Investigation of Optimal Parameter Settings in Super Duplex Welding
Super steel materials play a vital role in the
construction and fabrication of structural, piping and pipeline
components. In assuring the integrity of onshore and offshore
operating systems, they enable life cycle costs to be minimized. In
this context, Duplex stainless steel (DSS) material related welding on
constructions and fabrications plays a significant role in maintaining
and assuring integrity at an optimal expenditure over the life cycle of
production and process systems as well as associated structures. In
DSS welding, factors such as gap geometry, shielding gas supply
rate, welding current, and type of the welding process are vital to the
final joint performance. Hence, an experimental investigation has
been performed using an engineering robust design approach
(ERDA) to investigate the optimal settings that generate optimal
super DSS (i.e. UNS S32750) joint performance. This manuscript
illustrates the mathematical approach and experimental design,
optimal parameter settings and results of the verification experiment.
[1] HSE, “Chloride stress corrosion cracking in austenitic stainless steel:
assessing susceptibility and structural integrity,” Health and Safety
Laboratory, Health and Safety Executive, 2011, http://www.hse.gov.uk/
research/rrpdf/rr902.pdf (accessed on 29.12.2014).
[2] R. M. C. Ratnayake, “An algorithm to prioritize welding quality
deterioration factors: A case study from a piping component fabrication
process,” Int. J. Qual. Reliab. Manag., vol. 30, no. 6, pp. 616–638, 2013.
[3] J. Xu, L. Chen, C. Ni, “Effect of vibratory weld conditioning on the
residual stresses and distortion in multipass girth-butt welded pipes,” Int.
J. Pres. Ves. Pip., vol. 84, no. 5, pp. 298–303, 2007.
[4] P. Sathiya, M. Y. Abdul Jaleel, “Grey-based taguchi method for
optimization of bead geometry in laser bead-on-plate welding,” Adv.
Prod. Eng. Manag., vol. 5, no. 4, pp. 225–234, 2010. http://maja.uni-mb.si/files/apem/APEM5-4_225-234.pdf (accessed on 01.09.2013).
[5] R.M.C. Ratnayake, "A methodology for assessing most vulnerable
welding procedure specifications and imperfection factors," Int. J. of
Data Anal. Techniques and Strategies, vol. 6, no. 4, pp. 362–383, 2014.
http://www.inderscience.com/info/ingeneral/forthcoming.php?jcode
=ijdats (accessed on 29.12.2014).
[6] J. Mirapeix, P. B. García-Allende, A. Cobo, O. M. Conde, and López-J.
M. Higuera, “Real-time arc-welding defect detection and classification
with principal component analysis and artificial neural networks,” NDT
& E Int., vol. 40, no. 4, pp. 315–323, 2007.
[7] R. M. C. Ratnayake, “A mathematical framework for parameter
designing under the noise: A case study from a conventional turning
machine,” Proc. IEEE Int. Conf. Industrial Engineering and
Engineering Management, DOI: 10.1109/IEEM.2013.6962420, 2013,
pp. 290–294.
[8] M. S. Phadke, Quality Engineering using Robust Design. Englewood
Cliffs, New Jersey: PTR Prentice-Hall, Inc., 1989.
[9] R. Unal, “Taguchi approach to design optimization for quality and cost:
an overview,” Ann. Conf. International Society of Parametric Analysts,
1991. ftp://ns1.ystp.ac.ir/ystp/ 1/1/ROOT/DATA/ PDF/INNOVATION/
conf-13-ispa-unal+dean.pdf (accessed on 04.04.2013).
[10] S. Kamaruddin, A. Zahid Khan, and S. H. Foong, “Application of
Taguchi method in the optimization of injection moulding parameters
for manufacturing products from plastic blend,” IACSIT International
Journal of Engineering Technology, vol. 2, no. 6, ISSN: 1793–8236,
Dec. 2010.
[11] F. M. Pati, Study of Parametric Optimization of Microdrilling Operation
using Taguchi Method, 2010. http://ethesis. nitrkl.ac.in/ 2066/
1/PROJECT_REPORT4.docxnew1.pdf (accessed on 04.04.2013).
[12] G. Taguchi, and M. S. Phadke, “Quality engineering through design
optimization,” Conf. Rec., GLOBECOM 84 Meeting, IEEE
Communications Society, Atlanta, GA, November 1984.
[13] M. S. Phadke, “Optimization of product and process design for quality
and cost,” Qual. Reliab. Eng. Int., vol. 4, no. 2, pp. 105–112, 1988.
[14] J. C. Lippold, W. Lin, S. Brandi, I. Varol, W. A. Baeslack III, Proc.4th
Int. Conf. Duplex Stainless Steels, Glasgow, Scotland, 1994 November
13–16, vol. 2, Paper 116.
[15] J. O. Nilsson, “Super duplex stainless steels,” Mater. Sci. Tech., vol. 8,
pp. 685–700, 1992.
