineering. and Matilainen et al., 2014). Contact Persons: Antti Salminen, Professor of Laser Materials Processing, +358 40 767 4387, antti.salminen@lut.fi, Ilkka Poutiainen, Laboratory Manager, +358 400 330 245, Ilkka.poutiainen@lut.fi Olli-Pekka Hämäläinen, Timo Björk, Matti Koskimäki and Antti Salminen Lappeenranta University of Technology P.O. Journal of Laser Applications 27, S29201 (2015). 28 (2014), (5-6), pp. 032002-1 032002-9 Qian, B., Taimisto, L., Lehti, A., Piili, H., Nyrhilä, O., Salminen, A. 28 (2014) (5-6). and Salminen, A., Effects of Process Parameters in Laser Cladding on Substrate Melted Area and Substrate Melted Shape. Pekkarinen, J., Goodarzi, D.M
Welding research activities increased significantly in 2004, when the FMT Research Group was founded and the first research projects in FMT were launched. In addition to these, there have been numerous Master’s theses related to the field of welding. 23/ 20 15 70 WELDING IN FINLAND [ www.hitsaus.net ] High-Level Welding Research at the University of Oulu David Porter, Kari Mäntyjärvi and Jouko Leinonen Welding research activities at the University of Oulu are concentrated in the Materials Engineering Research Group and in the Future Manufacturing Technologies Research Group, FMT. Thus, the mechanical properties and microstructure of a certain point in the HAZ can be measured in a Gleeble-simulated test specimen. After the heating and annealing periods, the specimen is cooled under controlled conditions. At the University of Oulu, the Gleeble ® 3800 simulator is usually used for steel development or welding research. The subjects of three doctoral theses focused on weld pool solidification and weld defects and, additionally, one doctoral thesis investigated cast-to-cast variations in weld penetration. The weldability of such steels plays a significant and central role in most practical applications. Moisio, T.: Solidification microstructure and hot cracking in austenitic stainless steel weld metal (1974) Suutala, N.: Solidification studies on austenitic stainless steels (1982) Kujanpää, V.: Studies on weld defects in austenitic stainless steels (1984) Leinonen, J.: Cast-to-cast variations in weld penetration in austenitic stainless steels (1987) Tian, D.: Microstructure, cleavage fracture and toughness of granular bainite in simulated coarse-grained heat-affected zones of low-carbon high-strength steels (1998) Nevasmaa, P.: Predictive model for the prevention of weld metal hydrogen cracking in high-strength multipass welds (2003) Laitinen, R.: Improvement of weld HAZ toughness at low heat input by controlling the distribution of M-A constituents (2006) Nousiainen, O.: Characterization of second-level lead-free BGA interconnections in thermomechanically loaded LTCC/PWB assemblies (2010) HT_2-3_15.indd 70 15.5.2015 16.00. The maximum cooling rate is of the order of 50 to 200 °C/s, depending on the length and thickness of the individual specimen. The Materials Engineering Research Group at the University of Oulu has been active in welding research since 1972, the initial research having been focused on the welding of austenitic stainless steels 1,2 and the application of Barkhausen noise to the measurement of weld residual stresses 3 . Both groups belong to CASR, The Centre for Advanced Steels Research, founded in 2006 at the University of Oulu. Later theses have since been directed more towards the welding of differTable 1 . In collaboration with steel producers and other research institutes, the University of Oulu is presently investigating and developing novel high-strength, ultra-high-strength and special stainless steels and their properties via many common projects. The thermal history of a certain HAZ zone can be simulated and later, the microstructure and mechanical properties of that zone can be measured, e.g., Fig. 1. During the last decades, very different materials related to various research topics have been studied at the University of Oulu, e.g., austenitic and ferritic stainless steels, high-strength and ultra-high-strength low-alloyed steels, high-strength aluminium alloys, coated sheet metals, inter alia. The fast heating and cooling cycles which occur during welding in the HAZ can be reproduced via simulation in a macroscopic volume of a test specimen. These welding activities were concentrated essentially on laser welding and its different applications. 1. Dating back to the early 1990s, numerous welding investigations have been conducted using a Gleeble® 1500 thermomechanical simulator, since replaced by a Gleeble® 3800, as presented in Fig. Table 1 details the doctoral theses related to welding research that have been presented at the University of Oulu. Gleeble ® thermomechanical simulators were originally developed for the investigation of weld HAZs. Doctoral theses on welding at the University of Oulu . Since 1976, Outokumpu has been producing austenitic stainless steels and nowadays, also produces ferritic stainless steels in Tornio, Finland. ent special steels and other metal alloys, e.g., high-strength, ultra-high-strength and abrasion-resistant steels. A test specimen (sheet, bar or cylinder) is resistively heated by an electric current with a maximum heating rate of about 1000 °C/s, as shown in Fig. Gleeble ® 3800 thermomechanical simulator (upper) and simulated annealing of a steel sheet (lower). 1. The Gleeble ® 3800 equipment is ideal for HAZ investigations
Microstructure of a laser weld joint in a novel, ultra-fine-grained, high-strength austenitic stainless steel. 2. 2. Nevasmaa P.: Predictive model for the prevention of weld metal hydrogen cracking in high.strength multipass welds, Acta Universitatis Ouluensis, Technica, Oulu 2003, C 191. Laitinen R.: Improvement of weld HAZ toughness at low heat input by controlling the distribution of M-A constituents, Acta Universitatis Ouluensis, Technica, Oulu 2006, C 234. Results obtained via simulation have often been used in the development of new high-strength steels 4-6 . Weldability problems of different ferritic stainless steels have been studied intensively during recent years. Joining of Metals, Helsingör, 1995, European Institute for the Joining of Materials. 6. Fig. 196-200. 15 HT_2-3_15.indd 71 15.5.2015 16.00. References 1. Karjalainen P., Porter D. Karjalainen, L.P., Moilanen, M., Rautioaho, R.: Evaluating the residual stresses in welding from barkhausen noise measurements, Materialprüfung/Materials Testing 22 (1980) 5 , pp. 5. Cvetkovski S., Karjalainen L.P., Kujanpää V. Grain refinement in 21 % Cr ferritic stainless steel using shielding gas mixtures in GTA welding 9 by using nitrogen plus oxygen additions to the argon shielding gas in gas tungsten arc (GTA) welding (Fig. Karjalainen P., Takalo T. Substantial grain refinement was achieved Fig. In another study, experimental investigation was carried out to evaluate the possibilities of inducing grain refinement in welds of 21 % Cr ferritic stainless steels that would otherwise solidify in a columnar fashion 9 . Fig. Microstructural investigations form an essential part of welding research, requiring a wide range of research equipment. Weld metal on the left. For colour-coated sheet metals, a special laser welding process has been developed in the FMT Group. Type and distribution of M-A constituents in the ICCGHAZ of a high-strength steel 5 . With respect to stainless steels, emphasis has been placed on the influence of the shielding gas on the static and dynamic strengths of laser welds 11 . 3. 7. 2. 