Abstract: In a method for producing welded helical seam tubes having optimized tube geometry a metal strip is helically formed into an open seam tube by means of a forming unit and the converging strip edges are welded together, wherein an actual diameter determined on the welded tube is compared with a specific target diameter and a possible deviation lying outside a tolerance threshold is used to correct the actual tube diameter, wherein the strip edges are completely welded in a two stage step, including tack welding as a first step immediately after the shaping to form an open seam tube and thereafter final welding as a second step. The tube diameter is measured after the complete shaping to form an open seam tube and before the final welding. For this purpose, the diameter measuring device is arranged in such a way that either the completely shaped open seam tube or the only tack-welded tube is measured.

Abstract: There is provided a high power laser tool system for transmitting and delivering high power laser energy within the interior of pipes, which includes a high power laser-pig and long distance high power optical tether. The high power laser system performs high power laser pigging operations and other operations, such as, cleaning, assembling, maintaining and monitoring of pipelines.

Abstract: In order to evaluate the welding current for the resistance seam welding of an overlap seam of container bodies, a welding with changing welding current intensity is carried out for a container body of the production series, resulting in a changing welding of the seam, ranging from the welding with a too high temperature to the welding with a too low temperature. The electric energy for this welding is determined several times during this welding and/or the temperature of the weld seam is determined several times and the welding current intensity is determined at which the welding of the individual container body is too cold and the welding current intensity at which the welding is too hot. This determination is based on the determined electric energy values and/or on the determined temperature values and based on this determination a preferred range for the welding current intensity within these limits of too hot and too cold is determined.

Abstract: A method produces a welded connection between first and second components each having inner and outer sides interconnected by an end face. The first component has a ferritic basic body carrying a plating at the inside and having an end face with a buffer layer of Ni-based alloy. The second component is of austenitic material. The end faces of the components enclose a weld groove. An austenitic root, connecting the plating to the end face of the second component, is welded in the weld groove. An intermediate layer of a nickel alloy having at least 90% nickel is welded onto the root. The intermediate layer is connected to the end faces of the plating and the second component. A weld seam is then produced in the remaining weld groove using a nickel-based welding additive. A method for repairing a welded connection between first and second components is also provided.

Abstract: A welding apparatus of a stainless steel pipe comprises a welding torch jetting argon gas for shielding oxygen into a gap of the steel pipe rolled in a circular shape, while fusing any one of base metal and a welding material; and a gas supply pipe installed inside the steel pipe, the gas supply pipe having a jetting nozzle which jets argon gas at a rate of 4 to 20 l/min toward the inner surface of a welding bead portion, where welding has been already completed and which is positioned backwardly at a predetermined distance from a welding bead portion where welding is being performed by the welding torch.

Abstract: A method for Magnetic Arc welding for metallic materials wherein at least one of the workpieces to be welded has an open cross-section. The method comprises bracing the two workpieces and moving them together, wherein the open cross-section of one workpiece is bridged by a metallic auxiliary part to form a conducting closed region, and after the activation of a magnetic field of a magnet coil system and of the current required for welding, the workpieces are placed with a defined spacing and an electric arc is ignited, the magnetic field of the magnet coil system sets the electric arc in rotation in order to uniformly heat the end surfaces to be welded, and subsequently, the surfaces, which are to be welded, of the workpieces are pressed against one another.

Abstract: A unique tubular work piece is disclosed along with a novel method and apparatus for manufacturing tubular work pieces from sheet metal stock lighter and stronger structures with less waste and less cost than prior methods.

Abstract: A method of joining pipes (3) to produce underwater pipelines (2), wherein the facing free ends (15) of two adjacent pipes (3), aligned along an axis (A), are welded to define a cutback (18); a protective sheet (22) of plastic material is extruded close to the cutback (18); and the protective sheet (22) is wound about the cutback (18).

Abstract: A welded assembly of combustion chamber elements is disclosed. Two subassemblies of the combustion chamber are fabricated by butt-welding, and a first subassembly has an intermediate connection ring welded thereto suitable for performing final welding with the second subassembly.

