Ultrasonic impact methods for treatment of welded structures

• US 6,171,415 B1
• Filed: 09/03/1998
• Issued: 01/09/2001
• Est. Priority Date: 09/03/1998
• Status: Expired due to Term

• Current Assignee: Progress Rail Services Corporation (Caterpillar Incorporated)
• Original Assignee: Underground Imaging Technologies LLC
• Inventors: Statnikov, Efim S.
• Primary Examiner(s): WYSZOMIERSKI, GEORGE P
• Application Number:
  US09/145,992
• Time in Patent Office: 859 Days
• Field of Search: 148/585, 148/558, 228/110.1
• US Class Current: 148/525
• CPC Class Codes: B23K 13/00 Welding by high-frequency current heating
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: B23P 9/04 Treating or finishing by hammering or applying repeated pressure
• CPC Class Codes: C21D 10/00 Modifying the physical properties by methods other than heat treatment or deformation
• CPC Class Codes: C21D 2201/00 Treatment for obtaining particular effects
• CPC Class Codes: C21D 7/04 of the surface
• CPC Class Codes: C21D 9/50 for welded joints

Abstract

This invention provides methods of treatment for welded products by pulse impact energy, preferably ultrasonic, at original production, during the active life period for maintenance and after failure in a repair stage to improve the strength at the weld sites and to fashion stress patterns that reduce stress centers and micro-stress defects. The basic method steps are nondestructive in nature, inducing interior pulse compression waves that temporarily plasticize the metal to relax stresses and redistribute stress patterns in a gradient of metallic grain structure between a higher strength substantially grainless white layer at the weld seam to an internal base metal region in the welded body. Thus, a renewed longer life span and higher strength weld joint regions are generated in welded products.

Claims

1. The method of treatment of a welded structure in the vicinity of weld seams for improving life and load bearing strength, comprising the steps of:

applying ultrasonic energy non-destructively without mechanical deformation of said welded structure at a warm external surface area alongside and spaced from a weld seam on said structure being heated by a concurrently used welding arc a multiplicity of shock pulses of a magnitude and sequential relationship to induce internal plasticity in a region below the external surface of the structure, thereby creating a dynamic treatment zone of plastic material adjacent to said weld seam,

inducing by reaction to said shock pulses in said treatment zone a gradient stress pattern between the surface area and a remote location in the welded body with reduced stress concentrations in the vicinity of the surface, and

withdrawing the shock pulses in a manner that freezes said gradient stress pattern in place to produce a welded product with higher fatigue strength and load bearing capacity.

2. The method of claim 1 comprising applying said shock pulses in the form of ultrasonic energy with an ultrasonic transducer in contact with said external surface.

3. The method of claim 2 further comprising treating iron and steel products by the step of creating in the gradient stress pattern at said surface area a substantially grain free layer.

4. The method of claim 1 comprising applying the method in an initial production stage of a welded body product to produce a product with higher fatigue strength and higher load bearing strength.

5. The method of claim 1 comprising applying the method in a maintenance stage in the interim life of a welded product in service to relax residual corrosion stresses and to improve fatigue resistance.

6. The method of claim 1 further comprising detecting a stress concentration zone in said welded body, and applying the shock pulse treatment steps to the stress concentration zone to relax the stress and restructure stress patterns in the welded body for greater load bearing capacity.

7. The method of claim 1 further comprising detecting a catastrophic failure region in the welded body structure, and thereafter welding to repair the catastrophic failure with a weld seam before applying said shock pulses in the vicinity of the catastrophic failure region.

8. The method of treatment of a welded structure in the vicinity of weld seams for improving life and load bearing strength comprising the steps of:

applying to an external surface area in the vicinity of a weld seam on said structure a multiplicity of shock pulses of a magnitude and sequential relationship to induce internal plasticity in a region below the external surface of the structure, thereby creating a dynamic treatment zone of plastic material adjacent to said weld seam,

inducing by reaction to said shock pulses in said treatment zone a gradient stress pattern between the surface area and a remote location in the welded body with reduced stress concentrations in the vicinity of the surface,

withdrawing the shock pulses in a manner that freezes said gradient stress pattern in place to produce a welded product with higher fatigue strength and load bearing capacity,

detection of a catastrophic failure region in the welded body structure and thereafter welding to repair the catastrophic failure with a weld seam before applying said shock pulses in the vicinity of the catastrophic failure region,

wherein the catastrophic failure comprises a visible crack located on the external surface of the welded body further characterized by the step of mechanically chamfering the lips of the crack and thereafter welding to repair the crack.