323328; Welding in the World, Vol. Simulation has also been used to estimate the heat absorbed by the base metal during TIG and laser welding 7 . One study was conducted on the feasibility of welds produced by the use of ferritic stainless steel filler metals for ambient temperature applications 8 . The primary focus of the welding research conducted by the FMT Group is the laser welding of ultra-high-strength (UHS) steels and abrasion-resistant (AR) steels. 4. & Moisio T.: Factors affecting on ferrite content in austenitic stainless steel (in Finnish), Hitsaustekniikka 23 (1973) 6, 146-152. 53, Special Issue, 2009. In relation to UHS and AR steels, the research focus is mainly on the improvement of the fatigue strength of laser-welded components 10 . & Karjalainen P.: (In Finnish) Runsasseosteisen austeniittisen ruostumattoman 6Mo-teräksen hitsaus, Hitsaustekniikka 40 (1990) 2, s. out causing damage to the coating on the back of a lap joint 12 , as presented in Fig 4. shows an example of a novel, ultrafine-grained, high-strength austenitic stainless steel, developed in the Materials Engineering Research Group and laser-welded in the FMT Research Group. and Ahmad A.: Estimation of heat input in TIG and laser welding of stainless steel sheet, Proceedings of the IIW International Conference on Advances in Welding and Allied Technologies, IIW, Singapore, 16-17 July, 2009, pp. The production of lightweight structures 13 and small batch production using laser welding 14 have also been the subjects of the FMT Group’s research. Järvenpää S., Leinonen J. & Xu Z.: Influence of steel composition on impact toughness of simulated high energy welds, JOM-7, Seventh Int. 69 – 78. 23/ 20 15 71 WELDING IN FINLAND [ www.hitsaus.net ] by hardness, tensile and impact toughness testing. Fig. 4. Using limited penetration laser welding, it is possible to join colourcoated sheet metals by laser welding, withFig. 3). 5. The University of Oulu is equipped with a wide range of modern tools for metallurgical research, including optical and scanning laser microscopes, electron microscopes, spectroscopes, tensile, hardness and impact testing equipment. 5. Laser-welded, colour-coated sheet metal without damage to the coating 12 . Conf. According to the results, the strength and ductility of the welds are acceptable, but the major limiting factor is the accompanying reduced toughness, even with different sheet thicknesses. 3. An example of a simulated HAZ (ICCGHAZ) in a high-strength steel is illustrated in Fig
Welding, machining and laser cutting release huge amounts of hazardous particles into air. Leinonen, Jouko: Mechanical properties of weld joints in a novel high-strength austenitic stainless steel. F. 13. Learn more at: www.genanosolutions.com 12. 23/ 20 15 72 WELDING IN FINLAND [ www .hitsaus .net ] 8. No filters, meaning continuous performance without regular and expensive filter changes. 473, Trans Tech Publications, ISBN 13 978-3-03785-083-1 (2011). 9. Jär venpää A., Lämsä J., Hietala M., Mäntyjärvi K: Mechanical properties of a sandwich panel manufactured using longitudinally laminated forming tools, Key Engineering Materials 611 612, 781-785. 15. Mäkikangas J., Mäntyjärvi K., Keskitalo M., Karjalainen J. Rasmus M., Mäntyjärvi K., Karjalainen J.A.: Small Batch Laser Welding using Light Fasteners and Laser Tack Welding, International Journal of Key Engineering Materials Vol. H.: Laser welding of duplex stainless steel with nitrogen as shielding gas , Journal of Materials Processing Technology, pp. We have developed a method to get rid of them. http://www.scientific.net/ KEM.611-612.781 (2014). Significant energy savings due to effective units that recycle purified air back inside. Pentti; Lantto, Seppo: Mechanical properties of ferritic stainless steel welds in using type 409 and 430 filler metals, Welding in the World 57 (2013) 3, 335-347. 7th European Stainless Steel Conference, 21-23 September, 2011, Como, Italy, (2011). Genano 1000 series for industrial air cleaning Superior cleaning power protects sensitive equipment and your workers, keeping production quality high. Well-being at work We protect your most valuable investment – people. 14. 11. Anttila, Severi; Karjalainen, L. 381-384 (2015). Keskitalo M., Mäntyjärvi K., Kiuru T.: The low cycle fatigue strength of laser welded Ultra high strength steel, International Journal of Key Engineering Materials Vol. Anttila, Severi; Porter, David: Influence of shielding gases on grain refinement in welds of stabilized 21 % Cr ferritic stainless steel, Welding in the World 58 (2014) 6, 805-817. 10. A., Niemelä J., Ojala J: Laser welding of coated sheet metal constructions, Proceedings of the 11th NOLAMP Conference in Laser Processing of Materials, August 2007, Lappeenranta, Finland, pp 340-348, ISBN 978952-214-412-6 (2007). 473, Trans Tech Publications, ISBN 13 978-3-03785-083-1 (2011). Keskitalo M., Mäntyjärvi K., Sundqvist J., Powell J., Kaplan A. David Porter Professor, Materials Engineering Research Group Kari Mäntyjärvi Research Director, FMT Research Group Jouko Leinonen Professor (Adj.), Materials Engineering Research Group University of Oulu Box 8000 90014 Oulun Yliopisto Finland www.oulu.fi HT_2-3_15.indd 72 15.5.2015 16.00
In addition, education and research in the field of coating technologies by thermal spray processing and laser technologies are handled by the research group on surface engineering, headed by Professor Petri Vuoristo. Fig. The Department of Mechanical Engineering and Industrial Systems (MEI) is a comprehensive research and education unit in the field of mechanical engineering. The cornerstone of research and education at DMS is the high-level, basic investigation of the structure, properties, processing and use of materials. It is also the only higher education unit in Finland which examines all material groups, i.e., metals and their alloys, ceramic materials, polymers and composites. In addition, DMS operates in very close cooperation with Finnish industry, in areas related to applied materials research and product development. The Department of Materials Science (DMS) is one of the largest education and research units at TUT. For more than 25 years, research has been conducted in this area at DMS, with involvement in both national and European projects. DMS and MEI co-operation in the Laser Application Laboratory. 23/ 20 15 73 WELDING IN FINLAND [ www .hitsaus .net ] Education and Materials Joining Research Methods at Tampere University of Technology Pasi Peura, Petri Vuoristo and Jorma Vihinen At Tampere University of Technology (TUT), education and research related to joining technologies are performed by two university departments, the Department of Materials Science (DMS) and the Department of Mechanical Engineering and Industrial Systems (MEI). At present, DMS comprises 9 professors and approximately 130 total personnel. In practice, this means that in the case of metallic materials, the areas explored through research and education also additionally cover the important subjects of soldering, brazing, surface coating, welding and adhesive bonding. The DMS and MEI departments collaborate in the field of materials joining technologies, with activities related to laser materials processing carried out in the Laser Application Laboratory, shown in Fig. 1. HT_2-3_15.indd 73 15.5.2015 16.00. The MEI’s teaching and research focus encompasses not only the basic mechanical engineering technologies, but also the entire production process of a mechanical system, from product development to production engineering and life-cycle management, with the intersecting areas of engineering intelligence and sustainable mechanical systems. Regarding the groups which focus on materials other than metals, the joining of polymers and composite materials is handled by Professor Jyrki Vuorinen and his unit, with Professor Erkki Levänen leading the field of ceramic materials. Many of the research activities are conducted via close collaboration between these two units. As education at DMS embraces all material groups and their related material science, joining methods are also considered from a much broader perspective. There are about 100 employees in the department, including 12 professors. MEI has access to modern laboratories equipped with all the tools necessary for education and research. At DMS, the teaching and research of metals joining methods were previously performed by Emeritus Professor Tuomo Tiainen and, subsequently, by Associate Professor Pasi Peura after the former’s retirement. 1
