• Journal of the Korean Institute of Gas
• /
• v.20 no.5
• /
• pp.96-103
• /
• 2016

Proper repair methods of damaged city gas pipeline is important factor to safely transmit gas and to reduce economical loss caused by failure of gas pipelines. Repair methods such as surfacing, type-A and type-B welding and composite sleeve method have been used to repair damaged city gas pipelines. In this paper, among repair methods, composite sleeve repair methods were conducted since they are rather simple processes and their repair quality is not sensitive to workers' ability compared with other repair methods. We discussed composite repair processes especially using carbon fiber prepregs and the experimental results.

• Transactions of the Korean Society of Pressure Vessels and Piping
• /
• v.11 no.1
• /
• pp.79-86
• /
• 2015

The purpose of this study is to evaluate structural integrity of a weldment which is partially screwed and then welded. Two finite element models are constructed and solved: operating temperature and internal pressure are considered in the first simple model, and welding process and normal operating condition including heat-up process are simulated in the second model. Structural integrity assessment criteria are satisfied with both finite element models, therefore the repair weldment finely sustains structural integrity of this assembly and prevents leakage. Stresses are dramatically increased when weld residual stress is considered, but it should be considered as a secondary stress.

• Proceedings of the KWS Conference
• /
• 2007.11a
• /
• pp.196-198
• /
• 2007

Laser cladding technology was studied as a method for upgrading the present repair procedures of damaged tubes in a nuclear steam generator and Doosan subsequently developed and designed a new Laser Cladding Repair System. One of the important features of this newly developed Laser Cladding Repair System is that molten metal can be deposited on damaged tube surfaces using a laser beam and filler wire without the need to install sleeves inside the tube. Laser cladding qualification tests on the steam generator tube material, Alloy 600, were performed according to ASME Section IX.

• Journal of Ocean Engineering and Technology
• /
• v.22 no.3
• /
• pp.89-95
• /
• 2008

Fatigue cracked components often needs to be repaired during service. Standard repair schemes involve strengthening the component by connecting reinforcing members by means of rivets or welding by reducing the crack-tip stress intensity factors. Recent technological advances in fiber reinforced composite materials and adhesive bonding have led to the development of efficient repair schemes. In this study, the influence of various shape parameters on fatigue crack growth in the CCT type uniform thickness plates and the thin-ta-thick type stiffened panels repaired with woven fabric type Kevlar-Epoxy composite patch are studied experimentally.

• Proceedings of the KWS Conference
• /
• 2003.05a
• /
• pp.40-42
• /
• 2003

In general, nickel-base superalloy has been extensively used as land-based gas turbine blades and vanes. Plasma transferred arc welding(PTAW) has been considered as a repair welding process of nickel-base superalloy. This research evaluated the relationship between hot ductility behavior and hot cracking susceptibility in nickel-base superalloys. Ductility recovery rate of nickel base superalloys was found to be poor due to incipient melting and constitutional liquation. This seems to increase the hot cracking susceptibility.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.20 no.9
• /
• pp.1-10
• /
• 2021

Recently, the repair and recycling of damaged mechanical parts via metal additive manufacturing processes have been industrial points of interest. This is because the repair and recycling of damaged mechanical parts can reduce energy and resource consumption. The directed energy deposition(DED) process has various advantages such as the possibility of selective deposition, large building space, and a small heat-affected zone. Hence, it is a suitable process for repairing damaged mechanical parts. The shaft is a core component of various mechanical systems. Although there is a high demand for the repair of the shaft, it is difficult to repair with traditional welding processes because of the thermal deformation problem. The objective of this study is to propose a repair procedure for a damaged shaft using the DED process and discuss its applications. Three types of cases, including a small shaft with a damaged surface, a medium-size shaft with a worn bearing joint, and a large shaft with serious damage, were repaired using the proposed procedure. The microstructure and hardness were examined to discuss the characteristics of the repaired component. The efficiency of the repair of the damaged shaft is also discussed.

• Journal of Welding and Joining
• /
• v.28 no.5
• /
• pp.51-57
• /
• 2010

Brittle microstructure created in a heat affected zone (HAZ) during the welding of low alloy steel can be eliminated by post-weld heat treatment (PWHT). If the PWHT is not possible during a repair welding, the controlled bead depositions of multi-pass welding should be applied to obtain tempering effect on the HAZ without PWHT. In order to anticipate and control the tempering effect during the temper bead welding, the definition of temperature curve obtained from the analytical solution was suggested in this research. Because the analytical solution for heat flow is expressed as a mathematical equation of weld parameters, it may be effective in anticipating the effect of each weld parameter on the tempering in HAZ during the successive bead depositions. The reheating effect by the successive bead layer on the brittle coarse grained HAZ formed by earlier bead deposition was estimated by comparing the overlapped distance between the temperature curves in the HAZ. Three layered weld specimens of SA508 base metal with A52 filler were prepared by controlling heat input ratio between layers. The tempering effect anticipated by using the overlapped distance between the temperature curves was verified by measuring the micro-hardness distribution in the HAZ of prepared specimens. The temperature curve obtained from analytical solution was expected as a good tool to find optimal temper bead welding conditions.

