Patent Application
20140301776
The present invention relates to a welding method in box-welding a gusset plate to high-tensile steel in a welded structure using the high-tensile steel.
For the purpose of increasing in size of welded structures such as ships, marine structures, bridges and the like and for weight saving and safeness accompanying the increase in size, high-tensile steels having tensile strength enhanced from conventional 500 MPa up to 1000 MPa are used recently.
In proportion to increase in tensile strength, also fatigue strengths of a base material typified by fatigue life and fatigue limit thereof increase. However, in a welded part, fatigue strengths are not improved so long as conventional welding technologies are used.
There are various welded parts such as a butt-welded part, a fillet-welded part, a box-welded part and the like. Especially, a box-welded part formed by welding a gusset plate to high-tensile steel as a base material shows the lowest fatigue strength (about 1/7 as compared with the base material), therefore, the design load (permissible load) of a welded structure shall be determined by this box-welded part.
However, in the case of use of a conventional welding technology for this box-welded part of a gusset plate, the fatigue strength of a welded part is not improved as described above. Thus, merits of weight saving and safeness due to use of above mentioned recent high-tensile steel having enhanced tensile strength cannot be performed sufficiently.
Decrease in fatigue strength in a conventional box-welded part of a gusset plate is attributed to significant degree of stress concentration derived from change of cross-sectional shape at a weld toe, and additionally, to extreme local increase in tensile force at a weld toe accompanied also by an adverse effect of generation of residual tensile stress due to welding heat stress.
This fact will be illustrated using
F represents external tensile load in the longitudinal direction of the flat plate 10, 90 represents distribution of actual tensile force along the short side direction (width direction) passing a weld toe 33 of the box-welded part 32 generating on the flat plate 10 by load, stress concentration and residual tensile stress, 91 represents stress of the end part of the short side direction of the flat plate 10, and 92 represents stress of the central part.
As shown in
The gusset plate 20 and weld metals of weld parts of 31 and 32 expand by heat in welding and contracts by the subsequent cooling. However, expansion and contraction of the flat plate 10 are smaller than expansion and contraction of the gusset plate 20, thus, residual tensile stress ascribable to welding heat stress is generated in the welded parts 31, 32 of the gusset plate 20, and especially this residual tensile stress is the largest at the weld toe 33 of the box-welded part 32.
As described above, fatigue strength drops significantly at the box-welded part of the gusset plate.
For improving fatigue strength, technologies of performing a hammer peening treatment and a laser peening treatment on a welded part have long been developed. However, these are not generally in widespread use due to large workload.
In this decade, a low transformation temperature welding material which may lower a martensitic transformation temperature of weld metal and a welding procedure using such a welding material have been developed in order to reduce residual tensile stress of the welded parts (Patent documents 1 to 6). Even if such technologies are used, however, the degree of improvement in fatigue life of a welded part is still at most only about 1.5 to 2-fold as compared with conventional technologies.
In view of the above-described problems of conventional technologies, the present invention has an object of providing a welding method capable of dramatically improving fatigue strength of a box-welded part of a gusset plate and high-tensile steel, and a weld joint welded by this welding method.
The present inventors have intensively studied to solve the above-described problems and, focusing attention on the length of a bead from the end of a gusset plate at a box-welded part, performed ordinary box welding at a bead length of 7 mm generally called leg length, then, formed elongation beads of various lengths at the leading end of this box-welded part, and conducted an experiment on relation between the length of an elongation bead and the degree of stress concentration at the leading end of the elongation bead.
Main experimental conditions in this case are as described below. That is, 800 MPa high-tensile steel (size: width 200×length 1000×thickness 20 mm) was used as a base material and 800 MPa high-tensile steel (size: width 50×length 200×thickness 20 mm) was used as a gusset plate.
The experimental results are shown in
As described above, by providing an elongation bead having a length of 10 mm or more, stress concentration is relaxed sufficiently, consequently leading to improvement in fatigue strength at a box-welded part.
Next, the present inventors conducted an experiment on relation between residual tensile stress ascribable to welding heat stress, the length of an elongation bead, and the kind of a welding material. That is, ordinary box welding (bead length (leg length) 10 mm) was carried out using a conventional welding material and a low transformation temperature welding material giving a weld metal with martensitic transformation start temperature (Ms temperature) of 350° C. or lower, then, residual tensile stress was measured at a surface position and a position of a depth of 5 mm at the leading end of the elongation bead, changing the length of an elongation bead.
