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NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 ‘UDCE21.791.01:539.4 Development of High-Performance Welding Technology for Steel Plates and Pipe for Structural Purposes Abstract: Yukito Hti™™ Kouichi Shinada** Shigeru Okta"* Kunio Koyama" il development is proceeding into arctic and deep-sea regions, and efficiency of the operation of oil pipelines and refining facilities is being improved by a high pressure process. The properties required of steel structures in the energy field are higher than ever low-temperature toughness and strength as well as greater weldability, these include lower preheat temperature and higher welding efficiency. Sulfide stress cracking (SSC) resistance and localized seawater corrosion resist- ance must also be satisfied in some cases. stronger steels, such as TS780 and T8590, and now demands fire resistance as well. The construction field calls for The compatibility between steels and welding materials assumes increasing importance with these stricter property requirements. From the standpoint of oxide metallurgy, technologies for microstructural control and weld metal design have been developed for specific steels, and welding technology is now available offshore structures, SSC-resistant steel pipe, and fire-resistant steels, among other things. 1. Introduction Development of oil and gas resources is expanding into the North Sea, the Arctic Ocean and other frigid regions, and pipeline and other oil and gas production and refining facilites fare operating at increasing pressure for higher efficiency. The ‘changes in steel property requirements accompanying these worldwide moves in the energy development field are summa- rized a6 the relationship between the tensile strength and Charpy test temperature of steels in Fig. 2 As offshore oil drilling structures increase in water depth and size, the substructure must be built of steel of greater thickness to avoid buckling, and the steel of the superstructure must be stronger to reduce weight. Cold and other arctic regions call for “1 Tecnial Develpman Bore ‘maximum Charpy impact and CTOD (crack tip opening displace- ‘ment) test temperatures of —60°C and —40°C, respectively, ‘hich are lower than those for conventional regions. ‘The high pressure transmission through pipelines is eccelerat- ing the use of steel pipe of higher strength: X-70 and X-80” in place of X-55. Technical trends in the energy development field are clearly toward greater strength and toughness. Furthermore, there is a call for steels weldable with high heat inpet which can be fabricated on existing equipment efficiently. ‘New properties are being demanded in addition to strength and low-temperature toughness. In icy sea regions, welds in the splash zone must be protected against localized seawater corro- sion’. Sulfide stress cracking (SSC) is a problem with pipeline and tanks for gas and oil containing hydrogen sulfide (H.S)". To prevent SSC, Vickers hardness of welds is often specified at 248, ‘or less. Environmental disruption also has drawn attention, and —15— NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 —= pens ofstore (a) Acicularfervite (AP) Ts Cl of tieell ie soto Spe gheten roc 8 Loclind (Charpy test emperature (0) é fail vib econ of eile oe Aris in ey se Sesrestars 25a crop ae ‘Tensile strength (Nima?) Fig. 1 Changes in tenth and toughness required in the energy developmen: field oil tankers must now be constructed with double-hulls ro prevent oil from spiling even if a tanker is grounded. This double-hull requirement as increased the length of one-side welding and fil- Jet welding by about 1.5 times, ealing for improvement in weld- ing efficiency" Emphasis in Japan is now on augmentation of social capital and expansion of domestic demand. In the construction field, earthquake resistance is accomplished by reducing the yield ratio of welded joints, and rigid joins where the weld metal does not yield before the base metal are considered essential. The Yokotama Landmark Tower is built of new SMS80 stel in com- bination with conventional SM490 steel”. TS780 ste! is required for high-rise building, and itis necessary to develop steels and welding techniques with weldabilty in mind®. The development of fire-resistant steels” has called for fire-resistant welding maeri- als, ‘The energy and construction fields demand material of higher strength, toughness, and