Proceedings of the 2012 9th International Pipeline Conference IPC2012 September 24-28, 2012, Calgary, Alberta, Canada

IPC2012-90555

A STUDY OF DEFORMATION BEHAVIOR OF DOUBLE JOINTING GIRTH WELDS

Tomoyuki Yokota JFE Steel Corporation Chiba, Japan Yoshiaki Murakami JFE Steel Corporation Kurashiki, Japan

Takahiro Sakimoto JFE Steel Corporation Chiba, Japan

Satoshi, Igi JFE Steel Corporation Chiba, Japan

Shigeru Endo JFE Steel Corporation Chiba, Japan

ABSTRACT Demand for double jointing technology is increasing to improve pipeline construction productivity. Submerged arc welding (SAW) utilized for double jointing is likely to cause a much wider heat affected zone (HAZ) than those of typical field welding by gas metal arc welding (GMAW), and it should be taken into account for strain-based design of high strength line-pipes. However, guidelines for SAW welds properties to ensure strain capacity of high strength line-pipes such as X80 have not been established yet. In this study, a submerged arc weld joint was produced using tensile strength (TS) over-matching welding consumable. API standard type transverse weld tension test was conducted to measure local elongation at weld metal, HAZ, and base material. Elongation at weld metal increases prior to base material, but soon after that elongation at the HAZ softening region and base material adjacent to the HAZ catch up with the elongation in the weld metal, and finally, deformation concentrates at the HAZ softening region before final fracture. Deformation behavior of the joint was analyzed to verify applicability to double jointing girth welds for strain-based design. From finite element (FE) analysis of notched wide plate test which characterizes tensile strain capacity of a pipeline, it is suggested that ductile crack would not initiate before base material start necking in this particular TS over-matching weld joint in which the defect size is 1mm of notch depth and 25mm of notch length. Thus, the weld joint would be applicable for double jointing girth welds based on strain-based design. INTRODUCTION In response to increased energy demand, natural gas pipeline construction is getting extended to arctic and seismic regions. It is assumed that pipelines will be subjected to large

deformation due to large ground movement associated with liquefaction or faults in seismic regions and frost heave and thaw settlement in permafrost regions [1]. Because the conventional stress-based design method cannot be applied in cases where strain greatly exceeds the yield stress of the material, application of strain-based design is under active study [2-4]. Assuming large bending deformation of the pipeline, the key issues for strain-based design of pipelines are local buckling of the pipe itself on the compression side of bending, and the tensile fracture from defects, particularly in girth welds, on the tension side of bending. The tensile strain capacity of a pipeline is usually characterized using uniaxial tests such as the curved wide plate test [5]. The most critical fracture mode in pipelines is considered to be ductile fracture initiated and propagated from defects in girth welds. Equivalent plastic strain obtained from SENT tests is proposed as the criterion of ductile crack initiation, and used for the prediction of strain capacity of girth weld of high-strain pipeline for strain-based design [6]. Recently, demand for double jointing technology is increasing to improve pipeline construction productivity. SAW utilized for double jointing is likely to cause a much wider HAZ than those of typical field GMAW, and it should be taken into account for strain-based design of high strength line pipes. However, guidelines for SAW welds properties to ensure strain capacity of high strength line-pipes such as X80 have not been established yet. In this study, a submerged arc weld joint was produced using TS over-matching welding consumable and transverse weld tensile test was conducted. Deformation behavior of the joint was analyzed to verify applicability to double jointing girth welds for strain-based design.

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PREVIOUS STUDY The Double Jointing Program [7] TransCanada has established programs for both welding procedure design of high strength line-pipes and complementary program for double jointing weld evaluation. The primary objective of the welding procedure development was to design a welding procedure specification that can be used to produce pipe double jointed high strength line-pipes such as X80 and achieve their goals for strain-based design requirements for the weld. On the other hand, the primary objective of the double jointing weld evaluation program was to measure the weld zones mechanical properties for both stress-based design and strain-based design and to establish mechanical property requirements that are practical and yet economical. In the evaluation program, pipe body longitudinal tensile test and all weld metal tensile test with both of strip type configuration and round-bar type configuration were conducted for X80 double jointing weld. The strip type all weld metal tensile specimen is able to represent the average weld properties through the full thickness, while the round-bar type all weld metal tensile test specimen represents weld properties of either outer weld or inner weld. Figure 1 shows stress-strain curves of the pipe body and the weld metal [7]. Weld strength over-matches the pipe beyond about 3% strain. However, weld strength does not always over-match the pipe at 0.5% strain.