3. As an example, MEI has collaborated with Osaka and Okayama Universities (Japan), in order to research the laser-based micro-welding of Si/glass. The laser welding cell for polymers and the welded, microfluidic, immunoassay cartridge. 2. Both iron-based and non-iron alloys have been widely examined. a) Laser-welded grid pattern in Si/glass. Compulsory laboratory sessions involve practical joining experiments, requiring each student to produce joints using several different welding methods, as well as to create multi-metal adhesive bonds. One such process module has been created especially for polymer welding, the laser welding process being a fast and accurate method for the bonding of polymers. In addition to normal metal-to-metal welding, a significant amount of research has been conducted on the laser welding of multi-materials and the welding of polymeric materials. As presented in Fig. 23/ 20 15 74 WELDING IN FINLAND [ www .hitsaus .net ] Thus far at DMS, more than 60 Master’s theses have been prepared on welding, laser coating and brazing/soldering, with adhesive bonding being investigated in some 10 Master’s theses. Six doctoral degrees have been awarded in the disciplines of welding and coating, with an additional doctorate awarded in the field of adhesive bonding. In recent years, an important topic has been the electron beam welding of thick copper plates. The background is studied in basic courses such as those related to phase transformations and heat treatments of metals. There is currently one ongoing doctoral study on adhesive bonding. Fig. b) Cross section of Si/glass, welded by 20-ps laser pulses. MEI is also involved in the elaboration of various production concepts. a b HT_2-3_15.indd 74 15.5.2015 16.00. 2, the research revealed that this technology enables the possibility of joining Si/ glass at a high spatial resolution, without preand post-heating and electric fields. The main application areas are packaging and encapsulation of multi-functional micro-systems. The tasks which DMS has performed have been related to the HAZ and weld bead microstructures, and to the increased understanding of mechanisms that affect final structures. The main topics of this course are welding metallurgy, principal welding methods, residual stresses and deformations, weldability of different metals and welding practices, soldering, brazing and adhesive joining. 3. Fig. In the case of steels, the welding of high-strength steels has been of particular interest. Examples of an investigated laser weld. Multi-material joints produced via brazing and soldering methods have also been investigated and the department has been active in the development of lead-free solders for the electronics industry. Welding, brazing and soldering At DMS, welding research has been concentrated mainly on the effects of welding on the final microstructure and the resulting properties. Another course on offer, Coatings and Surface Treatments, approaches such topics as thermal spray coating and laser cladding. Welding research at MEI MEI focuses mainly on laser welding research. In addition, a brief investigation of mechanical joining methods is included. Teaching of joining methods With regard to teaching, emphasis is placed on the effect of welding techniques and joining methods on the microstructure and resulting properties of the joint. Joining-related research In addition to welding-based joining methods, a significant amount of research has been carried out in the areas of brazing and soldering and, as already mentioned, the adhesive bonding of metals has been an active research focus for more than 25 years. More information is obtainable via the 5-credit unit course, Joining Methods for Metals. Laboratory work includes the characterisation of the resulting microstructures and final properties. In the case of adhesive bonds, the aging behaviour of the adhesive is investigated under different environmental conditions. In addition to its various research projects, DMS also offers research services in the field of welding. The department has developed a so-called micro-factory concept, where small parts are fabricated using small devices, as shown in Fig
This microscope is used primarily for studying the internal structure and chemistry of materials at a high spatial resolution. DMS also has several scanning electron microscopes which are equipped with energy dispersive X-ray spectrometers, as well as micro-hardness testers and electron backscattering detectors and software (EBSP). Fig. Through research collaboration, combined with their longstanding experience in thermal spray technology, the two organisations are destined to operate a recognised research platform, with world-class expertise and competitiveness in the field of thermal spraying. 4. In a previous project, a model capable of predicting the lifetime of bonds has been developed. Other equipment used for the characterisation of the microstructure of materials include, for example, an atomic force microscope/scanning tunnelling microscope (AFM/STM), an X-ray diffractometer, an IR spectrometer, thermal analysis equipment (DSCs, TG, STA, DMTA), amongst others. The possible temperature interval is -40°C…+115°C m 0,5°C, with the humidity range of 10…98% RH m 5% RH, and the lowest condensation temperature of +5°C. The Laser Application Laboratory (LAL) is equipped with up-to-date manufacturing technologies, including high-power (4-6 kW), medium-power (0.1-1 kW) and low-power lasers. 