weldabilty (lower preheat temperature and greater efficiency), and have also added those that ae resist- ant to corrosion and fire. Various types of steels to meet these requirements have been developed utilizing the thermomechanical control process (TMCP). To make the best use of the properties of these new steels requires appropriate welding technology, and the development of suc technology which meets recent requie- ments i reviewed here. 2, Problems with Welding Materials for Low- ‘Temperature Service Welding materials for low-temperature service can be catego- rized into three main types by their toughening. mechanism: the lowenickel type where 11%% oF less nickel is added 10 improve 16 ig. 2 TEM observation examples of low-aloy scl weld meal toughness by the solid solution of nickel; te ttanium-boron type where the grain size of the microstructure is refined by adding titanium and boron"; and the high-nickel type where austenite are fully formed to prevent bridle fracture. The low-nickel type and high-nickel type are not suited for welding with high heat input, but the titanium-boron type permits high-heat input welding. It is anticipated that welding technology will be developed to guaran tee the specified impact suength at —60°C or less for steels with a tensile strength of 490 10 $90 Nim ‘The titanium-boron type produces ferrite called acicular fer- site (AF) and radially wansforms from the nucleus of a nonmetal- lic inclusion as shown by the dark area in Fig. 2. Each acicular fervte grain acts as a fracture facet; this assures high toughness With the non-titanium-boron types, adjacent ferrite grains trans- form into almost parallel upper bainite (Bu) grains. However, ‘two or more adjoining Bu grains usualy fall at the same time, resulting in larger facets and lower toughness. Mig. 3 shows the toughness of welds made from stels with different aluminum and other strong deoxidizer content using Some welding materials of type. It is found that the toughness of the weld metal depends on its aluminum content, and there is an ‘optimum aluminum content for toughness. When the aluminum content is optimal, the weld metal consists of acicular ferrite With higher aluminum content, the weld meal is upper bainite and toughness is reduced, and with lower alminum content the ‘weld metal is grain-boundary ferrite (GBF). Aluminum content changes with dilution from the base metal, and the aluminum content ofthe base metal is seen to influence the toughness of the weld metal High-heat input weldable steels based on different concepts of toughness improvement, such as TiB steel”, TIN steel and TiO see", were developed as TMCP steels for low-temperature serv- ice. These steels differ greatly in aluminum content. When the service temperature is low and the dilution rate is high, welding materials appropriate for specific steels are required. The transfor- ration nucleus of Fig. 2 was regarded as oxide inclusion contin ing TiO". There have been examples of the formation of acic- SORFATT (8) aa bo Aluminum in weld meal (v0) Fig. Effect of alumiaum on toughness of T-B weld meal ular ferrite in the weld metal being governed by the aluminum content of the base metal, and acicular ferrite being obtained ‘without appreciable titanium addition". Stable acicular ferrite formation technology must be analyzed from the standpoint of oxide metallurgy, 3. Stable Formation of Acicular Ferrite by Oxide ‘A weld metal with an AF + GBF microstructure (A), one with a Bu microstructure (B), and one with an AF + GBF microstructure (C) (Table 4) were deposited using titanium- ‘Table 2 Chemisal compositions of weld mals for analysis of nonmetallic acusons NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 boron-bearing, non-ttanium bearing, and trace tianium-bearing electrodes, respectively, and analyzed for nonmetallic inclusions. ‘The X-ray diffraction results of the electrolytic extraction residues of the three samples are shown in Fig. 4, and TEM observations of the nonmetallic inclusions in Fig. 5. The weld ‘metal B with the upper bainite microstructure has no particular peaks in the X-ray diffraction spectrum of Fig. 4, and its electron beam analysis image shows a halo pattem; this means that the nonmetallic inclusions in this metal are amorphous. The weld metals A and C, each with acicalar ferrite, have almost the same direction peaks (Fig. 4), meaning that they contain the same nonmetallic