Abstract: A device for purging gas comprises a conduit assembly defining an interior volume. The conduit assembly comprises a first conduit portion having an open first end and an open second end and a second conduit portion having an open first end and a closed second end. The open second end of the first conduit portion is disposed proximate to the open first end of the second conduit portion to define a weld region. The device further comprises a supply element supplying a gas to the interior volume at a substantially constant rate and a vent element venting the gas from the interior volume at a rate that maintains the gas in the interior volume within a pressure range suitable to hold a weld bead in the weld region in equilibrium during formation of a weld to join the first conduit portion and the second conduit portion.

Abstract: The invention relates to a measurement system constructed and arranged to measure geometrical data from two pipe end bevels of two pipes that need to be joined. The measurement system being provided with a measuring device, wherein the measurement system is constructed and arranged so that the measuring device is moveable in between the two pipe end bevels and the measuring device has a part of a different one of the two pipe end bevels within its measurement angle.

Abstract: A tubular assembly comprising a first iron based tubular having a first non-cladded inner surface; and a second iron based tubular having a second non-cladded inner surface, wherein the first tubular is connected to the second tubular using a non-iron based bonding material. Preferably, the non-iron based bonding material has a lower crack growth rate than the iron based tubulars.

Abstract: A hollow rotor shaft for use in a small twin spool gas turbine engine in which the hollow rotor shaft is assembled by welding two hollow shaft sections together to form the single shaft assembly. One of the hollow shaft sections includes a lip that functions to form a snug fit prior to welding and also functions as a weld filler material. The hollow shaft ends each include a hole to allow for pressure equalization during the welding process to prevent bulging of the hollow shaft. To ensure a full penetration weld, an orbital welding process is used while passing an insert gas such as argon through the hollow shaft to minimize the buildup of material on the inner surface of the weld from the welding process. The shaft ends are pre-heated prior to welding. An insert gas is passed through the inner surface of the shaft sections during welding to prevent buildup of material on the inner surface of the hollow rotor shaft.

Abstract: The invention relates to a method for connecting thick-walled metal workpieces by welding. In order to create the weld joint, the cross-sections are provided with a maximum of three weld regions according to wall thickness, the welding being carried out by a combined use of welding methods: the first weld region (root) is welded by means of laser beam welding or hybrid laser-arc welding, the second weld region is welded by means of hybrid laser-arc welding, and the third weld region required occasionally depending on the thickness of the sheet metal is welded by means of hybrid laser-arc welding or simply arc welding. The invention also relates to a seam preparation corresponding to the respective welding method used.

Abstract: Apparatus and method for welding steel boiler tubes in a space restricted area using a pulsed-arc welding process. The process includes the use of a consumable insert ring having a T-shaped profile and flux material to provide deep weld penetration by a GTAW welding machine. Notches in the consumable weld ring allow for inspection of tube fit prior to weld.

Abstract: Welding repairs are performed in an underwater environment adjacent the bottom head of the nuclear reactor vessel. To provide a dry welding environment, segments of a lower caisson are passed through the core plate holes and assembled along the interior surface of the bottom head. The assembled segments are held down by brackets and sealed to one another and to the bottom head by a water curable polymer. An upper caisson is passed through the core plate hole to sealingly engage the lower caisson. The caissons are pumped dry and welding equipment is passed through the caissons to effect weld repairs about the stub tube or along the bottom head cladding.

Abstract: A method for welding a pipe section and a connector, where each of the pipe and connector have inner and outer beveled surfaces forming only a single angular alignment land when mated. The pipe and connector are welded together with only a single interior welding pass and with more than one exterior welding pass to fill the weld joints at the outer beveled surface, so as to weld the connector to the pipe.

Abstract: A method and apparatus for joining pipe sections (102, 104) together to form an underwater pipeline. The pipe sections (102, 104) are in an abutting position and have a generally vertical orientation. The apparatus comprises at least two welding equipment carriers (148, 152) and at least two welding heads (110, 112). Each welding head is connected to an equipment carrier (148, 152) by means of at least one umbilical (130, 132). The apparatus further comprises a welding head guide assembly (113) which is adapted to be fixed to one of said upper of lower pipe sections. The welding head guide assembly (113) guides the welding heads about the pipe sections (102, 104). The apparatus further comprises a guiding device (133) which guides the welding equipment carriers (148, 152) around said welding area (115). The welding equipment carriers (148, 152) are movable independently from one another.

