Figure 1.
(a) Diagram of the tube to tube plate setup arrangement; (b) diagram of the backing block (supporting block).
Figure 1.
(a) Diagram of the tube to tube plate setup arrangement; (b) diagram of the backing block (supporting block).
Figure 2.
(a) Schematic diagram of the Interference fit method; (b) diagram of tensile test fixture along with tested specimen.
Figure 2.
(a) Schematic diagram of the Interference fit method; (b) diagram of tensile test fixture along with tested specimen.
Figure 3.
Radiography test sample FWTPET sample of rotational tool speed (1300 rpm), projection (1 mm), and depth of cut (0.5 mm).
Figure 3.
Radiography test sample FWTPET sample of rotational tool speed (1300 rpm), projection (1 mm), and depth of cut (0.5 mm).
Figure 4.
Main effects plot for S/N ratio of (without a hole (WOH)) on the tube using backing block.
Figure 4.
Main effects plot for S/N ratio of (without a hole (WOH)) on the tube using backing block.
Figure 5.
Main effects plot for means of (WOH) on the tube using backing block.
Figure 5.
Main effects plot for means of (WOH) on the tube using backing block.
Figure 6.
Interaction plot of without-hole on the tube using backing block.
Figure 6.
Interaction plot of without-hole on the tube using backing block.
Figure 7.
Percentage of the contribution of (WOH) on the tube using backing block.
Figure 7.
Percentage of the contribution of (WOH) on the tube using backing block.
Figure 8.
GA graph plot for data means (WOH) in the tube using backing block.
Figure 8.
GA graph plot for data means (WOH) in the tube using backing block.
Figure 9.
Main effect plot for S/N ratio (WH) on the tube using backing block.
Figure 9.
Main effect plot for S/N ratio (WH) on the tube using backing block.
Figure 10.
Main effect plots for means of with-hole on the tube using backing block.
Figure 10.
Main effect plots for means of with-hole on the tube using backing block.
Figure 11.
Interaction plot of (WH) on the tube using backing block.
Figure 11.
Interaction plot of (WH) on the tube using backing block.
Figure 12.
Percentage of Contribution of (WH) on the tube using backing block.
Figure 12.
Percentage of Contribution of (WH) on the tube using backing block.
Figure 13.
GA graph plot for data means of (WH) on the tube using backing block.
Figure 13.
GA graph plot for data means of (WH) on the tube using backing block.
Figure 14.
Main effects plot for S/N ratio of without-hole on the tube in-absence of the backing block.
Figure 14.
Main effects plot for S/N ratio of without-hole on the tube in-absence of the backing block.
Figure 15.
Main effects plot for means of without-hole on the tube in-absence of the backing block.
Figure 15.
Main effects plot for means of without-hole on the tube in-absence of the backing block.
Figure 16.
Interaction plot of (WOH) on the tube in-absence of the backing block.
Figure 16.
Interaction plot of (WOH) on the tube in-absence of the backing block.
Figure 17.
Percentage of contribution of (WOH) on the tube in-absence of the backing block.
Figure 17.
Percentage of contribution of (WOH) on the tube in-absence of the backing block.
Figure 18.
GA graph plot for data mean (WOH) on the tube in the absence of backing block.
Figure 18.
GA graph plot for data mean (WOH) on the tube in the absence of backing block.
Figure 19.
Main effect plot for S/N ratio with-hole on the tube in the absence of the backing block.
Figure 19.
Main effect plot for S/N ratio with-hole on the tube in the absence of the backing block.
Figure 20.
Main effect plots for means with-hole on the tube in the absence of the backing block.
Figure 20.
Main effect plots for means with-hole on the tube in the absence of the backing block.
Figure 21.
Interaction plot with-hole on the tube in the absence of the backing block.
Figure 21.
Interaction plot with-hole on the tube in the absence of the backing block.
Figure 22.
Percentage of contribution with-hole on the tube in the absence of the backing block.
Figure 22.
Percentage of contribution with-hole on the tube in the absence of the backing block.
Figure 23.
GA graph plot for data means with-hole on the tube in the absence of the backing block.
Figure 23.
GA graph plot for data means with-hole on the tube in the absence of the backing block.
Figure 24.
Hardness plot-Interference Fit for the tube with and WOH by employing backing block.
Figure 24.
Hardness plot-Interference Fit for the tube with and WOH by employing backing block.
Figure 25.
Hardness plot-Interference Fit for the tube with and without a hole in the absence of backing block.
Figure 25.
Hardness plot-Interference Fit for the tube with and without a hole in the absence of backing block.
Figure 26.
Grain size measurement of base metal—tube (36.9 µm).
Figure 26.
Grain size measurement of base metal—tube (36.9 µm).
Figure 27.
Grain size measurement of base metal—tube plate (52.3 µm).
Figure 27.
