International Scientific-Technical and Production Journal
May
2012
# 5
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
Editor-in-Chief B.E.Paton
Yu.S.Borisov V.F.Khorunov
A.Ya.Ishchenko I.V.Krivtsun
B.V.Khitrovskaya L.M.Lobanov
V.I.Kyrian A.A.Mazur
S.I.Kuchuk-Yatsenko
Yu.N.Lankin I.K.Pokhodnya
V.N.Lipodaev V.D.Poznyakov
V.I.Makhnenko K.A.Yushchenko
O.K.Nazarenko A.T.Zelnichenko
I.A.Ryabtsev
CONTENTS
SCIENTIFIC AND TECHNICAL
. and
. Flash-butt welding of thick-walled pipes from
high-strength steels of K56 strength class .................................................. 2
. and
.
Experimental study of the mechanism of hydrogen embrittlement of
metals with the bcc lattice .......................................................................... 8
. and
N.P.Alyoshin (Russia)
U.Diltey (Germany)
Guan Qiao (China)
D. von Hofe (Germany)
V.I.Lysak (Russia)
N.I.Nikiforov (Russia)
B.E.Paton (Ukraine)
Ya.Pilarczyk (Poland)
G.A.Turichin (Russia)
Zhang Yanmin (China)
A.S.Zubchenko (Russia)
V.N.Lipodaev, V.I.Lokteva
A.T.Zelnichenko (exec. director)
A.A.Fomin, O.S.Kurochko,
I.N.Kutianova, T.K.Vasilenko
N.A.Dmitrieva
D.I.Sereda, T.Yu.Snegiryova
. New capabilities of
mechanized arc spot welding using pulse effects ....................................... 12
. and
. Effect of structural-phase transformations in aluminium-lithium
alloy 1460 joints on physicalmechanical
properties .............................................................................. 17
. and
. Microstructural features of fatigue damageability and methods
to improve the fatigue life of welded joints from 09G2S steel ...................... 26
. Effect of additions of aluminium to flux-cored wire
on properties of high-carbon deposited metal ............................................ 31
INDUSTRIAL
. and
. Equipment and technology of EBW in finishing
smoothing and repair of reverse beads of welds of tubular products ........... 37
. and
.
Development of surface crack-like defect in welded joints of
06GB-390 steel at cyclic loading................................................................ 40
. and
State Registration Certificate
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© PWI, International Association «Welding», 2012
. Method for
manufacture of large-sized forged-cast billets using electroslag
welding .................................................................................................... 43
. Experience of application of plasma hardening unit
UDGZ-200 at enterprises of the Urals region .............................................. 46
Light-weight welding tractors of the E.O. Paton Electric Welding
Institute .................................................................................................... 49
BRIEF INFORMATION
Thesis for a scientific degree .................................................................... 51
NEWS
Our congratulations! ................................................................................. 52
News ....................................................................................................... 53
INFORMATION
Presentation of technology of arc welding of position butts of pipes
of main pipelines ...................................................................................... 54
.
New technology of electric arc bath welding of rails on tram and
crane tracks ............................................................................................. 33
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Стр.1
FLASH-BUTT WELDING OF THICK-WALLED PIPES
FROM HIGH-STRENGTH STEELS
OF K56 STRENGTH CLASS
S.I. KUCHUK-YATSENKO1, Yu.V. SHVETS1, V.F. ZAGADARCHUK1, V.I. SHVETS1, V.I. KHOMENKO2,
S.I. ZHURAVLYOV2, A.Ya. SUDARKIN2, V.L. KOLIKOV3, S.A. KHOMICHENKO3
1E.O. Paton Electric Welding Institute, NASU, Kiev, Ukraine
2CJSC «Pskovelektrosvar», Pskov, RF
3OJSC «Mezhregiontruboprovodstroj», Moscow, RF
Technology was developed for flash-butt welding of 1219 mm diameter pipes with 27 mm wall thickness from 10G2FB
steel of strength class K56, designed for construction of off-shore gas pipelines. Admissible limits of variation of the
main welding parameters ensuring the required quality of welded joints were determined. Required level of mechanical
properties of the joints is achieved by local postweld high-temperature heat treatment in combination with accelerated
cooling.
Keywords: flash-butt welding, pipelines, high-strength
steel, normative requirements, weldability, welding mode, welding
mode parameters, welding process programming, flashing
process, set power, mechanical testing, reject indications, heataffected
zone, joint quality, heat treatment, microstructure,
grain, ultimate tensile, strength, impact toughness
In 1980—1990s flash-butt welding (FBW) was widely
used for joining position butts of pipes in construction
of various pipelines with up to 20 mm wall thickness
from steels of K52—K54 strength class.
Technology and equipment for FBW performance
were developed at the E.O. Paton Electric Welding
Institute together with Pskov Plant of Heavy Electric
Welding Equipment (PPHEWE) with the participation
of organizations of USSR Minneftegazstroj.
Starting from 1980, PPHEWE mastered industrial
production of equipment complexes «Sever-1», which
include in-pipe welding machine USO 400 (K700)
with internal flash-remover, external flash-remover,
device for cleaning pipe inner surface to accommodate
contact shoes and mobile electric power plant of
1000 kV⋅A power. «Sever-1» complexes were used to
weld more than 6000 km of 1420 mm diameter pipelines
(predominantly in Extreme North regions). Here
high productivity of FBW process was achieved at
minimum labour consumption [1]. Experience accumulated
over many years of FBW application is indicative
of stable high quality of welded joints that
is practically independent of weather conditions or
operator qualifications.
Over the last decade, intensive construction of super
high-capacity pipelines operating at increased
pressure (12—150 MPa) is observed. They are constructed
of pipes from high-strength steels of K56—K65
strength class with wall thickness of 27—36 mm and
more. Higher requirements are made of the quality of
such pipe joints that is specified in modern normative
documents.
As labour consumption of operations on welding
position butts of thick-walled pipes in pipeline construction
is considerably increased, application of
high-efficient FBW process is highly promising.
Equipment available for performance of FBW, as
well as «Styk» complexes for flux-cored wire arc welding,
which were widely applied in the USSR, cannot
be used to solve the above task, because of their technical
capabilities. In addition, higher requirements
are now made of mechanical property values of welded
joints compared to normatives of 1980—1990s.
In this connection in recent years the E.O. Paton
Electric Welding Institute and «Pskovelektrosvar»
plant (RF) performed integrated development of new
generation technology and equipment for FBW of
thick-walled pipes. Under this project, weldability of
thick-walled pipes from 10G2FB steel of strength class
K56 was studied. These steels are applied in construction
of off-shore pipelines. The objective of these investigations
was development of the technology of
welding pipes from the above-mentioned steel with
27 mm wall thickness that ensures improvement of
mechanical properties of the joints, in keeping with
current standards [2, 3].
Selection of the scope of investigations was determined
by customer requirements to the first samples
of developed equipment for the purpose of its application
at construction of off-shore pipelines.
Development of welding technology was performed
on large-size samples-sectors with welded
cross-section of 8640 mm2. Sectors of width B =
= 320 mm were cut out of pipes with wall thickness
δ = 27 mm, made from sheet steel 10G2FB produced
© S.I. KUCHUK-YATSENKO, Yu.V. SHVETS, V.F. ZAGADARCHUK, V.I. SHVETS, V.I. KHOMENKO, S.I. ZHURAVLYOV, A.Ya. SUDARKIN, V.L. KOLIKOV,
S.A. KHOMICHENKO, 2012
2
5/2012
Стр.2