Download or read book Welding with Low Alloy Steel Filler Metal of X65 Pipes Internally Clad with Alloy 625 written by Evan Daniel O'Brien and published by . This book was released on 2016 with total page 162 pages. Available in PDF, EPUB and Kindle. Book excerpt: In the oil & gas industry, extraction of oil reserves from pre-salt subsea oil fields requires pipelines and risers to be joined with welds that overmatch the X65 pipe yield strength by 100 MPa, have high toughness, and do not utilize a PWHT. In typical oil extraction, these internally clad pipes are welded with fill passes of Alloy 625 that match the internal clad, however, the strength requirement for reeling is not met with this alloy. To meet the strength requirement, low alloy steel consumables were studied as fill passes to join X65 pipes that are internally clad with Alloy 625 with root passes welded using 625 filler metal. The problem with this metallurgical combination is that solidification cracking can occur in the low alloy steel weld passes that have been diluted by Alloy 625. Computational modeling was performed to screen potential consumables and welding trails were completed for consumables that demonstrated compatibility. Upon establishing welding parameters, bead-on-plate design of experiments were performed with low alloy steel (ER100S-G) welded over two different nickel-based alloys (Alloy 625 and Alloy 686). Buffer layer solutions were also tested using two other Ni-based alloys, UTP A 80 Ni and Alloy 625 LNb, to isolate the root pass material from the fill pass material. Solidification cracking was eliminated in bead-on-plate welds of ER100S-G over Alloy 625 using small weave amplitudes, however, Alloy 686 was determined to have better compatibility with the low alloy steel filler metal to avoid solidification cracking. Welding experiments in a narrow groove were performed for the compatible combination, ER100S-G fill passes over a root pass of Alloy 686, and solidification cracking was eliminated from the fill pass welds. During this study, a defect previously thought to occur only in castings has been identified in welds of low alloy steel filler metals over Ni-based alloy substrates. Referred to in this study as “shrinkage porosity”, these defects were encountered in the compositional transition zone of these welds and were related to the large difference in solidification temperature ranges between the low alloy steel filler metal and the Ni-base alloy substrate.