Grain size measurement of base metal—tube plate (52.3 µm).
Figure 28.
Grain size measurement of weld interface (19.919 µm).
Figure 28.
Grain size measurement of weld interface (19.919 µm).
Figure 29.
SEM images at various tool rotational speeds ((a) 700 rpm, (b) 1000 rpm, and (c) 1300 rpm).
Figure 29.
SEM images at various tool rotational speeds ((a) 700 rpm, (b) 1000 rpm, and (c) 1300 rpm).
Figure 30.
Scanning electron microscope with EDS at (a) 700 rpm, (b) 1000 rpm, (c) 1300 rpm
Figure 30.
Scanning electron microscope with EDS at (a) 700 rpm, (b) 1000 rpm, (c) 1300 rpm
Figure 31.
XRD analysis image at the weld interface (a) 700 rpm, (b) 1000 rpm, (c) 1300 rpm
Figure 31.
XRD analysis image at the weld interface (a) 700 rpm, (b) 1000 rpm, (c) 1300 rpm
Table 1.
Alloy chemistry of SA213 tube and mechanical properties used in this study.
Table 1.
Alloy chemistry of SA213 tube and mechanical properties used in this study.
E | Mn | Cr | Mo | Ni | Cop | Ti | Fe | Mechanical Properties UTS (MPa) | %EI |
---|
Weight percentage | 0.51 | 1.46 | 0.42 | 0.046 | 0.044 | 0.090 | 97.1 | 420 | 30 |
Table 2.
Alloy chemistry of SA387 tube plate.
Table 2.
Alloy chemistry of SA387 tube plate.
E | Mn | Cr | Mo | Va | Ti | Fe | Mechanical Properties UTS (MPa) | %El |
---|
Weight percentage | 0.75 | 1.55 | 0.38 | 0.041 | 0.087 | 96.7 | 690 | 18 |
Table 3.
Alloy chemistry of tungsten carbide.
Table 3.
Alloy chemistry of tungsten carbide.
E | C | H | Fe | O | Ni | Mo | Ti | V | Pd | W |
---|
wt% | 0.08 | 0.015 | 0.25 | 0.13 | 0.75 | 4.31 | 0.4 | 4.5 | 0.2 | 89.365 |
Table 4.
L9 orthogonal array factors and levels.
Table 4.
L9 orthogonal array factors and levels.
FACTOR | LEVELS |
---|
1 | 2 | 3 |
---|
Speed (rpm) | 700 | 1000 | 1300 |
Projection (mm) | 0 | 1 | 2 |
Depth of Cut (mm) | 0.2 | 0.4 | 0.6 |
Table 5.
Design of experiments of L9 orthogonal array.
Table 5.
Design of experiments of L9 orthogonal array.
Experimental Number | Input Parameters |
---|
Tool Rotational Speed (rpm) | Tube Projection (mm) | Depth of Cut (mm) |
---|
1 | 700 | 0 | 0.5 |
2 | 700 | 1 | 1 |
3 | 700 | 2 | 1.5 |
4 | 1000 | 0 | 1 |
5 | 1000 | 1 | 1.5 |
6 | 1000 | 2 | 0.5 |
7 | 1300 | 0 | 1.5 |
8 | 1300 | 1 | 0.5 |
9 | 1300 | 2 | 1 |
Table 6.
Input and output parameters of (WOH) on the tube using backing block.
Table 6.
Input and output parameters of (WOH) on the tube using backing block.
Experiment Number | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
1 | 700 | 0 | 0.5 | 612.35 |
2 | 700 | 1 | 1 | 580.35 |
3 | 700 | 2 | 1.5 | 565.65 |
4 | 1000 | 0 | 1 | 548.35 |
5 | 1000 | 1 | 1.5 | 711.45 |
6 | 1000 | 2 | 0.5 | 679.45 |
7 | 1300 | 0 | 1.5 | 791 |
8 | 1300 | 1 | 0.5 | 836.8 |
9 | 1300 | 2 | 1 | 723 |
Table 7.
Response table for signal-to-noise (S/N) ratio of without-hole on the tube using backing block.
Table 7.
Response table for signal-to-noise (S/N) ratio of without-hole on the tube using backing block.
Level | Speed | Projection | Depth |
---|
1 | 55.35 | 56.16 | 56.95 |
2 | 56.16 | 56.92 | 55.75 |
3 | 57.87 | 56.29 | 56.69 |
Delta | 2.51 | 0.76 | 1.20 |
Rank | 1 | 3 | 2 |
Table 8.
Analysis of variance of (WOH) on the tube using backing block.
Table 8.
Analysis of variance of (WOH) on the tube using backing block.
