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Forge Bonding How does the process Work

Discover the mesmerizing art of forge bonding in this captivating video! Uncover the secrets of friction welding, a revolutionary process that forges an unbreakable connection between metals. Watch as a heavy axial load and rotational motion transform the metal’s texture, rendering it malleable like clay. Witness the magic of plasticizing as two distinct metals fuse together, creating a bond that surpasses their individual strength.

Prepare to be amazed as we delve into a real-life application of this cutting-edge technique. Join us on an intriguing journey to a refinery in the bustling Houston area, where engineers faced an extraordinary challenge. Follow their ingenious welding procedure to repair a plate made of 2205 duplex material, bridging the gap between different metallurgies with remarkable finesse.

The forged bonding process um is takes place by applying a heavy we call it an axial load on the stud it’s uh and and then we we rotate that stud for just seconds and um we’re we’re applying this load against a tank shell a tank roof it could even it can be applied on any metal surface and during that rotation at the tip of that stud there’s some friction generated that that heats the uh the tip of that stud and the base metal uh that it’s being pressed against and those metals are softened to a clay-like consistency it’s called plasticizing the metal and it never reaches the molten temperatures like like fusion welding does um and so it’s that’s one of the reasons uh that it produces such little thermal energy so under this pressure and rotation while that metal is plasticized the the two metals are fused together and that that bond that’s created at the base of that stud is actually stronger than either of the two metals that are being fused together and uh this process friction welding in general is very capable of joining dissimilar metals which is uh more difficult for fusion welding technologies um so we commonly are bonding uh our stud is made out of a different material than the base material that’s a very very common process and uh we we can also bond on exotic metals we’ve recently qualified zirconium we’re bonding zirconium studs on zirconium base plates and so the metallurgy is very important in the process and the recipe that it takes to join the two metals if you if you’ve been noticing in fact mike pointed out earlier in the discussion the the uh the repair plate that’s behind him that’s at a refinery in the texas area in the houston area and that happens to be a 2205 duplex scrubber um and that plate the repair plate is also 2205 duplex material and we had to choose the stud um such that it matched it wasn’t the same metallurgy but it was a similar metallurgy that had the capability of performing a very high quality high strength bond so our engineers had to work on developing that welding procedure and welding process and of course qualify it to asme section nine and then we had to uh educate our technicians on um on that what new welding process specifically for this metallurgy and that that’s common for us to have to adapt our process uh and our equipment is very capable of adapting the process to the metallurgy involved um so there’s there’s many parameters that can be involved uh that are involved in adjusting the welding procedure so that we can uh bond on just about any surface and uh it it turns out that um friction welding is is very capable of being used on a very wide variety of materials it can actually be used on on non-metal products although uh forge tech uh has perf all of the work that we’ve performed today has been on metal but there’s other materials that can be friction welded but we’re not getting into those at this point in time that that may be in our future but when you when you apply a large force to a stud um to perform the forged bonding process you’ve got to be able to attach your equipment to the tank and you it’s the amount of force we need is far greater than a technician could produce just by holding the machine by hand and pressing it against the surface it takes many many times more uh pounds of force uh to to uh be able to generate uh a a bond with that stud against the material um so we use uh clamps there’s a variety of different clamps we use to attach the forged binding machine to the tank or vessel for that matter we do pressure vessels as well we’ve made in fact that we’ve done quite a few pressure vessels up to we did a 99 psi tower recently uh we’vewe’ve actually uh implemented a process up to 150 psi for applications is that high and we’ve tested it in our shop well over a thousand psi so the capabilities for our technology um uh we haven’t even seen the limits yet um but we we use various clamping techniques to apply this force to the stud and uh i won’t get into too much detail on those but just in general there’s if it’s a small vessel such as the one uh that that mike has behind him that’s i think that was five foot in diameter um we’ve bonded on smaller diameters that and uh of course uh when the diameter gets uh so well on smaller diameter um vessels you can actually wrap something around the vessel to hold the machine against it but when you get on the large vessel say a 300 foot diameter crude oil storage tank you’re not going to be wrapping a uh a cable or a clamp a chain around that uh that vessel to hold the machine against it so we use vacuum to hold our machine against the tank shell and we have uh various techniques and frequently that’s part of our design is designing a vacuum clamp uh so to speak um we designed the vacuum clamp to adapt to the particular situation to avoid obstacles you can see in that uh that picture behind mike to the left of that plate there’s an obstruction there that would prevent us that could prevent us from attaching our vacuum clamp to the the shell of that vessel and so we have to get creative sometimes in and that becomes part of the design process we have to get creative in designing the the vacuum clamp to attach our machine to the shell and then the machines simply run off of air there’s no electricity no electronics you can say that we weld with air with our process and it’s all powered off of a uh a 185 cfm air compressor or larger typically that’s towed in behind a truck and it sits on the ground typically it can be inside or outside the dike depending on the uh the permitting uh and the requirements of our customer of the equipment owners um and um and so it’s it’s a very straightforward process uh air is very safe to work with and it’s frequently we’re operating under cold work permits sometimes the customers are comfortable with that so they’ll permit us with a low energy hot work and sometimes after they see our process at work on a few jobs they’ll downgrade us to cold work so it all depends and we work with the customer very closely it all depends on the conditions that we’re working in um but uh but but yeah that’s that kind of sums up the uh the way that our forged bonding process works to join a stud to a tank you.

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