Download or read book Welding of X65 Internally Clad with Precipitation Strengthened Ni based Superalloy Filler Metal written by Graciela Carolina Penso and published by . This book was released on 2016 with total page 151 pages. Available in PDF, EPUB and Kindle. Book excerpt: Giant oil reservoirs were found off the coast of Brazil in the Santos Basin Bay. They are located under a geological salt layer; thus they are called pre-salt. The fact that these reservoirs are located far from shore, has presented some technological challenges. Currently, X65 pipes internally clad with Alloy 625 are used for traditional subsea oil extraction. Such pipes are joined using Alloy 625 filler material. Since the depth and the amount of risers and pipelines to be installed in the pre-salt oil reserves are very large, pipe reeling is considered the most efficient technology for pipeline installation. For pipe reeling, it is necessary for the welds joining the pipes to overmatch the X65 base metal yield strength by 100 MPa, without any post wed heat treatment, thus Alloy 625 does not meet those requirements. The objective of this project was to explore the applicability of precipitation strengthened nickel-based filler metals for welding of internally clad X65 pipes for application in pipelines and risers for oil extraction from pre-salt subsea oil fields. Ni-base super alloys 718 and 282 were considered as potential welding consumables for this application. The solidification behavior in the weld metal of these alloys diluted with the Alloy 625 pipe cladding was evaluated using thermodynamic simulations with Scheil-Gulliver module of Thermo-CalcTM. The Alloy 718 / Alloy 625 system exhibited almost constant solidification temperature range of about 250 oC with formation of Laves phase at the end of solidification throughout the whole dilution range. The Alloy 282 / Alloy 625 system exhibited potential for lower susceptibility to solidification cracking with the solidification temperature range gradually degreasing to 150 oC and no formation of Laves at dilutions lover than 70%. The compatibility of Alloy 718 and Alloy 625 filler metals with alloy the 625 cladding and X65 steel base metal was evaluated by performing bead-on-plate welding and producing multilayer buildups using cold metal transfer (CMT) and gas metal arc welding pulsed (GMAWp) processes. No solidification and liquation cracking or lack of fusion defects were experienced in large range of welding parameters with both filler metals. The precipitation behavior during multipass welding in both alloys was evaluated as a potential strengthening mechanism to meet the weld metal overmatching strength requirement. Hardness mapping on multipass weld buildups has shown that at least two reheats by high heat input subsequent weld passes with GMAWp are needed to cause precipitation hardening in Alloy 718. Significant precipitation hardening in Alloy 282 occurred by three reheat weld passes with CMT. Tensile testing in all-weld metal multipass buildups showed that multipass welding with GMAWp cannot generate sufficient precipitation strengthening in Alloy 718 filler metal to meet the X65 yield strength overmatch requirement of 550 MPa. With yield strength of 620 MPa, Alloy 282 multipass weld buildup produced with CMT met this requirement. Successful test groove welds in low alloy steel were produced with Alloy 718 and Alloy 282 using correspondingly GMAWp and CMT processes. A root pass of Alloy 625 was used to simulate pipe internal cladding. Welding parameter optimization allowed to resolve center line solidification cracking and lack of fusion defects in welds of both alloys. As a final step, narrow groove welding of X65 pipe with Alloy 282 was performed using CMT process. Additional welding parameter optimization was performed to produce welds free of center line cracks and lack of fusion defects. Flat to convex pool surface with elliptic shape was obtained by controlling welding travel speed and wire feeding rate. The weaving amplitude and frequency were adjusted to consistently penetrate the bead toe / groove surface intersection points. Metallurgical characterization was performed on the bead-on-plate samples, weld buildups, and groove welds. The weld metal and heat affected zone microstructure was characterized using light optical microscopy and scanning electron microscopy (SEM). Energy disperse spectroscopy (EDS) within the SEM was used to study the composition gradients across the base metal / filler metal transition zone and across the weld metal layers. The results of this study have shown that Alloy 282 filler metal provides a potential solution for welding X65 pipes internally clad with Alloy 625 in terms of producing defect free welds and meeting the base metal overmatching requirement for reeling applications.

Download or read book Using Duplex Stainless Steel to Join X65 Pipe Internally Clad with Alloy 625 for Subsea Applications written by Emeric Emmanuel Suma and published by . This book was released on 2017 with total page 207 pages. Available in PDF, EPUB and Kindle. Book excerpt: Oil reserves off of the coast of Brazil have been discovered under a geological layer of salt. These pre-salt sea oil fields present high material requirements for extraction. The oil itself is high in H2S and other contaminants that make it extremely corrosive. The reserves are below 2 km water, 2km rock, and 2km requiring a stronger pipeline material. X65 pipe internally clad with Ni-based Alloy 625 was chosen for the risers and pipelines to meet these requirements. Joining of these pipelines will occur on-shore, after which the pipes will be loaded onto ships by being reeled onto spools with diameter of 20m. A high deposition rate process is required to make production efficient. The welds cannot be post-weld heat treated (PWHT) and their yield strength must over-match the base metal’s by 100 MPa (550 MPa), so that plastic strain occurs in the base metal, not the weld. The yield strength requirement is determined by DNV-OS-F101, a standard for offshore pipeline systems [1]. The primary issue is that weld consumables that meet this strength requirement have a higher melting point than Alloy 625. The increased energy required to melt the consumable results in greater melting of the substrate and increased dilution. If a low alloy steel were utilized, the increased dilution from Alloy 625 results in extensive solidification cracking in the weld metal. From a fundamental perspective, this project is about welding a higher melting point consumable over a lower melting point substrate. The objective of this project was to evaluate the applicability of Duplex and Super Duplex Stainless Steel (DSS, SDSS) filler metals for welding of X65 steel pipes internally clad with Alloy 625 utilizing low heat input Gas Metal Arc Welding (GMAW) process. The problem of solidification cracking in welding with higher melting point consumable over lower melting point substrate was addressed by developing a comprehensive consumable selection and evaluation procedure. The latter included: 1) material selection based on reported yield strength, 2) solidification simulations to determine solidification cracking risk, 3) bead on plate welding parameter variation trials to assess general weldability, 4) flat position narrow groove welding for parameter development, 5) pipe narrow groove welding, and 6) metallurgical characterization and mechanical testing. Alloy 686 was considered alongside Alloy 625 for the root pass. DSS 2209, SDSS 2594, & SDSS 2594-CuT filler metals were considered to fill the groove or act as a buffer layer between the Ni-based alloy root and a low alloy steel fill consumable. Because dilution from the Ni-based alloy root pass could increase solidification cracking risk, low heat input weld processes GMAW-Pulse, Cold Metal Transfer (CMT), and CMT+Pulse were used to minimize dilution.

