Methods For Modifying Surface Properties Using Exothermic Reactive Powder Mixtures

Abstract

Various methods are provided to produce welded structures resistant to hydrogen induced cracking (HIC), improve wear resistance, reduce manufacturing steps including pre/post weld treatments, and improving corrosion resistance. Exemplary methods include using exothermic reactive powder mixtures on as-welded hot surface(s) during weld cooling which generate rapid exothermic reaction melting and hydrogen removal which results in reduction of hydrogen, creation of a wear/corrosion prevention or reduction layer, and a reduction of residual stresses effect in the weld initially formed in initial welding. Alternative embodiments can also employ post cooling re-heating and application of one or more alternative methods using exothermic reactive powders.

Claims

1. A method of production of a high strength welded metal structure including a dehydrogenation treatment to reduce the hydrogen concentration of a weld metal section comprising: providing metal sections and welding the metal section to produce a weld section with a weld surface section; depositing an exothermic reaction powder mixture on the weld surface during cooling stage of the weld to bake out hydrogen during welding process to produce a hydrogen absorber section in at least a portion of the weld section.

2. The method as in claim 1 wherein said exothermic reaction powder comprises titanium and carbon.

3. The method as in claim 1, wherein the metal sections comprise Inconel 718 alloy.

4. The method as in claim 1, wherein the metal sections comprise steel sections.

5. A method manufacturing comprising: providing a cooled steel section comprising a weld surface; heating at least the weld surface to a predetermined temperature; and applying a reactive powder mixture to at least the weld section for a predetermined period of time.

6. The method of claim 5, wherein the predetermined temperature is an exothermic reaction temperature of the reactive powder mixture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0010] FIG. 1 shows an exemplary flow diagram describing various process steps followed in application of reactive powder and forming a reactive product layer on a weld surface; and

[0011] FIG. 2 shows a cross sectional view showing an exemplary formation of exothermic reactive powder layer dissipating heat to underlying weld and HAZ regions.

DETAILED DESCRIPTION OF THE DRAWINGS

[0012] The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

[0013] Generally, various embodiments of the invention provides methods including steps to produce high strength welded steel structure/joints, superior in hydrogen embrittlement crack resistance of weld and heat affected zone (HAZ), reduction/elimination of residual stresses without employing conventional methods such as pre/post weld heat treatment, and additionally providing a hard, corrosion and wear resistant plus weld hydrogen absorber/trapping coating on welded surface. This method, avoids having to employ conventional procedures of weld improvement, such as, using low hydrogen filler metals, or specially alloyed filler metals.

[0014] Embodiments can include a method involving spraying/applying a predetermined amount and type of exothermic reactive material powder/coating on the as welded surfaces consisting of both weld and HAZ, of the high strength metals or steels during the weld cooling stage when weld surface is hot, and is applied at a weld surface temperature corresponding to ignition temperature of reactive powder. Thus, the technique uses the heat of the hot surface of the weld to ignite the thermite exothermic reactive powder mixture. The exemplary hot weld surface temperature should be sufficient to provide enough heat to the reactive powder components on the hot weld surface, thus initiating a controlled thermite type reaction releasing exothermic heat of reaction to the weld and HAZ surfaces. In addition, the exothermic reaction is characteristically very fast consuming significantly less time in its completion and otherwise releasing a significant amount of heat in a very short time, thus reduces the cycle time, cost and be deposited in desired quantities. The exemplary released exothermic heat from the surface reaction delivered like a laser pulse energy of predetermined quantity, is sufficient enough to quickly either bake out or absorbs hydrogen entrapped in the weld during welding, and reduces the residual stresses formed during weld cooling, and prevents hydrogen embrittlement cracking, and simultaneously forms reaction products, creating a material bond between the reaction product and underlying welded surface. Exemplary reaction product can thereby be formed and bonded to the weld and HAZ surfaces which further create improved wear and corrosion resistance coating on the surface beneficial for future service life, has higher absorptivity for the diffused and trapped hydrogen which evolves from the weld and HAZ so as to be able to trap that hydrogen due to higher chemical affinity of the products to the hydrogen, thus stronger ability to draw or absorb weld produced hydrogen.

