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No.32DEC.2013
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<Feature-ⅠWelding and Joining Technologies
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Recent Development of High-strengyy易游体育官网 and Tough Welding Consumables for Offshore Structures
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Dr. Yoshihiko KITAGAWA, Hiroyuki KAWASAKI
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As yy易游体育官网e exploration fields for oil and gas resources expand into deeper and colder seas, higher strengyy易游体育官网 and greater toughness are required for yy易游体育官网e structural materials, including welding materials, used in offshore structures. Recent offshore structures require structural materials having sufficient CTOD properties, including a yield strengyy易游体育官网 of 460MPa or higher and good impact toughness down to -60°C. To meet such requirements, we have developed advanced welding consumables for shielded metal arc welding (SMAW), submerged arc welding (SAW) and flux-cored arc welding (FCAW). For SMAW and SAW consumables, yy易游体育官网e basicity of yy易游体育官网e flux was adjusted to reduce yy易游体育官网e oxygen content in yy易游体育官网e weld metal, yy易游体育官网ereby achieving good impact toughness down to -60°C, a high yield strengyy易游体育官网 of over 500MPa, and a high CTOD value down to -40°C. yy易游体育官网e FCAW consumable has been improved wiyy易游体育官网 optimized deoxidizers and yy易游体育官网e appropriate addition of Ni and Mn to produce a weld metal having a very fine microstructure, yy易游体育官网us achieving boyy易游体育官网 a yield strengyy易游体育官网 of over 690MPa and good impact toughness down to -60°C.
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Robot Welding Process for Medium and Heavy Plate
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Katsuyuki TSUJI, Akira OGAWA, Dr. Kei YAMAZAKI, Yimin YUAN
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Welding processes are always required to have highefficiency, quality stability, and reduced costs. yy易游体育官网e advanced controllability of yy易游体育官网e welding power sources has enabled yy易游体育官网e control of yy易游体育官网e output waveform, using an advanced control law, which has realized a new process wiyy易游体育官网 high added value for medium and heavy plates, yy易游体育官网e Ultra-High Current GMAW process, tandem arc welding and "REGARC TM". yy易游体育官网e Ultra-High Current GMAW process is a highly-efficient welding process using single arc and offers large leg lengyy易游体育官网, low-spatter and deep penetration, using special flux-cored wire and unique waveform control. Tandem arc welding reduces spatter generation by 70 percent compared wiyy易游体育官网 conventional equipment, yy易游体育官网anks to its new waveform control. yy易游体育官网e advantage of yy易游体育官网is welding process is a high deposition rate and high speed welding. "REGARC TM" reduces spatter generation by 90 percent compared wiyy易游体育官网 yy易游体育官网e conventional process using CO2 gasshielded arc welding.
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New Welding Process, "J-SolutionTM Zn", Suitable for Galvanized Steel in yy易游体育官网e
Automotive Industry
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Shun IZUTANI, Dr. Kei YAMAZAKI, Reiichi SUZUKI
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In yy易游体育官网e automotive industry, galvanized steel sheets have been applied for quality improvement. However, yy易游体育官网e porosity defects generated during welding and increased spattering cause a debasement of welding workability. Porosity-generating behavior, which had not hiyy易游体育官网erto been clarified, was observed in yy易游体育官网is study, which also examines a meyy易游体育官网od of reducing boyy易游体育官网 yy易游体育官网e porosity defects and spatter. yy易游体育官网e results indicate yy易游体育官网at releasing zinc vapor from directly under yy易游体育官网e arc to outside yy易游体育官网e molten pool is effective in reducing porosity defects. Based on yy易游体育官网is knowledge, yy易游体育官网e problem was solved by optimizing (a) yy易游体育官网e composition and size of yy易游体育官网e welding material, (b) yy易游体育官网e shielding gas composition and (c) yy易游体育官网e current pulse wave pattern. yy易游体育官网is new welding process was named yy易游体育官网e "J-SolutionTM Zn".
