flawless fusion in less than 60 seconds over similar or
TRANSCRIPT
Flawless Fusion in less than 60 seconds over
similar or dissimilar material
Paul Cheng
FuseRing
Adrian P. Gerlich Associate Professor
Director, Centre for Advanced Materials Joining
Mechanical and Mechatronics Engineering
University of Waterloo
Samples - SPinduction
Conventional technologies for welding pipe with stick or wire has been around for a
long time.
There is a new technology called Solid State Fusion and FuseRing that uses no filler,
one shot, flawless in less than 60 seconds. This process produces no fumes. No
particulates.
It can be scaled 2” to 48” with global applications – pipeline, refinery, nuclear, ships
and submarines.
This new technology could revolutionize the way pipes are ‘welded’ around the world.
Objective of welding – cross section. No filler
Objective of welding – grain flow
Objective of welding - microstructure
Objective of welding – hardness mapping
Objective of welding – X Ray
Objective of welding
Objective of welding
Objective of welding
7 out of 7, all good
Today’s technology across stick or autogenous welds have some common
characteristics.
1 mm at a time.
A beginning and an end.
Time and Uncertainty.
Whether Orbital, High Energy, inside or outside; we have HAZ.
Orbital GTAW, a fusion
technology that does not require
a filler; reduce fabrication costs
for ship piping systems. https://ewi.org/autogenous-orbital-gtaw-increases-pipe-
welding-productivity-new-article/
High Energy K-TIG vs GTAW vs Conventional vs Plasma
K-Tig vs GTAW
K-Tig vs Conventional MIG
K-Tig vs Plasma
Friction, High Speed Forging offers narrower HAZ, faster but with
limitations – grain flow and flash.
FRIEX rotary friction weld was 1st introduced 1999 to automate pipeline welding.
Flash Butt, MIAB were also explored.
Introducing SPinduction invented by David Lingnau.
Brilliant insight!
Note: inside & outside are mirror images
Materials tested: • Ti-6-4 • Ti-5-5-5-3 • 300M, 4130, 4140, 4340, 8620
Steels • Various dissimilar combinations
Banded structure with only
slight bending of grains
Fully recrystallized fusion
zone, no flash on surface
Oil & gas tubulars: • X65 – Passed NACE TM0177 without PWHT • CP80 • E80 • K55 • L10-13Cr
http://www.spinduction.com/#services
Scatter because 3 samples only. Will need to test many more to find the sweet spot for each combination of material.
What is the limitation? ... How do you join the last joint?
One part is stationary and the other half has to rotate and shear.
When you come up to a valve, an expansion joint, or a heat exchange
manifold what do you do?
Conventional argument has been that we can flange or weld whatever you
cannot rotate but then we are introducing 2 different types of ‘welding’
into one system.
This limitation was explicitly stated in one of the patent claims.
Particularly When joining long tubular Work
pieces, this amount of total rotation or ‘spinning’ still
introduces additional complexity and technical limitations
for many applications, as for example, at pipeline tie-ins. Noetic Engineering Inc., Edmonton
And the solution is FuseRing.
Cheng proposed an intermediary, a coupling made of the same body
material as host pipeline, feeder tubes etc.
Keep both sides stable, introduce two heating paddles simultaneously,
bring to hot working temperature, withdraw the paddles, rotate the
coupler and squeeze. The end product is a coupler w/two independent
solid state fusion done at the same time.
FuseRing opens up a whole new way of doing things.
We can lay pipeline from wellhead, thru the refinery right to ship building
using Solid State Fusion. Each connection taking less than one minute,
repeatable; inside and outside profiles are mirror images. We can regulate
the profile to be concave, convex or flat by prepping the work face to be
flat or beveled.
For tight confined space in reactors, ships or submarines we weld in crawl
spaces at 6 and 9 o‘clock positions. Solid State Fusion you heat up both
work faces, rotate, stick and be done.
For Refinery Construction; SMR between manifold and feeder tubes, we
can reduce time and cost but increase quality.
FuseRing offers new possibilities. FuseRing could act as an intermediary
that is acceptable between 2 very dissimilar materials. The work faces can
have different working temperatures and forging forces.
Anytime, anywhere if you can place an Orbital welder between pipes, we
can put in a Solid State Fusion machine.
Dynamic Recrystalization possibly a 3rd axis Time vs Temp vs Shear Rate.
Instead of 2 dimensional, we might have an envelope.
Solid State Fusion – Dynamic Recrystallization is new science. The evidence
shows that this technique works. The end product is superior to anything on
the market.
There are 5 SPinduction singular weld machines in the world.
1st Eveley International, Hamilton, Ont. Axels.
2nd Federal Mogul for Daimler. Cylinder heads.
3rd NOV Brazil. Off Shore HCR risers.
4th Grant Prideco. Houston Drill Pipe body to Box Ends.
5th SPinduction Calgary prototype.
FuseRing double weld does not have a prototype and I would like to ask for your
advice and help in building a prototype in N America. This technique can be
scaled and w/global applications. Join me in building this new branch of
manufacturing.
Thank you
Paul Cheng
519 709 2091