[0015] Generally, a high strength welded steel pipe can be produced with improved hydrogen embrittlement cracking resistance of weld metal produced by applying exothermic reactive powder mixture of Titanium and Carbon referenced in paper of Manukyan, whose ignition temperature is below 327 C. This nano sized Ti+C powder mixture can be ignited in few seconds after coming to an ignition temperature while coming in contact with hot weld surface going to through cooling. A sudden release of exothermic heat, e.g., 51 kcal/mole, of ignition reaction from Ti+C=TiC, is released to the cooling weld and HAZ surfaces of the steel in which the hydrogen was diffused from the environment. This suddenly released exothermic heat acts as a dehydrogenation heat treatment, which bakes out the entrapped hydrogen from various detrimental locations and eliminates residual stresses being built in those locations at the same time. Thus the suddenly released heat acts as in process weld heat treatment and eliminates pre or post weld heat treatment. In addition the reaction product TiC forms a hard, wear resistant layer which can absorb the hydrogen released from the weld and acts as a hydrogen trapping site. An amount of exothermic reactive powder can be controlled as needed. An amount of the exothermic heat suddenly released per unit surface area J/m.sup.2 designated by term e.sub.s in the following equation can be associated with the weight and thickness of the reactive powder present per unit weld surface area, which is applied at the reaction ignition temperature designated as T.sub.i in equation 1.

[00001]$\begin{array}{cc}T\left(x,t\right)-T_i=\frac{e_s}{k.Math.\sqrt{.Math..Math.t.Math.\text{/}.Math.}}.Math.\exp \left(-\frac{x^2}{4.Math..Math..Math.t}\right)& \mathrm{Equation}.Math..Math.1\end{array}$

where: (x, t) is the transient temperature inside the weld and HAZ at various locations and distances x; t=time in seconds for dehydrogentation; =thermal diffusivity of steel weld m.sup.2/sec; and k=Thermal Conductivity of steel weld J/msC.

[0016] In at least some embodiments, it is assumed that exothermic heat is completely released to the weld and HAZ per unit area like a laser pulse energy. Patent Publication No. 2014-8,653,400 B2 provides exemplary information on a heating temperature T [ C.] of an exemplary dehydrogenation treatment is in the range of 150 to 500 C., and the heating time is t[s] or more as described in Equation 2 from the weld metal heightmm and heating temperature T.

[00002]$\begin{array}{cc}t=\frac{{\left(\frac{x}{16}\right)}^2}{{\exp }^{\left(-\frac{957}{273+T}\right)}}& \mathrm{Equation}.Math..Math.2\end{array}$

[0017] Referring to FIG. 1, at Step 201: Make reactive powders of Ti+C using High Energy Ball Milling; At Step 301: Calculate the amount and thickness of reactive powders of Ti+C to be deposited on the weld surface using, e.g., Equations 1 and 2 given in method section; Step 401: Weigh predetermined amount of the above reactive powder mixture; at Step 501: Place the weighed powder in a powder application/spraying/delivery system; at Step 601: Prepare two or more steel components for arc welding; at Step 701: Arc weld the components using welding filler rods to produce a weld surface; at Step 801: Calculate weight and thickness of the reactive powder to be deposited based on at least one of the following factors: desired exothermic response, degree of hydrogen mitigation desired, depth of the steel components targeted for hydrogen removal, thickness of resulting exothermic reaction protective melt or treated zone, and heating duration; at Step 901: Spray predetermined amount of reactive powder on a top of the weld when the weld surface temperature is at or between 400-500 C., is above an ignition temperature of the as high energy ball milled reactive Titanium+Carbon powder, or is above an ignition temperature of the reactive powder.

[0018] FIG. 2 shows a cross sectional view showing an exemplary formation of exothermic reactive powder layer dissipating heat to underlying weld and HAZ regions. In particular, FIG. 2 shows an unaffected zone 161 which is an area of welded materials which has not been impacted by welding (e.g., subjected to formation of weld induced hydrogen), a heat affected zone 151, a weld interface 141, a weld nugget fusion zone 131, and a reactive powder mixture section 171.

[0019] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.