Welding Research Institute

PUBLICATION

2023
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Investigation of Longitudinal Bending Distortion of a DoubleSided Edge Welded Fin Plate by Study of Plastic Zones	V. Sudharsanam, C. Sathiya Narayanan, B. Shanmugarajan and L. Prakash	Archives of Civil and Mechanical Engineering, Elseveir, Vol. 23, Article number: 88
2	Microstructural Characterization of Cold Bent and Subsequent Thermal Aged Inconel Alloy 617	G Vimalan	Transactions of the Indian Institute of Metals (TIIM) volume 76, pages 3105–3114
3	Finite element simulation of feedback-controlled, resistance-based local heating – A closer prediction	L Prakash, K R Balasubramanian, G Sankar & V Sudharsanam	Sadhana, a springer journal, Vol 48 – No 193
4	Failure analysis of High Strength Friction Grip (HSFG) bolt used in the thermal power plant	G Vimalan and R Senthil Murugan	Transactions of the Indian Institute of Metals, volume 76, pages 1593–1603
2022
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Finite Element Simulation of Edge Welding in a Fin Plate: A Study Incorporating Experimental Measurement of Input Factors	V. Sudharsanam, C. Sathiya Narayanan, B. Shanmugarajan and L. Prakash	Archives of Civil and Mechanical Engineering, Elsevier, Vol.22.Article 208
2	Optimization of process parameters for the A-TIG welding of Inconel 617 using particle swarm optimization and genetic algorithm.	S. Senthil kumaar, Nanda naik korra, k. Devakumaran and k. Ganesh kumar	Surface Review and Letters, Vol.29. No 10

2019
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Effect of Shielding Gases in Autogenous Laser Welding of P92 Material	B. Shanmugarajan, P. Sathiya and G. Buvanashekaran	Transactions of the Indian Institute of Metals, Vol.72

2018
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	“Construction of continuous cooling transformation (CCT) diagram using Gleeble for coarse grained heat affected zone of SA106 grade B steel”	G. Vimalan, Muthupandi, and Ravichandran V. G.	AIP Conference Proceeding (020013) 1-6, May 2018. Doi: 10.1063/1.50386, 92 s,
2	Comparison of response surface methodology and genetic algorithm in parameter optimization of laser welding process	K. Vijayan, P. Ranjjithkumar and B. Shanmugarajan	Applied Mathematics & Information Sciences, Vol.12

2017
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Studies on hot cracking susceptibility and establishment of welding procedure of austenitic stainless steel grade UNS S31035 for power plant application	Ravibharath Rajanbabu, Muthupandi Veerappan, Ravichandran Ganesan, Easwaran Ramakrishna iyer	Transactions of the Indian Institute of Metals. 70(3), 721-727 22 February 2017 DOI: 10.1007/s12666-017-1077-y
2	Phase transformation behaviour in P91 during post weld heat treatment: A Gleeble study	G. Vimalan, Ravichandran and Muthupandi G. V.	Transactions of the Indian Institute of Metals. Volume 70, Issue 3, pp 875–885
3	Study of Dissimilar Header Welding Between 2.25Cr– 1Mo Steel and 9Cr–1Mo Steel with 9018 B9 Electrode Under Various Conditions of Post Weld Heat Treatment	Abdur Rahman Sultan, R. Ravibharath, R. Narayanasamy	Transactions of the Indian Institute of Metals 02 January 2017 DOI: 10.1007/s12666- 016-1029-y
4	Metallurgical Study of Stellite 6 Cladding on 30916L Stainless Steel	Mohammed Mohaideen Ferozhkhan, Kottaimathan Ganesh Kumar, Rajanbabu Ravibharath	Arabian Journal for Science and Engineering, March 2017, DOI 10.1007/s13369-017-2457-7

2016
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Plasma Transferred Arc Welding of Stellite 6 Alloy on Stainless Steel for Wear Resistance	Mohammed Mohaideen Ferozhkhana, Muthukannan Duraiselvam, Kottaimathan Ganesh kumar, Rajanbabu Ravibharath	Procedia Technology, 25 ( 2016 ) 1305 – 1311
2	Optimisation of Laser Welding Parameters for Welding of P92 Material using Taguchi Based Grey Relational analysis	B. Shanmugarajan, P. Sathiya and G. Buvanashekaran	Defence Technology, Vol. 12 Issue No. 4
3	Mechanical and Metallurgical Properties of Autogenous Laser Welded P92 Material	B. Shanmugarajan, P. Sathiya and G. Buvanashekaran	Journal of Manufacturing Processes, Vol.24, Part 1

