• Journal of Welding and Joining
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• v.18 no.2
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• pp.77-85
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• 2000

There are many weld defects such as surface crack, lack of fusion, and incomplete penetration (IP) in the butt joint weld of existing steel bridges. The crack-like defects may significantly reduce the fatigue life of the structure. This paper presents the procedure and the results of the fatigue life assessment of the butt joints with weld defects in the existing steel girder bridge. The butt joint welds with incomplete penetration were instrumented with strain gages to determine the stress histogram under normal traffic. Based on the measured stress histogram the crack propagation analysis were performed for the fatigue life assessment. By using the suggested procedure and methodology, one can decide the time of periodic inspection and the necessity of repair of the butt joint welds with serious weld defects in the existing steel bridge.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.10
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• pp.873-881
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• 2008

Weld overlay is one of the residual stress mitigation methods which arrest crack initiation and crack growth. Therefore weld overlay can be applied to the region where cracking is likely to be. An overlay weld used in this manner is termed a preemptive weld overlay(PWOL). In pressurized water reactor(PWR) dissimilar metal weld is susceptible region for primary water stress corrosion cracking(PWSCC). In order to examine the effect of PWOL on residual stress mitigation, PWOL was applied to a specific dissimilar metal weld of Kori nuclear power plant by finite element analysis method. As a result, strong compressive residual stress was made in PWSCC susceptible region and PWOL was proved effective preemptive repair method for weldment.

• Journal of Ocean Engineering and Technology
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• v.22 no.3
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• pp.82-88
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• 2008

The diesel engine of the merchant ship has been aperated in severe environments more and more, because the temperature of the exhaust gas of a combustion chamber is getting higher and higher with increasing use of heavy oil of law quality, due to the significant increase in the price of oil in recent some years. As a result, the degree of wear and corrosion between exhaust valve and seat ring is more serious compared to other engine parts. Thus the repair welding of exhaust valve and seat ring is a unique method to prolong the life of the exhaust valve, from an economical point of view. In this study, the corrosion property of both weld metal and base metal was investigated using electrochemical methods such as measurement of corrosion potential, cathodic and anodic polarization curves, cyclic voltammogram, and polarization resistance in 5% H2SO4 solution. The test specimen was a part of an exhaust valve stem being welded as the base metal, using various welding methods. In all cases, the corrosion resistance as well as hardness of the weld metal zone was superior to the base metal. In particular, plasma welding showed relatively good properties for both corrosion resistance and hardness, compared to other welding methods. In the case of DC SMAW (Shielded metal arc welding), corrosion resistance of the weld metal zone was better than that of the base metal, although its hardness was almost same as the base metal.

• Journal of Advanced Marine Engineering and Technology
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• v.23 no.3
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• pp.331-337
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• 1999

Cracks on the cylinder block of diesel engines will often happen due to cyclic load and thermal stress. According to the Classification Societies' rules welding reparis of cylinder block made of cast irons are generally not permitted. However such welding repairs became inevitable taking enormous cost and time for their renewal into consideration. In this study repair welding methods for the clinder blocks made of gray cast irons were reviewed and the tests of their welds were carried out in order to purpose the repair welding meth-ods of packing seat and o-ring seat of cylinder block and apply them to the practice. The following conclusions are botained :1 The tensile strength of weld of cast iron more than that of base metal can be obtained by means of preheating keeping temperature above $100^{\circ}C$ between welding pass-es preventing slag inclusion peening and cramping weld metal by studs. 2. The suspected crack by a magnetic particle test due to different magnetic permeability can be identified which are not associated with a mechanical discotinuity.

