Professional Documents
Culture Documents
20
IWS 2k18
THE JOURNAL OF
QUARTERLY PUBLICATION
Jan 2019 Weld: 17 Bead: 4
PRESIDENT
SHRI S BISWAS
Immediate Past President
SHRI S GOPINATH
Past President
AROUND IWS
SHRI A V KRISHNAN
Vice Presidents
SHRI A MARUTHAMUTHU
SHRI U D RANE
IWS AWARDS 2018
SHRI M P JAIN
Hon. Secretary
GET-TOGETHER MEETING WITH
SHRI N RAJASEKARAN OTHER PROFESSIONAL BODIES
Hon. Treasurer
SHRI G RAJENDRAN
Dr K Asokkumar
Members
Shri R Subburayalu
KNOWLEDGE SHARING
Mrs. A Santhakumari Dr. T Senthil Kumar SHORT TERM CERTIFICATE COURSE IN
Shri S Rajendran Dr. K Siva Prasad WELDING TECHNOLOGY (Level-1) FOR
Dr G Madhusudan Reddy Dr Shashikantha Karinka PRACTICING WELDERS AT NORTH EAST
Shri Narain Dharmendra Dr V R Krishnan INDIA
Prof. Sunil Pandey Dr G Padmanabham
Shri Basu B K Shri Muneesh Narain
INTERNATIONAL WELDING SYMPOSIUM
Shri Umesh Agarwal Dr T A Daniel Sagaya Raj
2018 (IWS 2K18) AT MUMBAI
Shri Sandeep Mohan Ubhaykar Shri Uma Shanker G
WORKSHOPS AND SEMINARS
Shri Amit Agarwal Dr T J Prasadarao COURSES BY SZ
Shri Viral Ashok Shah Shri S N Roy
Shri Easwaran R Prof. V Balasubramanian
Shri Tamboli V B Dr M Kamaraj
Sincerely Thanks
Page 3 of 25
M ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT AWARD 2017
IWS JOURNAL
CONGRATULATES
Dr. V R KRISHNAN
THE RECIPIENT OF
M ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT
AWARD 2017
IWS FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT AWARD 2018
IWS JOURNAL
CONGRATULATES
Mr. V K SHIRGAOKAR
THE RECIPIENT OF
IWS FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT
AWARD 2018
Page 5 of 25
IWS MERITORIOUS AWARD 2017
IWS JOURNAL
CONGRATULATES
Mr S GOPINATH
THE RECIPIENT OF
IWS MERITORIUS AWARD 2017
IWS MERITORIOUS AWARD 2018
IWS JOURNAL
CONGRATULATES
Mr R EASWARAN
THE RECIPIENT OF
IWS MERITORIUS AWARD 2018
Page 7 of 25
IWS Zonal Meritorious Award 2018
IWS JOURNAL
CONGRATULATES
Mr RAJESH KUMAR GUPTA
Mr PRATAP K SUPALI & Dr K MOHAN
RECIPIENTS OF
IWS ZONAL MERITORIOUS AWARD 2018
IWS HONORARY FELLOW MEMBERSHIP 2018
IWS JOURNAL
CONGRATULATES
Mr A V KRISHNAN
RECIPIENTS OF
Mr V B TAMBOLI
Dr K ASOKKUMAR
IWS
Mr G RAJENDRAN HONORARY
Mr S SINGARAVELU FELLOW MEMBERSHIP
&
2018
Mr MUNEESH NARAIN
Page 9 of 25
GET-TOGETHER MEETING WITH OTHER PROFESSIONAL
BODIES
AROUND
On October 18, 2019, on the day of
Ayudha Pooja Celebrations, a get-together
meeting with other professional bodies,
viz. IIM, IIW and CSI was conducted at the
Institutional Building, Kailasapuram Township,
Tiruchy by the Southern zone.
Chairman (IWS, SZ) & Chairmen of other professional bodies and host
of senior members from all professional bodies graced the event.
It is the 8th in the sequel and 5th consecutive event at Mumbai by IWS, WRI, MDI, ME, DVS and
AWF.
Dr. V R Krishnan has been conferred with the M. ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT
AWARD 2017.
Mr. V K Shirgaokar conferred with the FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT AWARD
2018.
Page 11 of 25
Mr A V Krishnan, Former President, Mr G Rajendran Hon. Treasurer, Mr Muneesh Narain & Mr V
B Tamboli former vice presidents, Dr. K. Asokkumar, Former Secretary and Mr. S. Singaravelu Vice
Chairman, IWS, SZ were conferred as Fellow Members of IWS.
In total 93 papers were received and 85 were presented including 8 overseas papers.
Participation was from 82 organisations and senior consultants. The participants from major
corporate companies in strategic sectors included BHEL, NTPC, DRDO, EIL, BEML, ISRO, HPCL,
Indian Railways, L&T, ADOR, D&H, etc. in the 2018 edition
252 delegates registered for the event from all categories and 226 attended the event. Free
Delegates from IWS Student forum were allowed to
attend the three-day event.