Source | DF | Seq.SS | Adj.SS | Adj.MS | Percentage of Contribution |
---|
Speed rpm | 2 | 61,455 | 61,455 | 30,728 | 73.08 |
Projection, mm | 2 | 6369 | 6369 | 3185 | 7.57 |
Depth mm | 2 | 14,129 | 14,129 | 7065 | 16.80 |
Error | 2 | 2137 | 2137 | 1068 | 2.5 |
Total | 8 | 84,090 | | | 100 |
Table 9.
Comparison of experimental and software predicted value (WOH) in the tube using backing block.
Table 9.
Comparison of experimental and software predicted value (WOH) in the tube using backing block.
Method | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
GA | 1270.666 | 0.5 | 1 | 837.4 |
Experimental | 1300 | 0.5 | 1 | 836.8 |
Table 10.
Input and output parameters with hole (WH) on the tube using backing block.
Table 10.
Input and output parameters with hole (WH) on the tube using backing block.
Experiment Number | Input Constraints | Output Constraints |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
1 | 700 | 0 | 0.5 | 590.45 |
2 | 700 | 1 | 1 | 550.35 |
3 | 700 | 2 | 1.5 | 520.7 |
4 | 1000 | 0 | 1 | 596.35 |
5 | 1000 | 1 | 1.5 | 670.3 |
6 | 1000 | 2 | 0.5 | 630.15 |
7 | 1300 | 0 | 1.5 | 710.2 |
8 | 1300 | 1 | 0.5 | 789.35 |
9 | 1300 | 2 | 1 | 746.4 |
Table 11.
Response table for Signal to Noise Ratios WH on the tube using backing block.
Table 11.
Response table for Signal to Noise Ratios WH on the tube using backing block.
Level | Speed | Projection | Depth |
---|
1 | 54.86 | 55.99 | 56.45 |
2 | 56.01 | 56.43 | 55.93 |
3 | 57.48 | 55.93 | 55.96 |
Delta | 2.62 | 0.50 | 0.53 |
Rank | 1 | 3 | 2 |
Table 12.
Results obtained from ANOVA of (WH) on the tube using backing block.
Table 12.
Results obtained from ANOVA of (WH) on the tube using backing block.
Source | DF | Seq.SS | Adj.SS | Adj.MS | Percentage of Contribution |
---|
Speed, rpm | 2 | 57,650 | 57,650 | 28,825 | 87.3 |
Projection, mm | 2 | 2831 | 2831 | 1416 | 4.30 |
Depth, mm | 2 | 4838 | 4838 | 2419 | 7.40 |
Error | 2 | 662 | 662 | 331 | 1.0 |
Total | 8 | 65,982 | | | 100 |
Table 13.
Comparison of experimental and software predicted value of (WH) on the tube using backing block.
Table 13.
Comparison of experimental and software predicted value of (WH) on the tube using backing block.
Method | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
Genetic Algorithm | 1300 | 0.5 | 1 | 786.95 |
Experimental | 1300 | 0.5 | 1 | 789.35 |
Table 14.
Input and output parameters of (WOH) on the tube in-absence of the backing block.
Table 14.
Input and output parameters of (WOH) on the tube in-absence of the backing block.
Experiment Number | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
1 | 700 | 0 | 0.5 | 582.5 |
2 | 700 | 1 | 1 | 525.7 |
3 | 700 | 2 | 1.5 | 578.9 |
4 | 1000 | 0 | 1 | 610.7 |
5 | 1000 | 1 | 1.5 | 661.1 |
6 | 1000 | 2 | 0.5 | 624.3 |
7 | 1300 | 0 | 1.5 | 651.8 |
8 | 1300 | 1 | 0.5 | 762.2 |
9 | 1300 | 2 | 1 | 668.6 |
Table 15.
Response table for S/N ratio of without-hole on the tube in-absence of the backing block.
Table 15.
Response table for S/N ratio of without-hole on the tube in-absence of the backing block.
Level | Speed | Projection | Depth |
---|
1 | 54.99 | 55.77 | 56.29 |
2 | 56.01 | 56.15 | 55.54 |
3 | 56.81 | 55.89 | 55.98 |
Delta | 1.82 | 0.39 | 0.74 |
Rank | 1 | 3 | 2 |
Table 16.
Analysis of variance of without-hole on the tube in-absence of the backing block.
Table 16.
Analysis of variance of without-hole on the tube in-absence of the backing block.
Source | DF | Seq.SS | Adj.SS | Adj.MS | F | Percentage of Contribution |
---|
Speed, rpm | 2 | 26,098 | 26,098 | 13,049.1 | 324,849.35 | 71.38 |
Projection, mm | 2 | 1944 | 1944 | 971.9 | 337,748.35 | 5.32 |
Depth, mm | 2 | 8288 | 8288 | 2243.9 | 1,703,186.23 | 22.6 |
Error | 2 | 228 | 228 | 2014.2 | | 0.7 |
Total | 8 | 36,558 | | | | 100 |
Table 17.
