Method of manufacturing structural component for joining with another structural component by stress protected groove weld

Method of manufacturing first structural component for or joining with second structural component by groove weld is provided. The first structural component has first surface, second surface and end portion. The component is bent at end portion to form bent portion defining convex and concave faces. First portion of bent portion is removed at convex face in form outer weld surface having first face extending from first surface, and second face connected to first face. Second portion of bent portion is removed at concave face to form inner edge surface having arcuate profile. Inner edge surface extends from second surface and connects to second face via transition portion. A portion of first face, second face, transition portion, and inner edge surface define root protrusion, having a root protrusion height, for first structural component. The root protrusion defines stress protected weld root region isolated beyond and away from root stress flow path.

TECHNICAL FIELD

The present disclosure generally relates to stress protected groove welds, and more particularly, relates to a method of manufacturing a structural component to be joined with another structural component by stress protected groove welds.

BACKGROUND

Groove welds are known to be used to join structural components to form one or more weldments of a wide variety of numerous different types of structures. In particular, a groove weld may be a means by which two structural components or other metal components are joined together by the affixation of adjacent and/or mating edges or surfaces as a result of a mutual thermal bonding transformation therebetween which may be provided, at least in part, by heated filler material. At least a part of the interior of the groove weld may be composed of the filler material which may engage and thermally bond with the adjacent surfaces and edges of the pre-existing parent material of the structural components or other metal components, including at a bottom, or “root” portion of the groove weld and the structural components.

While groove welds may be widely used as an effective means by Which structural components are joined to form a wide variety of numerous different types of structures, typical, conventional groove welds may be subsequently susceptible to fatigue or failure. For example, the welded structure may be subject to cyclic loading, forces and/or stresses, which may include, in part, tensile or bending forces that produce stresses on the weld and structural components. When loading, forces, and/or stresses are applied to the structure and the groove weld, portions of the groove weld, may be incapable of absorbing and withstanding loading, forces, and/or stresses applied thereto, and thus may be particularly susceptible to fatigue or failure.

U.S. Pat. No. 7,374,823 (hereinafter referred to as the '823 patent) provides a weld assembly including first and second members having inclined portions that are joined by a weld bead. However, the failure of groove weld joints continues to he problematic in the field because the weld root and/or the weld toe remains subject to high stresses.

SUMMARY OF THE INVENTION

In an aspect of the present disclosure, a method of manufacturing first structural component for joining with second structural component by groove weld is provided. The first structural component includes a body having a first surface, a second surface and an end portion. The method includes bending the first structural component at the end portion to form a bent portion defining a convex and a concave face. The first portion of the bent portion is removed at the convex face to form an outer weld surface having a first face extending from the first surface, and a second face connected to the first face. Further, the second portion of bent portion is removed at the concave face to form an inner edge surface having an arcuate profile. The inner edge surface extends from the second surface and connects to the second face via a transition portion. A portion of the first face. the second face, the transition portion, and the inner edge surface define a root protrusion, having a root protrusion height, for the first structural component. The root protrusion defines a stress protected weld root region isolated beyond and away from root stress flow path that propagates through the first structural component.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numbers will be used throughout the drawings to refer to the same or corresponding parts.

The present disclosure relates to a structure having two or more structural components joined by groove welds according to the embodiments of the present disclosure.FIG. 1illustrates an exemplary structure100including a first structural component102and a second structural component104joined by a groove weld106to form a weldment and the resultant structure100. Although the illustrated embodiments show two structural components, it may be contemplated that the structure100may include any number of structural components which may be joined by numerous groove welds, without deviating from the scope of the claimed subject matter.

Each of the first structural component102and the second structural component104may be composed of a metal, including but not limited to iron, steel, aluminum, or any other metal, or any alloys thereof, capable of being joined via a groove weld, such as the groove weld106of the present disclosure. For the purposes of the present disclosure, the term “welding” (or “weld”), includes any process or result thereof wherein two structural components or metal components are joined together by affixation of adjacent and/or mating edges or surfaces as a result of a mutual thermal frictional, or any other type of bonding transformation therebetween.

The groove weld106may include, but not limited to, shielded metal arc welding, gas tungsten are welding, or tungsten inert gas welding, gas metal are welding or metal inert gas welding, flux-cored are welding, submerged are welding, electroslag welding, and the like. The groove weld106may also include cladding, brazing, soldering, friction stir welding, laser welding, and hybrid laser arc welding.