• Journal of Welding and Joining
• /
• v.33 no.2
• /
• pp.40-46
• /
• 2015

This study was performed to investigate the effect of ultrasonic nano crystal surface modification (UNSM) on residual stress mitigation after Weld Inlay repair for butt dissimilar metal weld with Alloy 82/182 in reactor vessel In/Outlet nozzle. As-welded and Weld Inlay specimens were made in accordance with design standard of ASME Code Case N-766, and two planes of their weld specimens were peened by the optimum UNSM process condition. Peening characteristics for weld specimens after UNSM treatment were evaluated by surface roughness and Vickers hardness test. And, residual stress for weld specimens developed from before and after UNSM treatment was measured and evaluated by instrumented indentation technique. Consequently, it was revealed that the mitigation of residual stress in weld metal after Weld Inlay repair of reactor vessel In/Outlet nozzle could be possible through UNSM treatment.

• Journal of Welding and Joining
• /
• v.33 no.5
• /
• pp.26-30
• /
• 2015

Hastelloy X in this study was applied in jet engine F-15 air fighter as shroud to isolate the engine from outer skin. After 15 years operation at elevated temperature the mechanical properties decreased gradually due to the precipitation of continues second phases in the grain boundaries and precipitated inside the grain. The crack happened at the edge of the shroud due to the thermal and mechanical stress from jet engine. Selective TEM analysis found that the grain boundaries consist of $M_{23}C_6$ carbide, $M_6$ Ccarbide and small percentage of sigma(${\sigma}$) phase. Furthermore, it was confirmed the nano size of ${\sigma}$ and miu (${\mu}$) phase inside the grain. In this study, it was investigated the microstructure of the degraded shroud component and HAZ of repair welded shroud. In the HAZ, it was observed the dissolution of the $M_{23}C_6$ carbides and smaller precipitates, the migration of the undissolved larger $M_{23}C_6$ carbide and $M_6$ Ccarbide. It is also observed the liquation due to the simply melt of the segregated precipitates in the grain boundaries. Interestingly, the segregated second phases which simply melt in the grain boundaries more easily happened at higher heat input welding condition. High temperature tensile test was done at $300^{\circ}C$, $700^{\circ}C$ and $900^{\circ}C$. It was obtained that the toughness of welded sample is lower compare to the non-welded sample. The solution heat treatment at $1170^{\circ}C$ for 5 minutes was suggested to obtain a better mechanical properties of the shroud. The high cycle fatigue number of the repair welded shroud shows a much lower compare to the shroud. In addition, the high cycle fatigue number at room temperature after solution heat treatment was almost double compare to the before solution heat treatment under 420-500MPa stress amplitude. However, the high cycle fatigue number of repaired welded sample was shown a much lower compare to the non- welded shroud and solution treated shroud. One of the main reasons to decrease the tensile strength and the high cycle fatigue properties of the repair welded shroud is the formation of the liquid phase in HAZ.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.235-243
• /
• 2002

Ni-base superalloys are used extensively in industry, both in aeroengines and land based turbines. About 60% by weight of most modern gas turbine engine structural components are made of Ni-base superalloys. To satisfy practical demands, the efficiency of gas turbine engines has been steadily and systematically increased by design modifications to handle higher turbine inlet or firing temperatures. However, the increase in operating temperatures has lead to a decrease in the life of components and increase in costs of replacement. Moreover, around 80% of the large frame size industrial/utility gas turbines operating in the world today were installed in the mid-sixties to early seventies and are now 25 to 30 years old. Consequently, there are greater opportunities now to repair and refurbish the older models. Basically, there are two major factors influencing the weldability of the cast alloys: strain-age cracking and liquation cracking. Susceptibility to strain-age cracking is due to the total Ti plus AI content of the alloy; Liquation cracking is due either to the presence of low melting constituents or constitutional liquation of constituents. Though Rene 41 superalloy has 4.5wt.% total Ti and Al content and falls just below the safe limit proposed by Prager et al., controlled grain size and special heat treatments are needed to obtain crack-free welds. Varying heat treatments and filler materials were used in a laboratory study, then the actual welding of service parts was carried out to verity the possibility of crack-tree weld of components fabricated from Rene 41 superalloy. The microstructural observations indicated that there were two kinds of carbides in the FCC matrix. MC carbides were located along the grain boundaries, while M$_{23}$C$_{6}$ carbide was located both inter and intra granularly. Two kinds of filler materials, Rene 41 and Hastelloy X were used to gas tungsten arc weld a patch into the sheet metal, along with varying pre-weld heat treatments. The microstructure, hardness and tensile tests were determined. The service distressed parts were categorized into three classes: with large cracks, with medium cracks and with small or no visible cracks. No significant difference in microstructure among the specimens was observed. Specimens were cut from the corner and the straight edge of the patch repair, away from the corner. The only cracks present were found to be associated with inadequate surface preparation to remove oxidation. Guidelines for oxide removal and the welding procedures developed in the research enabled crack-free welds to be produced.d.