Comparison of experimental and software predicted value (WOH) in the tube in the absence of the backing block.
Table 17.
Comparison of experimental and software predicted value (WOH) in the tube in the absence of the backing block.
Method | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
GA | 1300 | 0.5 | 1 | 771.3 |
EXPERIMENTAL | 1300 | 0.5 | 1 | 762.2 |
Table 18.
Input and output parameters of with-hole on the tube in-absence of the backing block.
Table 18.
Input and output parameters of with-hole on the tube in-absence of the backing block.
Experiment Number | Input Constraints | Output Constraints |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
1 | 700 | 0 | 0.5 | 610.3 |
2 | 700 | 1 | 1 | 597.63 |
3 | 700 | 2 | 1.5 | 536.4 |
4 | 1000 | 0 | 1 | 650.8 |
5 | 1000 | 1 | 1.5 | 680.3 |
6 | 1000 | 2 | 0.5 | 615 |
7 | 1300 | 0 | 1.5 | 630.5 |
8 | 1300 | 1 | 0.5 | 700.8 |
9 | 1300 | 2 | 1 | 645.6 |
Table 19.
Response table for the signal to noise ratios with-hole on the tube in the absence of backing block.
Table 19.
Response table for the signal to noise ratios with-hole on the tube in the absence of backing block.
Level | Speed | Projection | Depth |
---|
1 | 55.28 | 55.99 | 56.13 |
2 | 56.23 | 56.36 | 56.00 |
3 | 56.37 | 55.52 | 55.75 |
Delta | 1.09 | 0.84 | 0.39 |
Rank | 1 | 2 | 3 |
Table 20.
Results obtained from ANOVA with-hole on the tube in the absence of the backing block.
Table 20.
Results obtained from ANOVA with-hole on the tube in the absence of the backing block.
Source | DF | Seq.SS | Adj.SS | Adj.MS | Percentage Of Contribution |
---|
Speed, rpm | 2 | 10,639 | 10,639 | 5319.4 | 57.10 |
Projection, mm | 2 | 5507 | 5507 | 2753.7 | 29.7 |
Depth, mm | 2 | 2050 | 2050 | 1025 | 10.9 |
Error | 2 | 444 | 444 | 222 | 2.3 |
Total | 8 | 31,129 | | | 100 |
Table 21.
Comparison of experimental and software predicted value with a hole in the tube in the absence of the backing block.
Table 21.
Comparison of experimental and software predicted value with a hole in the tube in the absence of the backing block.
Method | Input Parameters | Output Parameters |
---|
Speed (rpm) | Projection (mm) | Depth (mm) | Tensile Strength (MPa) |
---|
GA | 1300 | 0.5 | 1 | 702.67 |
Experimental | 1300 | 0.5 | 1 | 700.8 |
Table 22.
Comparison between WOHs and WHs on the circumference of the tube using the backing block.
Table 22.
Comparison between WOHs and WHs on the circumference of the tube using the backing block.
Conditions | Tube Preparations | Method of Analysis | Input Specifications | Output Specifications |
---|
Speed mm | Projection mm | Depth mm | Tensile Strength MPa |
---|
Using backing block | WOH | GA | 1300 | 1 | 0.5 | 837.4 |
Experimental | 1300 | 1 | 0.5 | 836.8 |
WH | GA | 1300 | 1 | 0.5 | 786.95 |
Experimental | 1300 | 1 | 0.5 | 789.35 |
Without using backing block | WOH | GA | 1300 | 1 | 0.5 | 771.3 |
Experimental | 1300 | 1 | 0.5 | 762.2 |
WH | GA | 1300 | 1 | 0.5 | 702.67 |
Experimental | 1300 | 1 | 0.5 | 700.8 |
Table 23.
Inheritance % of most influencing factors using backing block.
Table 23.
Inheritance % of most influencing factors using backing block.
Parameters | Percentage of Inheritance (%) |
---|
Employing Backing Block | In the Absence of Backing Block |
---|
Tube Preparation | WOHs | WHs | WOHs | WHs |
Speed (rpm) | 73.08 | 87.3 | 71.38 | 57.10 |
Projection (mm) | 7.57 | 4.30 | 5.32 | 29.7 |
Depth (mm) | 16.80 | 7.40 | 22.6 | 10.9 |
Table 24.
Hardness tests comparison table (HV).
Table 24.
Hardness tests comparison table (HV).
Conditions | Tube Preparation | Base Tube | Heat Affected Tube | Weld Interface | Heat Affected Plate | Baseplate |
---|
With backing block | WH | 179 | 256 | 290.22 | 273 | 205 |
WOH | 180 | 281 | 339.50 | 283 | 205 |
Without backing block | WH | 179 | 234.90 | 273.40 | 249.3 | 205 |
WOH | 180 | 243.7 | 296.32 | 260 | 205 |