2015
SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Development and evaluation of SUS 304H — IN 617 welds for advanced ultrasupercritical boiler applications	A.H.V. Payan, K S N Vikrant, R. Ravibharath, Kuivir Singh	Materials Science & Engineering A, 642 (2015) 32 - 41
2	Creep-rupture behavior of SUS 304H – IN 617 dissimilar metal welds for AUSC boiler applications	A H V Pavan1, R Ravibharath and Kulvir Singh	Materials Science Forum , 830-831 (2015) pp 199-202
3	Welding and Heat Treatment Behaviour of T23 (2.25Cr-1.6W-V-Nb) Steel Tubes in Power Plant Applications	R. Easwaran, G. Vimalan, R. Ravibharath, P. Sundaramoorthy, N. Raju, G. Ravichandran,	Frontiers in Materials Processing, Applications, Research and Technology, pp 179-190
	Application of Integrated Soft Computing Techniques for Optimisation of Hybrid CO₂ Laser-MIG Welding process	Sudipto Chaki, B. Shanmugarajan, Sujit Ghosal and G. Padmanabham	Applied Soft Computing, Vol. 30

2014

SL. NO.

TITLE OF THE PAPER

AUTHOR

PUBLICATION

Effect of focal position on CO₂ laser beam welded AlMg-Mn alloy

K. Subbaiah, M. Geetha, B. Shanmugarajan and SR. Koteswara Rao

International Journal of

Advanced Engineering Research, Vol. 8

2013

SL. NO.

TITLE OF THE PAPER

AUTHOR

PUBLICATION

Studies on Autogenous Laser Welding of Type 304B4 Borated Stainless Steel

B. Shanmugarajan, J.N. Chary, G. Padmanabham, B. Arivazhagan, S.K. Albert and A. K. Bhaduri

Optics and Lasers in Engineering Vol. 51, Issue No.11, 2013

Metallurgical analysis of SA-106 Gr. B pipe failure during hot bending,

A.H.V. Pavan, K.S.N. Vikrant, G. Vimalan, Kulvir Singh

Case Studies in Engineering Failure Analysis, Volume 1 – Issue 2, Page 120-130, 2013

Shielding Gas Effect on Weld Characteristics in Arc Augmented Laser Welding Process of Super Austenitic Stainless Steel

P. Sathiya, Mahendra Kumar Mishra, R. Soundararajan and B. Shanmugarajan

Optics & Laser Technology, Vol.45, 2023

Power Beam Processing of Stainless Steels

B. Shanmugarajan and G. Buvanashekaran

Advanced Materials Research, Vol. 794

Creep Failures in Laser Welded 316L (N) Stainless Steel Joints

DH Kumar, T. Sakthivel, MN. Gopal, SK. Albert, Hemanth Kumar, B. Shanmugarajan and A. Somi Reddy

Journal of Materials Science Research, Vol. 2, Issue No. 1

Effect of welding speed on CO2 laser beam welded aluminum-magnesium alloy 5083 in H321 condition

K. Subbaiah, G. Manivasagam, B. Shanmugarajan and SR Rao

Advanced Materials Research, Vol. 685

Laser Based Joining of Metallic and Non Metallic

Materials

G. Padmanabham and B. Shanmugarajan

Laser Assisted Fabrication of Materials – Springer Series in Materials Science, volume 161)

Application of submerged arc welding technology with cold wire addition for drum shell long seam butt welds of pressure vessel components

Mr. M. Ramakrishnan
Mr. V. Muthupandi

The International Journal of Advance Welding technology, Volume 65 2013

Studies on fracture toughness of cold wire addition in narrow groove SAW process

Mr. M. Ramakrishnan
Mr. K. Padmanaban
Mr. V. Muthupandi

The International Journal of Advance Welding technology, Volume 68 2013

Analysis of angular Deformation in a full penetration Un-symmetrical Tee Joint

Dr. N. Raju
Dr. S. Suresh
Mr. D. Davidson Jebaseelan
Dr. A. Ramakalyan

Journal of Manufacturing Engineering, Technical University of Kosice, Slovakia
2009

Prediction of Longitudinal Distortion in Tubular Structures using Statistical Analysis

Dr. N. Raju

7th Asia Pacific International Congress-Singapore
IIW 2013

Dry Sliding Wear of laserHardened Low Alloy Steel at Room and Elevated Temperatures

P Dinesh Babu,
Dr. G. Buvanashekaran
K R Balasubramanian

InternationalJournal of Engineering Tribology

Weld defect to signature correlation in pulsed GMAW process

Mrs. A. Santhakumari

JWRI-INDO workshop 2013, Osaka, Japan

Plasma welding studies on Aluminium and high temperature materials

Mr.B.Shanmugarajan

JWRI-INDO workshop 2013, Osaka, Japan.