The low transformation temperature welding material described above denotes a welding material which forms a weld metal having a Ms temperature of 350° C. or lower by welding with a material to be welded. The welding material itself has a Ms temperature of 250° C. or lower.
Main experimental conditions in this case are as described below. That is, 800 MPa high-tensile steel (size: width 200×length 1000×thickness 20 mm) was used as a base material and 800 MPa high-tensile steel (size: width 50×length 200×thickness 20 mm) was used as a gusset plate. The chemical composition of a conventional welding material contains C 0.12 wt %, Ni 1.5 wt % and Mo 0.5 wt % and the chemical composition of the low transformation temperature welding material contains C 0.05 wt %, Cr 14 wt % and Ni 9 wt %.
The measurement results are shown in
In the case of use of a conventional welding material, when box welding is performed (bead length (leg length) 10 mm), the generated residual tensile stress is about 300 MPa at a surface position and about 680 MPa at a position of a depth of 5 mm, as shown in
In the case of use of a low transformation temperature welding material, residual tensile stress when box welding is performed (bead length (leg length) 10 mm) is 300 MPa at a position of a depth of 5 mm. However, residual tensile stress at a bead length of 17 mm (elongation bead length 7 mm) disappears. When the bead length becomes over 17 mm, compression residual stress is generated contrastingly. When the bead length becomes larger, this compression residual stress becomes larger, and finally, a large compression residual stress of about 300 MPa is generated.
Regarding the surface position, when box welding is performed, a compression residual stress of about 170 MPa is already generated, and at a position of a bead length of 80 mm, a compression residual stress of about 580 MPa is generated.
A length of 7 mm of the above-described elongation bead is also a length with which degree of stress concentration can be lowered sufficiently in
It is understood as described above that between a conventional welding material and a low transformation temperature welding material, elongation of the bead length exerts an inverse influence on residual stress, and in the case of a low transformation temperature welding material, compression residual stress is surely generated by forming a bead having a length of 17 mm or more from the longitudinal end of a gusset plate (hereinafter, also referred to simply as “gusset plate end”), thus, fatigue strength at a box-welded part can be significantly improved.
It is understood from the above descriptions that by forming an elongation bead so as to give a bead length from the end of a gusset plate of 17 mm or more in parallel to the gusset plate using a low transformation temperature welding material giving a weld metal with a Ms temperature of 350° C. or lower after ordinary box welding, stress concentration derived from a geometrical factor of a weld toe can be relaxed, and additionally, large compression residual stress can be generated, thereby, fatigue strength can be improved significantly.
Fatigue strength can be improved significantly likewise by also forming an elongation bead so as to give a bead length from the end of a gusset plate of 17 mm or more in parallel to the gusset plate using a low transformation temperature welding material giving a weld metal with a Ms temperature of 350° C. or lower after ordinary box welding using a conventional welding material.
Since the bead length from the end of a gusset plate dominates strongly the content of residual stress, fatigue strength can be improved significantly also when a bead having a length of 17 mm or more is formed simultaneously with box welding, likewise when an elongation bead having a length of 17 mm or more is formed after ordinary box welding as described above.
For improving fatigue strength at a box-welded part, post treatments such as dressing and the like have been conventionally carried out after welding. However, improvement in fatigue strength by these treatments is not sufficient, and its effect is unstable.
In contrast, high fatigue strength can be stably obtained by forming a bead having a length of 17 mm or more using a low transformation temperature welding material giving a weld metal with a Ms temperature of 350° C. or lower in the present invention.
The present invention is based on these findings, and the invention of Claim 1 is:
The invention of Claim 2 is the welding method according to Claim 1, wherein the above-described method of forming a bead is a bead formation method of further forming an elongation bead at the leading end of the bead at the longitudinal end of the above-described gusset plate formed by box welding, after the box welding.
The invention of Claim 3 is the welding method according to Claim 1, wherein the above-described method of forming a bead is a bead formation method of forming a bead having a length of 17 mm or more at the longitudinal end of the above-described gusset plate, in box welding.
The present invention further has the following characteristics.
The above-described bead having a length of 17 mm or more is formed in the longitudinal direction of a gusset plate. Though the bead width is not particularly restricted providing it is not smaller than the box-welded part width (D) shown in
That is, the invention of Claim 4 is the welding method according to any one of Claims 1 to 3, wherein the bead width of the above-described bead is larger than the box-welded part width.
