Figure 1.
Furnace wall panel elements connected by spot welds.
Figure 1.
Furnace wall panel elements connected by spot welds.
Figure 2.
CAD and FEM model of the industrial furnace wall panel.
Figure 2.
CAD and FEM model of the industrial furnace wall panel.
Figure 3.
Sequence of welds in the numerical simulation of the welding process of the industrial furnace wall panel; (a) welds S.1–S.3 joining metal sheets (stage 1), (b) welds S.4 and S.5 joining ribs made of angles to the metal sheets (stage 2), (c) welds S.6–S.17 joining the ribs made of flat bars to the metal sheets (stage 3), (d) welds S.18–S.36 joining the ribs made of flat bars to the channel sections of the frame and ribs made of angles (stage 4), (e) welds S.37–S.40 joining the channel sections of the outer frame to the metal sheets (stage 5), and (f) welds S.41–S.44 joining the channel sections of the outer frame (stage 6).
Figure 3.
Sequence of welds in the numerical simulation of the welding process of the industrial furnace wall panel; (a) welds S.1–S.3 joining metal sheets (stage 1), (b) welds S.4 and S.5 joining ribs made of angles to the metal sheets (stage 2), (c) welds S.6–S.17 joining the ribs made of flat bars to the metal sheets (stage 3), (d) welds S.18–S.36 joining the ribs made of flat bars to the channel sections of the frame and ribs made of angles (stage 4), (e) welds S.37–S.40 joining the channel sections of the outer frame to the metal sheets (stage 5), and (f) welds S.41–S.44 joining the channel sections of the outer frame (stage 6).
Figure 4.
Diagram of the distribution of restraint points in four variants of the numerical simulation of the welding process of the industrial furnace wall panel; (a) model 1, (b) model 2, (c) model 3, and (d) model 4.
Figure 4.
Diagram of the distribution of restraint points in four variants of the numerical simulation of the welding process of the industrial furnace wall panel; (a) model 1, (b) model 2, (c) model 3, and (d) model 4.
Figure 5.
Diagram of the distribution of restraint points in model 1 (
Figure 3a) of the welding process of the industrial furnace wall panel.
Figure 5.
Diagram of the distribution of restraint points in model 1 (
Figure 3a) of the welding process of the industrial furnace wall panel.
Figure 6.
Diagram of the distribution of restraints in the furnace wall panel structure during welding.
Figure 6.
Diagram of the distribution of restraints in the furnace wall panel structure during welding.
Figure 7.
Diagrams of restraint boundary conditions after panel welding; (a) no node displacement in the X, Y, and Z directions, (b) no node displacement in the X and Y directions, and (c) no node displacement in the Y direction.
Figure 7.
Diagrams of restraint boundary conditions after panel welding; (a) no node displacement in the X, Y, and Z directions, (b) no node displacement in the X and Y directions, and (c) no node displacement in the Y direction.
Figure 8.
Distribution of selected measurement points where deformation values were determined in the numerical simulation of the furnace wall panel welding process.
Figure 8.
Distribution of selected measurement points where deformation values were determined in the numerical simulation of the furnace wall panel welding process.
Figure 9.
View of the furnace wall panel elements connected by spot welds to the restraint system according to model 1.
Figure 9.
View of the furnace wall panel elements connected by spot welds to the restraint system according to model 1.
Figure 10.
Distribution of the strain field of the industrial furnace wall panel in the X direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 10.
Distribution of the strain field of the industrial furnace wall panel in the X direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 11.
Distribution of the strain field of the industrial furnace wall panel in the Y direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 11.
Distribution of the strain field of the industrial furnace wall panel in the Y direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 12.
Distribution of the strain field of the industrial furnace wall panel in the Z direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 12.
Distribution of the strain field of the industrial furnace wall panel in the Z direction; (a) 1st restraint model, (b) 2nd restraint model, (c) 3rd restraint model, and (d) 4th restraint model.