2012

SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Laser welding studies on P91 steel	Mr. B. Shanmugarajan Mr. G. Padmanabham Dr. G. Bhuvanasekaran	SOJOM 2012
The weldability issues in P91 steels are high air hardenability leading to hard martensitic microstructures, formation of δ- ferrite in the fusion zone (FZ) which can reduce the creep properties, hydrogen embrittlement due to hard HAZ and formation of inter-critical zone (ICZ) away from the FZ leading to creep failure in service. Laser welding due to its concentrated nature and low heat input can reduce the size of HAZ and more amenable to effective shielding which can be useful in reducing hydrogen induced cracking. The effect of parameters like laser power density, heat input, shielding gas and focal position were studied in detail and reported.
2	Friction stir welding of Copper: WRI Experience	Mr.Dileep K. Gupta Mr. Lucky Gaur Mrs.A. Santhakumari Mr.N. Rajasekaran Dr. K. Asokkumar Dr. A. Raja	SOJOM 2012
Copper which has much higher thermal diffusivity than steel cannot easily be welded by conventional fusion welding techniques. Friction stir welding technique was successfully applied to the butt joining of pure copper plates of 6 mm thickness. The welds were developed in square butt joint configuration with the fixtures designed and fabricated in-house. Parameters are established for setting defect free welds.
3	Effect of varying process parameterson weld quality of activated TIG welding for tube to tube joint	Mr. Dhanesh K Verma Dr. A. Raja Mr. N. Rajasekaran Mrs. A. Santhakumari Mr.A. Ananda	SOJOM 2012
In this work, the effect of parameters on penetration in ATIG welding has been discussed based on the experimental results on 7 mm thick tube welds. This work also explores the ATIG welding process for improving the weld penetration depth and productivity for carbon steel and low alloy steel tube materials. It was found that the consistent quality, simpler edge preparation, reduced distortion and improved productivity make ATIG welding process more attractive than the conventional TIG process in tube welding.
4	Automation and robotics: Emerging trends	Dr. A. Raja	SOJOM 2012
The automation of arc welding processes like GMAW, SAW, GTAW, PTA, FCAWimproves the operator factor and permits higher welding currents and speeds to be used thereby enabling significantly higher productivity besides consistent weld quality. Mechanical systems can travel at higher speeds, can use much higher currents and can be more uniform in travel speed. All these help increase productivity and quality. Automation is also sought after when jobs involve inconvenient welding positions or the material to be welded is hazardous.
5	Analysis of thermal effects in welding using finite element method	Dr. G. Ravichandran	SOJOM 2012
Case studies for the thermal analysis include study of thermal cycles in a dissimilar plate weldment between carbon steel and stainless steel, pulsed current welding and laser beam welding have been carried. The analyses have used in plane two dimensional finite element model as the plate thickness in all the cases is less and the temperature gradient in the thickness direction can be neglected. The case studies for the elastic plastic analysis include the study of axis shift distortion in a circumferentially welded pipe, residual stress build up in a dissimilar weldment and distortion and residual stresses in a stitch welded plate. For the analysis, plane stress elements and degenerated shell elements have been employed.
6	Analysis and control of welding distortion during fabrication of a large welded structure	Dr. N. Raju Dr. S. Suresh	SOJOM 2012
By employing an optimum welding sequence or other distortion controlling methods, the welding distortion can be kept to an acceptable level so that the fabrication cost can be considerably reduced. To arrive at the appropriate control method an in-depth analysis of the component and the factors that affect the distortion is essential.
7	Characteristics and performance of different types of GMAW power sources	Dr.P.R. Venkateswaran Dr.K. Devakumaran Dr.G. Buvanashekaran Dr. A. Raja	SOJOM 2012
It is often found that during dynamic operating conditions, especially in welding of high creep strength materials, the power source shows large variation of current and voltage. The deviation from the rated values of electrical parameters exceeding critical limits results in poor weld bead appearance, porosity, more spatter and fumes. The performance of the power source has been evaluated with respect to the variation of current and voltage under different wire feed rate. The data is analysed for identification of optimum working range of current and voltage with reference to less spatter and porosity as well as good weld bead appearance.