Abstract: In one embodiment, the present invention relates to a method and system of determining the weld bead sequence on a mechanical component is disclosed. In one specific embodiment, the sequence is determined by numerical analysis of a plurality of weld bead sequences to determine the weld bead sequence. Then, after this sequence is determined, a weld overlay is placed onto the mechanical component using the sequence. In particular embodiments, a weld bead sequence is applied to a boiler tube panel wherein the sequence begins at the crown of the tube, progresses down the walls of the tube to the tube and membrane interface, and concludes on the membrane. The new bead sequence reduces residual and distortional stresses as created by applying a weld overlay.

Abstract: A method and apparatus for joining materials having primarily ferritic properties is described. The method includes joining the ferritic materials using a welding process and a weld material having a primarily austenitic microstructure. The resulting weldment enhances the properties of yield ratio, uniform elongation, toughness and tearing resistance thereby producing superior strain capacity. High strain capacity produces a structure that accommodates high axial loading. The weldment can also accommodate larger than conventional weld flaws while maintaining sufficient strength, tearing resistance, and fracture toughness under high axial loading.

Abstract: A method for manufacturing a roller body, wherein pipe sections, each made of steel having a carbon equivalent of at least 0.45 and a wall thickness of at least 130 mm each are arranged axially next to each other and connected to each other by means of electron-beam welding.

Abstract: A self-adhesive purge dam for retaining purge gas around a weld zone includes a base configured to substantially obstruct an air passage leading to the weld zone and an adhesive skirt extending from the base and configured to engage portions of the air passage. An adhesive on the adhesive skirt allows the skirt to be adhered to the air passage. An optional removable backing covers the adhesive prior to installation. The adhesive skirt is deployable from a stowed position wherein the adhesive is generally disposed in an interior portion of the purge dam to an installation position wherein the adhesive can be pressed against a surface to which the purge dam is to be adhered. The purge dam can be installed by inserting it in the air passage with the adhesive skirt in the stowed position, removing the removable backing prior to or after insertion in the air passage, exposing the adhesive, and deploying the skirt to the installation position for adhesion.

Abstract: A method of manufacturing an electric resistance welding pipe is provided in which a lateral edge shape is made to be an appropriate shape immediately before electric resistance welding is performed, whereby penetrators are securely removed during the electric resistance welding and, consequently, an electric resistance welding pipe having excellent characterization of welded seam can be obtained. A fin shape in finpass forming is printed to lateral edges of a strip, whereby the lateral edges of the strip are shaped with predetermined tapering.

Abstract: Contemplated methods for welding stainless steel substantially improve welding speed and quality. Most typically, such attributes are achieved by welding a root pass using GMAW-Sm to thereby depositing a root, welding a hot pass using GMAW-P to thereby deposit additional weld metal onto the root, and by welding at least one of a fill pass and a cap pass using at least one of GMAW-P and FCAW.

Abstract: A welding process for end connection of a first tube to a second tube along a circumferential joint by means of a weld bead, in which the first and the second tube are arranged with respect to one another in the position which is necessary for formation of the circumferential joint, a heat sink for the extraction of coolant is inserted into the first and/or the second tube such that the coolant emitted from it can cool at least one of the tubes in the area of the end to be welded, the tubes and a welding burner for production of the weld bead can be moved relative to one another along the circumferential joint and are welded by the welding burner, and the coolant is used at specific intervals.

Abstract: A method for repairing a heat recovery steam generator (HSRG) header to tube attachment damage, includes providing an access window in the header opposite the damaged header to tube attachment location; removing the header to tube attachment damage; inserting a tapered stub tube into a header penetration centered axially immediately over the tube; effecting a profile weld between the header and the tapered stub tube at the header penetration from the inside surface of the header; welding the tapered stub tube to the existing tube through the header inside diameter; welding shut the access window; and completing a post weld heat treatment of all the welds.

