friction stir welding of api grade x65 steel...
TRANSCRIPT
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Friction Stir Welding of API Grade X65 Steel Pipes
Zhili Feng*, Russell Steel**, Scott Packer** and Stan A. David*
* Oak Ridge National Laboratory, Oak Ridge, TN** MegaStir Technologies, Provo, UT
April, 2005
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Acknowledgement
• Research was sponsored in part by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program under contact DE-AC05-00OR22725 with UT Battelle, LLC.
• Technical and financial support of MegaStir Technologies.
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Why FSW of Pipeline Steels
• Ultra high-strength steels• Properties• Productivities?• Hydrogen issue• Weld metal property matching the base
metal
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Material
• API 5L Grade X-65 steel− Common in oil and gas industry for pipelines− 0.08C-1.0Mn-0.235Si-0.04Al-0.016Nb− Ceq = 0.14
• ERW Line Pipe − OD: 12.75” (324 mm)− Wall thickness: 0.25” (6.35 mm)− Base metal properties per mill specification
Yield: 67 ksiUltimate tensile: 77 ksiElongation: 33%
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Welding• Polycrystalline cubic boron nitride
(PCBN) tool− Shoulder diameter: 1”− Pin length: 0.22”
• Girth weld − Square butt joint configuration− No special groove preparation− Surface ground before welding− Single pass full penetration from
OD• Welding parameters
− 500 - 600 rpm− 4 - 6 in/min− Welding forge force: 6500 lbf
• Special run-off tab to eliminate the exit hole on the pipe
• Argon shielding gas from the tool to protect weld from oxidation
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Field deployable FSW system
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Hydraulic internal support/fixture
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Welding movie
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Finished pipe
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Finished pipe
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Microstructure and Mechanical Evaluation
Scale: 1:5
12x3.14=37.7” Each section: 9” long after metallography samples
9”Weld start
1” (OD weld width)
Exit tab
0° 0°270°180°90°
3 cr
oss-
wel
d te
nsile
:4”
wid
e
3 BM tensile:4” wide
9 HAZ Charpy:4.5x3”
18 WM Charpy:9x3”
(4) Metallographic samples
Face for Metallography
9 BM Charpy:5x3”
Tool rotation: CCW
Advancing Side
Retrieving Side
Scale: 1:5
12x3.14=37.7” Each section: 9” long after metallography samples
9”Weld start
1” (OD weld width)
Exit tab
0° 0°270°180°90°
3 cr
oss-
wel
d te
nsile
:4”
wid
e
3 BM tensile:4” wide
9 HAZ Charpy:4.5x3”
18 WM Charpy:9x3”
(4) Metallographic samples
Face for Metallography
9 BM Charpy:5x3”
Tool rotation: CCW
Advancing Side
Retrieving Side
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Mechanical Testing• Tensile
− Room temperature− 3 cross-weld tensile: (1-in wide strip) API 1104− 3 Base metal at room temperature
Orientation: AxialASTM E8, rectangular flatFull stress strain curve. Yield stress at 0.2% offset plastic strain and at 0.5% total strain
• Charpy V notch: ASTM E23, 10x5x50 (sub-sized due to wall thickness) − side V-notch through thickness− 3 repeats at each temperature.− Base metal: axial orientation @ -50, 0, 20C− HAZ: @ -50, 0, 20C− Weld: @ -50, -30, -20,-10, 0, and 20C
Weld Notch
Location
HAZ Notch
Location
~ 0.3”
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Tensile properties• Base Metal
• Cross-weld
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Samples failed outside the weld and HAZ during cross-weld tensile test
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Charpy V-Notch Impact Test
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Charpy V-Notch Impact Test• ASTM E23• 10x5x50 mm, sub-sized• All samples showed 100% shear
0
20
40
60
80
100
120
140
-60 -50 -40 -30 -20 -10 0 10 20 30
Temp, C
Ener
gy, J
Weld
HAZ
Base Metal
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Weld Cross-Section Macro
2mm
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
The interface is not easily distinguishable under high magnification
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Evidence of lack of bonding on the root face
• Relative small ~ 0.15 mm• Oxide layer• Did not affect the mechanical
tensile and impact properties
0.15mm
0.07mm
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Microstructure
Base Metal
TMAZ
Stir zone
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Cross-weld section micro-hardness profile
0 2 4 6 8 10 12 14 16 18 20 22
0
0.8
1.6
2.4
3.2
4
4.8
Postion (mm)
Posi
tion
(mm
)
160-170 170-180 180-190 190-200 200-210 210-220
50
100
150
200
250
Hv @
200
g 1/2t
1/4t
3/4t
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OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Summary
• A portable, field deployable FSW system has been developed for successful welding of X65 pipe
• Fully consolidated weld joint can be obtained in a single pass
• Welding speed• Microstructure/microhardness• The girth show superior tensile and
impact properties