8	Weldments of S-ten material,their metallurgical properties and corrosion behaviour	Dr.R.Nagalakshmi Mr. R. Ravibharath Mr.S.Manimozhi Dr. S.Suresh	SOJOM 2012
S-TEN, a corrosion resistant steel which is widely used in flue gas treating equipment such as air pre heaters, smoke stacks and ducts as a counter measure for low temperature corrosion caused by acidic oxides. The steel has excellent corrosion resistance at waste incinerating facilities, where acid dew corrosion resulting from lower temperature waste gas, is anticipated. S-TEN material is a high-quality, economical steel material having such high corrosion resistance and produced under the same quality control as that for power station boiler tubes.
9	Feasibility studies on the application of waveform controlled submerged arc welding of low carbon steel pressure vessels	Mr.K. Ganesh Kumar Mr. M. Kayarohanam Mr.M. Ramakrishnan Dr. G. Buvanasekaran	SOJOM 2012
Introduction of highly efficient variable AC square wave controlled SAW power sources will allow full control of wave shape by varying in balance, offset and frequency of input power characteristics. The present investigation weldability of a low carbon steel plates having thickness of 16, 25, 50 mm has been studied by using full SAW process (Root and Subsequent passes). Because of the multilayer, in 50 mm thick plate the weld metal microstructure has been found comparatively finer with more reheat refinement than 16 mm and 25 mm thick plates, with improved properties.
10	Establishment of narrow gap submerged arc welding technology for highpressure joints	Mr.M.Ramakrishnan Dr.G.Buvanashekaran Mr.AjyaAsalkar	SOJOM 2012
Narrow gap provides an increase in productivity without an accompanying increase in heat input. It also provides a finer grain structure and narrow heat affected zone than conventional submerged arc welding. NDT testing like, ultrasonic and radiographic inspections were conducted to assess the narrow gap welds in addition to destructive testing like all weld tensile test, transverse tensile test, charp V-notch impacts, side, root, face bends and hardness surveys. This paper describes the experimental work carried out to study the effect of NGSAW process parameters on the weld and metallurgical property of thick section welds using SA 299 material
11	NDE of welds - Present and Future	Mr.N.Dhanasekaran Dr. S. Suresh	SOJOM 2012
The popularity which NDT methods have earned recently has inadvertently made them emerge as an integral part of various fields. Extremely beneficial for evaluating product and material quality, researching and troubleshooting, the biggest advantage NDT methods offer is, they do not affect the object that is being tested in even a slight manner. The paper provides an overview of emerging trends in NDT, emerging techniques, recent developments in the fields of ultrasonic testing, eddy current testing, surface inspection, visual inspection, radiographic inspection and many more.
12	Metallographic Characterisation on Weldments of Dissimilar Welds between AISI 347 and Haynes 230	Mr.R. Ravibharath Mr.K. Ganesh kumar Mr.AHV Pavan Mr.S. Manimozhi	SOJOM 2012
In this work, the microstructure of dissimilar welds between AISI 304L austenitic stainless steel to Haynes 230 was investigatedfor use in ultra super critical boilers. The welds were produced by gas tungsten arc welding using two different types of filler materials of nickel based alloys designated as ER NiCrCoMo-1 and ER NiCrMo-3. The interfaces and heat-affected zones were characterized by optical and scanning electron microscopy. The dilution effect of dissimilar joints is studied using micro hardness testing and energy dispersive spectroscopy.
13	Analysis of angular distortion in header to nipple welding	Mr.R.VetriSelvan Mr. V. Sudharsanam Dr.N.Raju Dr.G.Ravichandran Dr.S.Suresh
In this work, the effect of welding sequence on angular distortion in circumferentially welded t joint is studied. Two sequences were considered for the analysis. One is half circumferential welding and other is full circumferential welding. The small size header and its nipple welding is analysed for root welding by FEM using commercially available SYSWELD software.
14	Thermo mechanical simulation and metallurgical investigation in SA 106 grade B pipe that failed during hot bending operation	Mr.G.Vimalan, Mr.S.Manimozhi Mr. A.K. DhanuBharath Mr. AHV Pavan	SOJOM 2012
