USER MANUAL - histproject.no
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1. LLLI LIE EIE EE E AE E E EI aa 10 20 30 40 50 t8 5 seconds Nb 0 01 Acl 738 C Cel 0 36 Ce IIW 0 35 96 Ac3 864 C Cell 0 40 CeT 0 27 Pem 0 22 96 Ms 433 C Ce II 0 48 96 Ceen 0 34 CeWES 0 36 In this window you have the following options 1 Youcan select which material to use by scrolling and selecting from the menu You can move the sliders back and forth in order to reach the value you want The selected value will be shown in the value box on the left hand side of the slider 2 You can choose to insert the value itself in the value box and then use the slider to manipulate the value This can be an interesting option if you need the value for a specific material data sheet or from a specific material charge 3 Byentering the data and using the sliders for data manipulation the values in the yellow result boxes will dynamically update 4 Using the sliders as controls you can simultaneously see the influence of the chemical composition on the cooling curve between 800 and 500 degrees Grab the pointer on the slider by clicking on it with the left mouse button Then drag the mouse to the left or right If the slider has no value in the value box on the left hand side and no marking or indications on the slider line then this chemical composition is not valid for the material specified Iqsim user manual v 2 0 2010 11 30 13 of 45 When you click on the pointer a small value icon will be sh2. 40 45 50 55 60 65 70 omm imm 2mm 3mm 4mm Cap requirements 1SO 5817 2007 Class B s ClassC Class D Qa Maximum height 1SO 5817 2007 16 9 V Gas W asm jm gy 2 42 cm 2 The use of the sliders and other manipulation tools are as described earlier in page 12 NOTE The height of the cap on the cap and root side is given as well as the width of the top of the bevel Iqsim user manual v 2 0 2010 11 30 21 of 45 BUTT WELD X Bevel 10mm 30mm 50mm 70mm 0mm 5mm 10mm 15mm 20mm 255 a MN NN NM 30 35 40 45 50 55 60 30 35 40 45 50 55 60 0mm 10mm 20mm hn laa eB 0mm 10mm 20mm 30mm 40mm Px T L h n Cap requirements 1S0 5817 2007 Class B e ClassC Class D Az Qa Maximum height 1S0 5817 2007 3 1 2 L A moa M49 a Jes ue The use of the sliders and other manipulation tools are as described earlier in page 12 NOTE The sum of value c and value h can not be larger than material thickness The width of the bevels are given as well as the cap height on the cap and root side Iqsim user manual v 2 0 2010 11 30 22 of 45 FILLET WELD 0mm 20mm 40mm 60mm B0mm Re ul 0 i 1 LL CLE 0mm 5mm 10mm 15mm 20mm e c ey omm 2mm 4mm 6mm 0mm 2mm 4mm 6mm Bmm 10mm a Warning Fillet weld is not completely implemented Cap requirements 1S0 5817 2007 r a i aa ClassB s ClassC Class D Maximum height 1S0 5817 2007 amp Gauss Idi Nere 2 UE 12 00
3. cost m Meters of weld 1 Final cost 0 100 200 300 400 500 l Y 100 00 eating cost nour Total hours 0 _ 200 400 600 800 1000 100 00m 77 7 7 7 7 Meters of weld Iqsim user manual v 2 0 Data input Wire diameter Wire feed speed Efficiency Wire price kg Gas flow Gas price m3 Electrode diameter Kilo weld metal kg electrode Deposition rate Welding speed Duty cycle Labour costs hour Repair 96 Repair costs meter Heating costs Meters of weld 2010 11 30 33 of 45 A set of predefined wire diameters are given in the slider Click on the diameters and the slider will jump to the selected diameter Only the predefined values can be used Select the wire feed speed according your requirements The selected value will also be seen in the value box on the right hand side The speed is defined in metres per minutes Efficiency factor for the wire taking into consideration possible losses in weight from wire to weld metal Price in Euro per kilo for the wire In litre per minute Price in Euro per cubic meter of gas A set of predefined electrode diameters are given in the slider Click on the diameters and the slider will jump to the selected diameter Only the predefined values can be used Select the deposit value for the electrode Deposition rate for the selected electrode per hour Welding speed in centimetre
4. for economy simulation id i 12 B T Cross section 137 m Y j 1 20 mm 144mm wire metal arc ameter welding with inert gasshied Tamer 0 5 10 15 20 25 3 Do 7 G 19 m min Come elding spee C Deposited wire Required Weld metal 0 29 kg m 5 30 kg h ELIO G Deposition rate E 0 25 50 75 100 LT LL 1 817 999 883i dency Time to weld 1m Specific weight of steel 7800 kg m 0 lt b ie 4 6 8 10 v 1 20 Wire price7Kilo lume of gas m 10 15 20 28 15 l min as ow 0 3 4 6 8 10 l V 2 40 Gas price m3_ The user interface for the economic simulation follows the same path as for the other simulations As you move the sliders the resulting values are altered and shown in the yellow result boxes on the right hand side of the sliders The resulting impact on the overall simulation and the total cost for the weld is then shown on the result boxes on the right hand side Iqsim user manual v 2 0 2010 11 30 32 of 45 NOTE 1 A set of ON OFF buttons are situated at the upper right corner of the canvas The number of buttons will depend on the welding process By clicking on one of these buttons you will hide the related cost elements separately from the cost simulation This will enable you to work within a smaller are
5. in proportions which suit you 4 When you now alter the welding parameters these will directly be reflected in the cooling time graph and HAZ values mu ya LX 4 P vin eo Y 2000 121 Manual Metal Arc welding with covered electrode z 1900 1800 GNU roa 100A 140A 180A 220A 260A 300A 1700 W L v 170A 1600 1500 1400 ivi ov iov 20v _ 30 40V Ww v 25V 1300 1200 1100 m 0 10 20 30 40 0 S W min V 15 cm min oan 800 C C goo New 40 20 D 20 DEOR NN 700 t ex Y 20 c y orc 500 16 5 1 C pa 16 5s Un M 50 100 150 200 250 300 So RS T T T UE 3Usc aik 200 Hv 100 gt TV T 216 012 3 4 S 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 216 Time seconds omm 5mm 10mm iSmm 20mm Li This simulation has two extra features 1 Click into the small slider box at the bottom of the graph By doing so a new graph will be shown illustrating the cooling curve at the selected distance in the material from the HAZ itself By using this function you will get a pretty good idea of the heat distribution in the material 2 Both values for cooling time and Vickers hardness HV10 have two values shown in black and in red The black value shows the result from the current simulation The red value shows the results from the previous simulation 3 By opening the two icons for welding process and HAZ you may differentiate the welding
6. point selected at the slider Move a slider in steps For selection of electrode or wire diameters click on the relevant diameter value and the pointer will move to that diameter Select an exact value For chemical composition it is possible to enter exact values in the text box box beside the slider instead of using the slider Activate Deactivate Click on the icon yellow colour and it will deactivate some information and the icon will then turn white Clicking on the white icon will reactivate it giving the icon and associated tasks a yellow active colour Calculated results from the simulation will be shown with yellow colour background for example 1 74 kg m However in the welding calculations and the economic calculations other colour codes are used in addition for clarity purposes When you have selected the language you have to decide which evaluations and tasks you are going to carry out By selecting one of the icons in the banner area you have different options either to carry out a single task or to carry on with multiple task simulations If you want to carry out simulations which involves multiple tasks then you may freely move between the tasks in order to evaluate possible alterations on the fly All datasets will be updated immediately NOTE If you are using a Smartboard for communication with the system then tap on an icon or select a slider pointer and drag it across the slider The system is optimized for us