23/ 20 15 75 WELDING IN FINLAND [ www.hitsaus.net ] Research on thermal spray coating processes at DMS The Surface Engineering laboratory at TUT/ DMS benefits from longstanding experience in the research of thermal spray processes. Furthermore, research on coatings examines the technical properties of materials and application-related performances, e.g., corrosion, wear, high-temperature, friction, optical and electrical properties and tailored structures. HT_2-3_15.indd 75 15.5.2015 16.00. Thermal spray techniques include several spray processes of which DMS possesses a large majority: conventional flame, arc and plasma spraying and novel, advanced techniques such as high-velocity flame spray processes (High-Velocity Oxygen-Fuel, HVOF and High-Velocity Air-Fuel, HVAF) and cold spray processes. When associated with static or dynamic loading, these environmental factors tend to weaken joints. For example, DMS possesses several electron microscopes, including an analytical transmission electron microscope equipped with an energy-dispersive X-ray spectrometer and a scanning unit. 5, the measured residual strength values revealed the influences of the loading stress level and different pre-treatments on the durability of the adhesive joints, studied under temperature and humidity-induced aging conditions,. Recent laser research has focused on the development of high deposition rate laser metal deposition techniques, to be employed in laser cladding, re-manufacturing of serviceworn components and additive manufacturing, Fig. Adhesive bonding The long-term durability of adhesive joints has been an important area of interest at DMS. 4. Durability is dependent upon several variables which can be divided into the environmental, material and joining process-dependent categories. The DMS and MEI departments share a laboratory, the Laser Application Laboratory, which provides an environment conducive to the research of various laser surface engineering activities, including cladding and hardening. In thermal spraying, coatings can be produced from several materials (metals, metal alloys, ceramics, hard metals, polymers and composites) in the form of powder, wire or suspension feedstock. In addition, TUT and its research partners in Kokkola (Centria and KETEK) collaborate in the field of laser cladding and materials engineering research. For the durability testing of adhesive bonds, two on-site climate chambers are used, one measuring 600 litres and the other, 900 litres, both outfitted with rigs for static tension loading. The team comprises approximately 15 employees, including individuals awarded with doctoral degrees. Since the effect of surface pretreatment is one of the most important parameters that influence the strength and durability of adhesive joints, it is the topic of an ongoing doctoral study on epoxy-based, adhesive, aluminium joints. TUT/DMS has been involved in the large FIMECC/HYBRIDS research programme funded by TEKES, in which multi-functional thin and thick coatings and hybrids will be developed (2014-2018). Research facilities The research facilities at DMS can be divided into the materials characterisation and materials processing and treatment categories. The equipment is suitable for extended exposure testing both in stable and variable atmospheres. For the purpose of mechanical testing, DMS owns several hydraulic and mechanical materials testing machines and hardness testers. Research on laser metal deposition and laser cladding at DMS TUT also has quite a long history of research on laser metal deposition, or laser cladding and coating. Research has also included tailored coating structures and properties, industrial applications (including acceptance criteria) and materials science of metal and metal matrix composite coatings for the offshore, pulp and paper, mining, energy, steel and metals industries. Among the environmental factors, moisture and temperature have been identified to be predominant. For materials characterisation, the most important equipment and techniques are related to the determination of structure-property relationships, and include various types of microscopes, mechanical testing machines, equipment for thermal analysis, inter alia. LMD process based on 15 kW fiber laser, coaxial type powder nozzle and linear scanner. One of the main key areas is the development of functional coating solutions for demanding industrial applications, such as those encountered in the paper and energy industries, for instance. In 2015, TUT and VTT started close cooperation in the field of thermal spray coating processing, with the establishment of a new research platform, “Thermal Spray Center Finland” (TSC Finland), located at TUT in Tampere. The equipment is appropriate for most ISO, ASTM and other standards tests. The lasers are used for materials processing, such as laser cladding, surface hardening, welding, surface patterning and micromachining. As seen in Fig. This world-leading research was conducted within the framework of FIMECC’s Innovations & Network (2009-2014) research programme. At this moment in time, thermal spray research focuses on the processingstructure-properties-performance relationships of coatings, prepared via the use of thermal spray and laser surface treatments
Ruoranen, J., Tiainen T., The influence of surface pre-treatments on the strength of epoxy-based adhesive aluminium joints under combined static loading and environmental aging conditions, proceedings of EURADH 2012, 9 th European Adhesion Conference, Friedrichshafen, Germany, 2012. Hybrid materials will also offer new possibiliFig. The measured residual strength values revealed the influence of the loading stress level and different pre-treatments on the durability of the adhesive joints, studied under temperature and humidity-induced aging conditions. With these materials, it is possible to obtain huge improvements, for example, in the specific strength properties of construction materials (strength/weight, strength vs elastic modulus or ductility), in the wear and corrosion properties of bulk and coating materials, and in many other mechanical, physical and chemical properties of the materials. 23/ 20 15 76 WELDING IN FINLAND [ www .hitsaus .net ] Future outlook One of the research directions selected by DMS is hybrid materials, which can be tailored to utilize the quite different properties and behaviours of the various basic material groups. 10 kW fiber laser Robot GMA welding with 12 m gantry 2 kW SM fiber laser, Remote welding Submerged arc welding HT_2-3_15.indd 76 15.5.2015 16.00. We have extensive experience in managing, facilitating and coordinating a wide range of metal industry projects, and participating in various international development and territorial cooperation programmes (e.g. 34273439. We provide unique machinery, modern technologies, professional expertise and links to universities for laser processing and welding technologies. This will also emphasize the importance of multi-material joints and their properties in demanding applications. FP7, Interreg, Lifelong Learning). 5. References Miyamoto, I., Okamoto, Y., Hansen, A., Vihinen, J., Amberla, T., Kangastupa, J., High speed, high strength microwelding of Si/glass using ps-laser pulses, (2015) Optics Express, 23 (3), pp. Box 589 33101 Tampere Finland www.tut.fi www.koneteknologiakeskus.fi YOUR FUTURE PARTNER IN RESEARCH AND DEVELOPMENT. ties for tailoring the functionality and processibility of materials. Pasi Peura, Associate Professor Petri Vuoristo, Professor Department of Materials Science Jorma Vihinen, Research Manager Department of Mechanical Engineering and industrial Systems Tampere University of Technology P.O. Kallio, P., Vihinen, J., Välimaa, P., Chandhary, V., Ready-to-use Microfluidic Cartridges for Affordable point-of-care Diagnostics, (2014) Technology report, Tekes. Hakala, K., Long-Term Durability of Adhesively Bonded Austenitic Stainless Steel Joint, Tampere University of Technology, Department of Materials Engineering, Licentiate Thesis 2002
