Hole Repair Equipment Design – For Solid State Friction Welding
The project aims to evaluate and design equipment required for repairing holes in primarily Power generation and Petro-Chemical components, using friction hydro pillar process (FHPP), which with the WeldCore® process currently relies on a ligament to build the repair weld. Industries in the current target market have expressed concern in the event of an unplanned through hole in their components during a typical WeldCore® application; this development will directly address this concern.
A large component of the Petro-Chemical industry HTP components are classified as thin walled and therefore in an attempt to derive the maximum benefit from the WeldCore® process, samples are removed from as great a depth as possible increasing the possibility of coring to depth which will not support the current FHPP repair process, or coring through the wall of the component. All of these instances require a manual repair which requires additional preparation and a dedicated manual welder which is time-consuming and costly.
This technique will open up the possibility to remove through wall core samples, increasing the data and value of the sample on thin-walled components and allowing for increased confidence in component lifecycle management decisions.
The end goal of the project would be a comprehensive understanding of the requirements for a successful through hole repair process using FHPP and a complete design for the equipment, ready for manufacturing, this will place us in a position where the equipment could be manufactured and the process verified on the equipment to successfully provide the FHPP repair procedure for a through hole.
There is currently no known repair of a through hole on these or similar components using friction hydro pillar processing. Practice is to replace or repair by welding a patch over the hole, which is time-consuming and costly. The Hole Repair Equipment Design is less costly, less time consuming, less invasive feasible repair technique.
Equipment to successfully sample and repair the sample site using the WeldCore® process on high temperature and pressure (HTP) components exists, however, the equipment required to successfully repair/fill a through hole using the FHPP process has not been developed. The purpose of the project is to evaluate equipment and process requirements on a process development system (PDS), design standalone equipment to successfully affect a through hole repair using FHPP on components which are typically sampled using the WeldCore® process.
Mr Donnie Erasmus - Deputy Director: Engineering Projects, Nelson Mandela University