Figure 13.
Macrostructure of the test joint with marked areas of the microstructure test: A—parent material, B—heat-affected zone (HAZ), C—weld and heat-affected zone boundary, D—weld, and E—heat-affected zone (HAZ).
Figure 13.
Macrostructure of the test joint with marked areas of the microstructure test: A—parent material, B—heat-affected zone (HAZ), C—weld and heat-affected zone boundary, D—weld, and E—heat-affected zone (HAZ).
Figure 14.
Microstructure of area A of the welded joint—parent material: (a) 100× magnification, and (b) 500× magnification. Ferrite—white precipitates, and perlite—dark precipitates at the ferrite grain boundaries.
Figure 14.
Microstructure of area A of the welded joint—parent material: (a) 100× magnification, and (b) 500× magnification. Ferrite—white precipitates, and perlite—dark precipitates at the ferrite grain boundaries.
Figure 15.
Microstructure of area B of welded joint—HAZ: (a) magnification 100×, and (b) magnification 500×. Ferrite—white precipitates, and perlite—dark precipitates at the ferrite grain boundary.
Figure 15.
Microstructure of area B of welded joint—HAZ: (a) magnification 100×, and (b) magnification 500×. Ferrite—white precipitates, and perlite—dark precipitates at the ferrite grain boundary.
Figure 16.
Microstructure of area C—fusion boundary: (a) 100× magnification, and (b) 500× magnification. Widmanstätten ferrite—white separations, hardening products, mainly bainite—dark separations.
Figure 16.
Microstructure of area C—fusion boundary: (a) 100× magnification, and (b) 500× magnification. Widmanstätten ferrite—white separations, hardening products, mainly bainite—dark separations.
Figure 17.
Microstructure of area D—weld: (a) 100× magnification, and (b) 500× magnification. Widmanstätten ferrite—white precipitates with different morphology, quenching products, mainly bainite—dark precipitates.
Figure 17.
Microstructure of area D—weld: (a) 100× magnification, and (b) 500× magnification. Widmanstätten ferrite—white precipitates with different morphology, quenching products, mainly bainite—dark precipitates.
Figure 18.
Microstructure of area E of welded joint—SWC: (a) magnification 100×, and (b) magnification 500. Ferrite—white precipitates, and perlite—dark precipitates at grain boundaries.
Figure 18.
Microstructure of area E of welded joint—SWC: (a) magnification 100×, and (b) magnification 500. Ferrite—white precipitates, and perlite—dark precipitates at grain boundaries.
Figure 19.
Macrostructure of welded joint with HV5 hardness measurement lines marked.
Figure 19.
Macrostructure of welded joint with HV5 hardness measurement lines marked.
Figure 20.
HV5 hardness distribution in the welded joint area; (a) measurement line 1, and (b) measurement line 2. PM—parent material, HAZ—heat-affected zone.
Figure 20.
HV5 hardness distribution in the welded joint area; (a) measurement line 1, and (b) measurement line 2. PM—parent material, HAZ—heat-affected zone.
Table 1.
Chemical composition of steel S235JRC+N (from metallurgical certificate) in wt.%.
Table 1.
Chemical composition of steel S235JRC+N (from metallurgical certificate) in wt.%.
Fe | C | Mn | P | S | Cu | N |
---|
balance | 0.14 | 0.48 | 0.013 | 0.007 | 0.014 | 0.003 |
Table 2.
Results, average value, and sum of displacements in the X direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Table 2.