On the one hand, these include the requirements of the final product with respect to loading, service environment and service, and on the other, welding production and its efficiency, productivity and quality, as well as delivery speed and certainty. Another route to an increase in productivity is the use of welding mechanisation and automation, for which VTT can offer a holistic approach which covers not only welding robot cells, but also the complete factory or production line design and layout for optimised material flows and minimised throughput times. Another group of materials of national importance to Finland is the family of high-alloyed stainless steels. Consequently, K JC needs to be measured directly using fracture mechanics tests on these steels. According to the results obtained at room temperature and at -40°C, the fracture resistance (J-R) tests indicated overall ductile behaviour. VTT employs a staff of 2600 and registers a turnover of 279 M€ (2013). Fracture mechanics analysis revealed that due to different constraints, the T estimates according to ASTM E 1921, based on fracture mechanics tests using small-scale, 3-point bent SE(B) specimens, were clearly conservative and hence on the safe side, in relation to the T estimates calHT_2-3_15.indd 77 15.5.2015 16.00. VTT is impact-driven and from its wide, multitechnological knowledge base, VTT can combine different technologies, produce information, upgrade technology know-how and create business intelligence and added value for its stakeholders. VTT is ranked as being among the leading European RTOs. (now SSAB). VTT’s current welding research areas and focus are hereinafter described, using selected project examples. Welding modelling and simulation have a long and established history at VTT. Apart from the stainless steel producers, there is also a strong and successful branch of process equipment fabricators and suppliers who seek VTT´s acknowledged know-how about these materials and their weldability. VTT’s activities are focused on three key areas: knowledge-intensive products and services; smart industry and energy systems; and solutions for natural resources and the environment. While artificial ageing (250 °C/0.5 h) alone increased the T temperature only slightly (. The activity was originally launched by the Finnish Army during World War II, following a proposal to establish a welding research group within the VTT Metals Laboratory in 1943. Since properties and production technologies of high-strength steels have developed at a rapid pace, the level of VTT’s in-house expertise has been raised accordingly. Regarding brittle fracture, the T reference temperature (K JC = 100 MPa?m) for the as-received material was around -50°C. Over the years, VTT has gained vast experience through its participation in numerous European R&D Framework Programme projects and in various other thematic programmes. The welding research personnel is always in close project-specific co-operation with other VTT experts specialised in, for e.g., service environment, structures, design, production, characterisation and testing. The application of novel, high-strength steel grades in welded constructions calls for high-quality fracture and failure analyses, as well as for tools for fatigue optimisation as part of the design process and service behaviour analysis. The special circumstances of the end product sector must also be taken into account. VTT is traditionally highly-competent in the areas of welding metallurgy and failure mechanisms of structural steels. This strengthens the role of welding as an enabling technology that is fully integrated as a part of the whole production system, whether in the machinery, process or other industrial sector. Mika Siren, Veli Kujanpää and Pekka Nevasmaa VTT Technical Research Centre of Finland Ltd. Essential factors in experimental and analytical welding research work are high-quality analysis and characterisation facilities. For the strength level studied, the relation between the T and the T 28J temperatures did not follow the general FITNET-based correlation. There are a few key starting points for VTT´s R&D work on welding processes and weld metallurgy. Owing to the high strength and small plate thickness, shear fracture occurred in the Ubeam and in the rectangular hollow-section tests. Additionally, they offer the possibility to improve productivity quite remarkably, provided that the pre-requisites for the investment exist. Ultra-High-Strength Structural Steels The fracture behaviour of direct-quenched, ultra-high-strength S960DQ steel in different conditions (i.e., as-delivered, cold-strained, cold-strained and artificially-aged) was jointly studied by VTT, the University of Oulu, Lappeenranta University of Technology and the former Ruukki Ltd. This investigation formed part of a more broadly-focused national R&D framework programme on materials characterisation and fracture behaviour of direct-quenched, ultrahigh-strength steel products. 23/ 20 15 77 WELDING IN FINLAND [ www.hitsaus.net ] Welding Research at VTT Ltd . For example, in power generation industries, the quality of materials and welds, as well as service life and reliability, often carry much more weight than the cost or productivity of production. Having recently celebrated its 70 th anniversary of existence, VTT’s history of involvement in welding research is quite longstanding. Thus, estimation of the fracture toughness using Charpy data would have led to severely un-conservative K JC estimates. is a state-owned and controlled, non-profit, limited liability company established by law, operating under the ownership steering of the Finnish Ministry of Employment and the Economy. Similarly, the Charpy tests indicated an increase of the T 28J temperature. The testing programme consisted of small-scale fracture mechanics and Charpy V testing, as well as bending tests on large-scale U-beams and cold-formed, rectangular hollow sections. Today, the work is aimed more and more towards complete simulation chains from weld pool behaviour using CFD, through FE analysis for distortion and residual stress state development evaluation, to optimised fatigue performance, based on the entire previous welding history and weld characterisation. Laser and laser hybrid welding provide a completely new and flexible means of controlling heat input and the heat effects of welding on new, high-quality steel grades. 10°C), the combination of cold-straining (15%) and artificial ageing resulted in a nearly 50°C increase in the T . However, this led to only a 10–20% decrease in the load-bearing capacity from the theoretical maximum load, according to the U-beam tests
New, austenitic stainless steels, strain-hardened by cold rolling, offer an attractive combination of elevated strength, high elongation and excellent toughness. The results demonstrated that once under-matching exceeded 20 %, overall failure appeared to be controlled by plastic collapse, due to a reduction in limit load. In the case of under-matching strength, it is therefore essential to apply appropriate limit load solutions to all of the different regions of the mis-matched weldment, in order to ensure sufficient conservatism of the FAD analysis is adequately preserved. 