Download or read book Girth Welding of Internally Clad API 5L Grade X65 Pipes Using Low Alloy Steel Filler Metal written by Alejandro Alvarez and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This study focuses on the development of low alloy steel (LAS) girth welds on internally clad API 5L Grade X65 steel by investigating the metallurgical phenomena of welds made using a high melting temperature consumable over a low melting temperature substrate. The metallurgical phenomena of welds made using a low melting temperature consumable over a high melting temperature substrate have been widely reported in literature. The solidification behavior of alloy 625 overlays on high-strength steel (HSS) has been reported in works pertaining to the oil and gas, petrochemical, and power generation industries. Extensive investigations have been conducted analyzing microstructural and compositional gradients along the fusion boundary and transition zone that degrade the mechanical properties of such welds. Alloy 625 girth welds on internally clad HSS have also become a topic of continued discussion as premature failures have been associated to the fusion boundary between the Ni-based alloy weld metal and HSS pipe. The oil and gas industry is investigating the potential replacement of alloy 625 girth welds with LAS girth welds. LAS girth welds could possibly reduce susceptibility to premature failures while also reducing pipeline manufacturing and installation expenses. Reel pipelay is a method of installing pipelines to the ocean floor from giant reels mounted on an offshore vessel. Reel pipelay is known to increase installation rates and reduce manufacturing expenses since welding and inspection is performed onshore. DNV-OS-F101, however, states that girth welds intended for reel pipelay applications shall overmatch the base metal yield strength by 100 MPa. Careful consideration is also required during girth welding to ensure that the corrosion resistant properties of the internally clad layers remain intact. Such girth welds have been challenging to develop due to poor weldability. Dilution from the low melting temperature substrate into the high melting temperature girth weld metal increases susceptibility to solidification cracking, liquation cracking and shrinkage porosity. Industry has not yet developed single U-groove LAS girth welds on internally clad HSS pipes due to a lack of understanding of the metallurgical phenomena in such welds. This study presents a methodology used for determining material compatibility to alleviate weldability concerns. Thermodynamic computational modeling is used to analyze the solidification behavior, partitioning characteristics, and phase transformations. Button melting, SS-DTA, and dilatometry is used to analyze the microstructural evolution in ER80S-G as a function of dilution from FM-686. Such testing methods help identify critical transformation temperatures such as AC1, AC3, Ms and Mf and, mechanisms that could be used to alleviate cracking susceptibility. Upon identifying the material compatibility between ER80S-G and FM-686, this study presents a procedure optimization approach to develop defect-free LAS girth welds. LAS girth welds are developed utilizing a combination of arc welding processes (i.e., CMT and GMAW-P) to minimize dilution from the Ni-based alloy substrate. A controlled sequence for depositing weld passes is also applied to further decrease dilution and create a temper bead welding effect to help reduce hardness. Lastly, this study subjects the newly developed LAS girth welds to metallurgical characterization and mechanical testing to develop a correlation between microstructure and mechanical properties. Testing is first conducted in accordance with DNV-OS-F101 to determine strength properties. Afterwards, hardness mapping and customized tensile testing utilizing Digital Image Correlation (DIC) is performed to determine the local mechanical properties of regions that contain both compositional and microstructural gradients. This study presents the successful development of LAS girth welds on internally clad API 5L Grade X65 steel. Girth welds exhibit a 200 MPa overmatching strength but failed to meet bend and hardness requirements stated by DNV. 1 of 3 bend specimens contained a crack longer than 3-mm that propagated from a pore. Per DNV, re-testing is required. Hardness is also above the 250 HV10 maximum requirement. Further testing is required to determine if PWHT could reduce hardness below the desired requirement.