Next, an elongation bead is provided at the leading end of a bead part formed by ordinary box welding, and it may also be permissible that an elongation bead is provided from the end of a gusset plate so as to cover a box-welded part. In this case, fatigue strength can be further improved by forming an elongation bead in smooth form without producing level difference at the connection to the end of a gusset plate after box welding, as shown in
Likewise, also in forming a long bead in box welding, fatigue strength can be further improved by forming the bead in smooth form without producing level difference at a connection to the end of a gusset plate.
That is, the invention of Claim 5 is the welding method according to any one of Claims 1 to 4, wherein a bead is formed while making a smooth connection to the longitudinal end of the above-described gusset plate.
Next, in the case of providing an elongation bead at the leading end of a bead part formed by box welding, after box welding, the elongation bead is usually provided so as to partially overlap the leading end of a box-welded part. Also in this case, it is preferable to provide an elongation bead in smooth form without producing level difference at a connection between the box-welded part and the elongation bead from the standpoint of improvement in fatigue strength.
That is, the invention of Claim 6 is the welding method according to Claim 1 or 2, wherein an elongation bead is formed while making a smooth connection to the above-described bead-welded part formed by box welding.
In a weld joint welded using the welding method described above, stress concentration is significantly relaxed and further, large compression residual stress is generated. Therefore, it can be provided as a weld joint having sufficiently improved fatigue strength.
That is, the invention of Claim 7 is a weld joint in which a gusset plate is welded to high-tensile steel using the welding method according to any one of Claims 1 to 6.
Next, the welding method according to the present invention exerts a significant effect on extension of fatigue life and fracture life in existing steel structures.
Namely, in infrastructures around the world, for example, in steel structures such as bridges, express ways and the like, repair and reinforcement were conducted periodically on a box-welded part in order to extend fatigue life and fracture life, at the present day. Also in conveyances and pressure containers such as ships and tanks, inspections and treatments are conducted in a like manner in order to extend fatigue life and fracture life.
For example, crack (fatigue crack) 40 is generated in some cases due to fatigue in use for a long period of time in a box-welded part 32 of a steel structure, as shown in
In conventional repairing methods, however, the length of the repair-welded part 34 is small, thus, stress concentration cannot be relaxed sufficiently and fatigue life and fracture life cannot be sufficiently extended.
In contrast, if the present invention is applied to a conventional repair-welded part formed previously, namely, a welding material giving a weld metal with a Ms temperature of 350° C. or lower is used and an elongation bead is formed so as to give a bead length of 17 mm or more in the longitudinal direction of the end of a gusset plate of a box-welded part to attain repair, then, fatigue life and fracture life can be sufficiently extended as described above.
Here, the effect of extending fatigue life and fracture life is manifested also by applying formation of an elongation bead based on the present invention to an existing steel structure on which a repair-welded part is not formed beforehand, or on which a repair-welded part has been already formed.
The effect by applying the present invention can be manifested not only in repair in the case of generation of crack but also in reinforcement as prior prevention, and fatigue life and fracture life can be significantly extended likewise. As a result, the period of regular inspection can be extended significantly and maintenance cost can be reduced considerably.
In the above-described bead formation, it is preferable to form a bead with bead width larger than the box-welded part width of a box-welded part, and it is more preferable to form a bead while making a smooth connection to the leading end of the bead of a box-welded part, as described above.
d) shows a specific example of the repairing method. In
That is, the invention of Claim 8 is a welding method of repairing or reinforcing, by welding, a box-welded part composed of a gusset and a base material in an existing steel structure, wherein a bead is formed so that the length of the bead part from the end of the above-described gusset plate is 17 mm or more, in the longitudinal direction of the end of the gusset plate of the above-described box-welded part, using a welding material giving a weld metal with a Ms temperature of 350° C. or lower.
The invention of Claim 9 is the welding method according to Claim 8, wherein a repair-welded part or a reinforcement-welded part is formed at the leading end of a bead of the above-described box-welded part, then, the above-described bead is formed.
The invention of Claim 10 is the welding method according to Claim 8 or 9, wherein the bead width of the above-described bead is larger than the box-welded part width.
Further, the invention of Claim 11 is the welding method according to any one of Claims 8 to 10, wherein the above-described bead is formed while making a smooth connection to the longitudinal end of the above-described gusset plate.
According to the present invention, the fatigue strength of a box-welded part between a gusset plate and high-tensile steel can be dramatically improved, thus, permissible load of a welded structure can be improved, and the tensile strength of the welded structure increases significantly. As a result, the present invention can significantly contribute to social needs for low carbon by means of weight saving and the like, further leading to improvement in safeness owing to increase in permissible stress.