• Journal of Welding and Joining
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• v.16 no.4
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• pp.9-18
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• 1998

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

• Corrosion Science and Technology
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• v.14 no.2
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• pp.54-58
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• 2015

A heavy oil of low quality has been mainly used in the diesel engine of the merchant ship as the oil price has been significantly jumped for several years. Thus, a combustion chamber of the engine has been often exposed to severely corrosive environment more and more because temperature of the exhaust gas of the combustion chamber has been getting higher and higher with increasing of using the heavy oil of low quality. As a result, wear and corrosion of the engine parts such as exhaust valve, piston crown and cylinder head surrounded with combustion chamber are more serious compared to the other parts of the engine. Therefore, an optimum repair welding for these engine parts is very important to prolong their lifetime in a economical point of view. In this study, 1.25Cr-0.5Mo filler metal was welded with SMAW method in the forged steel which would be generally used with piston crown material. And the corrosion properties of weld metal, heat affected and base metal zones were investigated using electrochemical methods such as measurement of corrosion potential, anodic polarization curves, cyclic voltammogram and impedance etc. in 35% $H_2SO_4$ solution. The weld metal and base metal zones exhibited the highest and lowest values of hardness respectively. And, the corrosion resistance of the heat affected and weld metal zones was also increased than that of the base metal zone. Furthermore, it appeared that the corrosive products with red color and local corrosion like as a pitting corrosion were more frequently observed on the surface of the base metal zone compared to the heat affected and weld metal zones. Consequently, it is suggested that the mechanical and corrosion characteristics of the piston crown can be predominantly improved by repair welding method using the 1.25Cr-0.5Mo electrode.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.534-537
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• 2008

In recent years, the dissimilar metal, Alloy 82/182 welds used to connect stainless steel piping and low alloy steel or carbon steel components in nuclear reactor piping system have experienced cracking due to primary water stress corrosion(PWSCC). It is well known that one reason of the cracking is the residual stress by the weld. But, it is difficult to estimate exactly weld residual stress due to many parameters of welding. In this paper, the analysis of 3 FEM models made by ABAQUS Code is performed to estimate exactly the weld residual stress on the dissimilar metal weld. 3 FEM models are Butt model, Repair model and Overlay model and are the plane.strain 2D model. The thermal analysis and the stress analysis are performed on each model and the residual stresses on each model were calculated and compared respectively. Also, the specimen of Butt model was made and the residual stresses were measured by X-Ray method and Hole Drilling Technique. These results were compared with the FEM result of Butt model.

• Journal of Ocean Engineering and Technology
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• v.28 no.4
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• pp.356-362
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• 2014

Wear and corrosion of the engine parts surrounded with combustion chamber is more serious compared to the other parts of the engine because temperature of the exhaust gas in a combustion chamber is getting higher and higher with increasing of using the heavy oil of low quality. Therefore, an optimum repair weldment as well as an available choice of the base metal for these parts are very important to prolong their lifetime in a economical point of view. It reported that there was an experimental result for repair weldment on the forged steel which would be generally used with piston crown material, however, it is considered that there is no study for the repair weldment on the cast steel of piston crown material. In this study, four types of electrodes such as 1.25Cr-0.5Mo, 0.5Mo Inconel 625 and 718 were welded with SMAW and GTAW methods on the cast steel which would be generally used with piston crown material. And the corrosion properties of weld metal, heat affected zone and base metal were investigated using electrochemical methods such as measurement of corrosion potential, anodic polarization curves, cyclic voltammogram and impedance etc. in 35% $H_2SO_4$ solution. In the cases of Inconel 625, 718, the weld metals and base metals exhibited the best and worst corrosion resistance respectively, however, 1.25Cr-0.5Mo and 0.5Mo indicated that corrosion resistance of the base metal was better than the weld metal. And the weld metal welded with electrodes of Inconel 625 revealed the best corrosion resistance among the electrodes, and Inconel 718 followed the Inconel 625. Hardness relatively also indicated higher value in the weld metal compared to heat affected zone and base metal. In particular, Inconel 718 indicated the highest value of hardness compared to other electrodes in the heat affected zone.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.11 no.2
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• pp.51-60
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• 2015

Local wall thinning and integrity degradation caused by several mechanisms, such as flow accelerated corrosion, cavitation, flashing and/or liquid droplet impingement, is a main concern in secondary steam cycle piping system of nuclear power plants in terms of safety and operability. Thinned pipe management program (TPMP) has being developed and optimized to reduce the possibility of unplanned shutdown and/or power reduction due to pipe failure caused by wall thinning. In this paper, newest technologies, standards and regulations related to the integrity assessment, repair and replacement of thinned pipe component are reviewed. And technical improvement items in TPMP to secure the reliability and effectiveness are also presented.