Further, each of the first structural component102and the second structural component104may be formed to embody any of variety of shapes, contours, profiles, bodies, structures or any combination or combinations thereof, as necessary to form a suitable or desired structure, such as the structure100of the present disclosure. In the illustrated embodiment, the first structural component102and the second structural component104may be planar to define a plate. Alternatively, the first structural component102and the second structural component104may include one or more of planar, arcuate, cylindrical, concave, convex, and/or incurvate shape, to form a contoured structure of the structural components102,104in a yet another non-limiting example, the structural components102,104may be tubular or cylindrical or curved to form a cylindrical tube or a non-cylindrical tube.

In an embodiment of the present disclosure, the first structural component102includes a first end108, and a weld end110having a first outer weld surface112and a first root protrusion114. Similarly, the second structural component104includes a respective first end116and a weld end118having a second outer weld surface120and a second root protrusion122. The weld ends110,118, the outer weld surfaces112,120and the root protrusions114,122are included at each of any one or more outer edges, sides, extensions, or boundaries of the first structural component102and the second structural component104, which are configured to be joined via the groove weld106to an adjacent, corresponding, opposing weld ends110,118, the outer weld surfaces112,120and the root protrusions114,122of an opposing, second structural component104and first structural component102(or any other structural component, including, in part, any root protrusion according to the present disclosure) to form the structure100.

In an embodiment of the present disclosure, the root protrusions114.122are configured to locate a weld root124of the groove weld106within a stress protected weld root region126. The stress protected weld mot region126corresponds to a negligible stress concentration zone isolated beyond and away from a root stress flow path128propagated through the structural components102,104of the structure100, such that fatigue failure does not occur in the weld root124and the stress protected weld root region126.

In an embodiment of the present disclosure, each of the first structural component102and the second structural component104are identical to each other. However, it may he contemplated that in various alternative embodiments, the structural components102,104may have different profiles, shapes and dimensions than one another, without deviating from the scope of the claimed subject matter.

Referring toFIGS. 2 to 7, an exemplary first structural component102′ is provided along with a method300for manufacturing the first structural component102having the profile as shownFIG. 1.

FIGS. 2 and 3illustrate an exemplary first structural component102′, hereinafter interchangeably referred to as the component102′, in the form of a plate202. The component102′ includes a body204defining the first end108′ and a second end206. The body204further includes a first surface208, a second surface210, a first side surface212, and a second side surface214. The component102′ further includes a first end portion216defined proximal to the first end108′ and a second end portion218defined proximal to the second end206(as shown inFIG. 3). The first surface208and the second surface210define a thickness T of the component102′, whereas the first side surface212and the second side surface214define a width W of the component102′. The first surface208may define an outer or upper surface of the component102′, whereas the second surface210may define an inner or lower surface of the component102′. Alternatively, the first surface208may define the inner or lower surface of the component102′, and the second surface210may define the outer or upper surface of the component102′ depending upon the type, use, application, constraints, or other considerations attendant to the structure100, including but not limited to the formation thereof. As such, although the relative terms “above”, “outer”, “upper”, “raised”, “below”, “lower”, “lowered”, or “inner” may be used, such terms are used exclusively for the purposes of identifying and disclosing the various features of the disclosure herein with respect to and relative to the orientation of the illustrated Figures, but should not be construed as limiting the scope of the disclosure as excluding orientations which may differ from the illustrated. Figures, but in all other respects are equivalent.

In the illustrated embodiment of the present disclosure, the first surface208is parallel to the second surface210, and the first side surface212is parallel to the second side surface214, thereby defining a cuboidal structure of the component102′. It may further be contemplated that the shape and dimensions of the component102′ are merely exemplary and may be varied to achieve similar results without deviating from the scope of the claimed subject matter.

Referring toFIGS. 4 to 7, an exemplary method300of manufacturing the first structural component102, from the first structural component102′, for joining with the second structural component104to form the resultant structure100, is disclosed. In an embodiment, as shown inFIG. 4, initially at step302, the first structural component102′ is bent at the second end portion218with respect to the first end portion216, to form a bent portion220therebetween. For example, the component102′ is bent in the component's rolling direction, as shown by the arrow222. The component102′ may be bent using dies, fixtures, or any other conventionally known bending process. It may also be contemplated that the bending of the component102′ may be done manually or by using automated machines.