Results, average value, and sum of displacements in the X direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Model | A1 | A2 | A3 | A4 | A5 | B1 | B3 | C1 | C2 | C3 | C4 | C5 | D1 | D2 | D3 | D4 | D5 | E1 |
1 | −0.19 | −0.49 | −0.79 | −1.02 | −1.50 | −0.89 | −0.71 | −0.41 | −0.66 | −0.85 | −1.03 | −1.24 | −0.37 | −0.59 | −0.78 | −1.00 | −1.28 | −0.88 |
2 | −0.19 | −0.48 | −0.77 | −1.00 | −1.48 | −0.87 | −0.71 | −0.41 | −0.64 | −0.83 | −1.01 | −1.20 | −0.37 | −0.58 | −0.77 | −0.98 | −1.24 | −0.85 |
3 | −0.22 | −0.50 | −0.77 | −1.00 | −1.43 | −0.86 | −0.71 | −0.42 | −0.64 | −0.83 | −1.00 | −1.18 | −0.39 | −0.58 | −0.76 | −0.97 | −1.21 | −0.85 |
4 | −0.21 | −0.49 | −0.77 | −0.99 | −1.42 | −0.85 | −0.71 | −0.42 | −0.63 | −0.82 | −0.99 | −1.16 | −0.39 | −0.58 | −0.76 | −0.97 | −1.20 | −0.84 |
Model | E2 | E3 | E4 | E5 | F1 | F2 | F3 | F4 | F5 | G1 | G2 | G3 | H1 | H2 | H3 | | | |
1 | −0.85 | −0.86 | −0.88 | −0.89 | −0.75 | −0.77 | −0.79 | −0.79 | −0.77 | −0.89 | −1.15 | −0.72 | −0.81 | −0.46 | −0.80 | | | |
2 | −0.83 | −0.84 | −0.86 | −0.87 | −0.72 | −0.74 | −0.76 | −0.76 | −0.75 | −0.84 | −1.15 | −0.69 | −0.81 | −0.41 | −0.77 | | | |
3 | −0.83 | −0.83 | −0.85 | −0.86 | −0.73 | −0.74 | −0.76 | −0.76 | −0.75 | −0.89 | −1.19 | −0.73 | −0.76 | −0.37 | −0.74 | | | |
4 | −0.82 | −0.83 | −0.85 | −0.86 | −0.71 | −0.73 | −0.75 | −0.75 | −0.74 | −0.87 | −1.20 | −0.72 | −0.76 | −0.33 | −0.72 | | | |
Table 3.
Results, average value, and sum of displacements in the Y direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Table 3.
Results, average value, and sum of displacements in the Y direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Model | A1 | A2 | A3 | A4 | A5 | B1 | B3 | C1 | C2 | C3 | C4 | C5 | D1 | D2 | D3 | D4 | D5 | E1 |
1 | 0.95 | 0.98 | 1.05 | 1.11 | 1.15 | 0.51 | 1.29 | 0.69 | 0.72 | 0.82 | 0.94 | 0.91 | 0.98 | 0.93 | 1.04 | 1.14 | 1.17 | 0.66 |
2 | 0.91 | 0.93 | 0.99 | 1.05 | 1.08 | 0.45 | 1.23 | 0.65 | 0.65 | 0.75 | 0.86 | 0.84 | 0.92 | 0.89 | 0.98 | 1.08 | 1.08 | 0.57 |
3 | 0.89 | 0.92 | 0.98 | 1.04 | 1.07 | 0.50 | 1.20 | 0.65 | 0.67 | 0.77 | 0.88 | 0.85 | 0.91 | 0.89 | 0.98 | 1.08 | 1.09 | 0.64 |
4 | 0.86 | 0.89 | 0.95 | 1.00 | 1.03 | 0.47 | 1.17 | 0.63 | 0.64 | 0.73 | 0.83 | 0.81 | 0.88 | 0.86 | 0.95 | 1.04 | 1.03 | 0.59 |
Model | E2 | E3 | E4 | E5 | F1 | F2 | F3 | F4 | F5 | G1 | G2 | G3 | H1 | H2 | H3 | | | |
1 | 1.21 | 1.25 | 1.24 | 0.88 | 1.08 | 0.77 | 0.74 | 0.68 | 1.23 | 0.83 | 0.82 | 0.82 | 1.09 | 1.09 | 1.09 | | | |
2 | 1.11 | 1.17 | 1.12 | 0.75 | 1.06 | 0.74 | 0.67 | 0.65 | 1.15 | 0.76 | 0.77 | 0.79 | 0.97 | 0.98 | 1.00 | | | |
3 | 1.22 | 1.26 | 1.22 | 0.81 | 1.01 | 0.66 | 0.62 | 0.56 | 1.12 | 0.78 | 0.78 | 0.78 | 1.00 | 1.00 | 1.00 | | | |
4 | 1.16 | 1.21 | 1.16 | 0.75 | 0.99 | 0.64 | 0.58 | 0.55 | 1.07 | 0.74 | 0.75 | 0.77 | 0.93 | 0.94 | 0.95 | | | |
Table 4.