inclusions. Considering the X-ray diffraction results in combination with the electron beam analysis results of Fig. 5, these nonmetallic inclusions were identified as spinel oxide (Mn0-ALO). The lattice misfit of the spinel oxide with alpha iron is 1.8% and is beter than 3.2% for titanium monoxide (TiO) which has reported as nucleation site, Acicular fervite can easily grow epitaxally from spine! nuclei. ‘The formation of acicular ferrite from an amorphous interface requires a large amount of energy. The microstructural difer- fences between samples A and B depend on whether or not the oxides contained are coherent. Manganese sulfide (MnS)", claimed to be effective for transformation in tel, was similarly deposited on both samples and was not effective in a weld metal. ‘The results of analysis by energy-dispersive X-ray spectroscopy (EDS) show that the three samples differ in the composition of their nonmetallic inclusions, only in that samples A and C contain titanium. This shows that cianium plays an important role in forming spinel. It is also known to be a glass crystallization cata- lyst, and is presence inthe oxide is considered to have promoted the formation of spinel. The titanium detected in both samples A z ‘TLB type 1000-29 250 te | arr 0 30 0 q ‘SkMn ype | @ ml Trace Ti ype 8 Bae se prem FO ha al 2 50 ic So 40 30 Cy e 40 30 a 0 Fig. 4. X-ry itfrcton analysis results of fie oxides ftom elcrostic extraction residues of weld mal ye NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 ® Om (Foie O.1um ® @ Fine t (&) Tob ype weld meu (AF > GBF) Fig. 5 TEM observations of nonmetallic ine sions jo A¥002,_THO.015, B:0.003, 0.004 B as BO; 0) 08 — 30940050 ‘Oxygen in weld metal (pm) Fig. € Optimum ranges of Al, Ty BN, and O in THB type weld metal and C is thought to have replaced some of the manganese and aluminum to form (Mn,T)O-(AL,T):O,. Since the oxidation reaction of deoxidaton elements in the weld pool proceeds in an increasing order of affinity for oxygen”, all oxygen reacts with aluminum at te high end of the aluminum range where the alu minum/oxygen ratio of 1.125 in ALO is exceeded. This pre- ‘vens the oxidation of titanium and hence the formation of spinel. ‘Both aluminum and titanium must be oxidized forthe formation ‘of spinel. An important condition isthe oxygen potential (AVO < 1.125) after cessation of aluminum deoxidation. In addition the consumption of free boron, which is necessary to inhibit the formation of grain-boundary ferrite must be prevented from oxy- (@) Sita pe weld meal (Bu) SO*FATT (€) AF Caczee. Fig. 7 Schematic showing eects of alloying elements on stength and toughres of TB ype weld meta ‘gen and nitrogen. It is important to strike a proper balance ‘among aluminum, titanium, boron, oxygen, and nitrogen by eon- sidering the amounts of these elements introduced from the base ‘metal. The optimum ranges of these elements are schematically shown in Fig. 6, 3.2. Increase in toughness by adjustment of other elements ‘The effect of other elements due to dilusion from the base ‘metal has been determined for the ttanium-boron weld metal ‘where acicular ferrite is obiained by the optimization of alu- ‘minum, titanium, boron, oxygen, and nitrogen’. This effect is schematically shown in Fig. 7, together with the optimum strength and alloy content for the toughness of the weld metal. Grain-boundary ferrite and upper bainite increase more than acic- ular ferrite, respectively, when the actual alloy content is smaller and greater than the optimum level. Toughness declines in each ~B— SOBFATT CO) ~~ SmSSCOSSC« Oxygen conten in weld etl (ppm) Fig, 8 Effect of oxygen content on toughness of weld meal ‘case. Copper and nickel are relatively wide in the optimum range, while manganese and molybdenum are narrower in the ‘optimum range. The effect of dilstion from the base metal must be carefully controlled. If the AVO rato is held constant, the lower the oxygen content, the higher will be the toughness as shown in Fig. 8. ‘The oxygen content should be keep as low as possible, 4, Increase in Toughness of Reheated Weld Metal For welding in multiple passes with a ttanium-horon bearing system and high heat input, the heat-fected zone (HAZ) in the weld metal rebated by the welding beat of the successive passes, is embrited like the HAZ in the base metal. Since such brite 2ones are @ governing factor for the CTOD valve of the weld meta, measures should be