[16] The International Molybdenum Association (IMOA), Practical
Guidelines for the Fabrication of Duplex Stainless Steel. London, UK,
2009, pp. 1–64, ISBN 978-1-907470-00-4.
[17] W. A. Baeslack, W. F. Savage, and D. J. Duquette, “Effect of nitrogen
on the microstructure and stress corrosion cracking of stainless steel
weld metals,” Weld. Res. Supplement, pp. 83s–90s, 1979.
http://www.aws.org/wj/supplement/WJ_1979_03_s83.pdf (accessed on
29.12.2014).
[18] TWI, “Duplex stainless steel - Part 22,” 2014, http://www.twiglobal.
com/technical- knowledge/job-knowledge/duplex-stainless-steelpart-
2-106/ (accessed on 29.12.2014).
[19] R. Francis, Papers presented. Proc. 4th Int. Conf. Duplex Stainless
Steels, Glasgow, Scotland, 13-16 November 1994, Abington Publ.,
1995, vol. 2: Welding processes.
[20] Lincoln, Guidelines for welding Zeron 100 super duplex stainless steel,
Lincoln Smitweld, http://www.lasgroepzuid.com/documenten/
Guidelines _Zeron.pdf (accessed on 29.12.2014).
[21] C. Daniel, Applications of Statistics to Industrial Experimentation. New
York: John Wiley and Sons, 1976.
[22] F. Kolahan, M. Manoochehri, and A. Hosseini, “Application of Taguchi
method and ANOVA analysis for simultaneous optimization of
machining parameters and tool geometry in turning,” World Acad. Sci.,
Eng. Tech., vol. 74, pp. 82–85, 2011.
[23] F. Kolahan, M. Manoochehri, and A. Hosseini, “Simultaneous
optimization of machining parameters and tool geometry specifications
in turning operation of AISI1045 steel,” World Acad. Sci., Eng. Tech.,
vol. 50, pp. 785–788, 2011.
[24] S. Kumar, M. Gupta, P. S. Satsangi, and H. K. Sardana, “Modeling and
analysis for surface roughness and material removal rate in machining of
UD-GFRP using PCD tool,” Int. J. Eng. Sci. & Tech., vol. 3, no. 8,
2011, pp. 248–270.
[1] HSE, “Chloride stress corrosion cracking in austenitic stainless steel:
assessing susceptibility and structural integrity,” Health and Safety
Laboratory, Health and Safety Executive, 2011, http://www.hse.gov.uk/
research/rrpdf/rr902.pdf (accessed on 29.12.2014).
[2] R. M. C. Ratnayake, “An algorithm to prioritize welding quality
deterioration factors: A case study from a piping component fabrication
process,” Int. J. Qual. Reliab. Manag., vol. 30, no. 6, pp. 616–638, 2013.
[3] J. Xu, L. Chen, C. Ni, “Effect of vibratory weld conditioning on the
residual stresses and distortion in multipass girth-butt welded pipes,” Int.
J. Pres. Ves. Pip., vol. 84, no. 5, pp. 298–303, 2007.
[4] P. Sathiya, M. Y. Abdul Jaleel, “Grey-based taguchi method for
optimization of bead geometry in laser bead-on-plate welding,” Adv.
Prod. Eng. Manag., vol. 5, no. 4, pp. 225–234, 2010. http://maja.uni-mb.si/files/apem/APEM5-4_225-234.pdf (accessed on 01.09.2013).
[5] R.M.C. Ratnayake, "A methodology for assessing most vulnerable
welding procedure specifications and imperfection factors," Int. J. of
Data Anal. Techniques and Strategies, vol. 6, no. 4, pp. 362–383, 2014.
http://www.inderscience.com/info/ingeneral/forthcoming.php?jcode
=ijdats (accessed on 29.12.2014).
[6] J. Mirapeix, P. B. García-Allende, A. Cobo, O. M. Conde, and López-J.
M. Higuera, “Real-time arc-welding defect detection and classification
with principal component analysis and artificial neural networks,” NDT
& E Int., vol. 40, no. 4, pp. 315–323, 2007.
[7] R. M. C. Ratnayake, “A mathematical framework for parameter
designing under the noise: A case study from a conventional turning
machine,” Proc. IEEE Int. Conf. Industrial Engineering and
Engineering Management, DOI: 10.1109/IEEM.2013.6962420, 2013,
pp. 290–294.
[8] M. S. Phadke, Quality Engineering using Robust Design. Englewood
Cliffs, New Jersey: PTR Prentice-Hall, Inc., 1989.
[9] R. Unal, “Taguchi approach to design optimization for quality and cost:
an overview,” Ann. Conf. International Society of Parametric Analysts,
1991. ftp://ns1.ystp.ac.ir/ystp/ 1/1/ROOT/DATA/ PDF/INNOVATION/
conf-13-ispa-unal+dean.pdf (accessed on 04.04.2013).