Download or read book Induction Bending of Internally Clad Steel Pipes written by Rex Thomas Alexandre and published by . This book was released on 2016 with total page 178 pages. Available in PDF, EPUB and Kindle. Book excerpt: Cracking in corrosion resistant clad overlays on low alloy carbon steel pipes made with Alloy 825 has been experienced in the industry in an effort to reduce production costs by changing the cladding material from the more costly Alloy 625. A detailed metallurgical investigation was carried out to understand the root cause of the cracking phenomenon. Analysis consisting of optical and scanning electron microscopy along with hardness traverses and mapping revealed weld metal heat-affected zone liquation cracks in the second overlay after welding, as well as a region of high hardness in the planar growth region of the weld metal directly adjacent to the dissimilar metal weld interface. Serial sectioning shows that ductility-dip cracks form between the pre-existing weld metal liquation cracks and microcracks forming in the embrittled planar growth region, ultimately leading to through-thickness cracks of the overlay during induction bending. The strain-to-fracture test was modified to replicate the bending procedure, and an optimal parameter window consisting of bending temperature, total strain, and strain rate was identified based on test results. ThermoCalc pseudo-binary phase diagrams were created using both the equilibrium and Scheil models. Neither diagram predicts the formation of any low melting eutectic constituents that could lead to liquation during welding. EDS results show spikes of titanium in the bulk weld metal, presumably due to the presence of titanium carbide particles. A plot of solidus temperature versus weight percent titanium created in Thermocalc reveals severe melting point depression in the Alloy 825 matrix as the titanium content increases. It is hypothesized that the weld metal heat-affected zone liquation cracking occurs via constitutional liquation of titanium carbide particles in close proximity to the fusion zone during welding of the second overlay. The region of high hardness at the DMW interface was observed to correlate with microcracks forming in that region as initial straining began during induction bending. Gleeble testing showed that avoidance of microcrack formation by manipulation of bending parameters is not possible. A study on hardness at the interface during processes steps was performed, revealing that the hardness increase occurs during the normalizing post-weld heat treatment before bending. A DICTRA diffusion model was carried out to further understand the mechanism behind the increased hardness in the planar growth region. Results show a pile-up of carbon extending approximately 100-150 microns into the weld metal at the DMW interface. It is theorized that avoidance of microcracks at the DMW interface is best achieved by elimination of the PWHT. Replication of the induction bending process in the Gleeble thermo-mechanical simulator was achieved by modification of the strain-to-fracture test. Results show that reducing the strain rate opens the safe bending parameter window in terms of temperature and total strain. A bending temperature of 975 ± 25 °C is suggested to successfully induction bend pipes without causing ductility-dip cracking.

Download or read book Superalloys 2020 written by Sammy Tin and published by Springer Nature. This book was released on 2020-08-28 with total page 1098 pages. Available in PDF, EPUB and Kindle. Book excerpt: The 14th International Symposium on Superalloys (Superalloys 2020) highlights technologies for lifecycle improvement of superalloys. In addition to the traditional focus areas of alloy development, processing, mechanical behavior, coatings, and environmental effects, this volume includes contributions from academia, supply chain, and product-user members of the superalloy community that highlight technologies that contribute to improving manufacturability, affordability, life prediction, and performance of superalloys.