ABSTRACT
1.0 INTRODUCTION
Magnetism and magnetic phenomena have been known for a long time. While magnetism was
observable only in magnetic iron ore, one can see it in many natural phenomena and technical
applications today. In terms of Physics, the strength of a magnetic field can be defined by the
magnetic field strength H and the magnetic flux density B (magnetic induction). The higher the
field strength H, higher the flux density B. When H becomes zero, a residual flux density remains.
Residual magnetism is the reason for arc instability during welding, the arc weaves and is
deflected, drops do not evenly detach, sidewall fusion is improper and the welding result is of
poor quality.
Ferromagnetic material is magnetic without the influence of an external field. The reason for this
can be looked at in different ways. While, at the atomic level, electron shells interact via orbital
and spin angular momenta to create a parallel alignment of the atomic magnetic moments
causing magnetisation. Physicist Weiss came up with the idea of interpreting the phenomenon
due to the existence of magnetic domains. Each Weiss domain has all magnetic moments within
it aligned in the same direction and has a neighbour of identical size which points in the opposite
direction. Magnetic fields in semi-finished products made of ferromagnetic materials neutralize
each other in the semi-finished product after production and cooling, as the Weiss domains are
in equilibrium. When producing metal pipe and tube cuttings from a continuously cast semi-
finished product, the Weiss domains are separated from each other and are no longer in
equilibrium. These imbalances influence the arc during welding and it may occur at edge prepared
sidewalls to be welded joint. Magnetic particle testing carried out especially at the edge
preparation ends of pipes and tubes using direct current / half wave DC may also cause
magnetism in the pipe and tube sections.
Ferromagnetic materials which are processed or come into contact with magnets, can easily
become magnetized. Other causes include welding, grinding, bending, machining, deep drawing
and even mechanical vibrations and magnetic particle testing. Depending on the type of material
structure, alloy, this magnetism may be retained in the object. The consequences of residual
magnetism may be desirable, problematic or even very costly. A nut that clings to the end of a
screwdriver is handy. Having two products stick together in welding is an undesirable situation;
this interrupts production and therefore costs time and money.
Unwanted residual magnetism can cause many problems in a production process, such as:
In other words: undesired residual magnetism costs time and money and has a negative impact
on the quality of finished products.
Magnetic arc blow can be a serious issue with welding jobs. Arc blow can stop a job dead in its
tracks - no good welds so no progress. This can be a great frustration to welders and result in very
Page 17 of 25
expensive project delays. Arc deflection, or indeed extinction away from the point of welding due
to magnetism, is generally referred to as arc blow. This may result in poor quality welding and
usually occurs if the material being welded has residual magnetism. The effect occurs because of
the interaction between the magnetic field of the welding arc and the field of the residual
magnetism. The effect is most pronounced in ferromagnetic steels and although the magnetism
in the material (measured in air at the end of the tubes) may only be a few tens of gauss, after fit
up, the field becomes concentrated in the gap between the two tubes. In this situation the field
may reach very high value. The effect of the magnetic field depends on the welding process but
a good estimate is to assume that fields greater than 30 gauss will cause problems.
During welding, high-temperature plasma is created between cathode and anode by the ionized
gas and freely moving charge carriers. The plasma column is infinitely mobile and behaves like an
electrical conductor towards electrical and magnetic fields and it is sensitive to electrical and
magnetic interference. If a critical magnetic flux density B exists in the material to be welded, the
plasma column is attracted or repelled, depending on the polarity. The arc is then deflected,
irrespective of the welding torch position, and behaves unstably. As a result of arc deflection,
energy cannot be applied where it is needed. From the user's point of view, all this leads to
insufficient welding results, a great amount of finishing work and to repair or reject hence lead
to serious losses in quality and economy. Prevailing magnetism affects arc processes differently
depending upon the strength B. At levels of 30 to 50 G, arc deflection already results in the fusion
faces not being adequately melted. Shielding gas coverage is not guaranteed as welding
consumables are being fed in. This results in the formation of pores in the weld pool, which in
turn requires reworking or scrapping. Starting at about 80 G, it becomes nearly impossible to
control the process as well. The result is spatter formation and with strong magnetic fields, arc
interruption, re-ignition and thus defects in the weld seam.