7. process welding methods and welding parameters and at the same time see the result of the manipulation with the sliders directly in the graph 800 C S ME 7 6s j 76s Hoo V 271 271 Red numbers give the result from the previous simulation Black numbers are the result from the current one Iqsim user manual v 2 0 2010 11 30 26 of 45 HAZ and cooling time The window for these calculations gives you the following information Maximum hardness in HV10 in the heat affected zone Cooling time from 800 to 500 degree Cooling time a given distance form the centre point in the weld itself Tensile strength Hardness at given distances in the HAZ Calculate width of the HAZ itself asm DN gr 1900 enu e acp Advanced 1800 1700 1600 1500 1400 1300 1200 m 3 B 1100 3 E 1000 m fs 900 3 800 C o 800 ii Z N 700 E be 4 600 ox C 500 7 6 s 400 Ux 200 4 100 wv 255 0 12 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 28 26 27 28 29 30 Time seconds Moving your cursor to the line at any arbitrary point will give you the temperature and cooling time at that specific point Note that the values for HAZ and cooling time are shown in black and red The black value to the left is the current value you get from this simulation The red value to the right is the value obtained in the previous simulation However the button Define current as refer
8. see later are strongly influenced by these alloying elements Iqsim user manual v 2 0 2010 11 30 39 of 45 Ce values for different steel grades and industry usage 1 General rules There are some recommendations for content by weight 96 for some alloying elements 10 12 Alloying Composition elements Preffered in 96 High in 96 Carbon 0 06 0 25 0 35 Manganese 0 35 0 80 1 40 Silicon 0 10 or less 0 3 Sulphur 0 035 or less 0 05 Phosphorus 0 030 or less 0 04 I rule of thumb gt when Ce is less than 0 40 cracking is unlikely gt when Ce is between 0 40 0 60 weld preheat may be necessary gt when Ce is above 0 60 preheat is necessary post heat treatment may be necessary and techniques to control the hydrogen content of weld are required II rule of thumb gt if Ce lt 0 14 excellent weldability no special precautions necessary gt if Ce 0 14 lt Ce lt 0 45 96 martensite is more likely to form and modest preheats and welding with low hydrogen electrodes become necessary gt if Ce gt 0 45 96 extreme precautions weld cracking is very likely hence preheat see above in the range 100 400 C and low hydrogen electrodes are required The ability to form hard metallurgical microstructures like martensites or any other hard phases is dependent on the Ce and cooling rate of the steel involved in cooling from y a
9. 010 11 30 41 of 45 CeIIW C 90 6 Pcm Celto Besseyo C 5B 96 7 Example for steel AH36 from Co Oakley Steel Ce 0 38 for plate thickness less than 50 mm and Ce 0 4 for plate between 50 100 mm thickness 6 2 Ce values for stainless steels 9 For stainless steels and welds between carbon steels and stainless steels the equivalent nickel content Nie and equivalent chromium content Cre usually used together and in conjunction with the Sch ffler Delong diagram are considered more accurate for measuring estimating weldability 6 3 Some new types of Ce formulas 6 3 a Ce for steel grades WES 135 and WES 136 7 8 11 CeWES C 96 8 6 3 b Cen 11 In the recent years complicated formulae have been developed including welding parameters effects of inclusions chemical composition etc It is generally perceived that for workshop usage without access to a PC to perform calculations this is not practical The following carbon equivalent considers this effect and can evaluates weldability of steel with a wide range of carbon Cen C 4 KG T e 9 where f C 0 5 0 25 tanh 20 C 0 12 96 With decreasing carbon content f C decreases from 1 0 to 0 5 Therefore Cen is close to CeIIW when C is higher than 0 1596 and Cen approaches to Pcm as a carbon content decreases Cen is stipulated in ATM A 1005 A 00 and ASME B16 49 2000 The newest carbo
10. 999 v 0 A 0 0 0 Tsetse d d d E EE EE EE E EE E EE E EE E EE E E EG E GU Cr 0 15 Hp 0 3 0 0075 DAAE SIENER RIEC GO GO G G GO Eee 0 0 025 o 000625 P 0 o 0 0 03 0 00075 Ni fois A SNAREN 0 0 3 0 0075 Ti 0 A 0 0 0 Al 0 0 0 0 Mn o4 yp Se o4 los 0 0125 Ferra A EAEE Jae YO PP B 0 0001 L 0 0 0001 0 0000025 ems ag pa a gr rg d d d d d E d d d d E d d d d b d d d pr d d p p a rr gr ng Mo 0 25 f 9 0 25 0 35 0 00249999 Se eee N 0 1 ps 0 2 0 005 Nb 0 0 0 0 The material data can also be run in an Advanced mode By doing so you may do the following e Adjust the minimum and maximum values for the chemical elements e You may alter the steps in the slider e You may add chemical elements which were not included in the material composition of the material you selected Please note If a chemical element has a minimum and maximum value equal to zero then the slider will be void and can not be used If a numerical value is entered which is above or below the max or min value then a red border will be seen on the value box Iqsim user manual v 2 0 2010 11 30 35 of 45 References For calculation of HAZ and cooling time Yurioka http homepage3 nifty com yurioka exp html E1 Basic formulas found here with references to additional papers Rosentahl Calculation of preheat EN1011 2 Iqsim user manual v 2 0 2010 11 30 36 of 45 Appendix A Un
11. Iqsim user manual v 2 0 2010 11 30 B Education and Culture DG Lifelong Learning Programme IQSim USER MANUAL 1 of 45 Iqsim user manual v 2 0 2010 11 30 2 of 45 List of Content Linarsreltra stole PM E cc 3 THO 1G a E E EE 3 oyster EOQuiTetmenfs sssi ei aeaiiai ea preme bres Rn Rie gies eae 3 Project Lead Ore ani Zain ss cueste pete tu E pete dete E cova adeps 3 Participating organizations eesseeeeesssseessssresssereesssrtersssreesssreesssereessereessssteesssstesssent 4 Start the S VS OT exorta enir a REO a r E E ae YA ue MUS 6 General user Ip Utes P 7 Different alternative Simulations s 5 ciscisiesdededsccesscevadeiacsasvasstasedgeaiostdnvdassivezscstarstepe adceaatneans 8 A Material COMIPOSINON gcc ecu enacted ode Dudes Susu d oues eae ee 8 A B C Material composition versus hardness and cooling rate 8 D E Geometrical Properties 0 usceesteac dye ei esee a eie tesa pue bl puc e aet seu dadUs 8 D E F Geometrical properties versus welding costs eere 8 G H Welding parameters versus hardness and cooling time 9 I J K L Geometry and welding parameters versus welding costs 9 Evaluation and its consequences eee eese eese eee eene tenete tnnt tn sets stata 10 Moving the icons in the Can Via cassecsicsszesa te Cete teer deie qu ere Dueh ost ein tern u
12. a of the overall calculation and concentrate on fewer variables thus creating a smaller canvas area NOTE 2 For the wire or electrode diameter the pointer will jump between the defined values of the slider Just click the slider value and the pointer will move NOTE 3 The total welding cost will be automatically updated if you go back into the geometry part and alter the geometrical information NOTE 4 Variation of amperage voltage and welding speed will not alter the deposition rate of the filler material NOTE 5 The total cost is shown without any digits therefore the total costs are calculated from the background data in the system where the data are stored with digits Consequently it may seems that the calculation are not 10096 correct This is due to the way the data are shown Total hours are the number of hours to be used for welding of the selected number of metre weld NOTE 6 When selecting the language during start up of the system the currency is automatically defined as the local currency Gm im bo 15 oOo cuc cosy F gt an T V 9 LB it T E UMEN 0 13 uty cycle 10 20 30 40 50 60 Labor cost m abor cost hour with overheads Actual repair cost m 4000 d Total heating cost 0 _ 5 10 15 20 28 5 poo 4 28 26 Repair m Total cost m 0 1000 2000 3000 1000 00 I epair
