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Application of Hybrid Laser Arc Welding for Construction of LNG Tanks Made of Thick Cryogenic 9% Ni Steel Plates

Lasers in Manufacturing and Materials Processing 2023年第4期10卷 659-680页

作者： Gook, Sergej El-Batahgy, Abdel-Monem Gumenyuk, Andrey Biegler, Max Rethmeier, Michael Joining and Coating Technology Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany P. O.Box: 87 Helwan El-Tabbin Cairo Egypt Unter den Eichen 87 Berlin12205 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Hybrid laser-arc welding (HLAW) was applied for butt welding of 14.5 mm thick plates of ferritic cryogenic steel X8Ni9 containing 9% Ni, which is used for manufacturing storage and transport facilities of liquefied natural gas (LNG). The weld seam formation and the achievable metallurgical and mechanical properties of the hybrid welds were investigated experimentally for two types of filler wire, an austenitic wire dissimilar to the base metal (BM) and an experimentally produced matching ferritic wire. Safe penetration and uniform distribution of the austenitic filler metal in the narrow hybrid weld could only be achieved in the upper, arc-dominated part of the weld. The pronounced heterogeneous distribution of the austenitic filler metal in the middle part and in the root area of the weld could not ensure sufficient notched impact toughness of the weld metal (WM). As a result, a decrease in the impact energy down to 17 ± 3 J was observed, which is below the acceptance level of ≥ 34 J for cryogenic applications. In contrast, the use of a matching ferritic filler wire resulted in satisfactory impact energy of the hybrid welds of up to 134 ± 52 J at the concerned cryogenic temperature of -196 °C. The obtained results contribute to an important and remarkable conversion in automated manufacturing of LNG facilities. In other words, the results will help to develop a new laser-based welding technology, where both quality and productivity are considered. The efficiency of the developed welding process has been demonstrated by manufacturing a prototype where a segment of the inner wall of large size LNG storage tank was constructed. In this concern, hybrid laser arc welding was conducted in both horizontal (2G) and vertical (3G) positions as a simulation to the actual onsite manufacturing. The prototype was fabricated twice where its quality was confirmed based on non-destructive and destructive examinations. © 2023, The Author(s).

关键词： Welds

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Influence of superimposed low frequency oscillations on single-pass honing of long-chipping steel 6th

Influence of superimposed low frequency oscillations on sing...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Rozek, A. Pascalstraße 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany

Single-pass honing is used as a finishing process to meet high demands regarding form and dimensional accuracy of drilled bores. The disadvantages of single-pass honing compared to the conventional long-stroke honing are high process forces and torques as well as an increased risk of chip space clogging of the abrasive stones. A significant reduction in process forces and torques can be achieved by superimposing the axial movement with oscillations. In this work the kinematic basics of different oscillation parameters and their effects on single-pass honing of long-chipping steel are analyzed. It can be concluded that by superimposing low frequency oscillations in single-pass honing, the process forces and torques as well as the specific energy consumption can be reduced significantly without a decline in surface quality and form accuracy. © 2022 The Authors.

关键词： Honing

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PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENTS USING DIAMOND SLIDE BURNISHING

PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENT...

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2022 ASPE and euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing

作者： Polte, Julian Polte, Mitchel Lahoda, Christian Uhlmann, Eckart Fraunhofer Institute for Production Systems and Design Technology IPK Technische Universitat Berlin Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universitat Berlin Berlin Germany

ISBN: (纸本)9781713859192

Due to the increasing importance of lightweight design in terms of resource management, titanium aluminium (Ti-AI) alloys are gaining more and more significance. To fully exploit light weight design potentials additive manufacturing (AM) has the ability to shift state of the art product design towards maximised resource efficiency and physically minimized weight. Next to material standardization and qualification processes, major limitations for mass scale industrialization of additive manufacturing are high surface roughness values in a range of 5 μm ≤ Ra ≤ 15 urn and remaining tensile residual stress states. A promising approach to overcome these challenges shows a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing (DSB) process [1]. Within this work plastic deformation induced by DSB and the effects on the workpiece material properties were investigated. Copyright© (2022) by American Society for Precision Engineering (ASPE) All rights reserved.

