Its about modern welding technology which is flame proof, spark proof and environmental free.

1. FORGE BONDING:
A PROCESS
SAFER THAN HOT WORK
Prepared By : SAGAR PATEL
Guide : Dr. NITIN V. BHATE
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2. INTRODUCTION
 Forge welding is a solid-state welding process that joins two pieces
of metal by heating them to a high temperature and then joins by
means of applying pressure in form of hammering or any other
means.
 This technique is actually a FRICTION WELDING or FRICTION STIR
WELDING.
 Friction stir welding (FSW) produces welds by using a rotating, non
consumable welding tool to locally soften a work piece, through heat
produced by friction and plastic work, thereby allowing the tool to “stir”
the joint surfaces.
 Lohwasser D. , Chen z. ‘Friction stir welding From basics to applications’
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3. A BRIEF HISTORY
 In late 1991 this welding method was conceived at TWI (The Welding Institute).
 The process was duly named friction stir welding (FSW), and TWI filed for world-
wide patent protection in December of that year.
 TWI is a world famous institute in the UK that specializes in materials joining
technology.
 Compared to conventional friction welding, FSW uses a rotating tool to generate the
necessary heat for the process.
 FSW is a process that can be automated. It is also a cleaner and more efficient
process compared to conventional techniques.
 Lohwasser D. , Chen z. ‘Friction stir welding From basics to applications’
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4. CURRENT WELDING PRACTICES IN INDUSTRIES
 In chemical industries like petrochemical industries, refineries, spark or source of
ignition is strictly prohibited. There are so many examples of fire caused during HOT
WORK carried out in industries.
 WHAT IS HOT WORK ?
 Hot work is an operation that can produce a spark or flame or other source of ignition
having sufficient energy to cause ignition.
 Also during leaks from pipelines, valves method used to rectify it is ONLINE
SEALING or CLAMPING.
 WHAT IS ONLINE SEALING ?
 The injecting online leak sealing is a technique to prevent leakage of materials, while
installing special clamps at the leaking parts & by inject sealant to the cavity and full
the entire space, finally become a new structure to plug the leak paths.
 Safe Welding, Cutting, and Other Hot Work Practices in Refineries, Gas Plants, and Petrochemical Plants API PUBLICATION 2009, SIXTH
EDITION, SEPTEMBER 1995
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5. HAZARDS OF HOT WORK
 Potential hazards while drilling
 Weak or poorly threaded joint
 Uncontrolled process releases
 Temporary reusable Platform
 Exposures to metal fumes and to ultraviolet (UV) radiation
 Electric shock
 Fire and explosions
 Injuries from insufficient PPE
 Risk of skin cancer
 Wrong type of work permit used
 Wrong information about work required on the work permit
 Failure to recognise the hazards where work is carried out (e.g. flammable substances)
 Introduction of ignition source in controlled flameproof area (e.g. welding, non spark-proof tools, non-intrinsically
safe equipment used in intrinsically safe zones)
 Terms of work permit not adhered to (e.g. failure to isolate plant and/or drain lines of hazardous substances)
 Failure to hand-over plant in safe condition on completion of work/cancelling of work permit
 Unauthorised staff performing work permit functions
 Poor management of the work permit system
 Insufficient monitoring of the work permit system
Permit to Work Systems, HEALTH AND SAFETY EXECUTIVE
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6. EXAMPLES OF HOT WORK
 Worker busy in welding of pipe  Online sealing clamp to prevent
leak 6

7. WORKING PRINCIPLE
 Insertion of a non consumable rotating
tool with a specially designed pin and
shoulder between two plates which we
want to weld
 Rotation of pin tool
 Running of pin tool along the weld joint
 Bonding and joining of two metals
Mishra R.S., Ma Z.Y. ‘Friction stir welding and processing’
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8. ADVANTAGES OF FORGE BONDING
 Eliminates current drilling hazards
 Reliably strong, 100% forged joint
 No added leak points
 Enhanced corrosion properties
 Permanent reusable platform
 The relatively low temperature at which the weld is formed means that
the process can be adapted for applications such as welding on live
pipelines and in explosive environments.
 The absence of an electric arc and a liquid phase in the metal avoids
some of the potential problems encountered with arc welding such as
contamination of the weld with hydrogen, nitrogen and oxygen.
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9. SCHEMATIC DIAGRAM OF LEAK ATTENDING BY APPLICATION OF STUD AND
PLATE
‘Valve, pipe and pipe component repair ’, forge tech inc., US 20140216566, 2014
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10. LEAK ATTENDING PROCEDURE IN VALVES
Drill & Tap Injection Port
Friction Forge Injection Port
Friction Forged Injection Port
Friction Forged Stud
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11. TESTING METHODS OF FORGE BONDING
 VISUAL INSPECTION
In this type of testing a person or group of people will examine the
quality of weld on the basis of its look and their experience.
 RADIOGRAPHY
In this type of testing weld can be examined to verify its internal
structure and integrity. Industrial radiography can be
performed utilizing either X-rays or gamma rays.
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12. CASE STUDY-1
 National Cooperative Refinery Association (NCRA) - McPherson, Kansas
 They have leak on roof of storage tank containing gasoline
Prepare the site
Affixing studs
Install 3/16” thick deck plate 12

13. CASE STUDY-2
 HARBISON-FISCHER, Crowley, Texas is which specializes in sub-surface
oil field rod pumping processes, had an issue with an integral pump part that
was taking too long to create and costing too much to produce.
 The part was component of the oil pump that used two dissimilar metals
 They had been mechanically joining the assembly by threading and
soldering a solid Monel rod on the end of mild steel tubes. Both parts
required an independent threading operation (one male external on the
Monel and one female internal on the steel tube). After cutting the threads on
each of the two separate parts they were then threaded together and brazed
to further lock the pieces in place and seal the joint.
 The proposed friction welding process would require only a “saw cut” end on
each of the two pieces prior to joining and could provide a stronger, leak
resistant joint.
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14. CONCLUSION
 Forge Bonding or Friction Stir Welding process is safer than
conventional metal joining procedure, which eliminates chances of
health and environmental hazards cause due to conventional process
and also it is beneficial in metallurgical point of view.
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15. THANK YOU
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