13. al composition of steel and by some other factors not discussed here This means the chemical composition of the steel will influence the hardness and the weldability of the steel the definition of weldability here is not discussed and as a result of this the quality of the joint will be remarkably influenced Higher concentrations of C and other alloying elements such as Mn Si Mo V Cu Ni will increase the hardness and decrease the weldability of the parent material s Each of these alloying elements tends to influence the hardness e g measured in HV and its value preferred to be about 320 340 HV 10 and weldability of the steel to different magnitudes However there is a need for making a method of comparison to judge the difference in hardness Iqsim user manual v 2 0 2010 11 30 37 of 45 between two alloys made of different alloying elements Cracking The metallurgical characteristics of steels are mainly dominated by their chemical composition Any small changes in chemical composition of the base and filler metals could substantially increase cracking tendency The risk of cracking also increases with increasing hardness of the Heat Affected Zone HAZ in welding for a particular H hydrogen level and welded joint restraint A general indicator which is Ce is a useful guide to estimate and assess the possibility of cracking in alloy steels by comparison with the equivalent plain un alloyed carbon steel The two mai
14. aneously monitor the result on the cooling time and temperature curve and Vickers hardness Comparisons can be performed showing two items side by side effectively showing the relationship between alterations of the geometry data and the cost data Iqsim user manual v 2 0 2010 11 30 11 of 45 Moving the icons in the canvas The icons can be moved around in the canvas if you wish The canvas is divided into different segments top and bottom segment left and right segment and the centre segment By dragging an icon into a segment the segment will circumscribed Release the icon and it will stay where it has been moved to Dragging the icon back into the top segment can be done Drag the icon and place it in between the other icons and see that a box will be highlighted then release the icon The icon will then be inserted 111 Manual Metal Arc welding Mu 4 70A 100A 140A Omm imm 2mm 3mm 4mm V 30 35 40 45 5S0 55 60 ctrode cost m of weld Cap requirements ISO 5817 2007 Class B Classc Class D Example of presenting results on the canvas Iqsim user manual v 2 0 2010 11 30 12 of 45 Evaluation of the chemical composition asm fa v 3 4 Y dim ISO 15608 group ISO 15608 subgroup Name Number 1 1 16Mo3 1 5415 e 1 1 P275NH 1 0487 1 2 P295GH 1 0481 1 3 P460NH 1 8935 Ly Advanced 500 Cu 0 Si 0 25 d Cr 0 0 300 OT AH 200
15. ary VuZ P SR Slovakia lzV Sbvene CFL Sweden Instructor training courses which target deployment and use of simulator video and Smartboard technologies Dedicated services for digital blackboards by using object oriented programming The graphical user interface hides all advanced calculations Seminars conferences and exhibitions for transfer of knowledge to stakeholders in Europe More information prosjekt hist no iqsim Students play with siders in order to define evaluate and redefine the geometry Trigger retiective cognition processes by judging different geometrical results What happens if University of Thessaly Greece HiST Kompetanse Norway HIST S r Tr ndelag University College Norway Coodinator John B Star Heat Affected Zone HAZ Simulation of the HAZ value and the dynamical extension of the zone are shown as the student plays with the essential parameters p tusata v Cabra Ua Lifeheeg Learning Progra ne HST Iqsim user manual v 2 0 2010 11 30 6 of 45 Start the system You enter into the system in the following manner Step 1 Log in with you user name Step 2 Enter your password and the system will go to the introduction page for IQSIM Step 3 Select which language to use within the system by clicking the flag icon on the right hand side This also defines the currency to be used in the calculations later ale English Fig 1 Select whi
16. c C X az AA 0 50 100 150 200 250 300 e q V 20 C The selected values will be shown in the yellow result boxes on the right hand side of the sliders The efficiency factor will be altered according the welding process you choose Arc energy and heat input will be calculated automatically as you are manipulate the sliders You may alter the following parameters 1 The amperage 2 The voltage 3 The welding speed or wire speed Iqsim user manual v 2 0 2010 11 30 24 of 45 4 The ambient temperature 5 The preheat temperature Note 1 Ambient temperature and preheat temperature do not influence the heat input calculation Efficiency factor are dependent on the welding process and is set automatically Ambient temperature is equal to material temperature Note 2 The alteration of amperage voltage and welding speed will of course also alter the deposition rate of filler material But be aware that we for the sake of simplicity do not update the deposition rate in the economic calculation based on the changes here Iqsim user manual v 2 0 2010 11 30 25 of 45 Welding parameters and HAZ cooling time Manipulating the welding parameters will directly influence the HAZ and the cooling time In order to see this influence directly you may do the following 1 Enlarge the browser window 2 Move the HAZ icon into the canvas and the canvas will be divided in two parts 3 Scale these parts
17. ch language to use within the system by clicking the flag icon on the right hand side and that language will automatically be selected Step 4 Select one of the system icons or tabs in the banner area to proceed with an action osm P5 s UU A Y dim Version 0 9 96 Nov 16th 2010 Build Time 21 00 als English Please keep in mind the following This software is intended for pedagogical use and will give indications of correct values but should not be used as a tool for estimating and do not use it for precise calculations The key element for the use of IQSim is that the user shall evaluate consequences of his her decisions what happens if I alter a parameter and what consequenses does it have IQSim have dynamic relations between the variable so one change of a parameter will automatically be seen as a consequence in other parts of the software As an example a change in material thickness will automatically show the new costs involved for that job The iQSim system may also be used by professional welding engineers in their daily work however although the system is not designed for that purpose and in the current version it will lack a lot of the information needed for the welding engineer Copyright 2009 iQSim Ser Trendelag University College HIST Trondheim Norway HIST Contract Research Trondheim Norway Centre for Flexible Learning Municipality of S derhamn Sweden CFL Hungarian Association of Wel