1. It is clear that this cannot be accomplished solely by the use of numerical computations, but that it would require experimental thin-section, wide-plate tests on austenitic steel (high-strain-hardening capacity), strain-hardened austenitic steel (lower-strainhardening capacity) and ultra-high-strength structural steel (low-strain-hardening capacity) welds, in order to identify the most appropriate solution for ‘L r max ‘ applied in the FADs for different steel grades. For this purpose, two different L rmax solutions for under-matching welds were applied, as according to FITNET. True stress-strain curves were successfully obtained using 1 × 2 × 8 mm flat-bar specimens. Both the Failure Assessment Diagram (FAD) analysis, according to the FITNET Mis-Match Option, and the outcome from the U-beam and hollow-section, large-scale test variants, all consistently showed that brittle cleavage fracture would not become the dominant fracture mode in the welded beam constructions studied, provided that the service temperature does not fall below -50°C. The degree of weld under-matching and material strain hardening were then evaluated against material-related Failure Assessment Diagrams (FADs). This would then enable the analysis of the true level of safety in structural integrity assessments, using FADs with the Mis-Match Option. Failure Assessment Diagram (FAD) for S960 steel weldment under tension load (membrane stress) and assuming maximum welding residual stresses and a semi-elliptical surface crack (mis-match = M; brittle fracture: K r ->1; L r ->0). For future purposes, it would be valuable to investigate how the limit load ratio affects the corresponding FAD in the case of a different crack size/crack location/weld width/ degree of under-matching combination, in order to reveal the actual level of built-in conservatism/un-conservatism in each respective case. Mis-Match The influence of weld under-matching strength on limit load and failure behaviour was studied jointly by VTT and the University of Oulu in a recent “MIS-MATCH” project, funded by the Finnish Funding Agency for Innovation (Tekes) and domestic industry. Applying these data in the form of the continuous strength function model, structural integrity assessment was conducted using the FITNET FFS Procedure Level 2 analysis and incorporating the MisMatch Option. A set of material-specific FADs was constructed, accounting for the degree of weld under-matching and strain hardening of the material. The inclusion of constraint also affects the analysis during ductile initiation and in the tearing region. With respect to welded joints, the distribution of plastic deformation is essentially affected by mis-matching, as quantified by the evolution of the plastic crack driving force and the plastic collapse limit load. VTT’s current research into mis-match have also focused on ferrite-austenite, dissimilar metal welds (DMW), with a view to characterizing how the strength/hardness mis-match between two adjacent weld zones affects fracture resistance and failure behaviour, particularly in terms of sudden crack deviation during the propagation stage. Their exploitation, however, requires that the effects of weld mis-match are understood and taken into account during structural analysis. Complete tearing analyses, based on the fracture resistance (J-R) curve, can be used for the optimisation of component design, as well as for gaining more performance from the material. HT_2-3_15.indd 78 15.5.2015 16.00. Plastic collapse can become a limiting issue as a result of under-matching, since crack initiation and propagation mechanisms are far less affected. Mechanical properties of mis-matching microstructural regions were determined using the miniature specimen technique, in conjunction with optical monitoring during the tensile test. Further studies on revised, therefore realistic and safe, Charpy toughness – fracture toughness correlation, also suitable for ultrahigh-strength materials, are currently underway within the national Fimecc “Breakthrough Steels and Applications” programme project, Extremest, carried out jointly by VTT, the University of Oulu and SSAB. Quasi-static bending tests on welded, fatigue-cracked, cold-formed, rectangular hollow sections at -40°C showed good agreement with non-linear FEA calculations using the J-integral approach. Especially with regard to the FITNET procedure, FADs produced from the true stress-strain curves were more accurate than if engineering curves had been used. 23/ 20 15 78 WELDING IN FINLAND [ www.hitsaus.net ] culated from the large-scale, U-beam, bending test data. Hence, safety margins can be smaller when applying FADs to actual structural design. The GMAW butt welds were made using different levels of heat input and incorporating various filler metal compositions. The influence of local softened regions on structural integrity and failure behaviour of welds under external static load was later evaluated, using mechanically-strain-hardened austenitic steel EN 1.4318 (AISI 301LN) of 5 mm plate thickness, cold-rolled to 2B, C850 and C1000 delivery conditions. Fig. Under-matching strength was found to be the most serious, considering plastic collapse and ductile tearing
2. a) A T-joint welded with multi-pass fillets, b) Laser scanning of the weld profile c) Scanned T-joint point cloud, d) Principal stresses in bending, calculated using the true weld profile the projects have been targeted on researching and developing the welding methods to be used in the assembly welding of vacuum vessel sectors. 23/ 20 15 79 WELDING IN FINLAND [ www .hitsaus .net ] Digital Welding Design and Production It is evident that there is a need to shorten the timespan for the design and development of new products in the Finnish machinery industry. All of these sealing and opening operations must be conducted using robots and remote control, since the radiation which remains in the vacuum vessel restricts the exposure time of any workers inside the vessel, or in a c d b HT_2-3_15.indd 79 15.5.2015 16.00. The coverage and digital processing of the interdependency of the welding process and its parameters, and the resulting weld fatigue properties in the simulations, are major challenges in the development of a tool for the design and simulation of the fatigue of welded structures. These methods have included multi-pass, filler metal, laser welding with a cold wire, hybrid laser welding, electron beam welding and other related aspects. In order to optimise both simultaneously, both the product and production requirements must be properly controlled, in such a way as to determine the absolute quality needed and the corresponding features necessary for each particular case. This challenge is being tackled within the scope of the “Future Digital Manufacturing Technologies and Systems” research programme by Fimecc (Finnish Metals and Engineering Competence Cluster), and the relevant technical solutions are being developed by the VTT coordinated “Digital Manufacture and Fatigue Optimisation for Superior Reliability (DIGFOSURE)” project. Most of Fig. The answer in response to both of the afore-mentioned demands is an integrated simulation and analysis toolbox which covers the entire design chain from the welding process to the resulting metallurgical properties, weld geometry, residual stresses and distortions, up to the fatigue strength and, eventually, the life cycle characteristics of the welded structure. Modern welding simulation software tools provide the means for rapid and accurate calculation of the welding deformations and residual stress state which result from a particular procedure. 