taken 1 avoid embritlement of the reheated zone a well a the as-welded zone desried in the pre ‘ious chapter. Heating temperature of the reheated zone continuously changes, making it difficult to analyze. Like the base metal the reheated zone was carefully analyzed using a weld thermal cyle Simulator. The results of themal cycle simulton are given in Fig. 9, and microstructures obtained at typical heating tempera- tures are shown in Photo 2. Cause ofthe formation of the brite one varies with Ge peak heating tempera. In the britlst, rain-refined zone (at about 950°C), ferrite grains are larger than AF grains, and the martensie-austrite constituent (MAC) is pre- sent. Inthe graincoarsened zone (ator above 1,000°C), GBF is more than in the as:velded zone. In the éuakphase zone (near 750°C), the MAC is formed in the solidified segregation region. Lowering the carbon content reduces the MAC content and improves the toughness of the grain-efined zone, but increases, GBF in te graincoarsened zone and embritls this zone. There NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 tor comesisho Di tov cen we © um caine a0} 0 Lm ean en SOSFATT CC) Iva Prk heating temperature CC) Fig. 9 Toughness of reheated zone in various wel! metal compositions is no other measure than a reduction in oxygen content to improve toughness that can be commonly applied to these zones Inthe case of low carbon-niekel type weld metal, retained austenite formed in place of the MAC, i ess embitld than the ‘molybdenum Weld meal (se Fig. 9) and low carborsckel type weld metal is suitable for use when the toughness of the reheated zone is critical. 5. Development of Welding Materials for Low- ‘Temperature Service 5.1. Development of low-temperature high-heat input welding ‘materials for specific steels Submerged arc welding (SAW) materials for steels with ten- sile strengths of 490 and 590 MPa were developed, based on the findings discussed above. Typical examples are given in Table 2. Localized seawater corrosion is reported not to cccur when the absolute value ofthe parameter AEC due tothe differences in copper and nickel content between the base metal and the weld metal is less than unity". Welding materials marked by an aster- isk are designed taking this into account 5.2 Development of low-harcenability high-toughness weld ing materials for SSC-resstant steel pipe Sulfide stress cracking (SSC) is likely 19 occur in pipeline handling large amounts of hydrogen sulfide (FS) and sour g3s. ‘To prevent SSC, hardness is often specified at Hv = 248. Since ith welds of pipes are made with @ low heat input of 1.0 km or less, the HAZ of the seam weld metal by girth welding is Photo. Rebeatng emperatures and mirosrvcral changes ee NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 ‘Table 2 Typical mechanical properties of SA. weld metal for low emperture service Wage | Sect RE Few ie] AW PTS] Eee ee [SRTATT] MRO [Conmectn] Fin We ae iam | othr | Biman | “ase as [PES] MES 7 45) AW [iso 365) Sos ps | as |ave2@ Jw | SDD purr |s03_599| eos isa | — [sven TR [SOL AW | 96 [eae rit | a8 [900 [ONT PSIORVON TN [a] as] AW] 6a] S057 se] 8 [=a 0 modem | eOLeYDNS Bait pout |503 a0] 5284 sise| —» [sense TO PAS AW se ee] IS sits | ear TS | BOONTON pant |3s7_6a| ‘aio | — | soe TN |e [ooo [AW 6 | ae — 68 | [earn [va aE faa [CAW Ls ave aoe | [aon Mee ase bev ae] Lae [ aw |= 68 | sat — a |= [aro [nde | S56 ADM Tid AW | =~ os 9593 | [ear NindSN|SS5E AVENT it [AW [ese 00 tt [= — EW ea S88 YOM Ta [AW [Sa ee6 st) Tres [60 [Ica S86: 927 [ AW [S156 | T4098 tari | 88 | -@CS [No.1 [SSE Tae VONT Tair [CAW |g) eta 86 eae Me Lon [as YSNT Teas SR BL CAW [aa et | ase 509 | ss |= iran AYO isa [ AW [asi ese a0 ama | = Ir to 035 04d CEQ «IW 430 CEQ and absorbed energy of low-niogenlow-onygen weld ‘metal for SSC-resistan ne pipe oe O50 hardened most. Therefore, the seam weld metals must have high toughness as well as adequate strength at low hardenabilty. Based on the findings described in the previous chapter, welding ‘materials were developed for SSC-tesistant ste! pipe. ‘The basic concept is to add titanium and achieve AVO < 1 (0.8), in order to produce a microstructure composed largely of acicular ferrite by bott-side single-pass welding. As discussed ‘Chapters 3 and 4, reduction of carbon and oxygen content is an effective means of increasing toughness without increasing hard- ‘enablty, and the carbon equivalent (CEQ) is made as low as possible