18. d using mathematical equations There are also several commonly used and empirically derived Ce equations as well These Ce values for expressing carbon equivalent are developed by different welding research organizations and metallurgical industry see later In practice it could be possible for individual steel grades to develop a special Ce value based on experimental laboratory practices because these relationships could not be derived purely theoretically The alloying constituent elements in steel are expressed in weight percent amount wt 96 the unit of chemical composition in wt of steel However steels could be classified on practical base and industrial practice therefore generally it is enough for individual steel grades un alloyed alloyed steel etc to derive a formula for Ce which can later be standardly applied for that particular grade of steels see later The Ce is a measure of the tendency of the weld to form martensite on cooling and suffer hydrogen induced cracking therefore some preheat predictive method uses Ce as well to determine the thermal history By varying the amount of carbon and other alloying elements in steel the designed strength levels can be achieved by proper heat treatment A better weldability and low temperature notch toughness can also be obtained Since Cr and Mn increase the susceptibility to hydrogen assisted cracking and hardenability of steel the value of both indicators Pem and CeIIW
19. derstanding equivalent carbon content Ce A review of literature General The welded joints in a welded structure should serve the planned loading of the structure with safety If there are some non conformities around welding then the welded joint s under load can fail The welded joints could be classified according their quality If high load and high safety is needed then high quality welded joint s should be produced etc During production some non conformities could occur because welded design is not friendly for the appropriate welding activity or on the other hand the parent material s used prescribed are technologically e g during welding not properly treated and welding parameters used may be not suitable In this latest case it means that the heat input and thermal history could be not correct In this context the characteristics of parent material mean chemical composition thickness of parent materials and mechanical strength of steel grade etc Alloying chemical composition hardness and weldability 12 Alloying and chemical composition The basic characteristic features of a metal can be changed in molten fluid state by adding some other elements this is alloying and the added element s are alloying elements If adding some small quantities of other molten metal or metals to the molten base metal this activity is called alloying The result after cooling is a solid stage called alloy or one or more compone
20. ding and Material Testing Budapest Hungary MHtE Klaipeda University Lithuania KU University of Thessaly Greece UTH Multilateral Pilot Project 142719 LLP 1 2008 1 NO LEONARDO LMP 2008 1924 E L Education and Culture DG Fig 2 Select an action by clicking on one of the graphical icons or tabs in the border to proceed Please note that the IQSim system is designed for educational purposes The key objective has been to develop a system with a simple and effective user interface which allows the students to evaluate the results and consequences of different decisions and thereby learn to see the fabrication process as a set of separate actions which influence each other To get exact data may in some cases not be easy but that has not been the intention of this user interface However some different solutions for obtaining exact results have been implemented and you will be notified when these tools and facilities are available in the different parts of the system Iqsim user manual v 2 0 2010 11 30 7 of 45 General user input To select a task Click on the icon in the frame and the task will open To move a slider Click on the slider pointer with the left mouse button Drag the mouse button to the left or right and the pointer will follow Note that a small information box appears above the pointer highlighting its value Or Click on the slider at an arbitrary point with the left mouse button and the pointer will jump to the
21. e Current as Reference then a red reference curve as well as the red reference value boxes will be shown The tensile strength value will be shown below the Vickers hardness values The Advanced button thus allows you to evaluate the temperature and hardness values in the welded connection and get a feeling for how the distribution of values will be through the material and the weld itself gt 5ag sumgiaduia t e o eo o 12 5s o 4 509 531 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 e time seconds 1 550 Petine current as reterence 1 615 o Iqsim user manual v 2 0 2010 11 30 31 of 45 Economic evaluations The economic evaluations are related to the joint configuration and import data from that part of the system This means that you may select a joint configuration and then create an economic simulation based on those data You can then move back to the geometry of the joint and alter the date in moving back to the economy to see the result of the graphical alterations Also note that the welding process is defined behind the welding icon and when you alter the welding method then the basic input in the economical calculation are altered E g When changing from MMA 11 to TIG 141 the interface will alter electrode to wire and add cost elements for gas When you alter the geometrical data for the joint configuration this will influence the cost calculation User interface
22. e slider by pointing at it and pressing the left mouse button down Then move the mouse to the left or right When you click on the pointer and held the mouse button down a small value icon will be shown above the pointer highlighting the current value this value icon will follow the pointer and give you the correct pointer value in decimals Note Some logical limitations are built into the system Ex Nose height can not be larger than the material thickness Likewise the nose height and the distance to the nose can not be larger than the material thickness 25 6 4 0 5 55 cm 2 4 36 kg m 13 9 3 0 Values which are calculated automatically by the system are shown above and the values are shown with yellow background Iqsim user manual v 2 0 2010 11 30 19 of 45 BUTT WELD I Bevel e ler Qe Cap requirements 1S0 5817 2007 Class B s ClassC Class D Qa Maximum height 1SO 5817 2007 5 9 mm 2 4 mm 2 cm 0 84 cm 2 kg 0 66 kg m L 5 9 mm 5 0 mm The use of the sliders and other manipulation tools are as described earlier in page 12 NOTE Recommendations according EN ISO 9692 1 for single and double sided welding has been added Minimum and maximum plate thickness is highlighted for different welding methods Iqsim user manual v 2 0 2010 11 30 20 of 45 BUTT WELD V Bevel asin fa 42 wl iwi ge Vit 10mm 30mm 50mm 70mm 4 Omm imm 2mm 3mm 4mm 5mm eL B 4 wi 30 35
23. e with a Smartboard Iqsim user manual v 2 0 2010 11 30 8 of 45 Different alternative simulations You have the following options to select sequences and combine tasks A Material composition Evaluate the consequences of alteration of the chemical compositions of the base material for CE PCM values and so forth Select the following icon A B C Material composition versus hardness and cooling rate Evaluate the consequences of the chemical composition for the hardness value and cooling parameters Select the following icons in the sequence indicated below D E Geometrical properties Evaluate the consequences of altering the dimensions of a given joint configuration for weld metal requirements Select the following icons D E F Geometrical properties versus welding costs Evaluate the consequences of altering the dimensions of a given joint configuration for welding costs Select the following icons in the sequence indicated below wa xw Wd Vv 1 Iqsim user manual v 2 0 2010 11 30 9 of 45 G H Welding parameters versus hardness and cooling time Evaluate the consequences of altering the welding parameters for the hardness and cooling Select the following icons in the sequence indicated below E dL OD am I J K L Geometry and welding parameters versus welding costs Evaluate the consequences of altering the welding parameters for the welding costs Select the following icons in the sequence indica