Download or read book Internal External Protection of Pipes written by R. J. Galka and published by Air Science Company. This book was released on 1990 with total page 378 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Proceedings of the International Conference on Offshore Mechanics and Arctic Engineering written by and published by . This book was released on 1992 with total page 656 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Welding Engineering written by David H. Phillips and published by John Wiley & Sons. This book was released on 2016-02-16 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: Provides an introduction to all of the important topics in welding engineering. It covers a broad range of subjects and presents each topic in a relatively simple, easy to understand manner, with emphasis on the fundamental engineering principles. • Comprehensive coverage of all welding engineering topics • Presented in a simple, easy to understand format • Emphasises concepts and fundamental principles

Download or read book Explosive Bonding written by V. D. Linse and published by . This book was released on 1967 with total page 38 pages. Available in PDF, EPUB and Kindle. Book excerpt: Describes basic mechanics of the process, practices of those in the field, metal combinations and configurations that have been bonded, and applications.

Download or read book Corrosion of Weldments written by Joseph R. Davis and published by ASM International. This book was released on 2006-01-01 with total page 228 pages. Available in PDF, EPUB and Kindle. Book excerpt: Corrosion failures of industrial components are commonly associated with welding. The reasons are many and varied. For example, welding may reduce the resistance to corrosion and environmentally assisted cracking by altering composition and microstructure, modifying mechanical properties, introducing residual stress, and creating physical defects. This book details the many forms of weld corrosion and the methods used to minimize weld corrosion. Chapters on specific alloys groups--carbon and alloy steels, stainless steels, high-nickel alloys, and nonferrous alloys--describe both general welding characteristics and the metallurgical factors that influence corrosion behavior. Corrosion problems associated with dissimilar metal weldments are also examined. Case histories document corrosion problems unique to specific industries including oil and gas, chemical processing, pulp and paper, and electric power. Special challenges caused by high-temperature environments are discussed. Commonly used methods to monitor weld corrosion and test methods for evaluation of intergranular, pitting, crevice, stress-corrosion cracking, and other forms of corrosion are also reviewed.

Download or read book Welding Metallurgy and Weldability of Nickel Base Alloys written by John C. Lippold and published by John Wiley & Sons. This book was released on 2011-09-20 with total page 370 pages. Available in PDF, EPUB and Kindle. Book excerpt: The most up-to-date coverage of welding metallurgy aspects and weldability issues associated with Ni-base alloys Welding Metallurgy and Weldability of Nickel-Base Alloys describes the fundamental metallurgical principles that control the microstructure and properties of welded Ni-base alloys. It serves as a practical how-to guide that enables engineers to select the proper alloys, filler metals, heat treatments, and welding conditions to ensure that failures are avoided during fabrication and service. Chapter coverage includes: Alloying additions, phase diagrams, and phase stability Solid-solution strengthened Ni-base alloys Precipitation strengthened Ni-base alloys Oxide dispersion strengthened alloys and nickel aluminides Repair welding of Ni-base alloys Dissimilar welding Weldability testing High-chromium alloys used in nuclear power applications With its excellent balance between the fundamentals and practical problem solving, the book serves as an ideal reference for scientists, engineers, and technicians, as well as a textbook for undergraduate and graduate courses in welding metallurgy.

Download or read book High strength steel Forgings written by H. J. Henning and published by . This book was released on 1961 with total page 68 pages. Available in PDF, EPUB and Kindle. Book excerpt: THIS REPORT IS MAINLY CONCERNED WITH FORGINGS MADE FROM MARTENSITIC STEELS HEAT TREATED TO STRENGTHS RANGING FROM 240,000 TO 300,000 PSI. FORGING CHARACTERISTICS, DESIGN LIMITATIONS, DIMENSIONAL TOLERANCES, AND QUALITY-CONTROL PROBLEMS ARE DISCUSSED. A CONSIDERABLE AMOUNT OF DATA ON MECHANICAL PROPERTIES IS ALSO PRESENTED. IN ADDITION, THE REPORT SUMMARIZES THE AVAILABLE INFORMATION ON FORGED, SEMIAUSTENITIAL STEELS. THIS COMPILATION IS BASED ON PUBLISHED ARTICLES, GOVERNMENT REPORTS, AND INTERVIEWS WITH PRODUCERS AND USERS OF STEEL FORGINGS.

