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Chandima Ratnayake1
Department of Mechanical and Structural
Engineering and Materials Science,
University of Stavanger,
Underwater Friction Stud
Stavanger N-4036, Norway
e-mail: chandima.ratnayake@uis.no Welding Optimal Parameter
H. O. Ytterhaug
Department of Mechanical and Structural Estimation: Engineering Robust
Engineering and Materials Science,
University of Stavanger,
Stavanger N-4036, Norway
Design Based Approach
e-mail: hans_olav_ytterhaug@hotmail.com
Underwater friction stud welding (FRSW) without a shroud around the stud requires con-
trolling welding parameters to achieve optimal joint strength. A hydraulic FRSW unit has
P. Bogwald been designed and fabricated to perform FRSW without a shroud via a remotely operated
Department of Mechanical and Structural
underwater vehicle (ROV). An experimental study has been initiated to investigate the
Engineering and Materials Science,
optimal FRSW parameter combinations and corresponding values leading to optimal ulti-
University of Stavanger,
mate tensile load capacity (UTLC) values in the welded joint. The engineering robust
Stavanger N-4036, Norway
design (ERD) approach has been deployed to run the experiment. Each weld has been
e-mail: pbogwald@gmail.com
made with a S355 M12 stud on S355 structural steel plate. This paper discusses the ex-
perimental approach, results and conclusions reached in the parameter evaluation, esti-
S. T. R. Nilsen mation, and experimentation. [DOI: 10.1115/1.4028466]
Department of Mechanical and Structural
Engineering and Materials Science, Keywords: underwater friction welding, engineering robust design, optimal parameter,
University of Stavanger, ultimate tensile load capacity
Stavanger N-4036, Norway
e-mail: str.nilsen@gmail.com
1 Introduction the quenching effect gives rise to excessive hardness and severe
cracking even at relatively shallow depths [9]. Although the cool-
The friction welding (FRW) of metals was proposed by the ma-
ing efficiency of the water is supposed to be independent of depth,
chinist Chudikov during the mid-1950s, and the approach was
there are slight changes due to the variation of temperature and sa-
patented (No. 106 270) during 1956 [1]. Although the possibility
linity [10,11]. The aforementioned becomes a significant chal-
of utilizing friction heat for welding had been indicated previously
lenge, especially in the case of subsea interventions for
in the literature, only Chudikov managed to prove that it is possi-
modifications and repair activities using FRW in the North Sea.
ble to make a high quality butt weld between two steels rods by
For instance, the FRSW has been “utilized to retrofit sacrificial
utilizing heat generated by friction [1]. Existing welding methods
anodes to subsea pipelines although the pipeline is live (that is, it
are broadly categorized in two classes: (1) fusion welding; (2)
proceeds to transportation hydrocarbons at pressure)” [5]. In some
solid state welding; and (3) brazing/soldering. The FRW is a solid
instances, the anodes are positioned on the sea bed “next to the
state welding process, in which the welded connection is formed
pipeline and a lug on a cable from the anode is connected to the
without melting the metal. The bonding takes place by joint plas-
stud welded on the pipeline” [5]. However, the effect of cooling
tic deformation of the pieces to be welded via heat generated from
rates due to the surrounding water is mitigated by the foamed
friction [2,3]. The FRW has advantages over the other welding
plastics, which are utilized to form a shroud around the weld
approaches as the “bonding in FRW [which] takes place below
region [12]. In essence, a shroud protects the friction welded joint
the melting point limits the extent and complexity of metallurgical
from the surrounding water during the FRW, minimizing the
reactions causing embrittlement (i.e., formation of intermetallic
quenching effect (i.e., minimized hardness changes) and giving
phases), cracking and porosity” [4]. Also, rotary FRW (in particu-
acceptable welds [13]. However, some of the tailor-made FRSW
lar stud welding) has been proven to be significantly easier to per-
applications demand that they are performed without a shroud. It
form underwater [5]. Hence, FRSW has been widely employed in
is a challenge to estimate optimum FRSW parameter settings,
the offshore oil and gas (O&G) industry, especially in subsea
under no shroud conditions, which meet the optimal UTLC
related repair and modifications [6].
requirements. Hence, the aforementioned kind of applications
The FRW processes are generally sensitive to the surroundings
requires the determination of those parameter settings which
in which they are made [7,8]. For instance, the underwater FRW
provide optimal UTLC and material property requirements in a
causes rapid cooling of the weld and leads to poor weld properties
friction welded joint.