24. ence will define both the current curve and values as reference when you are carrying out the evaluation Creating a new evaluation will then bring in a new cooling curve as well as new data for the cooling time and hardness The previous curve defined as reference will be shown in red text and the new one will be shown in black colour as illustrated in the following figure Iqsim user manual v 2 0 2010 11 30 27 of 45 cm 25 b Y dm 2000 Advanced 1900 1800 1700 1600 1500 1400 1300 1200 m 3 9 1100 3 E 1000 m 8 900 800 C 2 aoo Mi 700 Z aa 3A 500 C 600 sod 6 3s 400 G 7 6s 300 200 4 100 ld i 285 012 34 56 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Time seconds 271 Define current as reference NOTE The accuracy of the calculations has to verified by an appropriate test weld followed by a hardness test For the HAZ and cooling time calculation you have also two options By ticking off in the selection box available through the Advanced mode you can choose to view the temperature development at a certain distance outside the HAZ region Select the distance by using the slider The result will be seen as a new graph drawn in black Alternatively you may choose to see the maximum temperature profile through the weld by clicking on the selection box By using this graph as shown below you can get additional information or an indication of how the hea
25. for calculating weld metal tensile strength 3 11 CelII 2 C 96 13 Celll for calculating HAZ maximum hardness 11 Mn Cu Ni Cr M id CE C a aa 36 20 9 5 4 LITERATURE References 1 N Yurioka Comparison of preheat predictive methods Welding in the World vol 48 2004 p 21 27 2 N Yurioka and T Kasuya A chart method to determine necessary preheat in steel welding Welding in the World vol 35 1995 p 327 334 3 N Yurioka Prediction of Weld Metal Strength Report III IW Doc IX 2058 03 p 3 4 Norman Bailey Weldability of ferritic steels Abongton Publishing Woodhead Publishing 1994 United Kingdom ISBN 1 85573 0928 p 35 37 on web test pages 5 J H Devletian Carbon equivalent Pcm limits for thick Carbon and Low Alloy Steels Final Report 2000 April 4 Oregon Graduate Institute of Science and Technology p 2 4 6 H Kihara T Kanazawa and H Tamura Weldability and Toughness Specifications for Structural Steels in Japan With Special Reference to WES 135 and 136 e Philosophical Transactions of the Royal Society of London Series A Mathematical and Physical Sciences Vol 282 No 1307 Rosenhain Centenary Conference The Contribution of Physical Metallurgy to Engineering Practice Jul 8 1976 pp 247 258 article consists of 12 pages e Published by The Royal Society Iqsim user manual v 2 0 2010 11 30 44 of 45 Stable URL http www jst
26. g Temperature profile at 10 E 5 259mm 12 Additional temperature profile V 14 LT l ba 16 o 0 250 500 750 1000 1250 1500 C Maximum temperature C I a oy DE Iqsim user manual v 2 0 2010 11 30 29 of 45 Additional temperature profile If additional temperature profile is selected then the following will happen e Anew graph will appear showing the temperature profile at the material depth as defined through the use of the slider The selected value will also be shown in the dimension box above the slider e Anew vertical black line will appear on the profile graph This graph will give the temperature line for the material depth selected by the slider p m 1900 V Show max temperature profile 1800 2 Distance from origo to 1550 C line 1700 g aaa 2 4 5 259mm Estimated withd of HAZ 1600 Rd gt 6 Distance from origo to 5 4 895mm ee aod 1500 M 10 155mm 8 1400 5 Temperature profile at w 1300 z1 ae 1200 3 a 12 Additional temperature profile g 1100 V m 8 14 zi E 1000 A s V Calculate HV10 and Cooling time at current p sitioi o 16 I 900 0 250 500 750 1000 1250 1500 N 800 Maximum temperature C 700 600 500 7 9s 400 300 200 4 100 Y 0 253 012 34 567 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Time seconds Iqsim user manual v 2 0 2010 11 30 30 of 45 Note If you also select the button Us
27. l composition CE III Carbon Equivalent CE for evaluation of the Alternative algorithm defined by weldability of steel reference ISO 1011 but modified N Yurioka Corrections for chemical composition CE IIW_ Carbon Equivalent CE according IIW This carbon equivalent satisfactorily recommendations evaluates weldability whose carbon content is higher than 0 1296 CET Carbon Equivalent CE for evaluation of the Alternative algorithm defined by weldability of steel N Yurioka Corrections for chemical composition CEen Susceptibility to cold cracking is determined by hardness of welds HAZ and weld metal The weld hardness is determined by an interactive effect of weld harden ability and carbon content The following carbon equivalent considers this effect and can evaluate weldability of steel with a wide range of Iqsim user manual v 2 0 2010 11 30 14 of 45 carbon PCM Parameter Crack Measurement substitutes Ce values for carbon contents lower than 0 1296 Modern low alloy steel is mostly of a carbon reduced type C lt 0 12wt Weldability of this type of steel is more adequately evaluated by the following carbon equivalent CEWES Carbon Equivalent CE for evaluation of the weldability of steel Alternative algorithm defined by N Yurioka Corrections for chemical composition Alternative algorithm defined by N Yurioka See http homepage3 nifty com yurioka exp html For F
28. mm Df 2 80mm cm 0 79 cm 2 Mg 0 62 kg m LS L e mJ The use of the sliders and other manipulation tools are as described earlier in page 12 NOTE The fillet weld can be set to be concave or convex by clicking on the icons The selected icon will be highlighted Iqsim user manual v 2 0 2010 11 30 23 of 45 Welding Parameters The simulation of welding parameters directly influences the HAZ calculation and the cooling time You may choose to combine this simulation with the HAZ calculation and the temperature cooling graph and calculation of cooling time If so it is advisable to drag the HAZ calculation into the canvas so that you can directly observe the consequences of your manipulation of the welding data on the HAZ data set Based on the variables in the user interface the arc energy and heat input are shown as a result You may manipulate with the following variables by using the sliders in this interface Amperage Voltage Welding speed Ambient temperature Preheat temperature Welding process is selected through the pull down menu in the top of the user interface IREN 111 Manual Metal Arc welding with covered electrode v Quee NE x 70A 100A 140A 180A 220A 260A 300A WY l 170 A mm Th Effi iy ov 10V 20V _ 30V 40V ermal Efficiency v V V 25V 1 70 k3 mm m o i0 _ 20 30 40 0 4 min V 15 cm min Heat Input 7 a i 40 20 0 20 40 4 eo PPP Y 20
29. n equivalent formula 5 Cen applies to both traditional steels covered by CeIIW and low carbon low alloy steels covered by Pcm because of the hyperbolic tangent tanh term in the accommodation factor A C shown below Cen C A C 5B 10 where A C 0 75 0 25 tanh 20 C 0 12 In the higher C range A C approaches 1 and Cen approaches CeIIW Conversely at low carbon levels the Cen approaches Pcm This behavior of the Cen equation is due to the tanh hyperbolic tangent function Iqsim user manual v 2 0 2010 11 30 42 of 45 6 3 c Cel II III values The formulae given here are also for prediction of weld metal hardness and strength as reference on the martensite or bainite formation show They are dependent on different chemical compositions microstructure and cooling time t8 5 of steel The martensite hardness is determined solely by the carbon content and there is a relation to HAZ and it is assumed that the same relation holds in weld metal The index for hardenability is a function of carbon equivalency and for different microstructure there can be different equations as it can be seen and study below a Cel The formula 13 is obtained by a best fitting manner against the present database the effect of Mn is non linear as indicated as Mn 1 Mn This means that activity of Mn decreases as Mn content increases Ni and Cr are considered to show the same tendency but their effects c