Further, the life of a welded structure can be remarkably extended, thus, the present invention has merits also from the standpoint of repair and reinforcement of a structure. Most of structures 40 years old or more after postwar construction will outlive their usefulness in the next decade. The present invention is capable of manifesting a large effect on them also in the aspect of life extension by repair and reinforcement.
The present invention will be illustrated based on embodiments below. The present invention is not limited to the following embodiments. In the scope identical and equivalent to the present invention, the following embodiments can be variously altered.
First, summery of a weld joint of the present invention and summery of a conventional weld joint will be explained using drawings.
In a conventional weld joint shown in
In the weld joint of the present invention shown in
Next, preferable embodiments other than the bead forming method shown in
In the case of
In the case of
In the case of
Next, the results of an experiment conducted to show the excellent effect of the present invention will be described. In the experiment, ordinary box welding was conducted using a welding material having chemical composition containing C 0.1 wt % or less, Cr 8 to 13 wt %, Ni 5 to 12 wt % as base, and having a welded metal Ms temperature of 350° C. or lower. Then, each elongation bead having length shown in Table 1 was formed using the same welding material. Then, degree of stress concentration at the leading end of each elongation bead and the magnitude of residual stress were measured. A load of stress range of 150 MPa (load of ±150 MPa) was applied at a frequency of 10/second repeatedly as fatigue strength, and the number of repetition in breakage (fatigue break number) was measured. For comparison, ordinary box welding was conducted using a conventional welding material and the same measurement was conducted.
The bead length (leg length) in box welding was set at 7 mm as general bead length. As the base material, 800 MPa high-tensile steel (size: width 200 mm, length 1000 mm, thickness 20 mm) was used, and as the gusset plate, 800 MPa high-tensile steel (size: height 50 mm, length 200 mm, thickness 20 mm) was used.
The measurement results are shown in Table 1 together. In Table 1, degree of stress concentration is indicted in terms of relative value with respect to 1 representing the degree of stress concentration in the weld joint in
Fatigue strength is indicated based on the fatigue breakage number δ in the weld joint in
Table 1 teaches that by formation of an elongation bead of 10 mm, namely, a bead having a length of 17 mm, degree of stress concentration drops steeply from 1 to 0.4 and with elongation beads of 40 mm or more, degree of stress concentration remains 0.2 stably.
When only a box-welded part is formed and an elongation bead is not formed (Experiment Example 1-1), compression residual stress is generated on the surface, however, residual tensile stress is still generated at a position of a depth of 5 mm, accordingly, fatigue strength is only 1.5-fold of conventional strength. By forming an elongation bead of 10 mm, however, compression residual stress is generated also at a position of a depth of 5 mm, and fatigue strength increases up to 3-fold (Experiment Example 1-2) together with increase in compression residual stress at the surface. Further, with elongation beads of 40 mm or more, compression residual stress increases both at the surface and a position of a depth of 5 mm, and fatigue strength increases significantly up to 15-fold (Experiment Examples 1-4 to 1-6).
In the above-described experiments, an elongation bead is formed after box welding, however, the same effect can be obtained even if a long bead is formed in box welding.
From the above descriptions, it is understood that fatigue strength can be dramatically improved by forming an elongation bead of 10 mm or more, namely, a bead having a length of 17 mm or more from the end of a gusset plate using a low transformation temperature welding material. Even if an elongation bead of 40 mm or more is formed, the effect of improving fatigue strength is saturated, thus, it is understood that it is most preferable to form an elongation bead of 40 mm, namely, a bead having a length of 47 mm from the end of a gusset plate, using a low transformation temperature welding material.
As described above, fatigue strength can be dramatically improved by lowering of degree of stress concentration and generation of compression residual stress, according to the present invention.
In the following procedure, the effect of the present invention in repair and reinforcement of a box-welded part in an existing steel structure was confirmed.
Specifically, an elongation bead 35 having a length of 40 mm was formed using a low transformation temperature welding material so as to cover a repair-welded part 34 as shown in
The results are shown in Table 2. In Table 2, also the results when an elongation bead is formed for a reinforcement treatment in the same manner as in the case of repair are described.
Table 2 teaches that by providing an elongation bead by applying the present invention, fatigue strength can be dramatically improved and fatigue life and fracture life can be significantly extended, both in the case of repair and reinforcement.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-245441 | Nov 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/077790 | 10/26/2012 | WO | 00 | 5/8/2014 |