The bent portion220may define a bending radius RBthat is directly proportional to the thickness T of the component102′. In an embodiment of the present disclosure, the bending radius RBlies within a range of 1.5 times to 3.5 times the thickness T of the component102′. In one non-limiting example, the bent portion220includes a bending radius RBof 1.5 times the thickness T of the component102′, when the thickness T lies within 10 millimeters to 30 millimeters. In another non-limiting example, the bent portion220includes a bending radius RBof 3 times the thickness T of the component102′, when the thickness T lies within 30 millimeters to 50 millimeters. In a yet another non-limiting example, the bent portion220includes a bending radius RBof 3.5 times the thickness T of the component102′, when the thickness T is greater than 50 millimeters. Further, as shown inFIG. 4, the component102′ is bent at a bend angle AB, that is formed between the first end portion216and the second end portion218. The bend angle ABmay be directly proportional to the thickness T of the component102′. In an embodiment of the present disclosure, the bend angle ABlies within a range of 110 degrees to 135 degrees. In one example, the bend angle ABis 135 degrees.

The bent portion220defines a convex face224and a concave face226. As illustrated, the convex face224extends between a portion208′ of the first surface208associated with the first end portion216and a portion208″ of the first surface208associated with the second end portion218. Similarly, the concave tee226extends between a portion210′ of the second surface210associated with the first end portion216and a portion210″ of the second surface210associated with the second end portion218.

Subsequent to bending of the component102′ at step302, the method300proceeds to step304shown inFIGS. 5 & 6. In an embodiment of the present. disclosure, at step304, a first portion228of the bent portion220along with the second end portion218of the component102′, is removed from the component102′, to form the first outer weld surface112(as shown inFIG. 6). In various examples, removal of the first portion228and the second end portion218may be done using conventionally known machining methods, such as milling, laser cutting, etc. To this end, material of the component102′ may be removed across the width W, such that the first outer weld surface112extends across the width W of the component102′. However, it may be contemplated that the material may be removed partially between the side surfaces212,214so as to form partial outer weld surface(s) in certain applications. Although the first portion228and the second end portion218may be removed simultaneously, it may be noted that, in some embodiments, the second end portion218may be removed prior to the removal of the first portion228.

In an embodiment, as shown inFIG. 6, the first outer weld surface112of the component102′ includes a first face230and a second face232connected to the first face230to define an excluded angle D therebetween. The magnitude of the excluded angle D may lie within a range of 190 degrees to 215 degrees. In one example, the magnitude of the excluded angle D is 210 degrees. Further, the first face230defines an angle B with the portion208′ of the first surface208associated with the first end portion216of the component102′. In an example, a magnitude of the angle B may lie within a range of 110 degrees to 120 degrees. Furthermore, the first face230defines an angle C (e.g., an acute angle C) with the portion210′ of the second surface210associated with the first end portion216of the component102′. In one example, a magnitude of the angle C lies within a range of 60 degrees to 70 degrees.

The second face232defines an angle E with the portion210′ of the second surface210associated with the first end portion216of the component102′, For example, a magnitude of the angle E lies within a range of 85 degrees to 95 degrees. In one example, the magnitude of the angle E is 90 degrees, i.e., the second face232is perpendicular to the portion210′ of the second surface210associated with the first end portion216of the component102.

Subsequent to the removal of the first portion228and the second end portion218at step304, the method300proceeds to step306as shown inFIG. 7. At step306, a second portion234(as shown inFIG. 5) of the bent portion220at the concave face226is removed to form an inner edge surface236and accordingly obtain the profile of the first structural component102ofFIG. 1. In various examples, similar to the removal of first portion228at step304, the removal of the second portion234may also be done using conventionally known machining methods, such as milling, laser cutting, etc. Further, the material may be removed across the width W of the component102′, such that the inner edge surface236extends across the width W. However, it may be contemplated that the material may be removed partially between the side surfaces212,214so as to form a partial inner edge surface(s) in certain applications. In some applications, step304and step306may be performed simultaneously.