Abstract: One method of the invention is for welding and includes obtaining first and second members each including an extrusion having a through hole and includes obtaining first and second electrodes each having an electrode portion. The second member is positioned to have the second extrusion nest in the first through hole against the first extrusion. The first electrode is positioned to have the first-electrode portion nest in the second through hole against the inside of the second extrusion. The second electrode is positioned to have the second-electrode portion contact the outside of the first extrusion. Another method of the invention is for welding and includes obtaining a tube having an end form and a member having first and second portions. The tube and the member are positioned with the end form contacting the first portion while leaving a recess between the end form and the second portion.

Abstract: A purge gas introduction system for an orbital tube welding setup is provided, configured to inject high purity inert purge gas to the interior volume of a tube or tubular component. An o-ring is interposed between an annular base and an annular ring, their junction forming an annular o-ring groove, each part forming one sidewall, with the o-ring fully recessed within the groove, protecting the o-ring during the insertion and removal of a tube. The annular base and an annular ring are configured to receive a tube terminus. The sidewalls of the o-ring groove are divergent one to the other, wherein as the annular ring is drawn towards the annular base, the o-ring is forced partially out of the groove, forming a substantially leak tight seal between the tube and the o-ring. A purge gas from an external source is transmitted to the annular base through a purge connector, then, in turn, introduced to the interior volume of the tube.

Abstract: An annular facing is machined in an inside surface of the spherical wall around the periphery of a zone where the wall has a bore for securing the tube passing therethrough. A first welding material is deposited in the facing, and the bore is made by drilling through a portion of the spherical wall that is surrounded by the facing. The tube is engaged tightly in the bore, and a second welding material is deposited in the facing at the periphery of the tube in order to weld the tube to the first welding material. At least one of the operations of depositing the first and second welding materials in the facing is performed automatically by causing a welding torch to turn around the axis of the bore while moving the torch in a direction that is parallel to the axis of the bore and while causing it to pivot about an axis that is orthogonal to the axis of the bore while rotation is taking place.

Abstract: A method for fabricating a rotor shaft using a welding process. The method includes positioning a first rotor shaft section adjacent a second rotor shaft section, and using a submerged arc welding process with an included weld preparation angle of between about 0° and about 30° to join the first and second rotor shaft sections together.

Abstract: Welders and methods are presented for short-circuit arc welding a workpiece using a modified series arc welding configuration with two electrodes via a sequence of welding cycles, in which each cycle includes an arc condition a short-circuit condition, wherein one or both electrode currents are selectively reversed during a reverse boost portion of the welding cycle to transfer molten metal from the second electrode to the first electrode prior to a short-circuit condition of a subsequent welding cycle.

Abstract: A method of welding the ends of two pipe sections at the open root between said spaced ends, said method comprising: selecting a metal cored welding wire having a metal sheath and a core, the wire comprising about 0.08-0.13% by weight of carbon, about 0.60-1.20% by weight manganese, and about 0.0-0.40% by weight silicon, as well as sulfur, phosphorous, chromium, nickel, molybdenum, niobium, vanadium, nitrogen, copper, and aluminum.

Abstract: A projection weld element can include structure that prevents gases or other contaminants from passing through or around the weld element before, during or after attachment to a workpiece such as a vehicle body part. The projection weld element can include a barrel having a first axial end and a second axial end, a central axial bore being defined through the barrel from the first axial end towards the second axial end, and at least a portion of the central axial bore including an attachment structure, such as internal threads. A radial flange can extend from the second axial end of the barrel, with the flange including a distal axial face on a side of the flange facing away from the first axial end of the barrel and a proximal axial face on a side of the flange facing toward the first axial end of the barrel. The flange can include an annular projection weld ring formed along the proximal axial face of the flange on the same side of the flange as the barrel that extends from the flange.

Abstract: A method for manufacturing lead flashing for a roof pipe is disclosed. A lead pipe is straightened and then pushed into a frictionally engaged knurled clamp. Pressure is applied between a knurled head of a knurler and the inner surface of the lead pipe and the knurler is rotating about the inner surface of the lead pipe. This causes the lead pipe to conform to the knurles of the knurled clamp and the knurled head, while causing a portion of the lead pipe extending beyond the knurled clamp to be contoured and swaged into a flange. At a multi-position horizontally positioned rotatable table, the flange of the knurled lead pipe is flattened to overlap a flat lead sheet having a hole cut from its center. The knurled lead pipe flange and flat lead sheet are arc-welded together with a TIG weld gun. After welding, the finished lead pipe flashing is moved onto a packaging feed conveyor via a vacuum lifter.