3. An example of a 20 mm multi-pass weld created by hybrid laser welding (Nd: YAG-laser + MIG). Final closure is assured by a 2 mm, austenitic stainless steel (lip seal) bolt so that in the vessel, there is an ultra-high vacuum maintained during the fusion reactor operations. In addition, VTT has participated in the development of methods and the detailed work flow of sector assembly. ITER LipSeal There are 44 ports in the vacuum vessel of the ITER reactor through which the diagnostic tasks, heating and vacuum pumping and other service operations are conducted. On the other hand, the manufacturing parameters during the welding process can be optimised according to productivity or quality. Research on ITER (International Thermo-nuclear Experimental Reactor) VTT has contributed since 1998 to the development of welding technology related to the vacuum vessel of the experimental fusion reactor (ITER) under construction in France. The results of the projects have been reported in international journals, conference proceedings and public project reports. Furthermore, results can be used as source data for fatigue analysis and design, or for welding procedure optimisation for productive welding fabrication. One method for shortening the timeframe for the marketing of such products is the introduction of modern, integrated, digital design tools to support the industry´s product design and development efforts. This need emerges particularly in the fatigue design of welded machinery structures with long service life and high structural and operational reliability requirements. There have since been 10 projects. opened during different kinds of service operations, while being able to be re-sealed, via welding, however many repeated times during the lifetime of the fusion reactor. One remarkable part of ITER has also been the discovery of the hot cracking susceptibility of highly-alloyed, austenitic stainless steel, and the factors by which the risk of cracking can be minimized. The welding of a vacuum vessel is extremely challenging because of its large size (diameter approximately equal to 18 m, height 12 m), its very accurate tolerances, its double wall structure which requires welding from the inside, and its wall thickness of 60 mm. The seal must be made so that it can be Fig
The welded mockups were tested by clean-room experts during leak tests and weld quality was tested by NDT experts. Therefore, welding technologies have an extremely strong, yet indirect, influence on the nation´s welfare. Temperature distribution during the welding of a model fillet T-joint a) global and b) cross-section close proximity to it. The customer, ITER, was satisfied about the mock-up samples, as evidenced in the photograph above. Furthermore fusion welding processes (including arc, beam and hybrid welding methods) are key enabling technologies in virtually all exported machinery products. As part of the FiDiPro (Finnish Distinguished Professor) programme, VTT conducts research on CFD simulation in welding, in close collaboration with Prof. In order to maximise the added value which would be achievable with these high-quality products, their welding processes would need to be optimised in order to exploit their full potential in the service properties of the end products. Using half-sized parts, the work was demonstrated by TIG and laser welding separately. The thermal-elasto-plastic behaviour of the weld, including its deformations, distortion and residual stresses, is influenced not only by the size of the weld bead and the heataffected zone, but also by the temperature distribution and thermal history at every weld point, as well as by the phase transformation characteristics of the weldment. Suck-Joo Na of the Korea Advanced Institute of Science and Technology (KAIST), directly connected to the “Digital Materials Engineering and Modelling of Mass and Heat Flow for Optimisation of Joining of Materials” project. Fig. 4. Welding Simulation The machinery industry plays a determining role for the prosperity of the Finnish economy and society. Consequently, welded structures can be effectively designed through the elastic analysis of whole structures, by adopting the inherent strains in welds obtained after CFD simulations of welding processes and thermal-elasto-plastic analysis of the weldment. In addition, the laser head was planned with a separate order, and these projects reflected perfect examples of VTT’s combination of know-how in different fields of expertise. Mika Sirén Senior Scientist Veli Kujanpää Professor Pekka Nevasmaa Principal Scientist www.vttresearch.com b a Fig. 23/ 20 15 80 WELDING IN FINLAND [ www.hitsaus.net ] Fig. In the same regard, the deformation of welded structures can in turn be estimated and controlled accurately, once the results of proper thermal-elasto-plastic analysis of welds with CFD simulations are calculated and applied. The ITER organisation contracted lip seal welding work development and demonstration from VTT. 6. Welding experts developed two separate welding methods – laser and TIG welding – to weld the sealing lip in all positions, machining experts developed the opening of the weld, the environmental experts analysed the impurities, while robot experts developed the positioning, path planning and seam tracking systems. ITER lip seal: half-seal of mock-up with VTT researchers and ITER customers HT_2-3_15.indd 80 15.5.2015 16.00. In addition to welding researchers, the customer can benefit from the expertise of an entire 2,600-strong workforce and extensive and well-equipped research facilities. In comparison with welding simulation using thermal analysis by conduction only, welding processes can be effectively optimised by the introduction of computational fluid dynamics (CFD) in weld pool behaviour, where the recognition of interaction between the heat source and the workpiece is an essential pre-requisite for precise simulations. In addition, it is imperative to avoid any impurities (e.g., welding fumes, spatter and chips, etc.) inside the vessel chamber. The utilisation of weld simulation provides an excellent means for shortening the development cycle and hence, the time-to-market or profit of new products. Summary VTT offers welding research services at all levels, from small and rapidly-commissioned tasks, to wide-ranging national or international projects and research programmes, encompassing manufacturing on a scope larger than just one individual production technology. When compared to thermal analysis by conduction only, simulation results of CFD analysis will offer much more reasonable conclusions about temperature distribution and thermal history of the weld and, hence, will result in a more accurate estimation of thermal-elasto-plastic behaviour. Simulation is thus a powerful tool in the design of the welding procedure for advanced steel structures. 5. Lip seal robot welding with TIG and laser
23/ 20 15 81 WELDING IN FINLAND [ www.hitsaus.net ] Welding Society of Finland Member Companies A.Häggblom Oy Ab www.haggblom.fi AEL Oy www.ael.fi Aga Oy Ab www.aga.fi Air Liquide Finland Oy www.airliquide.fi Alexander Binzel Hitsaustekniikka Oy www.binzel-abicor.com Amec Foster Wheeler Energia Oy www.amecfw.com Amiedu www.amiedu.fi Ammattiopisto Lappia – The Vocational College Lappia www.lappia.fi Apricon Oy www.apricon.fi Arctech Helsinki Shipyard Oy www.arctech.fi Axxell Utbildning Ab www.axxell.fi Bronto Skylift Oy Ab www.bronto.fi Calortec Oy www.calortec.fi Caverion Industria Oy www.caverion.fi Cavitar Oy www.cavitar.com Cebotec Oy www.cebotec.tawi.fi Clean Flame Oy Ltd www.cleanflame.fi Control Express Finland Oy www.cef.fi Copax Oy www.copax.fi DEKRA Industrial Oy www.dekra.fi Delfoi Oy www.delfoi.com DNV GL Business Assurance Finland Oy Ab www.dnvba.com ESAB Oy www.esab.fi Euromaski Oy www.euromaski.fi FB Ketjutekniikka Oy www.fbketjutekniikka.fi Ferroplan Oy www.ferroplan.fi Finfocus Instruments Oy www.finfocus.fi Finnrobotics Oy www.finnrobotics.fi GaV Group Oy www.gavgroup.fi Haapaveden ammattiopisto – Haapavesi Vocational College www.jedu.fi Heatmasters Lämpökäsittely Finland Oy www.heatmasters.net High Metal Production Oy www.highmetal.fi Howden Turbo Fans Oy www.howden.com