A tube sample with prevailing magnetism which affects welding is demagnetized by the following
method. Copper cable is wound around the pipe (N turns). Copper cable coiling is done in an area
relevant to the welding process, i.e. near the weld seam to be created. A current I, which after a
certain time changes its direction of flow and also its amplitude to a lower value, is sent through
the windings around the tube. The amplitude of the current is reduced each time it passes
through the cable. As a result of this process, the magnetic field strength B and thus also the
residual magnetism in the material, is reduced to near zero ensuring by field indicator (Gauss
meter). Same effect of reducing current may also be achieved by moving the coil away from the
area of interest (withdrawal method). As a basic principle, however, the greater the number of
turns around the component, the more the residual magnetism is reduced. It is not possible to
make a thumb rule regarding exactly how many number of turns and maximum current to start
demagnetization since it depends on the existing magnetism, the material thickness and the
component length. Approximately 10 to 20 turns and 500 to 600 Amps DC have served the
purpose and the residual magnetism is reduced below comfortable level like less than 3 G.
SUMMARY
Arc deflection caused by magnetism is a known problem in joining technology. Due to its sporadic
occurrence, it is necessary to provide welders with fast and reliable methods in day-to-day work.
Simple demagnetizing technique with available facilities has been tried successfully.
Demagnetising technique is customized for the specific tube butt weld in the production line and
demonstrated for effective usage by production personnel very easily.
Figure 01 Workpiece magnetised » Heavy arc deflection Figure 02 Demagnetised » No arc deflection
Page 19 of 25
USE OF TIP-TIG TECHNOLOGY IN PROCESS EQUIPMENT PLANTS
Rakesh Choudhary & Mr. Plasch#
Head WAPS, Ador Welding Limited, Pune, India
#TiP-TiG Austria.
ABSTRACT
TIP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses
new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with
the lowest possible weld heat, all while still being user-friendly.
TiPTiG new welding with a hot wire process that can be used in every industry. It is very simple
to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat
input, reduced cycle time, and an overall better-quality welding advantage can be easily
achieved. The TIP-TIG welding
The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for
the weld solidification process and increasing the fluid weld area. This allows for a 100%-400%
increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster
speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall
process productivity.
The process is also slag free and uses the lowest possible heat input of any welding process,
producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It
produces some of the highest quality products with the best metallurgical and mechanical
properties on all alloys, but also increases production up to four times the normal speed. There
is also no inter pass cleaning, creating availability for an increased Arc on time and weld quality.
The TIP TIG process is available in manual and automated capability to attain weld and clad
quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG and the Flux
Cored process.
HOW IT WORKS?
4. Greater ability to accept more wire into the weld pool, result in a higher deposition
APPROVED ALLOYS
TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex
and super duplex stainless steels, Inconel, Titanium, Aluminum, Copper, Nickel, and many others
critical materials like P-91, which are used in process plant production.
HEAT EXCHANGERS
Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel,
Stainless Steel, Hastelloy, Inconel, or Titanium. There are certainly some unique applications and
challenges associated with the welding of heat exchangers, such as the position and access for
the popular circumferential welding of Tube to sheet welds or the half tube shell welding.
A trained TIP TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest
quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500
mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW
TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide
variety of torches for different applications, with modified 180 deg torch it allows a complete
tube sheet welds without repositioning the wire or
stopping, allowing for defect free welds.
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INCONEL CLADDING
TIP TIG produces the cleanest welds from lowest possible oxidation. The welds will have the
lowest possible weld pores and inclusions and the smallest possible weld HAZ.
WELDING OF P-91 MATERIAL
With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable
of producing toughness values comparable to or exceeding manual GTAW and that the process
provides an attractive alternative for welding P91 root and hot passes or the entire weld from
root to cap. Results of this study indicates that semiautomatic HDMT GTAW welding process is
capable of producing impact values comparable to or exceeding manual GTAWT. The process also
provides an attractive alternative for welding P91 root and hot passes or the entire weld from
root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy (heat
input), larger weld puddle and increased deposition rate while still providing tempering of the
previously deposited weld beads or layers.
TIPTIG HDMT FOCUS is a unique TIPTIG welding process its precision and reliability make the
TIPTIG HDMT FOCUS welding process particularly suitable for automated applications in
combination with linear axles, robots and other guiding systems. Nearly all steels, non-ferrous
metals or galvanized sheets can be welded in one layer with filler material; e.g. CrNi-steels with
a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint
preparation. Some of the welded examples are listed below.
It has also been tested that elimination of backing gas in austenitic stainless steel welds using
high deposition metal transfer gas tungsten-arc welding (HDMTGTAW)
Example:
Page 23 of 25
Material: CrNi 10+10 mm
TIP TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS
The following comparison shows the actual savings calculated on a real stainless-steel welding
application comparing conventional TIG and TIP TIG on a pipe application (2″ Sch 80 Stainless) in
the 5G position.
Wire deposition
mm/min 100 1900
speed
The above data shows, the deposition rates approx. 3 times to standard TIG process which
reduces the production costs by 60%
CONCLUSION
TiPTiG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW)
process. Its versatility and simplicity makes the manual welder to give higher output. The
Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines
controlled excitation of wire with a hot wire addition is gives very promising results to challenging
applications.
References
1. Paper on ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH
DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS by Charles W. “Pat” Patrick
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