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Research Papers

Three Dimensional Analysis of High Frequency Induction Welding of Steel Pipes With Impeder

[+] Author and Article Information
Hyun-Jung Kim

Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, 373-1 Guseong-Dong, Yuseong-Gu, Daejeon 305-701, Republic of Koreakim1392@kaist.ac.kr

Sung-Kie Youn

Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, 373-1 Guseong-Dong, Yuseong-Gu, Daejeon 305-701, Republic of Koreaskyoun@kaist.ac.kr

J. Manuf. Sci. Eng 130(3), 031005 (May 06, 2008) (7 pages) doi:10.1115/1.2844586 History: Received February 09, 2006; Revised November 16, 2007; Published May 06, 2008

High frequency induction welding is widely employed for longitudinal seam welding of small scale tubes and pipes due to its relatively high processing speed and efficiency. This research is aimed at understanding the variables that affect the quality of the high frequency induction welding. The welding variables include the welding frequency, weld speed, vee angle, and tube thickness. Temperature distribution of the tube is calculated through three dimensional coupled electromagnetic and thermal finite element analysis. The skin and proximity effects are considered in the electromagnetic analysis. The influence of the impeder is also analyzed. The effects of the operating welding variables on the temperature distribution are investigated quantitatively by exhibiting the heat affected zone. The results explain the mechanism of significant enhancement of welding efficiency when the impeder is used. Not only good weld state can be obtained but also overheated edge can be avoided by understating the effect of welding variables. Suggestions are made for the better induction welding conditions.

Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Flowchart of the analysis procedure

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Figure 2

Geometric information of the tube and impeder

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Figure 3

Results of electromagnetic and thermal analysis: (a) eddy current distribution and (b) temperature distribution

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Figure 4

Cross section of the skelp with an impeder

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Figure 5

Temperature distribution of HAZ and molten zone at the weld point

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Figure 6

Comparison of temperature distribution at the weld point between the tube without an impeder and the tube with an impeder

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Figure 7

Maximum temperature and average HAZ width with respect to frequency (weld speed: 18m∕min)

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Figure 8

Temperature distribution of HAZ and molten zone at the weld point with respect to frequency (723–1670°C)

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Figure 9

Result of thermal transient analysis with respect to weld speed

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Figure 10

Maximum eddy current density and temperature with respect to vee angle (weld speed: 18m∕min)

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Figure 11

Eddy current distribution at the skelp with respect to vee angle

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Figure 12

Simplicity of weld vee: (a) small vee angle and (b) large vee angle

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Figure 13

Temperature distribution of HAZ and molten zone with respect to vee angle (723–1750°C)

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Figure 14

Nondimensionalization of the critical vee angle

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Figure 15

Temperature toward the circumferential direction

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Figure 16

Average HAZ width with respect to vee angle

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Figure 17

Maximum eddy current density and temperature with respect to thickness (weld speed: 18m∕min)

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Figure 18

Eddy current distribution at the skelp with respect to thickness

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Figure 19

Nondimensionalization of critical thickness

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Figure 20

Maximum temperature with respect to impeder radius

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Figure 21

Temperature distribution of 4.2-mm- and 5.4-mm-thick tubes with respect to impeder radius

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