30. n problems faced in the cracking of the welded metals welds are hot and cold cracking Hot cracking occurs immediately after solidification in a weld caused by the segregation of certain alloying elements during the solidification process S B and other elements tend to segregate excessively They are reduced in order to prevent hot cracking Cold cracking also known as delayed or hydrogen induced cracking developing after solidification of the fusion zone nearby the HAZ as a result of residual stress Generally it occurs below 200 C sometimes even several days after welding Ce is sometimes useful in planning welding procedures Adabtability usability of Ce is limited if only the chemical composition of steel is considered because the section size being welded and joint restrain is of equal or sometimes greater importance than the value of Ce because of their strong relations to heat input and cooling rate there are issues in the details not discussed here Susceptibility to cold cracking is determined by hardness of welds HAZ and weld metal see above The weld hardness is determined by an interactive effect of weld hardenability and carbon content Preheating 11 The objective of preheating is to effuse diffusible hydrogen out of welds to prevent hydrogen assisted cold cracking The occurrence of cold cracking is influenced by the following factors chemical composition of steel thickness of parent metal s or pla
31. nt alloyed metal This activity will change or modify the basic characteristics of the parent metal now in our case that of the Fe which will be modified and or changed Therefore for the welded steel structure production chemically pure Fe is not used The welding industry producing steel structures uses significantly Fe based alloys Fe is the dominant element These materials of different chemical composition form different types of steels These are named in welded steel structure industry base or parent metal Un alloyed plain mild alloyed and high alloyed steels If the accumulated ingredients alloying elements are lt 5 and the rest is Fe then this kind of steel is generally named un alloyed steel If the volume of ingredients is about 5 96 the steel is low or medium alloyed steel If volume of ingredients is gt 596 the steel is highly alloyed steel Hardness and weldability All alloying elements and thermal history heat input and cooling rate influence the properties of parent material s and weld welded joint as well This effect could be estimated as positive e g having higher strength and corrosion resistance etc but some of the effects could have negative influence on the load bearing capacity of a welded joint e g bringing crack formation into action and or causing the welded joint under load to break fail According to practice such negative effect could be significantly influenced by the chemic
32. ontract Research Norway e Centrum for flexibelt l rande CFL Sweden e Hungary Magyar Hegeszt stechnikai s Anyagvizsg lati Egyes l s MhtE Hungarian Association of welding and Material testing Hungary e Klaipeda University Faculty of Marine Technology Lithuania e University of Thessaly Greece Iqsim user manual v 2 0 IQSim results 2010 11 30 5 of 45 e iQSim Innovative Simulator Tools for Quality Management Production Process Training in VET Leonardo da Vinci Development of Innovation Pilot Project 2008 2010 Develop new on line simulator services that help displaying critical production parameters in the mechanical industry sector Simulator tools include the 4 most frequently used welding joints and the calculation of production costs for these welding methods Validation of the new simulator tools in Vocational Education and Training in Norway Sweden Hungary and Lithuania New pedagogical methods which utilize face to face training e learning solutions simulations and high quality video Material constants Develop a database containing the chemical composition and other Important data of the materials The selected set of data provides the basis for the technical calculations Economy Optimize the production costs by using scenarios with on the fly simulation The scenarios include technical and economical cata from industry MHtE Hung
33. or org stable 74540 7 JIS G 3106 2008 rolled steel for welded structures WES 135 and WES 136 8 JIS G 3115 2005 Steels plates for pressure vessels for intermediate temperature service WES 135 WES 136 9 en wikipedia 10 www eng tips com faqs 11 N Yurioka Prediction of HAZ hardness of steels Metal Construction vol 19 1987 p 217R http homepage3 nifty com Yurioka exp Master code by N Yurioka Welding Calculation up dated 2007 May 12 www leonghuat com articles carbon 20equivalent htm 13 www staff ncl ac uk s j bull mmm373 WELDMAT Iqsim user manual v 2 0 2010 11 30 45 of 45 Appendix B Formulas used in the calculations Ac1 750 8 26 6C 17 6Si 11 6Mn 22 9Cu 23Ni 24 1Cr 22 5Mo 39 7V 5 7Ti 232 4Nb 169 4Al 894 7B AC3 937 2 436 5C 56Si 19 7Mn 16 3Cu 26 6Ni 4 9Cr 38 1Mo 124 8V 136 3Ti 19 1Nb 198 4AI 3315B Ms 521 353C 22Si 24 3Mn 7 7Cu 17 3Ni 17 7Cr 25 8Mo CEI l E CE C Si Mn Cu Ni n Cr 1 0 164 Cr Mo f B 24 6 15 30 8 4 CEII j Mi j Mi 2 2 Ti Gn M n Cu Ni Cr Mo Nb i 24 2 6 1 Mn 10 45 10 5 1 5Nb 10
34. ormulas used for the calculations see Appendix A NOTE All calculations are based on material ISO 15608 Group 1 ONLY Other material groups can not be added in the current version due to the use of algorithms optimized for this material group Iqsim user manual v 2 0 2010 11 30 15 of 45 Evaluation of the weld geometry The weld geometry may be evaluated in order to see the consequences of the alteration of the geometry dimensions for the welding itself If you choose only to evaluate the geometrical changes then the result will be calculated as cross area section and weld requirements per meter weld However you may choose to combine this evaluation also with the cost evaluation in order to see the consequences of geometrical changes for the weld economy iQSim me e Y 1 Select the icon for bevel configuration The canvas will show the alternative joint configurations 2 Click on the joint configuration you want to use You may select one of the four configurations The selected configuration will then be highlighted 3 Then select the icon for the weld bevel in the canvas and a new bevel interface will appear showing the evaluation parameters and the resulting data from the evaluation Iqsim user manual v 2 0 2010 11 30 16 of 45 emm ma A ia aS Example of selection of a joint configuration Iqsim user manual v 2 0 2010 11 30 17 of 45 General input for the bevel data Common to all be
35. ould be considered to be linear for Ni less than 3 5 and Cr less than 1 25 as it was indicated by the used database and Cu was considered not to contribute to hardenability thus Cu was ignored in 13 Cel for calculating weld metal tensile strength 3 11 Cel C 96 11 Cel for calculating HAZ maximum hardness 11 CE C Si Mn Cu Ni Mo Cr 1 016 Cr f 8 24 6 15 12 4 8 A f B an increase in HAZ hardenability due to boron C lt 0 8 N lt 0 01 11a 8 090001 B f C 0 09 HG Bx 0 0001 Bx 00004 0 0006 2 90020 0 0080 3f ict I C COSE A RO b Cell The case when the hardness of 0 martensite phase plus that due to precipitation hardening which arises only when t8 5 becomes long it is also function of Ce in the following equation 14 the effect of precipitation hardening elements of Cu Mo V Nb Ti are relatively high and the non linear effect of Nb considered as 2 2Nb 1 5Nb Cell for calculating weld metal tensile strength 3 11 Cell C 4 2V 90 12 Cell for calculating HAZ maximum hardness 11 Iqsim user manual v 2 0 2010 11 30 43 of 45 Si Mn Cu Ni Cr Mo V Nb CE C t 4 4 t4 24 5 10 18 5 25 5 3 12a c Celll The critical cooling time when martensite phases diminish and considered as an index of easiness of bainite formation in this case Ce is as it follows Celll
