Experience with shipyard installation of a hybrid pipe welding system
Laser-Gas Metal Arc (GMA) hybrid welding is fast making the transition from laboratory to production, in industries as diverse as shipbuilding to automobile manufacture. For the past 3 years, our team has striven to both develop a hybrid welding process for steel pipe, and to specify, build, and install a hybrid pipe welding system in a General Dynamics NASSCO shipyard. In March 2007, the system was successfully installed into the shipyard. This work presents a summary of our continued experimental explorations into various practical aspects of hybrid welding, discusses the system design, and provides an overview of the installation of the system into the shipyard. Test results are presented, as well as lessons learned throughout the project.
Arc augmented laser processing of materials
It has recently been found that an electric arc can be added to the interaction between a laser beam and a material surface in such a way that in welding and cutting it produces an effect similar to that from a more powerful laser. The experimental results are discussed together with an analysis of the process mechanism. In particular it appears that the arc strikes the work piece at the same interaction zone as the laser, and in so doing undergoes a contraction in width to near the same size as the laser beam. It also seems probable that some of the arc energy penetrates the laser generated keyhole. So far the experimental results have shown that arc augmentation of the laser by some 2 kW of arc power in the work piece can be achieved without unduly spoiling the high quality of the cut or weld that would be made by a laser alone of similar total power.
Intensification of Bubble Disintegration and Dispersion by Mechanical Stirring in Gas Injection Refining
Water model experiments were performed for establishing highly efficient gas injection refining processes. Mechanical stirring was applied to disintegrate the injected bubbles and to disperse them widely in the bath. The bubble disintegration and dispersion were investigated by changing rotation mode (direction of rotation), rotation speed, blade size of the impeller and gas flow rate. Forward rotation of the impeller induced a stable tangential flow and could not disperse bubbles in the bath due to formation of a vortex around the impeller shaft. The tangential flow could be suppressed by forward–interrupt rotation, which could reduce the vortex formation to some degree. However, forward–interrupt rotation could not disperse the bubbles widely in the bath. Forward–reverse rotation could prevent the vortex formation completely and create a strong shear stress field, which intensified the bubble disintegration and dispersion in the bath. Higher impeller rotation speed and larger blade length in forward–reverse rotation could enhance the bubble disintegration and make the dispersed bubbles smaller. The bubble dispersion zone became wider with larger blade length. The bubble size tended to be larger at higher gas flow rates. However, its dependence on the gas flow rate became smaller at higher impeller rotation speed.