During the incremental pipe bending operation in shop SA106 Grade B pipe cracked in the extrados surface at the bending temperature of 900°C. Hot ductility characteristic of a material is a critical factor in assessing the cracking tendency during the fabrication. Hot tensile was carried out using Gleeble Thermo mechanical simulator to calculate the % reduction in area. The %RA was measured for different hot working temperatures from 800-1000°C after the completion of hot tensile test. The stress- strain curves for different hot working temperatures from the cracked and non-cracked pipe materials were plotted.
15	Experimental studies on the influence of post weld heat treatment on the magnetic coercivity of welds of boiler grade ferromagnetic materials	Mr.V.Sudharsanam Mr. Vikas Srivastav Dr. N. Raju Mr.R. Vetriselvan	SOJOM 2012
In this study, the magnetic coercive force of weldments of three select boiler grade materials were measured using a portable device called as magnetic structurescope. Subsequently, the welds of each grade of material were subjected to different heat treatment cycles including the standard cycle prescribed by ASME Sec VIII and other variations involving decreased soaking time, increased soaking time and lower soaking temperature. It was observed that heat treatment of welds resulted in a decrease in coercivity and the extent of decrease depended on the proper heat treatment conditions.
16	Analysis and evaluation of stability of flux cored wire using Analysator Hannover	Mrs.A. Santhakumari Prof. Dr.-Ing. habil. D. Rehfeldt Dr. K. Asokkumar Dr. A. Raja Mr.C.P. Ravichandran Mr. N. Rajasekaran	IWS 2012
This paper discusses about the introduction of a statistical quality control system for welding consumable analysis and a statistical method to study the inhomogeneity of the flux distribution in flux cored wires. This paper envisages the use of ANALYSATOR HANNOVER as an instrumentation tool to carry out significant analysis on the stability criteria of the FCAW wires by Probability Density Distributions (PDD) of the welding voltage and welding current measurements.
17	The Role of Iron Powder Additions in SMAW Electrode Coatings	Mr.C.P. Ravichandran Dr. A. Raja Mr.T.S Sekar	IWS 2012
Iron powder is commonly added to the coatings of many types of SMAW electrodes. Such additions have a high influence on the characteristics like deposition rate, arc behavior, arc stability, oxygen content in the weld pool thereby changing the weld pool chemistry and thus the micro-structure. This paper examines the role of iron powder additions to various types of electrode coatings and analyses the net result in terms of parameters listed above.
18	Prediction of Weld Bead Geometry in Modified Waveform Control Root Pass Welding Using Factorial Design Approach	Mr.Dhanesh K Verma Mr. N Rajasekaran Mrs. A Santhakumari Dr.A Raja Mr. P. Vignesh	IWS 2012
This paper present a study on optimization of process parameter using response surface methodology to optimize the root pass welding of pipe to pipe joint using MODIFIED WAVEFORM CONTROL-GMAW process and the validity of the model was further confirmed by plotting scattered diagram using DOE++ software. Experiments were conducted based on design of matrix and mathematical models were developed correlating the important controllable MODIFIED WAVEFORM CONTROL process parameter like Peak current, welding speed, torch angle and tail out with frond width, back penetration and back width.
19	Welding Technology Development for Shipbuilding- WRI’s Contributions	Dr. A. Raja Mr.N.Rajasekaran Mr.R. Easwaran	IWS 2012
Shipbuilding requires high performance welding process to enhance the productivity and robust mechanized welding system to ensure quality and integrity of the welds produced. Semi-automatic processes such as CO2 welding and flux cored arc welding are well established for a long time. Simple automation using linear track mounted welding carriages equipped with GMAW or FCAW are widely used. Tandem GMAW is one high performance process which could help in further increase the productivity when integrated with the track mounted carriage or robot system. Similarly the electrogas welding, not a stranger to shipbuilding, also a high productive process needs to be custom-built to make it user friendly for shipyard use.
20	SAW weld geometry prediction using artificial neural networks	Dr. P.R. Venkateswaran Dr. G. Buvanashekaran K. Ganesh Kumar Mr. KrishnaiahJallu	IWS 2012