to meet the Charpy impact energy requirement of Exc A high-basivty fased flux was developed that accommodates the high-speed welding of UO pipe and assures low oxygen and nitrogen contents. Using this new flux, weld metals with differ- ‘ent CEQ values were prepared”. ‘The Charpy test results of the low-oxygen low-nitrogen weld metal as well as high-nitrogen i (bse meal) Ni (weld eta) 30 © 4 6 O.3ksimmii3. Tin) O.A.9 108d /mm(5 dn) cEQ aw) ig. 14, Hardenabiliy test esos of weld metal for SSC zesisan ne ie ‘weld metal and the high-oxygen weld metal used are given in Fig. 10. The low-oxygen low-nitrogen type has higher tough- ress than the high-nitrogen type and the high-oxygen type, despite its lower boron content. Using the method shown in the ‘upper part of Fig. 11, the welds were reheated to the same degree as reached during girth welding. The hardenablity ofthe reheated welds is shown in the lower part of Fig. 11, All welds ‘exceeded the HAZ hardness of 250 when the heat input was 0.5 ‘Kime. When the heat input was 1.0 ki/mm, the region where —»— a 2 “0 Applied stress (N/a) 8 4 baa Maximum surface hardness HY (4) New weld metl (low N, low 0, 9 ppm B NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 Foo} é a £0 a % i o@ 2200] 2 ‘wo tar ahs ia asad Maximum surface hardness Hy (©) Comparative weld meal (low N, high ©, 20 ppm B) Fig. £2 SOC charters of weld metas for SC: resistant ne pipe te hardness requirement of Hv < 248 can be met was near the CEQ value of 0.368. Both the high-irogen wype and the high oxygen type show almost dhe same degree of hardness as the low-oxygen low-nitto- gen weld metal with the boron content of | ppm, except for the high-itogen weld mecal with dhe heat input of 1.0 1/mm.. This is because the boron in the high-itrogen type and in the high oxygen type forms boron nitride (BN) and boron oxide (B10), respectively, and there is no free boron to increase the harden: ability. Sinee boron nitride is unstable, ebeating at 1.0 kim decomposes some of it in the high-nitrogen weld metal and fee boron is formed. This fee boron is probably responsible for the slight hardening observed in the high-itogen weld metal. In cater words, more boron should be allowed in te weld meta ‘ecause it contains more ntogen and oxygen. ‘The SSC resistance of the weld metal thus developed was evaluated by @ four-point bending test method under the NACE solution. The resus are shown in Fig. 22. Compared with the bigh-onygen weld metal, the newly developed weld metal cracked only when the hardness and applied stress were both highs its very good SSC resistance was thus confirmed. With the esab- lishment of technology to assure the desired toughness of low- alloy weld meal low-hardenabilty and high-oughness weld met- als can now be designed, The new welding material has already been applied to the production of more than 100,000 tons of S8C-esint see! pipe 6. Development of Welding ‘Technology for High- Functionality Steels in Construction Field ‘The Ministry of Construction of Japan conducted a project 10 develop technology for a fire-resistant design system for use in buildings to assure their safety. The new system resulted in designs complying with the high-temperature strength of steel and Jed to the development of fie-esistant construction steels with a ‘guaranteed resistance up to 600°C”. Fire-esistant steels have ‘many advantages, including the elimination or reduction of fire resistant coverings, reduction in construction cost, and effective utilization of space. Welding materials currently in use for heat- resistant steels ae of a beter quality than needed for fire-resistant steels, and new materials appropriate for the strength and price of fire-resistant steels must be developed. ‘The percentage of the room-temperature yield point that Fe freexatant sel SHA90.NER) For conventional sel (S50) ‘Test temperature C) aa 650 213 Temperature dependence of yelé strength of SA weld metal ‘eponted by welding rata for reese sel for ‘convention see! remains at 600°C depends on the molybdenum content, irrespec~ tive of the welding process employed. The optimum composition fof each fire-resistant steel was determined by considering the dilution rate for each welding process. The yield strength ofthe weld metal with high-temperature properties of the weld metal are given in Fig. 23. “righ-heat input SAW is applied to box column corner joints Formation of acicular ferrite by adding tanium and boron is req- site in terms of toughness. When the titanium and boron con- tents are high, the high-temperature ductility of the weld metal declines as shown in Fig. 14. The high boron content weld metal fractured at austenite grain boundaries and short-time creep strength was low at 600°C. This phenomenon was observed in high-heat input welds. Since these welds are large in austenite ‘grain size and likely o increase in grain-boundary boron concen tration, only the smallest necessary amounts of titanium and boron were added. 