As illustrated, the inner edge surface236includes an arcuate profile238, and extends from the second surface210(or a portion210′ of the second surface210) associated with the first end portion216and connects to the second face232of the first outer weld surface112. In an embodiment of the present disclosure, the arcuate profile238is an elliptical profile having a major radius RMJand a minor radius RMN, such that the major radius RMJis greater than the minor radius RMN. In one example, the major radius RMJis 2.5 times the minor radius RMN. For example, the minor radius RMNis 8 millimeters, and the major radius RMJis 2.5 times the minor radius RMN, i.e., 20 millimeters. It may be contemplated that the magnitude and proportion of the major radius RMJand the minor radius RMNwith respect to each other are merely exemplary and may he varied to achieve similar results without deviating from the scope of the claimed subject matter. In an alternative embodiment of the present disclosure, the arcuate profile238may be a circular profile, where the major radius RMJand the minor radius RMNare equal.

Furthermore, the inner edge surface236is connected to the second face232via a transition portion240including a first transition face242and a second transition face244. In an embodiment, and although not limited, the first transition face242may be machined and removed during the removal of the first portion228at step304from thee body204of the component102′ (i.e., the first transition face242may be formed along with the formation of the first face230and the second face232). The first transition face242may be a planar face that may be largely perpendicular to the second face232, although angular variations between the second face232and the first transition face242may be contemplated. According to an embodiment, the first transition face242may be disposed at an angle that lies within a range of 85 degrees to 95 degrees with respect to the second face232. Further, the second transition face244may be formed if the arcuate profile238of the inner edge surface236, extending from the portion210′ of the second surface210, defines a curvature that stops short of the second face232and the first transition face242. In other words, the second transition face244may be a portion210′″ of the second surface210itself (associated with the bent portion220) that does not encounter any machining and/or removal owing to the curvature defined by the arcuate profile238of the inner edge surface236stopping short of the second face232and the first transition face242.

In an embodiment of the present disclosure, a portion230′ of the first face230, the second face232, the transition portion240, and the inner edge surface236(having the arcuate profile238), define the first root protrusion114of the first structural component102, as shown inFIG. 1. The first root protrusion114extends radially outward from the portion210′ of the second surface210associated with the first end portion216of the first structural component102to an outer end246of the first root protrusion114, thereby defining a root protrusion height RPHextending from the second surface210of the component102to the outer end246of the first root protrusion114. As illustrated, in various embodiments, the outer end246of the first root protrusion114may correspond to the tint transition face242. Further, according to the disclosed embodiment, it may he contemplated that the minor radius RMNmay be defined so as to be aligned to and be equal to the height RPof the first root protrusion114, although in certain other embodiments the radius RMNmay be unequal to (e.g., higher than) the height RPH—or example, when the arcuate profile238defines a curvature that extends at least in part or fully beyond the second face232.

In an embodiment of the present disclosure, the first root protrusion114the arcuate profile238, the inner edge surface236, the root protrusion height RPH, and the portion230′ of the first face230of the first outer weld surface112, define the stress protected weld root region126(as shown inFIG. 1) isolated beyond and away from the root stress flow path128propagated through the body204of the first structural component102.

Referring toFIG. 8, the resultant first structural component102having the first root protrusion114manufactured from the first structural component102′ by method300, is illustrated. Similar to the first structural component102, the second structural component104is also manufactured by the same method300and includes the respective second root protrusion122(seeFIG. 1). The first structural component102and the second structural component104are joined by the groove weld106(which is a stress protected groove weld106) to form the structure100, as shown inFIG. 1. For example, the first outer weld surface112and the first root protrusion114of the first structural component102are aligned with the second outer weld surface120and the second root protrusion122of the second structural component104, thus defining a V-shaped receiving portion therebetween into which a weld material may be received to form the groove weld106, as illustrated inFIG. 1, and in turn joining the first structural component102with the second structural component104.

INDUSTRIAL APPLICABILITY

The present disclosure may be applicable to any structure100composed of at least two structural components, i.e., the first structural component102and the second structural component104joined by at least one groove weld106. The present disclosure may be applicable to any type of structural member, component, part, structure, and/or body which is capable of being joined to any other structural member, component, part, structure, and/or body via a groove weld, to form a weldment and resultant structure including the joined structural components.

Aspects of the disclosed method300of manufacturing the structural components102,104to be joined by the stress protected groove weld106may reduce manufacturing costs and at the same time, significantly reduce or eliminate damage, fatigue, or failure within the groove weld106(including, in part, the adjacent and/or mating edges or surfaces of the structural components102,104which are engaged and in thermal proximity with the groove weld106, and the filler material thereof, which are mutually thermally bonded and transformed via the energy of the groove weld106) which may be caused by cyclic loading, forces and/or stresses, which may include, in part, tensile or bending forces that produce stresses on the weld.