Improving

p g Competitiveness
p Using
g
Sub--Harmonic Vibrations
Sub

Byy
Thomas E. Hebel
Bonal Technologies
Technologies, Inc
Inc.
New Way to Become
More Competitive
Using Sub
Sub--Harmonic Vibrations
 How to Be More Competitive

1. Reduce Costs
(without sacrificing quality)
2. Reduce Time
3. Improve Quality
 Areas of Focus

11.Stress
Stress Relief
2.Welding
 1. Stress / Stress Relief

z Mechanical Stress is caused by forcibly

changing shape of grains (can be
calculated)
z Thermal Stress caused by thermal shock
(is vague,
vague hard to calculate)
 Problems Caused by
Thermal Stress

z Distortion After Machining

z Delayed Distortion
z Premature
P Fatigue
F i
 Solution

z Stress Relief
– Thermal stress relief
– Natural aging
– Cryogenics
– Stretch
– Compression
– Vibration stress relief (sub-harmonic)
 Caution:
Not All VSR Systems Work

z Resonant vsr is inconsistent *

Resonant-vsr
z Resonant-vsr may cause fatigue **

* US Dept of Energy
** US MIL Spec 810B
 Successful VSR (Meta
Meta--Lax®) is
Unique to Industry

z SUB Harmonic vibrations

SUB-Harmonic
z Can “certify” stress relief

Meta-Lax ® developed by Bonal Technologies, Inc.

Sub--Harmonic Processing is Not Heat
Sub
(weldment has ¼
¼--in wall thickness next to 7
7--in block)
No Concern for Heat Side Effects
(improve MPG)
 Sub--Harmonic Stress Relief
Sub

z Find harmonic curve

z Set frequency in leading portion
z Dwell
D ll for
f 15-60
15 60 minutes
i
Certification Sheet with 1st Scan
 How Stress Relief is Certified

z Take periodic scans

z Curve shifts over slightly
z Curve
C ““stabilizes”
bili ” ini new location
l i to
signify stress relief is complete
Complete Certification Sheet
 Sub--Harmonic SR vs. TSR
Sub

Similarities Differences
z Optimum zone z No distortion
z Dwell period z No scaling / discolor.
discolor
z Consistent results z No change in Mechanical
Properties
Neutron Diffraction Comparison
(stress levels before and after sub-
sub-harmonic treatment)
Ex 1 – Autobody Carrier
Ex.
(better distortion control than TSR, saved $150,000)
Ex 2 – Bulkhead for Lock and Dam
Ex.
(480,000--lbs., note equipment in upper left corner)
(480,000
Ex 3 – Airplane Wing Checking Fixture
Ex.
(50--ft., machine stability and eliminate delayed distortion)
(50
 Ex. 4 – Press Base
(80,000--lbs., machine distortion equal to TSR)
(80,000
Ex 5 – Vibration Screen Decks
Ex.
(eliminated cracking for four years)
Ex 6 – Surface Plate
Ex.
(0.002--inch flatness over 12 x 19-
(0.002 19-ft area)
 Increase Stress Relief Capability

z Semi finished / near net finished parts

Semi-finished
z Finished parts / assembled parts
z Hardened
H d d materials i l
z Thick/thin sections
 2. Welding – Advantages

z Reduce Weld Distortion (50

(50-95%)
95%)
z Reduce Weld Cracking (50-95%)
z Improve
I W
Weld
ld Q
Quality
li
 Vibrate “Base”
Base Metal
(Sub--Harmonic Weld Conditioning)
(Sub

z Apply sub-harmonic
sub harmonic stress relief during
welding
 Reduce Weld Distortion

z Molten metal stays molten longer

z Able to reduce weld amps
 Reduce Weld Cracking and
Improve Weld Quality

z Preheat
z Pulsate “weld” metal
z Vibrate
Vib “b
“base”
” metall ((sub-harmonic)
bh i )
 Metallurgical Changes

z More uniform weld grain

z Higher ductility (up to 400%)*
z Higher
Hi h iimpact (up
( to 75%)**

*Wayne State University

** Charles Bronson
Photomicrograph Comparison

Normal With Sub-Harmonic

U.S. Dept. of Energy Report
z “The 4140 plates not [sub-harmonic]
vibrated during
g weldingg were crackingg at
the weld crater at the end of each pass
made. This did not occur when [sub-
[
harmonic] vibrating.”
Ex 1 - Automotive Checking Fixture
Ex.
(81% less distortion than normal)
Ex 2 – Aluminum Bonding Fixture
Ex.
(69% less distortion than normal)
Ex 3 – Edge of Loader Bucket
Ex.
(400% longer service life)
Ex 4 – Life Boat Adaptor
Ex.
(0.003--inch distortion in 12-
(0.003 12-feet after welding)
Ex 5 – Wind Tunnel Part
Ex.
(0.032--in distortion in 32
(0.032 32--ft, stainless steel)
 Ex 6 – Platen
Ex.
(eliminated cracking upon cooldown)
 Competitive Summary from Using
Sub--Harmonic Stress Relief
Sub

z Reduce Mfg
Mfg. Costs and Time
z Match TSR for Effectiveness and
Consistency
z Increase Stress Relief Capacity
 Competitive Summary from Using
Sub--Harmonic Weld Conditioning
Sub

z Prevent Distortion (50

(50-95%)
95%)
z Prevent Cracking (50-95%)
z Improve
I S
Service
i Lif
Life ((up to 400%)
 Special Thanks to
z NASA-Langley, Advex, McDonnell-Douglas,
Woodward-Governor, General Motors, State
Fab, U.S. Army Corps. of Engineers, Steward
Machine, Boeing, J&J Burning,
D l C
Danly,Corrosion
i Engineering,
E i i K&M Machine,
M hi
Grumman Aerospace, U.S. Steel-GLS Div.,
NASA Edwards Purdue University,
NASA-Edwards, University and Build-
Build
A-Mold for photos of their parts.
 Direct Technical Questions
to:

Bonal Technologies
Technologies, Inc
Inc.
(developers of Meta-Lax technology)
Thomas E. Hebel, Vice President
Royal Oak, Michigan
(248) 582-0900

THebel@Bonal.com
www.Bonal.com