Results, average value, and sum of displacements in the Z direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Table 4.
Results, average value, and sum of displacements in the Z direction at characteristic measurement points, obtained in the numerical simulation of the welding process of the furnace wall panel.
Model | A1 | A2 | A3 | A4 | A5 | B1 | B3 | C1 | C2 | C3 | C4 | C5 | D1 | D2 | D3 | D4 | D5 | E1 |
1 | 5.59 | 7.43 | 8.01 | 7.94 | 6.14 | 7.58 | 7.36 | 2.82 | 4.68 | 4.98 | 4.56 | 2.94 | 2.40 | 3.83 | 4.55 | 4.67 | 2.86 | 1.56 |
2 | 5.23 | 7.05 | 7.57 | 7.48 | 5.64 | 7.27 | 6.94 | 2.44 | 4.32 | 4.58 | 4.15 | 2.46 | 2.03 | 3.44 | 4.09 | 4.18 | 2.28 | 1.42 |
3 | 5.25 | 7.13 | 7.70 | 7.56 | 5.68 | 7.28 | 6.93 | 2.81 | 4.72 | 5.00 | 4.57 | 2.87 | 2.38 | 3.85 | 4.53 | 4.60 | 2.68 | 1.50 |
4 | 5.05 | 6.90 | 7.45 | 7.29 | 5.41 | 7.10 | 6.69 | 2.57 | 4.51 | 4.78 | 4.33 | 2.57 | 2.15 | 3.63 | 4.27 | 4.32 | 2.34 | 1.43 |
Model | E2 | E3 | E4 | E5 | F1 | F2 | F3 | F4 | F5 | G1 | G2 | G3 | H1 | H2 | H3 | | | |
1 | 3.59 | 3.80 | 3.02 | 1.14 | 1.21 | 3.08 | 3.91 | 3.78 | 1.85 | 0.95 | 1.78 | 0.70 | 1.01 | 2.11 | 1.28 | | | |
2 | 3.32 | 3.58 | 2.82 | 1.05 | 1.09 | 2.78 | 3.51 | 3.23 | 1.39 | 0.65 | 1.34 | 0.46 | 0.65 | 1.47 | 0.72 | | | |
3 | 3.54 | 3.80 | 3.01 | 1.10 | 1.18 | 3.02 | 3.81 | 3.57 | 1.58 | 0.87 | 1.67 | 0.64 | 0.90 | 1.87 | 1.02 | | | |
4 | 3.38 | 3.67 | 2.89 | 1.06 | 1.11 | 2.85 | 3.58 | 3.26 | 1.33 | 0.68 | 1.39 | 0.50 | 0.67 | 1.49 | 0.69 | | | |
Table 5.
Deformation of the linear dimensions specified in the physical and numerical simulation of the welding process of the industrial furnace wall panel.
Table 5.
Deformation of the linear dimensions specified in the physical and numerical simulation of the welding process of the industrial furnace wall panel.