36. own above the pointer highlighting the current value NOTE A number of features are included in this window e Ifacomma has been typed into the value field then it will be automatically be changed to a dot e The system will give an error sign as a red border in the value box if the value is not allowed and coerce to the default min or max value e Ifa chemical component is not defined in a material then the slider for that component will not be active and it can not be moved NOTE If the border in a value box turns red then the value selected is outside the permitted value in the ISO standard for that material group AC1 738 C CEI 0 36 96 AC3 864 C CE II 0 40 CET Ms 433 C CEIII 0 48 96 CEen CEllV 0 35 96 Pcm 0 22 96 CEWES 0 36 Values which are calculated automatically in the material section are shown in yellow result boxes Values which will be altered dynamically during the simulation AC1 The temperature at which austenite begins to be formed AC3 The temperature at which the transformation of ferrite to austenite is completed Ms The temperature at which martensite formation begins during cooling of austenite CEI Carbon Equivalent CE for evaluation of the weldability of steel according ISO 1011 CE II Carbon Equivalent CE for evaluation of the Alternative algorithm defined by weldability of steel reference ISO 1011 but modified N Yurioka Corrections for chemica
37. per minutes Duty cycle or arc time in for the welding process This means effective welding 96 per hour Labour cost per hour Note It is wise to use the total price here That means the company costs and overhead should be added Alternatively one may use the company sales price per hour Repair 96 per meter weld Average number to be used Repair costs per meter should at least include the following elements e Cost for gauging and grinding in order to remove the weldment e Costs for re weld e Costs for renewed control with relevant NDT methods and documentation e Additional cost for handling equipment back and forth for control and welding purposes should also be included e Cost for documentation of the repair Cost for heating per meter This could be preheat and other heating activities required during the weld Meters of weld to be welded by this welding method Iqsim user manual v 2 0 2010 11 30 34 of 45 Administration of material data ISO 15608 group ISO 15608 subgroup Name 1 1 P275NH 1 2 P295GH 3 pasonn 1 8935 m Min Max Slider stepping VE EE EEG OE GE ETET Gg p d d p p d gd gp og d p d d p rr ar gd C 0 12 Ly 0 12 0 2 0 00200000 Cu 015 VEG OE EE OE OE GE GE GE GE GE GG GE P GO GE GO Gg GO Gg B G BL Gg GF B GN BGB GB GB NL GB GG B N n 0 0 3 0 0075 aaaaaaaaa ga aa ag d d d d E EE EE EE IEEE EE UA Si 0 175 oO D 0 35 0 00874
38. rovide easy to use graphical interfaces that optimize cost and time effective transfer of industrial production process and technology know how to VET students The combination of new pedagogical methodologies and simulator services extend existing training methods Partnership The IQSim consortium has a large industrial presence with strong ties to research within utilisation of new pedagogical methodologies HiST development of simulator tools that utilise CAS tools HCR and UTH and connections towards mechanical industry HiST CFL KU and MHtE for effective delivery of instructor training HiST offers expertise in distance learning methodologies blended learning and visual communication and collaboration services For Teachers Please note that the IQSim tool can be operated on a Smartboard Tm digital pressure sensitive board together with the other Smartboard tools The sliders and icons can then be operated tapping on the Smartboard surface A set of Teacher Use Cases have been developed in order to help the teacher formulating different questions to the students This document can be obtained from the project organization System Requirements Web browser preferably Firefox 3 5 Internet Explorer 7 Adobe Flash 10 plug in must be installed Project Lead Organization S r Tr ndelag University College Faculty of Technology Norway Iqsim user manual v 2 0 2010 11 30 4 of 45 Participating organizations e HiST C
39. s are the most important to focus on in a given context The IQSim tool is consequently a dynamic tool to be used in an evaluation process It is not intended as a tool for calculating a specific result instead the tools should be used to ask questions like What happens if I select this parameter instead of another IQSim is a tool for evaluation of consequences within the welding sector That means we have been interested in asking What happen if From a pedagogical point of view we want the students to make modifications and evaluate the consequences that these modifications will produce This means we are not interested in the exact answer but in the differences or relations that the modifications will give This is a tool developed through the IQSim project This project is sponsored by the Leonardo pilot Project programme within the EU NOTE This manual has been written for potential users of the program However it is assumed that the user has the basic knowledge of welding All welding terms and expressions herein are NOT explained A person unfamiliar with welding may therefore face difficulties with some of the expressions and the logic iQSim develops and disseminates a new generation of simulation services that will generate new training methodologies that are applicable to European wide mechanical industry sectors The on line simulator services that are interconnected to state of the art Computer Algebra Services CAS p
40. se EU besdeu UE Us 11 Evaluation of the chemical composition essent neret enne 12 Evaluation of the weld geottietry esent nne ete ese be EE RP SER CHI eene eei eos 15 General input for the bevel Mata sack si e rebas de tr altere rob evene din e run NETUS 17 BUTT WELD I Bevel sso ro i hec NER nto e o d det 19 BUTT WELD sV B Vel s uei retient E Deinen uA Tid eese suut bete RUE 20 DUTIIWEBLD s X Bevels oeste tede em weed ten cepimus eut atquo Cet dedo de fessa e 21 FILLET WELD orc cado a OR Dr A E Gee A ca EREE 22 Welding Parameters i nnda ee edd etenim ene dust M 23 Welding parameters and HAZ cooling time eee ceci eene eene eene nne nnnne 25 HAZ and COO LMG TIC acer Foe tr sce or eu Rea a Sp ra Da espe pesi un o up es EM Deep oed 26 Economic Cy AWA ONS esed Aeris o p turpiter ESO QU CRIME Ud 31 Administration of material datas pinea troppo Ce ibt uePo tern dpud MN DINE MIO 34 Ji nr MMC EM PR 35 For calculation of HAZ and cooling time eeessessessseseeseeeee nennen enne nnne 35 Calculation of preheat EIN1011 2 iere tritt p e reete e Rennen n aan eig ee Rena nne 35 Appendix ae an cs ota ERE 36 Appendix B os aseo doe quod Fete pet petuo SC mre rT inte ere ee eer ce 45 Iqsim user manual v 2 0 2010 11 30 3 of 45 Introduction The idea The idea behind the IQSim project is that teachers and students need to evaluate a set of parameters in order to find out which parameter
