Results and Conclusions
The various tests produced an acceptable fillet with no undercut at lengths just below 12mm. The results showed that a single run 10mm leg length fillet is achievable using tandem wire SAW and that some extra work and trials could probably achieve a 12mm leg length fillet weld. The test parameters also produced excellent penetration and offered a throat thickness greater than that of a 15mm leg length fillet.
The tests have led to tandem wire SAW welding being trialled on their Sri Lanka project by CBUK, with an associated increase in welding speed of over 100%, from 450mm per minute to 1000mm per minute, with an overall 12% increase in productivity across the whole process.
The results of the project are planned to be put to work in an ongoing contract in Sri Lanka, leading to significantly improved efficiencies. The work has also been extended by Cleveland Bridge’s welding engineer Dean Baker, resulting in the introduction of square wave technology, which has enabled improvements in quality and a reduction in the risk of centre line cracking. Cleveland Bridge is now planning to develop the square wave approach for other products, including the use of weathering steel.
Cleveland Bridge UK Ltd reported that the experience of working with TWI and the principal project leader, Glenn Allen, was extremely positive. This included a visit to TWI Middlesbrough to witness the welding trials and the valuable upfront procedure work completed by Glenn, which provided the initial parameters on which subsequent work was based.
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