[9]. For instance, practical experience, research and literature indi-
The ERD approach provides means of improving the perform-
cates that when the steel studs are friction welded to steel plates,
ance of an engineering application (e.g., FRW), while minimizing
the effect of inherent “noise” [Note: the noise is referred to as
uncontrollable variations (i.e., making underwater FRWs without
1
Corresponding author. a shroud and resulting changes) that may affect the performance
Contributed by the Ocean, Offshore, and Arctic Engineering Division of ASME
for publication in the JOURNAL OF OFFSHORE MECHANICS AND ARCTIC ENGINEERING.
of a particular engineering application] [14–16].
Manuscript received March 4, 2014; final manuscript received August 25, 2014; This paper focuses on a special case, in which a tailor-made
published online September 25, 2014. Assoc. Editor: John Halkyard. FRSW design is going to be integrated with an ROV and perform
Journal of Offshore Mechanics and Arctic Engineering FEBRUARY 2015, Vol. 137 / 011401-1
C 2015 by ASME
Copyright V
Steel C P Mn S Si
2 Industrial Challenge
There is considerable potential that it is possible to use FRW
processes in hostile environments due to the possibility of using
sophisticated ROVs together with advanced control systems. Fig. 4 Arrangement of stud and a sample plate in the FRSW
Hence, the FRW processes have been tailor-made for special test rig
requirements, and in some cases developed for use in irradiated
environments, high vacuum, underwater (even at great depth).
During the underwater FRW, the reduction of softened zones (i.e.,
responsible for the improvement in mechanical properties) results hydraulic powered systems are capable of being used with an
due to cooling [17]. Moreover, Darras and Kishta [18] have ROV and of operating at higher depths than air powered systems.
reported that the hardness of a submerged friction weld is higher Figure 2 illustrates the arrangement in the test rig to hold the plate
than that of a friction weld in air. They have also reported that and stud inside a container during FRSW to create underwater
more grain refinements are “attained under submerging conditions (or subsea) conditions.
due to faster cooling rate.” The aforementioned findings necessi- The tests have been performed using partially threaded M12
tate performing experiments to investigate the optimal FRW studs. Both the stud and plate are S355 steel. The S355 steel is
parameters which result in optimal UTLC in the welded joint. specified as a high-yield nonalloy steel. The chemical composition
is illustrated in Table 1.
3 Methodology The name S355 has been assigned [Note: First specified in the
European EN10025 standard and later published by the British
3.1 Design of the FRSW Test Rig. The FRSW test rig, Standards Institute (BSI) as BS EN 10025 S355, S355J2, and
which was designed to establish the initial welding parameters in S355J2 þ N, which have been superseded by BS4360 grades] due
Ratnayake [19], has been improved and is illustrated in Fig. 1. to the fact that the average minimum yield strength of the steel is
Then, the prototype of the designed test model was fabricated. 355 N/mm2 [20]. The M12 studs have been prepared using CNC
In general, while the motor, which may be the hydraulic or LB9 series turning center. Each stud has been held in place by
electric type, rotates the stud at high speeds, the pistons apply the simply screwing it into the motor coupling (see Fig. 3).
necessary axial force on the stud. Hydraulic cylinders have been Plates with 10 mm thickness have been cut to about (30 100)
introduced to the test rig to increase the accuracy. Moreover, mm pieces and tightened to the test rig (see Fig. 4).
Experiment number P S HT FT
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1
Journal of Offshore Mechanics and Arctic Engineering FEBRUARY 2015, Vol. 137 / 011401-3
Fig. 6 Plots of parameter effects versus levels. (a) Pressure versus S/N ratio, (b)
speed versus S/N ratio, (c) FT versus S/N ratio, and (d) HT versus S/N ratio.
P (kN) 69.4
S (rpm) 2798
FT (s) 7
HT (s) 10
1 429.0 4
2 396.3 4
3 341.0 4a
4 430.7 4
5 351.0 3b
6 337.0 4
7 393.3 4
8 366.7 4
9 414.3 5
a
25% below zone 5.
b
In between 3 and 4.
Journal of Offshore Mechanics and Arctic Engineering FEBRUARY 2015, Vol. 137 / 011401-5
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