关键词： Surface roughness

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Residual stress assessment during cutting tool lifetime of CVD-diamond coated indexable inserts 6th

Residual stress assessment during cutting tool lifetime of C...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Hinzmann, D. Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany

Insufficient coating adhesion limits reproducibility regarding tool lifetime as well as workpiece quality during the application of CVD-diamond coated cutting tools. Depending on the combination of tungsten carbide substrate material, coating thickness as well as coating morphology, individual residual stress conditions exist within CVD-diamond coated cutting tool specifications. The application of these tools is accompanied by coating delamination as primary cutting tool failure. The tool lifetime of the respective cutting tool composition depends on the corresponding residual stress condition until crack development within the CVD-diamond coating initiates tool failure. During external cylindrical turning of hypereutectic aluminium silicon alloy AlSi17Cu4Mg-T6 the residual stress condition of a CVD-diamond coated cutting tool is assessed along the cutting edge, the rake face as well as flank face throughout the respective tool lifetime. Consequently, the progression of the residual stress condition until cutting tool failure regarding coating delamination is observed. During the tool lifetime of the investigated CVD-diamond cutting tools, compressive residual stress σR,c shifts to tensile residual stress σR,t underneath the cutting edge corner. The approximated residual stress difference of σR ≈ 5 GPa indicates stress peak relaxation processes, such as crack initiation, within the CVD-diamond coating. © 2022 The Authors.

关键词： Residual stresses

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Experimental investigations of the workpiece-media-interaction and the surface topography formation in centrifugal disc finishing 10

Experimental investigations of the workpiece-media-interacti...

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10th CIRP Global Web Conference on Material Aspects of Manufacturing Processes

作者： Kopp, Marco Uhlmann, Eckart Kneider, Christian Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

In this study the workpiece-media-interaction in centrifugal disc finishing is investigated using a miniaturised free movable force measuring system. Characteristics of the workpiece-media-interaction are derived and correlated with the surface topography formation of Ti-6Al-4V workpieces. As a result, it was found that characteristics of the workpiece-media-interaction such as the contact force between the media and the workpiece, the contact duration and the contact frequency are dependent on the type of media as well as the rotational speed of the disc. Consequently, both, the type of media as well as the rotational speed of the disc have an influence on the resulting surface roughness. © 2022 Elsevier B.V.. All rights reserved.

关键词： Topography

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Residual stresses in additive manufactured precision cemented carbide parts 22

Residual stresses in additive manufactured precision cemente...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Polte, J. Polte, M. Hocke, T. Blankenburg, M. Lahoda, C. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Deutsches Elektronen-Synchrotron DESY Germany

ISBN: (纸本)9781998999118

Due to the good strength properties and high hardness, components made of cemented carbide are used in various industrial sectors as key components, e.g. mould making and matrices. Precision cemented carbide parts are mainly machined by milling and electrical discharge machining (EDM). Nevertheless, long machining times and excessive tool wear are remaining challenges at the state of the art. A promising approach to overcome these challenges is the machining of precise cemented carbide parts using a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing process. Within previous investigations a geometrical accuracy of ag= 10 µm and a reduction of the surface roughness by Ra = 89 % could be achieved. Within this work plastic deformation induced by the diamond slide burnishing and the effects on the material properties in the surface area were investigated, e.g. residual stresses. For this purpose, the lattice distortion of the metallic cobalt phase was measured by X-ray diffraction using high-energy synchrotron radiation. In addition, the height profile of the residual stresses was also recorded in distances of d = 3 µm to obtain information about the depth effect of the diamond slide burnishing process. Based on the investigations an increase of the residual compressive stresses could be obtained. This shows a particularly positive effect especially for additively manufactured components, as these often show a slight porosity and higher surface roughness as conventional manufactured components. In this way, crack propagation can be prevented and the fatigue strength can be increased. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Residual stresses

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Integrated Consideration of Data Flows and Life Cycle Assessment in Vehicle Dismantling processes

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Procedia CIRP 2024年 122卷 1018-1023页

作者： Janine Mügge Anne Seegrün Lynn Faßbender Theresa Riedelsheimer Philip Staufenbiel Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany LRP-Autorecycling Leipzig GmbH Priesterstraße 6 04509 Krostitz Germany

The pursuit of environmental sustainability and resource conservation has underscored the growing significance of the circular economy paradigm across industries. This transformation is particularly pertinent within the automotive industry, necessitating a profound restructuring of the value chain, with a specific focus on end-of-life considerations. Significant potential for circular economy arises from the thorough examination of end-of-life vehicles and processes, involving strategies such as component reuse, material recycling and primary resource reduction. Providing process-, product-, component-, and material-specific information at the end-of-life of automotive vehicles can improve decision-making regarding circular strategies. It also demands for new digital solutions. This paper addresses an integrated approach of data flow analysis and Life Cycle Assessment (LCA) to enable a comprehensive monitoring of the environmental impact of these processes. First, the use case of end-of-life dismantling processes is presented - including pyrotechnics neutralization, vehicle dehydration, disassembly of reuse components as well as vehicle compaction. Secondly, the data demand respective information and material flows is depicted. As a main result, the LCA data flow model specifically tailored to the end-of-life vehicle dismantling processes is described. This model serves as a fundamental basis for analyzing the environmental impact of end-of-life processes combined with the underlying data flow.