Distance | Deformation, mm |
---|
Physical Simulation | Numerical Simulation |
---|
Model 1 | Model 2 | Model 3 | Model 4 |
---|
C1–C5 | −2.00 | −1.65 | −1.61 | −1.60 | −1.58 |
D1–D5 | −2.00 | −1.65 | −1.61 | −1.60 | −1.59 |
E1–E5 | 0.00 | −1.77 | −1.72 | −1.71 | −1.70 |
F1–F5 | +1.00 | −1.52 | −1.47 | −1.48 | −1.45 |
G1–G3 | 0.00 | +1.65 | +1.55 | +1.56 | +1.52 |
H1–H3 | −2.00 | +2.18 | +1.97 | +2.00 | +1.88 |
Table 6.
Deformations in the Z direction at the measurement points of the furnace wall panel (physical and numerical simulation).
Table 6.
Deformations in the Z direction at the measurement points of the furnace wall panel (physical and numerical simulation).
Point | Deformation in the Direction of the Z axis, mm |
---|
Physical Simulation | Numerical Simulation |
---|
Model 1 | Model 2 | Model 3 | Model 4 |
---|
A1 | +4 | +5.59 | +5.23 | +5.25 | +5.05 |
A2 | +6 | +7.43 | +7.05 | +7.13 | +6.90 |
A3 | +7 | +8.01 | +7.57 | +7.70 | +7.45 |
A4 | +5 | +7.94 | +7.48 | +7.56 | +7.29 |
A5 | +13 | +6.14 | +5.64 | +5.68 | +5.41 |
B1 | +6 | +7.58 | +7.27 | +7.28 | +7.10 |
B2 | +6 | +7.36 | +6.94 | +6.93 | +6.69 |
C1 | −2 | +2.82 | +2.44 | +2.81 | +2.57 |
C2 | −2 | +4.68 | +4.32 | +4.72 | +4.51 |
C3 | −1 | +4.98 | +4.58 | +5.00 | +4.78 |
C4 | −8 | +4.56 | +4.15 | +4.57 | +4.33 |
C5 | −3 | +2.94 | +2.46 | +2.87 | +2.57 |
D1 | −3 | +2.40 | +2.03 | +2.38 | +2.15 |
D2 | −1 | +3.83 | +3.44 | +3.85 | +3.63 |
D3 | +1 | +4.55 | +4.09 | +4.53 | +4.27 |
D4 | +1 | +4.67 | +4.18 | +4.60 | +4.32 |
D5 | −1 | +2.86 | +2.28 | +2.68 | +2.34 |
E1 | +5 | +1.56 | +1.42 | +1.50 | +1.43 |
E2 | +4 | +3.59 | +3.32 | +3.54 | +3.38 |
E3 | +1 | +3.80 | +3.58 | +3.80 | +3.67 |
E4 | 0 | +3.02 | +2.82 | +3.01 | +2.89 |
E5 | −2 | +1.14 | +1.05 | +1.10 | +1.06 |
F1 | −4 | +1.21 | +1.09 | +1.18 | +1.11 |
F2 | +1 | +3.08 | +2.78 | +3.02 | +2.85 |
F3 | +1 | +3.91 | +3.51 | +3.81 | +3.58 |
F4 | −1 | +3.78 | +3.23 | +3.57 | +3.26 |
F5 | −4 | +1.85 | +1.39 | +1.58 | +1.33 |
G1 | −1 | +0.95 | +0.65 | +0.87 | +0.68 |
G2 | −3 | +1.78 | +1.34 | +1.67 | +1.39 |
G3 | −3 | +0.70 | v0.46 | +0.64 | +0.50 |
H1 | −3 | +1.01 | +0.65 | +0.90 | +0.67 |
H2 | 0 | +2.11 | +1.47 | +1.87 | +1.49 |
H3 | 5 | +1.28 | +0.72 | +1.02 | +0.69 |
Average of absolute values | 3.27 | 3.73 | 3.35 | 3.59 | 3.37 |