Abstract: The present invention is directed to a method for welding a pipe section and a connector, wherein each of the pipe and connector have inner and outer beveled surfaces and the joint is comprised of an angular alignment land. In one embodiment, an outer beveled surface on the pipe and an inner beveled surface on the connector cooperate to define the angular alignment land. In yet another illustrative embodiment, the inner beveled surface of the connector and the outer beveled surface of the pipe have a bevel angle of approximately 30 degrees, while the outer beveled surface of the connector and the inner beveled surface of the pipe have a beveled angle of approximately 45 degrees.

Abstract: The present invention is directed to a method for welding a pipe section and a connector, wherein each of the pipe and connector have inner and outer beveled surfaces and the joint is comprised of an angular alignment land. In one embodiment, an outer beveled surface on the pipe and an inner beveled surface on the connector cooperate to define the angular alignment land. In yet another illustrative embodiment, the inner beveled surface of the connector and the outer beveled surface of the pipe have a bevel angle of approximately 30 degrees, while the outer beveled surface of the connector and the inner beveled surface of the pipe have a beveled angle of approximately 45 degrees.

Abstract: Blades are connected to the surface of a disk and slots are formed in the surface of a shroud, which is opposite from the other surface of the shroud where the blades are to be welded. The blades are arranged on the opposite surface from the slots and a laser beam is applied from the surface in which the slots are formed, to weld the shroud and the blades. If powder is melted and put in the slots formed for welding in the shroud to fill the slots, thermal distortion occurs. On the other hand, if the slots are left empty, a problem of degrading the fluid performance arises. To solve these problems, components are installed on the surfaces of the slots on the opposite side from the blades after the blades and the shroud in which the slots are formed are welded. Alternatively, the slots are filled with a material different from that of the shroud, such as a resin. With this configuration, distortion caused by welding heat can be reduced without degrading the fluid performance.

Abstract: A method and apparatus for multi process welding includes providing a controlled short circuit output and a pulse output in response to a user selection across a workpiece output stud and a torch output stud.

Abstract: A system and method of fabricating tank car outer jackets are provided that include supporting a plurality of coils of sheet metal on a plurality of coil supports such that the central longitudinal axes of the plurality of coils are generally parallel to a central longitudinal axis of a mandrel adjacent the plurality of coils. A plurality of sheets of sheet metal are unwound from the plurality of coils by rotating each of the plurality of coils generally about the respective central longitudinal axes of each of the plurality of coils. As the plurality of sheets of sheet metal are wound onto the mandrel, adjacent sheets of the plurality of sheets of sheet metal are welded together using a plurality of automated welding torches proximate the mandrel. The plurality of automated welding torches may be coupled for communication with a programmable logic controller.

Abstract: Welding systems are presented, in which a single power source provides a first DC output to a plurality of digital waveform controlled chopper modules. Welding modules are also disclosed for converting an input DC signal to a welding signal, which are comprised of a down-chopper for providing a welding signal waveform according to a pulse width modulated switching signal, along with a digital waveform controller providing the switching signal according to a desired waveform.

Abstract: In a method of making a tube, a sheet metal blank is placed in a U-shaped cavity of a lower mold of a shaping tool, and pressed into the cavity by a ram to shape the blank into a U-shaped configuration. In a next process step, the U-shaped blank is formed between an upper mold and a lower mold of a molding press into a tubular configuration. The upper and lower molds of the molding press with accommodated tubular profile are then clamped together and the clamped upper and lower molds are then removed from the molding press. Subsequently, the confronting longitudinal edges of the tubular profile are welded together via an opening that provides access to the longitudinal edges. After separation of the upper mold from the lower mold, another shaping cycle may begin.

Abstract: A speedy method of welding in a tight space using a single pass is provided using a technique which involves the use of a particularly shaped, flux treated consumable insert to provide deep weld penetration by a GTAW machine which is compact and fits the narrow spaces found in applications such as feeder tube repair since it does not require an insert wire flux feed system and is thus capable of negotiating narrow spaces found in feeder tubes.