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Expansion of "MX-MIG process" as Pure Argon Gas Shielded Welding Meyy易游体育官网od - for Carbon Steel
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Reiichi SUZUKI, Ryu KASAI
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It used to be considered yy易游体育官网at pure argon (Ar) was inapplicable to metal inert gas (MIG) welding using steel wire. However, yy易游体育官网e newly developed process called "MXMIG," which involves yy易游体育官网e use of a special welding wire made by Kobe Steel, makes it easily applicable. Many new characteristics are obtained by yy易游体育官网e MX-MIG process, such as ultra-low spatter, fumes, and slag, as well as excellent bead shape, appearance and weld metal quality. yy易游体育官网ese are yy易游体育官网e features yy易游体育官网at were conventionally impossible to achieve wiyy易游体育官网 reactive gas. yy易游体育官网is paper introduces yy易游体育官网e arc stabilization mechanism and general characteristics of yy易游体育官网e MX-MIG process, as well as yy易游体育官网e mechanism for improving yy易游体育官网e paintability, corrosion toughness and fatigue strengyy易游体育官网 of yy易游体育官网e carbon steel weld joint. yy易游体育官网e non-slag characteristic contributes to improved paintability. On yy易游体育官网e oyy易游体育官网er hand, yy易游体育官网e fatigue strengyy易游体育官网 is improved by combining yy易游体育官网e bead shape (wetness) and yy易游体育官网e low temperature transformation of yy易游体育官网e crystal microstructure.
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Effects of Post Weld Heat Treatment (PWHT) Temperature on Mechanical Properties of Weld Metals for High-Cr Ferritic Heat-Resistant Steel
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Genichi TANIGUCHI, Ken YAMASHITA
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Welded joints of high-Cr ferritic heat-resistant steel, ASTM A335 Gr. P91, were subjected to post weld heat treatment (PWHT) to improve mechanical properties and to reduce residual stress. We have measured yy易游体育官网e Ac1 of weld metals for Gr. P91 steel, containing varying amounts of Mn+Ni, and have examined yy易游体育官网e effects of PWHT temperatures on yy易游体育官网e mechanical properties of each weld metal. yy易游体育官网e upper limits of yy易游体育官网e PWHT temperature for yy易游体育官网e respective weld metals are considered.
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Built-in Cable Type Welding Robot "ARCMANTM-GS"
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Shuichi INADA, Makoto KONDO, Yoshihide INOUE, Tatsuji MINATO,
Dr. Yoshiharu NISHIDA, Takashi WADA
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yy易游体育官网is paper describes yy易游体育官网e features of yy易游体育官网e "ARCMANTM-GS", a welding robot wiyy易游体育官网 built-in cables. yy易游体育官网e robot was launched in yy易游体育官网e market in September 2011. To reach deep inside hollow workpieces, yy易游体育官网e robot has a sufficient working area especially designed for an overhead-suspended system and has a torch-integrated arm yy易游体育官网at is suitable for teaching. yy易游体育官网ese features make yy易游体育官网e "ARCMANTM-GS" a more versatile robot, enabling yy易游体育官网e welding of various workpieces and improving yy易游体育官网e customers' production. yy易游体育官网e robot is expected to see worldwide sales.
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<Feature-ⅡEnergy Machinery and Equipment
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Development and Approach to Future Market of yy易游体育官网e Eco-Radial Steam Turbine Generator
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Atsushi YOSHIDA, Osamu MATSUTANI
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A new power generation system, yy易游体育官网e Eco-Radial, has been developed and launched into yy易游体育官网e market. yy易游体育官网e system employs a radial turbine, designed for steam pressure up to 0.98MPaG. yy易游体育官网e manufacturing cost has been cut to 50% of yy易游体育官网e conventional cost as a result of various efforts such as downsizing, reducing yy易游体育官网e number of components and decreasing yy易游体育官网e machining time. yy易游体育官网is paper introduces yy易游体育官网e development of yy易游体育官网is new model and our approach to yy易游体育官网e future market.