关键词： Circular Economy Sustainability Life Cycle Assessment Data Flow Decision Support

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End-of-life decision support to enable circular economy in the automotive industry based on digital twin data 33

End-of-life decision support to enable circular economy in t...

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33rd CIRP design Conference

作者： Mügge, Janine Hahn, Inka Rebekka Riedelsheimer, Theresa Chatzis, Johannes Boes, Joachim Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany TEC4U-Ingenieurgesellschaft MbH Saar-Lor-Lux-Straße 15 Saarbrücken66115 Germany

With the EU Green Deal and the UN Sustainable Developments Goals, the vision of a greenhouse gas-neutral and resource-efficient economy is already firmly anchored in world politics. In this context, the automotive industry faces many challenges including the increasing scarcity of natural resources, a rising demand in terms of sustainable vehicle design, production and materials sourcing. Due to all this, end-of-life decisions regarding dismantling have become increasingly important. A high proportion of secondary materials will be required in the vehicles of the future. To response to these challenges, companies have turned their focus towards the circular economy as a central approach to close material loops. In the German research project "Catena-X" a new data ecosystem with digital twins is one enabler that is being developed. The digital twins represent a promising approach to the circular economy by ensuring transparent, product-specific and end-to-end data exchange throughout the entire product lifecycle, from the material sourcing to the eventual dismantling and recycling. As one particular and unique solution, a decision framework that facilitates the best circular strategy at the end of a vehicle's life is developed and presented in this paper. The underlying data-driven decision support framework is based on circular economy KPIs. This includes material, components and specific vehicle KPIs to best identify the most suitable circular strategy. The framework was methodologically developed by an interdisciplinary team of partners, who are stakeholders throughout the value chain and participants in the Catena-X project. An integrated approach of user-centered design, an adapted version of the V-model and the Scaled Agile Framework were used for the methodology in the development of the solution. The paper presents the concept of a digital twin for a decision support system, that includes a central decision logic that also includes the relevant KPIs and a sur

关键词： Sustainable development

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Cooling Capacity of Oil-in-Water Emulsion under wet Machining Conditions 19

Cooling Capacity of Oil-in-Water Emulsion under wet Machinin...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Nabbout, Kaissar Sommerfeld, Martin Barth, Enrico Uhlmann, Eckart Bock-Marbach, Benjamin Kuhnert, Jörg Institute of Process Engineering Otto-von-Guericke-University Magdeburg Universitätsplatz 2 Magdeburg39106 Germany Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Industrial Mathematics ITWM Fraunhofer-Platz 1 Kaiserslautern67633 Germany

Many industrial machining operations are carried out under wet machining conditions. Modelling and simulating fluid-structure-interactions and conjugate heat transfer are still a challenge nowadays. In this paper, temperature dependent heat transfer coefficients (HTC) h(T) are experimentally estimated for wet machining-like conditions in a jet cooling experiment. The transient temperature is thereby used to solve an Inverse Heat Transfer Problem for HTC function estimation. Determined HTC are applied as input in related jet cooling simulation using the Finite-Pointset-Method (FPM) to validate the modeling approach. Additionally, wet cutting simulations numerically highlight the influence of determined HTC h(T) on turning. © 2023 Elsevier B.V.. All rights reserved.

关键词： Cooling

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SUPPORTING CHANGES IN DIGITAL OWNERSHIP AND DATA SOVEREIGNTY ACROSS THE AUTOMOTIVE VALUE CHAIN WITH CATENA-X

arXiv

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arXiv 2024年

作者： Manoury, Marvin Riedelsheimer, Theresa Hellmeier, Malte Meyer, Tom Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Software and Systems Engineering ISST Speicherstraße 6 Dortmund44147 Germany

Digital Twins have evolved as a concept describing digital representations of physical assets. They can be used to facilitate simulations, monitoring, or optimization of product lifecycles. Considering the concept of a Circular Economy, which entails several lifecycles of, e.g., vehicles, their components, and materials, it is important to investigate how the respective Digital Twins are managed over the lifecycle of their physical assets. This publication presents and compares three approaches for managing Digital Twins in industrial use cases. The analysis considers aspects such as updates, data ownership, and data sovereignty. The results based on the research project Catena-X © 2024, CC BY-NC-ND.

关键词： Supply chains

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