Hydros Oy www.hydros.fi Impomet Ab Oy www.impomet.com Inkone Ab Oy www.inkone.fi Inspecta Tarkastus Oy www.inspecta.com Insteam Oy www.insteam.fi Ionix Oy www.ionix.fi Irs M. Tähtinen Oy www.kttahtinen.fi Kart Oy Ab www.kart.fi Kavamet-Konepaja Oy www.kavamet.fi Kemppi Oy www.kemppi.com Keski-Pohjanmaan Aikuisopisto – Keski-Pohjanmaa Institute of Adult Education www.kpakk.fi Keski-Pohjanmaan ammattiopisto – Keski-Pohjanmaa Vocational College www.kpedu.fi Kirike Oy www.kirike.fi Koja Oy www.koja.fi Kokkola LCC Oy www.lcc.fi Konecranes Finland Oy www.konecranes.fi Kotkan-Haminan seudun koulutuskuntayhtymä Ekami – Etelä-Kymenlaakso Vocational College www.ekami.fi Laatukattila Oy www.laatukattila.fi Lapin ammattikorkeakoulu Oy – Lappi University of Applied Sciences www.lapinamk.fi Lapin ammattiopisto – Lappi Vocational College www.lao.fi Lappeenrannan teknillinen yliopisto – Lappeenranta University of Technology www.lut.fi LH Lift Oy www.lhlift.com Lincoln Electric Nordic Finland Oy www.lincolnelectricnordic.fi Luksia, Länsi-Uudenmaan koulutuskuntayhtymä – Intermunicipial Federation of Vocational Education in Western Uusimaa www.luksia.fi Länsirannikon Koulutus Oy Ltd, WinNova www.winnova.fi Majek Oy www.majek.fi Masino Welding Oy www.masino.fi Metawell Oy www.metawell.fi Metlab Oy www.metlab.fi METSTA, Mechanical Engineering and Metals Industry Standardization in Finland www.metsta.fi Meuro-Tech www.meuro-tech.fi Meyer Turku Oy www.meyerturku.com Migatronic Oy www.migatronic.com Migmen Oy www.migmen.fi Miilukangas Oy www.miilukangas.fi Mimet Oy www.mimet.fi Nordic Power Service Inspection Oy www.nordicpowerservice.com Optima www.optimaedu.fi OSTP Finland Oy Ab www.ostp.biz Ottia Oy Oulun Yliopisto – University of Oulu www.oulu.fi Outokumpu Stainless Oy www.outokumpu.com Outotec (Finland) Oy www.outotec.com Ovako Imatra Oy Ab www.ovako.com Palosaaren Metalli Oy www.palmet.fi Peikko Finland Oy www.peikko.fi Pekka Salmela Oy www.pekkasalmela.fi Pektra Oy www.pektra.fi Pemamek Oy www.pemamek.com Pieksämäen Hitsaus ja Koneistus Oy www.hitsausjakoneistus.fi Pohjois-Karjalan aikuisopisto – North Karelia Adult Education Centre www.pkky.fi Prewel Oy www.prewel.fi Pronius Oy www.pronius.fi Raahen Aiku – Vocational Adult Education Centre of Raahe www.raahenaiku.fi Rakennustempo Oy www.rakennustempo.fi Retco Oy www.retco.fi RKT Group, Rannikon Konetekniikka Oy www.rkt.fi Sah-Ko Oy www.sah-ko.fi Sammet Asennus Oy www.sahala.fi Savon ammatti-ja aikuisopisto – Savo Vocational College and Varkaus Upper secondary School www.sakky.fi Savonia ammattiokorkeakoulu – Savonia University of Applied Sciences www.savonia.fi Somotec Oy www.somotec.fi Sonar Oy www.sonar.fi SP stainless Oy, Savonlinna www.spstainless.fi SSAB Europe Oy www.ssab.fi Stadin ammattiopisto – Helsinki Vocational College www.stadinammattiopisto.fi Steel Production Maanselkä Oy www.veda.fi Steris Finn-Aqua www.steris.com Stresstech Oy www.stresstechgroup.com Suomen 3M Oy www.3m.com Suomen Levyprofiili Oy www.suomenlevyprofiili.fi Suomen Teknohaus Oy www.teknohaus.fi SVS Supervise Service Oy www.superviseservice.fi Tapex-QC Oy Technip Offshore Finland Oy www.technip.com Tekniset Asiantuntijat TA Ky www.tekniset-asiantuntijat.fi Telatek Oy www.telatek.fi Temet Oy www.temet.fi Teräselementti Oy www.teraselementti.fi Teräs-LVI Oy Ab www.teraslvi.fi Terässaari Oy www.terassaari.fi Transtech Oy www.transtech.fi Turun aikuiskoulutuskeskus – Turku Adult Education Centre www.turunakk.fi VaasaBall LNG Products Ltd. Kaasinen Oy www.irsmiikakaasinen.fi Isojoen Konehalli Oy www.ikh.fi John Deere Forestry Oy www.deere.fi Jomeco Oy Jucat Oy www.jucat.fi Jyväskylän aikuisopisto – Jyväskylä Institute of Adult Education www.jao.fi K.T. www.vaasaball.fi Vaasan Aikuiskoulutuskeskus – Vaasa Adult Education Centre www.vakk.fi Vahterus Oy www.vahterus.com Wallius Hitsauskoneet Oy www.wallius.com Valmet Technologies Oy www.valmet.com Vantaan ammattiopisto Varia – Vantaa Vocational College Varia www.varia.fi Weldforce Oy www.weldforce.fi Veslatec Oy www.veslatec.com Vexve Oy www.vexve.com Viitek Oy www.viitek.fi voestalpine Böhler Welding Nordic AB www.voestalpine.com Woikoski Oy Ab www.woikoski.fi VR-Track Oy www.vrtrack.fi YA! Yrkesakademin i Österbotten – YA! Vocational College of Ostrobothnia www.yrkesakademin.fi Yaskawa Finland Oy www.motoman.fi YTT-Konepaja Oy www.ytt.fi Zetanova Oy www.zetanova.fi HT_2-3_15.indd 81 15.5.2015 16.00
The Finnish Junior Welding Championships and Robotic Arc Welding Contest as well as several actual seminars will be organized as part of the Nordic Welding Expo 2016. Other themes include steel construction and maintenance. 23/ 20 15 82 WELDING IN FINLAND [ www.hitsaus.net ] Largest Trade Fair for the WELDING in Nordic Countries The Nordic Welding Expo is the most significant welding event in the Nordic countries. AT THE SAME TIME: Engineering Works – Trade Fair for Metal Industry Machinery and Equipment 15–17 March 2016 Tampere Exhibition and Sports Centre, Finland www.nordicweldingexpo.fi www.nordicweldingexpo.fi/stand Contact our sales +358 207 701 215 / Raimo Pylvänäinen +358 207 701 233 / Jukka Järvinen . The sixth NWE will provide a cross-section of new products and innovations in the fields of welding, cutting and joining. » Welding » Steel Construction » Maintenance Suomen Hitsausteknillinen Yhdistys The Welding Society of Finland HT_2-3_15.indd 82 15.5.2015 16.00. rstname.lastname@tampereenmessut.
Change of torch neck in one minute. rstname.lastname@tampereenmessut.. www.binzel-abicor.com ABIMIG ® A T LW. [ www.hitsaus.net ] T E C H N O L O G Y F O R T H E W E L D E R ‘ S W O R L D . The sixth NWE will provide a cross-section of new products and innovations in the fields of welding, cutting and joining. The new air-cooled welding torches ABIMIG ® A T LW. Without tools and with just a few steps directly at the workplace. With interface system »T« for the fast change of torch necks. Time to change. Other themes include steel construction and maintenance. The Finnish Junior Welding Championships and Robotic Arc Welding Contest as well as several actual seminars will be organized as part of the Nordic Welding Expo 2016. » Welding » Steel Construction » Maintenance Suomen Hitsausteknillinen Yhdistys The Welding Society of Finland 68 th IIW Annual Assem bly Helsinki FINLAND 28 th June – 3 rd July 20 15 68 th IIW Annual Assembly & International Conference 28 th June – 3 rd July 2015 Helsinki, Finland International Conference on High Strength Materials Challenges and Applications 2 nd – 3 rd July 2015 www.iiw2015.com IIW2015_postcard.indd 1 30.8.2013 9.26 HT_2-3_15.indd 83 15.5.2015 16.00. AT THE SAME TIME: Engineering Works – Trade Fair for Metal Industry Machinery and Equipment 15–17 March 2016 Tampere Exhibition and Sports Centre, Finland www.nordicweldingexpo.fi www.nordicweldingexpo.fi/stand Contact our sales +358 207 701 215 / Raimo Pylvänäinen +358 207 701 233 / Jukka Järvinen . For every welding task always exactly the torch neck with the best suitable geometry and alignment. Find out more now and test it! Alexander Binzel Hitsaustekniikka OY Kartanontie 53 FI-28430 Pori Phone: +358 2 634 4600 Fax: +358 2 634 4650 info@binzel.fi ABIMIG_A_T_LW_89x266_FI_GB.indd 1 26.03.15 07:29 PLATE & SHELL PLATE PLATE Fully welded Heat Exchangers Heat Exchangers Heat Exchangers www.vahterus.com Largest Trade Fair for the WELDING in Nordic Countries The Nordic Welding Expo is the most significant welding event in the Nordic countries
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