The relation between input and output parameters is of interest because it can help to predict operator’s settings for desired operation. Artificial Neural Network (ANN) is considered for modeling the relation between the parameters for prediction. Experimental data from SAW is taken and trained using ANN and then tested for prediction. The outputs are validated through theoretical understanding and then predictions are further experimentally verified. ANN Sensitivity tool is applied to realize the interdependence of process parameters on weld geometry.
21	Corrosion behaviour of AISI 310 and its conventional and pulsed GMAW weldments	Dr. R. Nagalakshmi Dr.K. Devakumaran Mr.Arunkumar Dr.S. Muthukumaran	IWS 2012
Present study includes the corrosion properties of SS 310 under SMAW, P-GMAW and DP-GMAW processes. In the present experiment the base metal and weld metals are cut separately and are suspended in to the corrosion medium 3.5% NaCl, 1% KOH and 1% HCl solution. The weight losses are measured regularly, corrosion rates are calculated as per ASTM G 31.Weld metal corrosion testing are performed in a Gill AC Weld corrosion analyser.
22	Experimental study on the selection of optimum pin length for friction stir welding of butt, “T” and lap joints	Mrs.A.Santhakumari Mr. Lucky Gaur Dr. K. Padmanaban Dr. A Raja Mr. N. Rajasekaran	IWS 2012
This paper describes the studies undertaken by WRI for an approach towards optimal selection of tool pin length with appropriate tool geometry and its associated plasticized zone characteristics and process parameters of FSW joints on hidden surfaces. It is an attempt to establish trends between the weld characteristics and the additional plasticized zone occurred below the tool pin during FSW. Further this study has been applied for welding of butt joint, “T” joint and lap joints using optimum tool pin length.
23	Evaluation of fracture toughness of thick section welds made with cold wire addition in narrow groove submerged arc welding process	Mr.M.Ramakrishnan Dr.G.Buvanashekaran Mr.R.Easwaran Dr.V. Muthupandi	IWS 2012
In this paper the comparative analysis of mechanical properties of conventional groove SAW and narrow groove SAW with cold wire addition has been presented. The evaluation of notch toughness and crack tip opening displacement for the two cases shows that the addition of cold wire improves the toughness by 40%. The details of the experimental work on the two cases and the results of the mechanical properties including CTOD are presented in this paper.
24	Automation with GMAW techniques: WRI’s experience	Mr. N. Rajasekaran Mr. Sushant Sharma Mr.Dhanesh K Verma Mrs.A. Santhakumari Dr. A. Raja	IWS 2012
The advent of the cost effectiveness electronic power sources has enabled additional process improvements to be made to the functionality and ease of operation of GMAW. The GMAW currently represents a widespread welding procedure, which applies to several industrial fields. This is due to the advantages presented by this welding procedure (high productivity, high quality link, various opportunities for its mechanisation or turning it robotic), high accessibility and easy to automatize / robotise
25	Investigations on the effect of post weld heat treatment on magnetic coercivity of SA106 gr C boiler grade steel using design of experiments	Mr. V. Sudharsanam Dr. N Raju Mr. K.Vinoadh Kumar Mr. R.Vetriselvan Dr. V Senthil Kumar	IWS 2012
In this study, an attempt is made to characterize the changes happening in the coercivity of welds of SA 106 Gr. C material vis-à-vis different post-weld heat treatment (PWHT) cycles. The Design of Experiments (DOE) method was adopted in designing and executing these PWHT cycles. It was found that magnetic coercivity reduced after heat treatment and the extent of reduction depended on the PWHT parameters viz. the soaking temperature and soaking time. A functional relationship was brought between the percentage change in MCF and the PWHT parameters.
26	Welding technology for boiler manufacturing	Mr. N. Rajasekaran Dr. A. Raja Mr. R. Easwaran	Steam & Boiler Review 2012
In the developing economies, the trend of growing energy demand is present and this growth will continue in the following decades. By many estimates, it is expected that thermal power plants will play a crucial role in satisfying increasing energy demands, for several decades ahead. Therefore, new materials and high efficiency welding processes are expected to develop tremendously and be applied more extensively for improved productivity. This paper is an attempt to showcase the developments in welding, that has taken place, in joining of boiler components.

