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Welding In Producing Mill Environments
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QBM is a Mechanical Engineer, Metallurgical Engineer, Materials Engineering Consultant with world-class expertise in failure analysis, metallurgical and mechanical engineering, metal and part manufacturing, service condition effects, limited information interpretation, and results presentation to non-metallurgists
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Metal being welded in production mill environments is unlike the metal joined in a customer's fabrication process. There are severe shape problems, residual stress issues, oxide interference, and possibly chemical variations. None the less, if atoms on one side connect with atoms on the other side, one gets a good metallurgical weld. Simply said, but requires care.
The simplest in mill connection is to link one coil to another so that the product can be pulled through a continuous line. The mechanical requirements on these welds are generally less than 100% strength. There are both welding and mechanical options which have been used by the expert.
The next step up to deal with chemical alloy incompatibility between the two coils is to utilize a third material which is compatible with both of the coil compositions. The expert has devised solutions to connect different ferrous alloys.
The ultimate connection in a mill environment is a weld which will be deformed in a rolling process. The expert has utilized processes ranging from GTAW, GMAW, and Submerged Arc welding to join coils which survive various high tension rolling mills. The expert has found that there are many factors, including grinding which require attention in order for the weld to survive the mechanical test of a rolling mill.
The ultimate experience is welding slab like assemblies of stainless plates over carbon steel cores that survive both heating and hot rolling. These welds involved both root passes with a GMAW process and filling with a submerged arc process. Details of fixturing were found to be important to improve survival through hot rolling.
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
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Indianapolis, Indiana 46268
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