Abstract: A TIG welding method of welding a first part with a first wall and an end edge to a second part with a second wall and an edge along a junction surface between said edges and along which the first wall forms a salient angle with the second wall. The TIG welding electrode is moved along the junction surface to weld the first part to the second part. The electrode being aligned on the side of the salient angle at an angle (?) with respect to the first wall smaller than 180° and with the longitudinal axis of the electrode running through the re-entrant angle associated with the salient angle.

Abstract: A process for the continuous production of longitudinally welded metal tubes where a metal strip (1) is drawn from a strip supply and gradually shaped into a slit tube in a shaping station (2). The slit tube is welded in a welding system (4) along the edges of the strip, and the welded tube (6) is extracted by an extraction device (5). The welding system (4) is a protective gas arc welding system with several electrodes supplied by separate sources (4c, 4d) of welding current. The electrodes are arranged in succession, in the direction of production. The welding system (4) has two welding devices (4a, 4b), whose electrode tips are directed at a common welding point. Only one of the welding devices (4a, 4b) is in operation at any given time, while the other welding device is in a standby position. When an electrode change becomes necessary, the arc of the welding device in the standby position is first struck by means of an auxiliary arc.

Abstract: A welding process for non-stainless steel workpieces using GTAW equipment and hydrogen containing shield gas on a first root pass is improved by using a shield gas delivery system comprising hoses or conduits made of elastomeric material having a moisture permeability coefficient of less that 275, preferably less than 100, and using a tungsten electrode composition comprising at least tungsten and lanthanum oxide, and preferably tungsten, lanthanum oxide, yttrium oxide and zirconium oxide. Preventing moisture permeation through the elastomeric hoses delivering hydrogen containing shield gas eliminates expulsion of fused weld metal during second pass filler welding over the root pass weld. Electrode life is enhanced using the tungsten compounds.

Abstract: A weld preparation process that translates a consumable or nonconsumable tool over an area that is subsequently to be welded to impart friction heating to the surface. Rotary or linearly oscillated motion between the tool and the workpiece is used to generate heat and produce deformation in the surface, resulting in recrystallization of the area being processed and a compressive residual stress.

Abstract: A self-adhesive purge dam for retaining purge gas around a weld zone includes a base configured to substantially obstruct an air passage leading to the weld zone and an adhesive skirt extending from the base and configured to engage portions of the air passage. An adhesive on the adhesive skirt allows the skirt to be adhered to the air passage. An optional removable backing covers the adhesive prior to installation. The purge dam is installed by peeling the removable backing (if present) and exposing the adhesive for adhesion.

Abstract: An apparatus and process for depositing an overlay weld on a boiler tube panel comprising a plurality of tubes with adjacent tubes joined together with membranes therebetween, and then straightening the panel in response to bowing that occurs as a result of depositing the overlay weld. The apparatus generally comprises an overlay welding apparatus that deposits an overlay weld on a surface of a boiler tube panel, and a straightening apparatus for straightening the panel following deposition of the overlay weld. The straightening process entails placing the boiler tube panel between two members, and the pressing a portion of the panel therebetween.

Abstract: A manufacturing method for an outer shell unit (10) provided with a cylindrical outer shell (3) housing a damping force generating mechanism and a knuckle bracket (7) mounted on the outer shell (3) to connect a knuckle. The knuckle bracket (7) is fixed by welding to the outer shell (3) after closing the bottom (31) of the outer shell (3) with a closing process. Consequently productivity is increased due to the fact that the number of processing operations for cutting an inlay and the number of operations for assembling the lower cap are reduced because the bottom is formed using a closing process. Furthermore productivity is increased since it is not necessary to seal the bottom by welding since the sealing characteristics of the bottom of the outer shell are ensured by the closing process.

Abstract: A method for metallurgically joining a tube to a member. A tube having a flange is obtained, and a member is obtained. A welding/brazing electrode wheel is obtained having an axis of rotation and having a rim. The tube and the member are positioned with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material. The rim of the electrode wheel is positioned in direct contact with the flange. A resistance welding/brazing current path is created through the flange and the member using at least the electrode wheel creating a seam weld/braze zone which includes at least some of the flange and at least some of the member. During the current path creation step, the electrode wheel is rotated about the axis of rotation.