2011

SL. NO.	TITLE OF THE PAPER	AUTHOR	PUBLICATION
1	Effect of Alternating Shielding Gases on weld metal properties in GMAW	Dr. A. Raja	IIW 2011
Alternating shielding gases GMAW is a new technology that supplies two different shielding gases viz. Argon and CO2 in the weld zone alternatively instead of the current method of using premixed shielding gas like 80%Ar+20%CO2. The improved weld quality is attributed to the periodically varying weld-pool dynamics caused by the alternating shielding gases. The arc varied significantly during the switching from argon to carbon dioxide giving the molten weld pool a vigorous stirring effect. This vigorous stirring has other potential benefits to the weld as it can lower the amount of porosity, gives a finer microstructure, and gives more even distribution of the weld bead.
2	Analysis of longitudinal distortion in tubular structures	Dr. N. Raju Dr. S. Suresh	IIW 2011
The factors like rigidity of the component, number of welds planned around neutral axis, number of weld passes, heat input etc play a vital role in designing a suitable weld sequence for a given structure. In this article, a study has been taken up to evaluate the influence of weld sequence on longitudinal bending distortion in panel type of structures. The study involves experimental trials and collection of data by varying three parameters namely; MI, heat input and welding sequence.
3	Analysis of fumes generated with GMAW process	Dr. N.Nagalakshmi Dr. S. Suresh Dr. S. Dharmalingam	IIW 2011
A model for GMAW (DC electrode positive) is proposed based on process parameters, (current, wire feed rate and wire composition) the surface area of molten metal in the arc and the partial vapour pressures of component metals of an alloy wire. The fume formation rate increases with increasing the current at a constant wire feed rate, while increasing the wire feed rate for the same current the fume formation rate decreased. Fume formation rate is found to be decreased at the lower droplet temperature and lower droplet surface area.
4	Finite element based prediction and analysis of angular distortion in Stainless steel T joint	Mr. R.Vetriselvan Dr. N. Raju Dr. S. Suresh	IIW 2011
A double side welded tee joint model has been considered for the study. The effect of welding sequence on angular distortion has been studied with a three dimensional thermo-mechanical model. The study deals with effect of weld sequence on the angular distortion of the Tee joint. Numerical simulation of the tee joint model for three sequences was carried out using commercially available finite element based SYSWELD software. The effect of Tack welding, Filler metal shrinkage, Welding sequence, Heat input, and Material properties on angular distortion was investigated. The study shows that the stainless steel produces higher angular distortion than carbon steel.
5	Evaluation of the activated TIG welding process for Fossil boiler tube applications	Dr. A. Raja Dr. K.AsokKumar Mr. N. Rajasekaran	IIW 2011
A-TIG welding process involves application of a thin coating of activating flux material on the joint surface prior to welding to enhance the weld penetration. The flux constricts the arc which increases the current density at the anode root and the arc force on the weld pool. Though A-TIG welding offers higher productivity, industry has been slow in exploiting this process. This work also explores the A-TIG welding process for improving the weld penetration depth and productivity for carbon steel and low alloy steel tube materials.
6	Influence of Ti-b microalloying additions on sub-zero notch-toughness of AWS E7018 electrode all-weld metal deposits	Mr. C.P.Ravichandran	IIW 2011
AWS E 7018 electrodes are tested at minus 30C for CVN impact properties. Experimental electrodes were designed and tested through a factorial testing method to understand the influence of simultaneous micro-alloying additions of titanium and boron on the CVN impact properties of all weld metal at minus 30C. The results show that Ti and B show a synergistic effect. The results are explained on the basis of nucleation and growth of acicular ferrite.
7	Investigations on electron beam welding of high thickness AA2219 aluminium alloy	Dr. G.Bhuvanashekaran Dr. S. Manoharan	IIW 2011
Aluminium alloy AA2219 is a binary Al-Cu heat treatable alloy. Absence of Mg is a significant factor contributing the good fusion welding characteristics. In this study, experiments were conducted to analyse the effects of input parameters like beam current, acceleration voltage and welding speed on bead geometry using 100mm thick AA2219 Al alloy plate samples. Results were analysed to study the effect of input parameters on depth of penetration. Using the results, 80mm thick plates were EB welded for studying the mechanical and metallurgical properties of the welded joint.
8	Failure analysis of aluminium oil cooler as per ASME code	Dr. G.Ravichandran Dr. S. Suresh	IIW 2011
Investigation on the premature failure of aluminium oil cooler was taken up to study the root cause of failure. The investigation revealed that the failure was in the weld after the cooler had been put into service. To determine the stress distribution in the fillet weld, finite element method was employed. One quarter of the oil cooler was considered for analysis with 10 nodded tetrahedral elements The reported fatigue lives for the component were found to lie between lower 68% prediction interval (mean - 1s) and upper 95% prediction interval (mean + 2s).
