Semiwelded Plate

Laser
• Light Amplification by Stimulated Emission

of Radiation
• Key holing: Laser welding transfer the

energy into the work piece through the
generation of a vaporised hole. The flow of
molten metal around the keyhole re-
solidifies in a chevron pattern when the
beam moves.
The semi-welded plate heat exchanger
Welded
channel for Flow pattern in a welded
aggressive plate heat exchanger
fluid
Peripheral
weld
Weld
Gasket
Gasketed
channel
for cooling
medium Gasket exposure to aggressive
fluid virtually eliminated
Why Laser Welding?
• Good weld quality
• High welding speed
• Minimal HAZ (Heat Affected Zone)
• No flux and filler material required
• Operates in air - no physical contact
Welding comparison of AISI 316
6 mm
Laser Plasma TIG MIG
Power (kW) 4 4 2 2,4
Speed (mm/s) 16 7 2 2
Heat Input (J/mm) 250 570 1000 1000

Intergranular corrosion
Chromium carbide precipitating between
the grains of the material.
• Carbon
• High temperature
• Time (7 - 20 minutes)
Laser welding of AISI 316 versus 316L
The carbon present in steel remain dissolved

until the steel is reheated to 350-850 C and
kept at this temperature for several minutes.
With AISI 316 you can stay at 675 C without
ANY risk for:
7 minutes with 0,05% carbon
20 minutes with 0,04% carbon (AL std material)
Actual cool down time is 5 - 20 seconds
5HDVRQV
• combination of thin sheet and large sheet
size
• shielding gas during welding give continues
heat removal
• low heat input ( small HAZ)
• high welding speed (2-4 m/min.)
• high thermal conductivity
Only a sealing weld
(replacing the gasket)
• The weld is a VHDO, not a pressure retaining
weld.
• The tightening forces (*) from the bolt
through plate contacts result in a
compressive force at the weld much higher
than the separating forces.
(*) the separating forces on the weld are the same as on a
gasketed PHE - only 5% of the tensile strength
Only a sealing weld
(replacing the gasket)
F max
P max = 30bar = 3 N/mm^2
5 mm
weld
F max = 5*3 = 15 N/mm weld = 5% of tensile strength

Equipment design and operation
• Joint design: Clamp force gives small gap.
• Shielding gas: Energy transfer through a
“key-hole” which must be protected by a
shielding gas (Ar, He). The shielding gas
also helps to cool down the material.
• Laser machine: Effect, speed, mode
structure and focal point distance are
evaluated for every thickness and material.
Advantages and limitations of
Twin Plates
+ High chemical resistance on welded side
+ High pressure performance on welded side
– Not possible to open welded side for cleaning

– Operating temperature is limited by ring
gaskets
– Chemical resistance on gasketed side is limited
by rubber material
Cleaning of welded heat
exchangers
• If possible, avoid to
immerse
Twin plate and Double
wall in acid baths as
the capillarity will
draw acid into the
crevices which will
cause corrosion
Twin Plate cleaning
• Welded side
– Cleaning should preferably be done by CIP or
pyrolysis.
• Gasketed side
– Cleaning by CIP or mechanically with brush or
high pressure water jet.
• Changing gaskets
– Clean first (CIP), remove gaskets in liquid
nitrogen, clean grooves and change gaskets.
Twin Plate cleaning (2)
• Refrigeration units0$< require drying at
temperatures > 100C and helium testing
after cleaning.
• Check plate thickness before cleaning on
units in H2SO4 duties.
• PTFE grooves are extremely sensitive to
dirt. In general PTFE gaskets should be
changed with every opening.
Twin plates in chemical baths
!!!!! Do NOT dip this way!!!!!
Dirt pocket
Air bubble
Twin plates in chemical baths (2)
!!!!! Dip in water first !!!!!
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Problem 1 - Micro Leaks
Micro leaks that cause attack and swelling of
the rubber core, attack of adjacent field
gaskets and cassettes.
– Scratch across the gasket groove => polish the
groove
– Cuts in PTFE => replace the ring gasket
– Hard particles on sealing surface => clean and
polish gasket and groove
– Too big tolerances between adjacent gasket
grooves => replace cassettes
Problem (2) - Leaks over Gaskets
Pores in welds resulting in attacks on adjacent
gaskets.
Action: replace cassettes with defect weld and

maybe also cassettes on both sides of
suspected cassette
Problem (3) - Severe Leaks over
several field gaskets
Leaks starting after a short period in operation,
caused by aggressive media on wrong
(gasketed) side.
Action: check gasket compatibility, change

gaskets and make sure that the piping is
connected correctly.
Problem 4 - Leak at endplates
Leaks at end plates caused by scratched or
deformed linings or too thick distance rings or
distance sheets.
Action: polish linings or change necessary

parts
Double Wall cleaning
• CIP cleaning is strongly recommended!
• Cleaning in caustic bath is possible when
the duty is < 100C
• Mechanical cleaning & high pressure water
jet is also possible
• NEVER use acid bath cleaning!!!!!
(the crevice between the plates will be filled with acid and
impossible to remove due to capillarity resulting in
corrosion)
Double wall crevices
Useable service tools
• tape gun
• adhesive tape
• solvents ( acetone)
• polish machine or Scotch-Brite
• sharp knife

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Laser

• Light Amplification by Stimulated Emission

• Key holing: Laser welding transfer the

Power (kW) 4 4 2 2,4

Heat Input (J/mm) 250 570 1000 1000

The carbon present in steel remain dissolved

P max = 30bar = 3 N/mm^2

F max = 5*3 = 15 N/mm weld = 5% of tensile strength

– Not possible to open welded side for cleaning

Action: replace cassettes with defect weld and

Action: check gasket compatibility, change

Action: polish linings or change necessary

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