TURNER-FAIRBANK HIGHWAY RESEARCH CENTER Office of Infrastructure RD&T Update on FHWA Welding and Fabrication Related Research Justin Ocel, PhD, PE Structural Steel Research Program Manager FHWA Turner-Fairbank Highway Research Center McLean, VA 22101 1
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Update on FHWA Welding and Fabrication Related Research
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TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Update on FHWA Welding
and Fabrication Related
Research
Justin Ocel, PhD, PEStructural Steel Research Program Manager
FHWA Turner-Fairbank Highway Research Center
McLean, VA 22101
1
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Electroslag Welding (ESW)
2
A very efficient welding
process with potential
reduced fabrication
cost.
– Application limited by
AASHTO/AWS D1.5
– Three full-scale
beams with
HPS/HPS and
HPS/50W flange butt
welds
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
SFOBB ESW Weld
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
SAW
ESW
2947 kips
(78 ksi)
SFOBB ESW Weld
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
SFOBB ESW Weld
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
“Development of Innovative Welding
for High Performance Bridge Steel”
6
• Small Business Innovative Research (SBIR)
grant
• Metric to develop process(s) demonstrated
faster than SAW for a hypothetical 3” x 30”
CJP butt weld
• Two vendors had Phase 2 contracts
– Hybrid Laser Arc Welding (HLAW)
– Resistance welding with a Homopolar Generator
(HPG)
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Homopolar Generator
7
** Images copyrighted KAI, LLC. **
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Homopolar Generator
8
** Image copyrighted KAI, LLC. **
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Homopolar Generator
9
** Image copyrighted KAI, LLC. **
TURNER-FAIRBANK HIGHWAY RESEARCH CENTEROffice of Infrastructure RD&T
Plasma Cut Holes
10
Tested the fatigue and static resistance of plasma cut