9	Laser surface transformation hardening on medium carbon steel using high power laser beam	Dr. G.Bhuvanashekaran Dr. S. Manoharan	IIW 2011
In this study, EN8 grade is surface transformation hardened using a 2KW CW Nd:YAG laser source with line beam configuration. The effect of scanning speed and the beam power is optimized to obtain an acceptable hardened layer using single track beads. Also, multi tracks were laid to study the microhardness and the depth of hardened layer in relation to the beam parameter and scanning speed. No under-bead bead cracking was observed in the overlap zone / back tempered region and the structural integrity is not affected due to laying of second / adjacent pass
10	Investigations on MIAB welding of high wall thickness tubes for economizer coil welding	Dr. G.Bhuvanashekaran Dr. S. Manoharan	IIW 2011
Experiments were conducted to establish the MIAB welding technology for welding of high wall thickness tubes ranging from 4 to 6.5mm and having weld surface area of maximum 1100 sq.mm. Axial offset between tubes was varied from 0.25 to 2.00mm in steps of 0.25mm and the angular offset was varied from 1 to 5 deg in steps of 1. The results show that axial offset up to 1.5mm passes tensile and bend tests, whereas 2.0mm axial offset resulted in failure in weld line with 20% reduction in UTS values. However, 2.0mm axial offset passes root and face bend tests. The angular offset up to 5deg passes tensile and bends tests.
11	Resistance projection welding of tube to sheet welding application	Dr. K..Asokkumar Mr. Lucky Gaur Mr. Dileep K Gupta Mrs. A Santhakumari	IIW 2011
The suitably shaped electrodes to concentrate a localized mechanical force and current to join tube to sheet metal assemblies in the machine. It compresses the fold against the tube in a resistance welding machine and passes current through them. The electrodes are designed to permit relative motion between the parts welded while they are hot, at temperatures close to the melting temperatures of the parts welded. The welding procedure establishment for the tube to sheet welding using the LPI test, macrosection and tensile test as the evaluation criteria were carried.
12	Studies on resistivity measurement approach for evaluation of resistance spot welded joints : case study	Dr. K.AsokKumar Mr. Lucky Gaur Mr. N. Rajasekaran	IIW 2011
In the present work an attempt has been made to study the effect of weld time, weld current on the resistivity property value using a specialized resistivity measurement system based four point probes available. The carbon steel sheet of thickness of 1.6 mm is used for evaluation and two applications were studied for its applicability.
13	Evaluation of structural integrity of repaired dynamically loaded engineering components	Dr. N. Raju Dr. S. Suresh	Commission XIII
The Moving beam of an 8000 Ton press had cracked during cold correction operation of a half shell of boiler drum of thickness 210 mm. A through crack was found to run vertically from the intersection point of the top flange towards the bottom flange at an angle of around 35 to 40 degree to the vertical. A detailed analysis and exhaustive investigation followed by meticulous repair procedure was drafted and implemented.
14	Analysis and control of distortion during fabrication of a large structure made of Austenitic stainless steel	Dr. N Raju Dr. S. Suresh Mr. M. Madhappan Mr. V. Raghavendran	CWS 2011
In industrial boilers a critical component by name Vortex finder is employed inside the cyclone separator. Most of joints are Tee-joints with fillet welds in this structure. During fabrication of this assembly, the angular tilt, local waviness and the diameter variation were the major issues. Since the structure is made of special grade Austenitic stainless steel to with stand high temperature, the structure is more vulnerable for deformation. This calls for control of distortion while fabrication itself. This paper deals with designing and implementation of suitable weld sequence to fabricate the vortex assembly to control distortion.
15	Abrasive water jet processing – a new alternative for shaping engineering materials	Mr.V Sudharsanam Dr. N. Raju Dr. S. Suresh	CWS 2011
This article presents the application studies carried out using abrasive water jet machining. In the first study the method of application of AWJ for manufacturing the constant load hanger components (CLH) of power plants and substitution of conventional chain of processes. The second study deals with application study of the technology to machine the components for primary air and forced draught fans for power plant application. In the third study a techno-economic comparison was carried out to analyse the cost effectiveness and the relative merits of this process over the conventional processes in case of machining stainless steel flanges and other components for power plant applications.

Welding Research Institute

Bharat Heavy Electricals Limited

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Tamil Nadu, India

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