Download or read book Applied Metallurgy and Corrosion Control written by Amiya Kumar Lahiri and published by Springer. This book was released on 2017-08-23 with total page 558 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book serves as a comprehensive resource on metals and materials selection for the petrochemical industrial sector. The petrochemical industry involves large scale investments, and to maintain profitability the plants are to be operated with minimum downtime and failure of equipment, which can also cause safety hazards. To achieve this objective proper selection of materials, corrosion control, and good engineering practices must be followed in both the design and the operation of plants. Engineers and professional of different disciplines involved in these activities are required to have some basic understanding of metallurgy and corrosion. This book is written with the objective of servings as a one-stop shop for these engineering professionals. The book first covers different metallic materials and their properties, metal forming processes, welding, and corrosion and corrosion control measures. This is followed by considerations in material selection and corrosion control in three major industrial sectors, oil & gas production, oil refinery, and fertilizers. The importance of pressure vessel codes as well as inspection and maintenance repair practices have also been highlighted. The book will be useful for technicians and entry level engineers in these industrial sectors. Additionally, the book may also be used as primary or secondary reading for graduate and professional coursework.

Download or read book Metallurgy of Welding written by J. F. Lancaster and published by Springer Science & Business Media. This book was released on 2012-12-06 with total page 267 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is intended, like its predecessor (The metallurgy of welding, brazing and soldering), to provide a textbook for undergraduate and postgraduate students concerned with welding, and for candidates taking the Welding Institute examinations. At the same time, it may prove useful to practising engineers, metallurgists and welding engineers in that it offers a resume of information on welding metallurgy together with some material on the engineering problems associated with welding such as reliability and risk analysis. In certain areas there have been developments that necessitated complete re-writing of the previous text. Thanks to the author's colleagues in Study Group 212 of the International Institute of Welding, understanding of mass flow in fusion welding has been radically transformed. Knowledge of the metallurgy of carbon and ferritic alloy steel, as applied to welding, has continued to advance at a rapid pace, while the literature on fracture mechanics accumulates at an even greater rate. In other areas, the welding of non-ferrous metals for example, there is little change to report over the last decade, and the original text of the book is only slightly modified. In those fields where there has been significant advance, the subject has become more quantitative and the standard of math ematics required for a proper understanding has been raised.

Download or read book Pressure Vessel Design Manual written by Dennis R. Moss and published by Butterworth-Heinemann. This book was released on 2012-12-31 with total page 825 pages. Available in PDF, EPUB and Kindle. Book excerpt: Pressure vessels are closed containers designed to hold gases or liquids at a pressure substantially different from the ambient pressure. They have a variety of applications in industry, including in oil refineries, nuclear reactors, vehicle airbrake reservoirs, and more. The pressure differential with such vessels is dangerous, and due to the risk of accident and fatality around their use, the design, manufacture, operation and inspection of pressure vessels is regulated by engineering authorities and guided by legal codes and standards. Pressure Vessel Design Manual is a solutions-focused guide to the many problems and technical challenges involved in the design of pressure vessels to match stringent standards and codes. It brings together otherwise scattered information and explanations into one easy-to-use resource to minimize research and take readers from problem to solution in the most direct manner possible. - Covers almost all problems that a working pressure vessel designer can expect to face, with 50+ step-by-step design procedures including a wealth of equations, explanations and data - Internationally recognized, widely referenced and trusted, with 20+ years of use in over 30 countries making it an accepted industry standard guide - Now revised with up-to-date ASME, ASCE and API regulatory code information, and dual unit coverage for increased ease of international use

Download or read book Handbook of Structural Welding written by J. F. Lancaster and published by Elsevier. This book was released on 1997-08-07 with total page 445 pages. Available in PDF, EPUB and Kindle. Book excerpt: This handbook provides a comprehensive analysis of the current state of welding technology as applied to large structures and process plant. The author takes account of the increasing necessity for engineers at all levels to be aware of problems such as fatigue failure and provides advice.