9. The method of treatment of a welded structure in the vicinity of weld seams for improving life and load bearing strength, comprising the steps of:

applying to an external surface area in the vicinity of a weld seam on said structure a multiplicity of shock pulses of a magnitude and sequential relationship to induce internal plasticity in a region below the external surface of the structure, thereby creating a dynamic treatment zone of plastic material adjacent to said weld seam,

inducing by reaction to said shock pulses in said treatment zone a gradient stress pattern between the surface area and a remote location in the welded body with reduced stress concentrations in the vicinity of the surfaces,

withdrawing the shock pulses in a manner that freezes said gradient stress pattern in place to produce a welded product with higher fatigue strength and load bearing capacity,

detection of a catastrophic failure region in the welded body structure and thereafter welding to repair the catastrophic failure with a weld seam before applying said shock pulses in the vicinity of the catastrophic failure region, and

identifying the end regions of a visible crack located on the external surface of the welded body, and before welding the crack, mechanically drilling small diameter holes in the end regions of the crack for achieving significant reduction in spreading of the crack.

10. The method of claim 9 further comprising the step of mechanically chamfering surface edges of the holes drilled in the end regions of the crack before welding.

11. The method of treatment of a welded structure in the vicinity of weld seams for improving life and load bearing strength, comprising the steps of:

applying to an external surface area in the vicinity of a weld seam on said structure a multiplicity of shock pulses of a magnitude and sequential relationship to induce internal plasticity in a region below the external surface of the structure, thereby creating a dynamic treatment zone of plastic material adjacent to said weld seam,

inducing by reaction to said shock pulses in said treatment zone a gradient stress pattern between the surface area and a remote location in the welded body with reduced stress concentrations in the vicinity of the surface,

withdrawing the shock pulses in a manner that freezes said gradient stress pattern in place to produce a welded product with higher fatigue strength and load bearing capacity,

detection of a catastrophic failure region in the welded body structure and thereafter welding to repair the catastrophic failure with a weld seam before applying said shock pulses in the vicinity of the catastrophic failure region, and

welding on the surface area a bracing member adjacent the crack before applying said shock pulses about a weld seam of the bracing member.

12. The ultrasonic impact treatment of a welded metallic product displaying a weld seam and characterized by internal metallic grain structure to reduce internal metal stress patterns within said grain structure thereby to produce a product with high fatigue resistance and high load bearing strength, comprising in combination the steps of:

reducing internal stresses of a welded body by applying near to but spaced from said weld seam a source of ultrasonic impact energy,

contacting an external surface of the product with a set of striking needles driven by an ultrasonic transducer emitting head,

introducing ultrasound compression wave energy into said product with said emitting head set of striking needles of a frequency and magnitude for temporarily plasticizing an internal region of the product remote from the weld seam and concurrently with welding of the seam to relax residual stress tensions in said metallic grain structure, and

removing the ultrasound compression energy to thereby retain a zone wherein the relaxed stress tensions are exhibited by reduced grain structure in said internal region.

13. The ultrasonic impact treatment of a welded metallic product displaying a weld seam and characterized by internal metallic grain structure to reduce internal metal stress patterns within said grain structure thereby to produce a product with high fatigue resistance and high load bearing strength, comprising in combination the steps of:

reducing internal stresses of a welded body by contacting near said weld seam an ultrasonic transducer emitting head having a set of striking needles with an external product surface,

non-destructively introducing ultrasound compression wave energy into said product with said emitting head of a frequency and magnitude for temporarily plasticizing a subsurface region of the product extending under the external product surface to relax residual stress tensions in said metallic grain structure,

removing the ultrasound compression energy to thereby retain a zone wherein the relaxed stress tensions are exhibited by reduced grain structure in said internal region.

14. The method of removing stress defects formed in a welded metal product, comprising in combination the steps of:

eliminating internal stress micro-damage to metal grain structure by applying ultrasonic impact energy to an external surface of the metal product at a frequency and magnitude extending compression waves internally into the welded product metal from an ultrasonic transducer site in the vicinity of and spaced from a weld seam without incurring substantial surface deformation to create a temporary internal plasticized region relaxing said stress micro-damage, and

withdrawing the ultrasonic energy gradually from said transducer site to establish in said region a frozen stress gradient pattern between the weld seam and a base point in the welded product metal having lower internal stress exhibited in the vicinity of the external surface.

15. The ultrasonic impact method of treating a welded metal product concurrently with a welding step forming a welded seam to increase its load bearing life and strength, comprising in combination, the steps of:

inducing at an outer surface site of said welded metal product ultrasonic compression wave energy at an internal product site in the vicinity of said welded seam at a temperature substantially cooler than molten metal,

establishing a wave energy frequency and magnitude creating by said ultrasonic compression wave energy a temporary plasticity zone internally in the metal product serving to rearrange crystalline structure of the welded metal product into a pattern of smaller grain structure near the weld seam increasing gradually in grain size as a function of distance from the weld seam to match the residual grain structure of the product metal at a base metal body location spaced from the welded seam, and

decreasing the internal ultrasonic wave energy magnitude in a manner establishing a fixed gradient grain pattern with substantially a grain free layer near said outer surface site.