TURKEY-‐MICHIGAN FORUM University-‐Industry CollaboraLon and R&D TRENDS IN RESEARCH AND DEVELOPMENT IN ADVANCED WELDED MANUFACTURING H. Didem GENÇKAN GEDIK WELDING Istanbul, Turkey www.gedikwelding.com
06.06.2012
WELDING IS A KEY MANUFACTURING TECHNOLOGY !
It contains MATERIAL SCIENCE and MECHANICAL ENGINEERING and AUTOMATION AND ROBOTIC
ADVANCED MANUFACTURING 06.06.2012
MATERIAL SCIENCE BASED WELDING RELATED PRODUCTS AND THEIR R&D ACTIVITIES
EXAMPLES OF R&D ACTIVITIES… POWDER (Flux) WIRES ELECTRODES 06.06.2012
CASE 1: SUBMERGED ARC WELDING (SAW) PROCEDURE • SAW – Submerged arc welding process u s e s W I R E a n d P O W D E R ( F l u x ) combinaLon. • The metal is joined by fusing with an electric arc between wire and the metal. Powder (flux) spread in a deep layer over the weld area. • Powder shields the arc and molten metal. POWDER CONTAINS VARIOUS ELEMENTS AND NEEDS FOR R&D FOR OPTIMUM COMBINATION!! FOR GOOD WELD, WE NEED QUALITY POWDER (FLUX)!! 06.06.2012
CASE 1: The First and Only Producer SAW Flux in TURKEY! In November 2011, GeKa Flux branded SAW flux has been put on the Turkish market with a capacity of 5000 tons/year. NO PRODUCTION IN TURKEY TILL 2011! FLUXES WIRES ELIFLUX BFB S1 / S2 ELIFLUX BAR S2Si/ S2 Mo ELIFLUX BFF S2 MoTiB ELIFLUX BSS S3 / S3Si ELIFLUX BSS S3Mo ELIFLUX PIPE S3NiMo1 ELIFLUX BMS S3MoTiB ELIFLUX 350 S3TiB END-‐USERS PROVISION OF WIRE & FLUX COMBINATION FOR 06.06.2012
CASE 1: GEDIK SOLUTIONS FOR WIND TOWERS ON-‐SHORE APPLICATION
OFF-‐SHORE APPLICATION
SUBMERGED ARC WELDED Towers
GEKA SUBMERGED ARC WELDING WIRES
S2Si & ELIFLUX BFB 06.06.2012
CASE 1: SAW APPLICATION IN PIPE PRODUCTION
SAW POWDER
SAW AT PIPE INTERNAL WELD PASS 06.06.2012
CASE 2: FLUX CORED ARC WELDING TECHNOLOGY (FCAW)
Flux-‐cored wire (FCW) • ConLnuously – feed consumable tubular wire • Contains flux and alloying elements • RuLle, basic, metal and stainless types
Diameter: 1.2 mm Outer layer of • Differences arise from characterisBc of powder metal (pipe)
Flux
R&D need for op_mum combina_ons of core ingredients of FCWs Deoxidizers Denitrifiers Arc Stabilizers Gasifiers Alloying elements
Seamless Bu] Lap Mn and Si Al Ka and Na Minerals: CaF2 and CaCO3 Typical Flux-‐cored wire configura_ons Cr, Ni, Ti, Mo, V 06.06.2012
CASE 2: FLUX-‐CORED ARC WELDING (FCAW) TECHNOLOGY IN GEDIK: Since 2010 GEDIK WELDING PRODUCTS ELCOR R 71 (RuLle) ELCOR R71 SC ELCOR R 71 Ni ELCOR R 71 CM ELCOR R 81 Ni /ELCOR R 81 NiSC ELCOR R 81 NİCu/ ELCOR R 81 NiCu SC ELCOR R 91/ ELCOR R 91 SC ELCOR R 110 / ELCOR R 110 SC ELCOR B 70 (Basic) ELCOR M 70 (Metal)
Gedik Welding Flux-‐cored wire producLon line
Capacity : 5000 tons/year 06.06.2012
CASE 2: FLUX CORED ARC WELDING TECHNOLOGY (FCAW) ON-‐SHORE APPLICATION
OFF-‐SHORE APPLICATION
GEKA FLUX CORED WELDING WIRES
ELCOR R71 / ELCOR R 71 SC ELCOR B70 / ELCOR B 70 SC 06.06.2012
CASE 3: MANUAL AND AUTOMATIC PIPELINE WELDING
ü Any panel thickness ü High cost-‐saving potenLal ü Faster welding Lme
ü Excellent root formaLon and quality weld seam ü No sagging of the molten metal ü Suitable for sheet metals and pipes in all posiLons 06.06.2012
CASE 3: GEKA AUTOMATIC PIPELINE WELDING WIRES R & D NEED FOR AUTOMATION AND SUITABLE WIRES ! We have number of wire alternaLves for different type of materials.
GeKa Pipeline Shielded Arc Welding Wires SG 2 SG 3 SG Mo SG NiMo1-‐IG
GeKa Pipeline Flux Cored Welding Wires Elcor B70/ Elcor B70 SC Elcor R71/ Elcor R71 SC Elcor R 81 Ni SC Elcor R 91 SC 06.06.2012
UNIVERSITY-‐INDUSTRY COORPERATION R&D PROJECTS EXAMPLES: 1.
Developing NaLonal Flux Cored Wire Welding Technologies
2.
Developing Welding Process and Filler Metals for High Strength Pipeline Steels
3.
Developing Low Temperature TransformaLon (LTT) Weld Filler Consumables for Manual Metal Arc and FCAW Processes
06.06.2012
Developing Na_onal Flux Cored Wire Welding Technologies Aim: Developing flux formulaLon and manufacturing flux cored wires Mo_va_on: Easy handling, suitability for otomaLzaLon, higher producLvity and significant lower risk of defects such as porosity and lack of fusion Dura_on: 16.03.2009 -‐ 31.12.2011 Budget : 1.900.000 USD
06.06.2012
Developing Welding Process and Filler Metals for High Strength Pipeline Steels
Aim: Developing submerged arc welding, gas metal arc welding and manual metal arc welding processes and developing consumables for high strength pipeline steels. Mo_va_on: ReducLon in pipe wall thickness, lower consumable consumpLon, shorter weld Lme and lower pipe transportaLon cost lead to reducLon in overall cost of the construcLon, operaLng pipelines with higher pressure resulLng an increase in gas transportaLon efficiency. Date: 01.09.2010 -‐ 01.09.2013 Budget : 680.000 USD 06.06.2012
Developing Na_onal Low Temperature Transforma_on Weld Filler Consumables for Manual Metal Arc and FCAW Processes
Aim: Developing low temperature transformaLon weld filler consumables Mo_va_on: Lowering amount of distorLon and tensile residual stresses. High faLgue strength and faLgue life for high strength steel structures. Date: 01.01.2011 -‐ 31.12.2012 Budget: 870.000 USD
06.06.2012
I have presented briefly some of our successful core research projects and university-‐industry cooperaLon projects in Welding Research at GEDİK…
THANK YOU FOR YOUR ATTENTION !
06.06.2012