2 NIPPON STEEL TECHNICAL REPORT No. 65 APRIL 1995 Elongation (3) ‘Test temperature (0) Fig. 24. Effet of tani and boron on hih-emperaure dusty of| ‘veld meal 20¢, RR v & T Hands of weld eta rome weld ence et HV 8 No eating {oy yp Nowa esl seg i al wld et est (Nine) Fig, 15 Relasonship among tensile stength,hardoss, and crcking of weld meta 6.2. Manufacturing technology for HTT780 steel box columns for superhigh-rise buildings Superhigh-rise buildings must be constructed of box columns with a tensile strength of 780 Nimm’. The primary problems involved in welding of such box columns are prevention of cold cracking and reduetion in preheat temperature. TS780 stel with lower preheat temperature was developed as reported else- where ‘The two-electrode AC-MIG technique was established 10 ‘make the best use of new steel. Use of large-diameter wire increased the welding current, improved welding efficiency, reduced hydrogen content to an extremely low level, and enabled the welding of 100mm thick plates with a prebeat of only 50°C. If welding material with a nominal srength of 490 Nisa’ is used for jig installation, cold cracking does not occur. AS the heat input is iow, strength of weld metal is over 780 Nim, and field \weldability does not sufer, as shown in Fig. 25. 7. Development of High-Productivity Technology Preventing oil spillage which is one cause of environmental pollution necessistes the double-hull construction of oil tankers and increases the weld length by about 1.5 times. Increase in Welding sped is expected to improve the construction efficiency Bol og seme £ | w i a a i 2 |comeimt ner Lia) Pla thickness (um) Fig. 26 Welding speed comparison of now on-si welding process with fourelectodes and conventional on-ide welding proest of double-bulled ships over that of conventional ships. By one- side single pass SAW with four electrodes (ewo electrodes for uranami formation and two electrodes for surface bead formation) and modification in flux, the welding speed was increased as, shown in Fig.16®. “The heat input is reduced, rotational deforma- tion that causes toe cracks, a problem in one-side welding, is halved, and repair time and labor is reduced. Fillet welding for a leg length of 5 mm can be performed at high speed of 1.5 m/min by the combination of a fluxccored arc welding (FCAW) technique and two-electrode fillet welding equipment” 8. Conclusions Greater strength and higher low-temperature toughness are demanded for welds in new steel structures fabricated inthe ener- ay and building constuction fields. In adiion welding effiien- cy calls for higher heat input, lower preheat temperature, and higher speed. Based onthe principles of oxide metallurgy, there is now technology to assure the desired toughness of the weld ‘metal, and itis possible to design weld meu that resist coro- sion and SSC and have otber properties and which are suitable for specific sels ‘A new Hux copper backing process (FCB) and filet welding process have more than doubled welding speed. Although not eseibed here, a new steel with good electron beam weldabilty has also been developed, making it posible to weld heavy-205e plates at higher speed Technology making it possible to impart higher stenglh and toughness to a weld metal and enbancing welding productivity Jas made great progress and will corns to do 30. References 1) Murata, S. tal: Joural of the Society of Neval Archies of Japan. 156, 489 (1988) 2) tara, Y. et al Jura of the Society of Naval Archit of Span 157, 889 (1985) 23) Natangi, H. eal: WELDING-90, July 1990, Hamburg, Germany ‘9 Lingo, DG: eal: Consion. Paper 385, 1986 5) Takahashi, A. et als CAMPAISU. 613), 644 (1954) ©) Miyazaki. etal: Hiahi Zoe Gio. 54 (1), 71 1993) Obit, Meal: CAMPASU. 6 @). 405 (194) 8) Yamasia, . et al; Tedkos Guts. 7 (8), 63 (1998) 9) Chiwa, R.ecal: Stance Gio. 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