[10] S. Kamaruddin, A. Zahid Khan, and S. H. Foong, “Application of
Taguchi method in the optimization of injection moulding parameters
for manufacturing products from plastic blend,” IACSIT International
Journal of Engineering Technology, vol. 2, no. 6, ISSN: 1793–8236,
Dec. 2010.
[11] F. M. Pati, Study of Parametric Optimization of Microdrilling Operation
using Taguchi Method, 2010. http://ethesis. nitrkl.ac.in/ 2066/
1/PROJECT_REPORT4.docxnew1.pdf (accessed on 04.04.2013).
[12] G. Taguchi, and M. S. Phadke, “Quality engineering through design
optimization,” Conf. Rec., GLOBECOM 84 Meeting, IEEE
Communications Society, Atlanta, GA, November 1984.
[13] M. S. Phadke, “Optimization of product and process design for quality
and cost,” Qual. Reliab. Eng. Int., vol. 4, no. 2, pp. 105–112, 1988.
[14] J. C. Lippold, W. Lin, S. Brandi, I. Varol, W. A. Baeslack III, Proc.4th
Int. Conf. Duplex Stainless Steels, Glasgow, Scotland, 1994 November
13–16, vol. 2, Paper 116.
[15] J. O. Nilsson, “Super duplex stainless steels,” Mater. Sci. Tech., vol. 8,
pp. 685–700, 1992.
[16] The International Molybdenum Association (IMOA), Practical
Guidelines for the Fabrication of Duplex Stainless Steel. London, UK,
2009, pp. 1–64, ISBN 978-1-907470-00-4.
[17] W. A. Baeslack, W. F. Savage, and D. J. Duquette, “Effect of nitrogen
on the microstructure and stress corrosion cracking of stainless steel
weld metals,” Weld. Res. Supplement, pp. 83s–90s, 1979.
http://www.aws.org/wj/supplement/WJ_1979_03_s83.pdf (accessed on
29.12.2014).
[18] TWI, “Duplex stainless steel - Part 22,” 2014, http://www.twiglobal.
com/technical- knowledge/job-knowledge/duplex-stainless-steelpart-
2-106/ (accessed on 29.12.2014).
[19] R. Francis, Papers presented. Proc. 4th Int. Conf. Duplex Stainless
Steels, Glasgow, Scotland, 13-16 November 1994, Abington Publ.,
1995, vol. 2: Welding processes.
[20] Lincoln, Guidelines for welding Zeron 100 super duplex stainless steel,
Lincoln Smitweld, http://www.lasgroepzuid.com/documenten/
Guidelines _Zeron.pdf (accessed on 29.12.2014).
[21] C. Daniel, Applications of Statistics to Industrial Experimentation. New
York: John Wiley and Sons, 1976.
[22] F. Kolahan, M. Manoochehri, and A. Hosseini, “Application of Taguchi
method and ANOVA analysis for simultaneous optimization of
machining parameters and tool geometry in turning,” World Acad. Sci.,
Eng. Tech., vol. 74, pp. 82–85, 2011.
[23] F. Kolahan, M. Manoochehri, and A. Hosseini, “Simultaneous
optimization of machining parameters and tool geometry specifications
in turning operation of AISI1045 steel,” World Acad. Sci., Eng. Tech.,
vol. 50, pp. 785–788, 2011.
[24] S. Kumar, M. Gupta, P. S. Satsangi, and H. K. Sardana, “Modeling and
analysis for surface roughness and material removal rate in machining of
UD-GFRP using PCD tool,” Int. J. Eng. Sci. & Tech., vol. 3, no. 8,
2011, pp. 248–270.
@article{"International Journal of Earth, Energy and Environmental Sciences:70099", author = "R. M. Chandima Ratnayake and Daniel Dyakov", title = "Investigation of Optimal Parameter Settings in Super Duplex Welding", abstract = "Super steel materials play a vital role in the
construction and fabrication of structural, piping and pipeline
components. In assuring the integrity of onshore and offshore
operating systems, they enable life cycle costs to be minimized. In
this context, Duplex stainless steel (DSS) material related welding on
constructions and fabrications plays a significant role in maintaining
and assuring integrity at an optimal expenditure over the life cycle of
production and process systems as well as associated structures. In
DSS welding, factors such as gap geometry, shielding gas supply
rate, welding current, and type of the welding process are vital to the
final joint performance. Hence, an experimental investigation has
been performed using an engineering robust design approach
(ERDA) to investigate the optimal settings that generate optimal
super DSS (i.e. UNS S32750) joint performance. This manuscript
illustrates the mathematical approach and experimental design,
optimal parameter settings and results of the verification experiment.", keywords = "Duplex stainless steel welding, engineering robust
design, mathematical framework, optimal parameter settings.", volume = "9", number = "7", pages = "789-6", }