41. sent in older steels then a modified ITW formula CeH is used which takes into account the effect of Si CeH 96 2 3 Ce value for for low carbon microalloyed steels if Ce lt 0 18 96 C 3a Pcm Ce formula for modern steels particularly for pipeline manufacture and C lt 0 11 0 1296 no more Ito Besseyo Carbon equivalent 4 10 11 Pcm is designed for newer steels with low carbon low alloy content Modern low alloy steel is mostly of a carbon reduced type C x 0 11 0 12 wt Weldability of this type of steel is more adequately evaluated by the Pcm carbon equivalent which was implemented by Ito and Besseyo in Japan and called Pcm The effect of carbon becomes critical to HAZ if it contains large amounts of martensite Thus Pcm is a good indicator of hydrogen assisted cracking in the HAZ because carbon is a heavily weighted factor in this formula as shown in Pcm Celto Besseyo equation 3 In the Pcm formula in equation 3 Ni does not raise the susceptibility to hydrogen assisted cracking to the degree that it increases hardenability Pcm Celto Besseyo C 5B 96 3 3b Diiren s formula from Germany is similar for steel grades mentioned above in 3a 4 10 11 Ceq C 4 4 Ce formula for modern low carbon and or microalloyed steels is 10 Ce C 96 5 6 Some other formulas 6 1 Ce values for shipbuilding steels Iqsim user manual v 2 0 2
42. t distribution will be in the material itself on each side of the HAZ region within a distance of approximately 12 mm This indicates how wide the HAZ region will be Iqsim user manual v 2 0 2010 11 30 28 of 45 Li Show max temperature profile Distance from origo to 1550 C line 5 259mm Estimated withd of HAZ Distance from origo to 5 4 895mm 10 155mm Temperature profile at 5 259mm Additional temperature profile E C a 800 C The picture on the canvas indicates where the temperature and the HAZ is measured If you click on the Advanced button then additional information will be available and also additional possibilities will be available The following information is calculated automatically e Distance from origo to the 1550 C line e Distance from origo to the 500 C degree line e Estimated width of the HAZ In addition you will get the following possibilities e Show max temperature profile e Additional temperature profile Show max temperature profile If you choose to tick the box selecting maximum temperature profile a graph will indicate the temperature profile vertically through the weld itself The red vertical line illustrate the 1550 C line and the blue dotted line will will be the temperature profile through the material ivi Show max temperature profile Distance from origo to 1550 C line 4 5 259mm Estimated withd of HAZ gt Distance from origo to 5 4 895mm S 10 155mm ww jevajyew oj yda
43. te or wall thickness weld metal diffusible hydrogen content welding heat input welding residual stresses or weld metal yield strength weld joint restraint notch concentration factor at weld toe and weld root or groove shape weld pass number preheating method heating rate heating width ambient temperature immediate post heating In this software we are dealing only with chemical composition Iqsim user manual v 2 0 2010 11 30 38 of 45 Carbon equivalent Ce Steels can be assessed in terms of the Ce which scales the concentration of each element by its ability to retard the y a transformation Ce is an empirical value relating to the combined effects of different alloying elements used in making of carbon and or alloyed steels to an equivalent amount of carbon The resulting equivalent carbon coefficient allows the alloy to be compared with un alloyed plain carbon steels to predict their weldability and hardness properties Relating to welding Ce governs the hardenability of the parent metal It is a rating of weldability related to C Mn Mo Cr Ni Cu and V content Application of the Ce is modified by the inclusion in a steel as inclusions can effect hardenability and susceptibility for forming crack The most common formulae for Ce to evaluate weldability depend on whether the metal is any alloyed steel or modern carbon steel see later The order of magnitude for Ce can be calculate
44. ted below iQSim A be Please NOTE Altering the welding parameters do not calculate the filler deposition If you want to alter some of the previous settings then move back to the icon where the settings are specified carry out the alterations and move back to the icon where you want to evaluate the consequences of the previous alteration You may also during the simulation decide to view two sessions or tasks in parallel That means you may choose to see the influence of altering the welding details on the HAZ values and the temperature curve for cooling time For example the HAZ icon may be dragged into the canvas and scaled to the size you want Each of the sessions may be scaled individually Later you may choose to put one of the icons back into the frame where the other icons resides in order to continue with one dataset only Iqsim user manual v 2 0 2010 11 30 10 of 45 Evaluation and its consequences 222 Manual Metal Arc welding with covered electrode 6 70A 100A 140A 180A 220A 260A 300A _ 170A 0 10 20 0 V 15 cm min in ias 100 150 200 250 300 L L 1 mmmunummummmmmummuuummuumm i 0 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Time seconds 10mm 15mm 20mm 1 1 1 Example The HAZ calculation graphs has been moved into the canvas and scaled so that the user can manipulate with the welding data in order to simult
45. transformation temperature The higher the Ce value the faster the cooling rate the higher the tendency for hard brittle phases to form during cooling period of time 2 Ce formula for common low carbon and carbon manganese steels implemented by IIW 4 5 11 The following carbon equivalent has long been used as an index representing the susceptibility to cold cracking or weldability Originally O Neil and Dearden s formula was simplified by ITW subcommission and in the last 25 years it is known as ITW Hydrogen cracking formula and it is valid for steels with low carbon content This CelIW is intended for sing e pass welding 4 The carbon equivalent formula CeIIW is one of the most widely used because it is a good measure of the hardenability for conventional steels This carbon equivalent satisfactorily evaluates weldability whose carbon content is higher than 0 12 CelIW is preferable for common carbon steels and carbon manganese steels while Pem is Iqsim user manual v 2 0 2010 11 30 40 of 45 designed for modern low carbon low alloy steels Steels with a CeIIW greater than 0 4 96 cannot be welded successfully unless precautions are taken In the CelITW formula the alloying elements are heavily weighted compared to carbon as shown below For steels C gt 0 12 0 18 96 C 4 13 CelIW C 96 1 For steels having Si in a significant volume 4 If Si content in the steel is similar to that pre
46. vel configurations are the following iQSim A en Y 10mm _ 30mm 50mm 70mm Al 0mm imm 2mm 3mm 4mm t LLLI II Cap requirements 1SO 5817 2007 Class B e ClassC j Class D b k ium F 1 N Maximum height 1S0 5817 2007 16 9 5 0 2 42 cm 2 1 90 kg m 2 0 3 0 1 You may use the sliders to alter the geometrical data for the joint By moving the sliders back and forth the data will be altered dynamically 2 By selecting the relevant classes for cap requirements Class B Class C or Class D according EN ISO 5617 2005 the maximum cap dimension will be included in the calculation of the cross section and the weld requirements in kg m weld Activate the button by clicking into it The maximum cap height will also be calculated for the cap and root side Special features You may scale the drawing of the welded joint by clicking on the magnification glasses or value You may switch the rulers ON OFF by clicking on the ruler icon amp wers You may switch the dimension lines ON OFF by clicking on the dimension icon Dimensions At the bottom of the canvas you will get information about some of the key data square area of the joint required filler metal per meter weld Main dimension of the joint with in the top bevel and root width Iqsim user manual v 2 0 2010 11 30 18 of 45 maximum height of cap and root according the selected quality level according EN ISO 5617 2005 Grab the pointer on th
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