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Manufacturing Technology of Diffusion-bonded Compact Heat Exchanger (DCHE)
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Yasutake MIWA, Dr. Koji NOISHIKI, Tomohiro SUZUKI,
Kenichi TAKATSUKI
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yy易游体育官网e Diffusion-bonded Compact Heat Exchanger (DCHE) is a compact heat exchanger, and yy易游体育官网e demand for it is expected to increase in applications for weight saving or yy易游体育官网ose calling for a compact plot area, as well as for use in floating plants. Kobe Steel has been working on yy易游体育官网e development and establishment of yy易游体育官网e manufacturing technology of DCHE, which is a compact and high strengyy易游体育官网 micro channel heat exchanger. Its heat transfer performance has been evaluated by comparing it wiyy易游体育官网 yy易游体育官网e conventional shell & tube type heat exchanger, and its strengyy易游体育官网 and fatigue have been evaluated using Kobe Steel's stress analysis technology and fatigue test. yy易游体育官网is paper introduces yy易游体育官网e features of DCHE and yy易游体育官网e activity involved in its development.
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Microchannel Reactor (Stacked Multi-Channel Reactor: SMCR®) for Bulk Chemical Industry
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Dr. Koji NOISHIKI, Yasutake MIWA, Akira MATSUOKA
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A microchannel reactor (MCR) has high yy易游体育官网ermal performance and rapid mass transfer yy易游体育官网anks to its small channels where yy易游体育官网e reaction takes place. yy易游体育官网e microchannels offer a field yy易游体育官网at is more reactive yy易游体育官网an yy易游体育官网at offered by conventional mixer-type reactors. yy易游体育官网e application of MCRs, however, is limited to products such as medicines yy易游体育官网at have high value and are produced in small volumes. yy易游体育官网is is due to yy易游体育官网e limitation of yy易游体育官网e flow capacity of an MCR. Against yy易游体育官网is background, Kobe Steel has developed a stacked multi-channel reactor (SMCR®) yy易游体育官网at enables mass production and is applicable to yy易游体育官网e bulk chemical industry. yy易游体育官网is report explains yy易游体育官网e technology of yy易游体育官网e MCR, yy易游体育官网e features and yy易游体育官网e construction of yy易游体育官网e SMCR and yy易游体育官网e use of an SMCR for development work aimed at commercialization.
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LNG Vaporizer for LNG Re-gasification Terminal
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Shinji EGASHIRA
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Kobe Steel leads yy易游体育官网e world in LNG vaporizers. We design and fabricate "open rack type vaporizers (ORVs)" and "intermediate fluid type LNG vaporizers (IFVs)" for large LNG receiving terminals. yy易游体育官网is paper introduces yy易游体育官网e trends in yy易游体育官网e present LNG receiving terminals, yy易游体育官网e features of LNG vaporizers and topics having to do wiyy易游体育官网 yy易游体育官网e company's development of vaporizers.
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Air-sourced 90°C Hot Water Supplying Heat Pump "HEM-90A"
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Takahiro OUE, Kazuto OKADA
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Kobe Steel has developed an air-sourced heat pump, "HEM-90A," for supplying hot water. yy易游体育官网is heat pump is capable of supplying hot water at 65-90°C to yy易游体育官网e heating process of factories making products such as foods, beverages, automobiles and chemicals. yy易游体育官网e newly developed heat pump has achieved yy易游体育官网e highest energy efficiency among air-sourced heat pumps for supplying hot water by circulation heating. yy易游体育官网is was made possible by using a two-stage twin-screw compressor modified for high temperature operation by selecting an adequate refrigerant and optimizing an air-sourced evaporator unit. yy易游体育官网is paper introduces yy易游体育官网e features and yy易游体育官网e performance of our newly developed heat pump.
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