Stress-strain curves of HAZ were also evaluated for X80 and X100 double jointing welds from transverse weld tensile tests and HAZ softening was determined to be about 4% below the respective pipes between yield and 4% strain. Due to the HAZ softening, localized HAZ deformation was generated in the pipe longitudinal direction. However, mechanical property requirements for weld metal that are practical and yet economical have not been clarified.

Round-bar type

Strip type

EXPERIMENTAL PROCEDURE Base material and welding conditions API 5L-X80 grade line pipe of 42OD x 12.7mm wall thickness was cut and flattened to use for base material. Table 1 shows SAW condition adopted in this study, which is used for double jointing girth welds [7]. Welded joint was made using tensile strength (TS) over-matching welding consumable to conduct transverse weld tension test as described afterward. To understand tensile properties of weld metal itself, strip type all weld metal tensile test specimen was machined from the welded joint. Figure 2 shows configuration of the weld metal tensile test specimen. This specimen configuration with full plate thickness can represent the weld properties on an average basis compared to standard round-bar type specimens [7]. Tensile test specimen with the same configuration as those used for weld metal was also machined from the base material. Obtained tensile properties of the weld metal and base material are listed in table 2. Tensile strength (TS) of the weld metal is 854MPa, and 0.5% on-set proof stress by under load method (0.5%PS) is 620MPa. From a point of view of TS, it is overmatching condition. On the other hand, from a point of view of 0.5%PS, it is almost even-matching. Figure 3 shows Vickers hardness distribution measured at cross section of the weld. Similar to tensile strength, it shows over-matching properties. Vickers hardness of HAZ softening region is around HV200.

Table 1 Welding conditions

Pipe body
Pass Current1) [A] 800 800 800
1) DCRP

Voltage Speed [V] [mm/min] 31 31 31 1100 1100 1100

Heat Input [kJ/mm] 1.35 1.35 1.35

Pre-heat /Interpass [] RT(2025) 100 150

IW-1 OW-1 OW-2

30

OW 3.0

12.7

6.7 3.0

Fig.1 Stress-strain curves of the pipe body and the weld metal [7]
30

IW

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A Weld metal 6 A 25 25

A-A cross section

12.7

10.2 6

Transverse weld tensile test To obtain fundamental data on deformation behavior of double jointing girth weld, transverse weld tensile test was conducted and deformation behavior was analyzed. API standard type transverse weld tension test specimen with reduced section length of 60mm and width of 38mm was machined from the welded joint. Excess weld metal was removed. Outer surface of the tensile test specimen was patterned with 5mm pitch grid by electrolytic etching as shown in Figure 4 to measure local straining at weld metal, HAZ, and base material and examine tensile deformation behavior. Weld metal width at outer surface was around 10mm as shown in Figure 3. The specimen was tested with stroke head speed of 3mm/min. The weld deformation process of the patterned specimens was taken by video camera and several pictures were captured every 30 seconds and local strain at weld metal, HAZ and base material was measured using deformed grid pattern.

Fig.2 Configuration of strip type all weld metal tensile test specimen
R25.4

Table 2 Tensile properties of weld metal and base material

0.5%PS [MPa] Base Material Weld Metal 592 620 TS [MPa] 721 854 El [%] 30.3 20.1

weld metal

38

Enlarged figure

50GL 60

5mm

5mm

400 350 HV 10kgf 300 250 200 150 0 5 10 15 20 Distance (mm) 25 30

Fig.4 Schematic illustration of 5mm pitch grid pattern on transverse weld tensile test specimen
mid-thickness outer surface inner surface
weld metal GL=50mm

Fig.3 Vickers hardness distribution across the weld

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FINITE ELEMENT ANALYSIS PROCEDURE While fundamental data on the deformation behavior of the welded joint was obtained using API standard type transverse weld tension test, tensile strain capacity of a pipeline is usually characterized using uniaxial tests so-called curved wide plate test. In this study, in order to simulate local deformation behavior around the notch tip in the wide plate tests, finite element (FE) analysis were performed using 3-dimensional models. FE analysis model for the wide plate test specimen is shown in Figure 5. Two types of initial notch configurations were examined to investigate the effect of notch size on ductile crack initiation. The one has notch depth of 1mm shown as a in Figure 5 and notch length of 25mm shown as 2c in the figure. This notch configuration is supposed to be the maximum defect size for undercut of SAW used for double jointing inside shops, which is the object of this study. For comparison, notch depth of 3mm and notch length of 25mm, which is supposed to be maximum defect size for incomplete fusion of GMAW used for field jointing, was examined. True stress - true strain curves of weld metal, HAZ, and base material used for FE analysis were constructed by indentation test in which Indentation load is continuously measured as a function of spherical indenter penetration depth both during loading and unloading [8] together with the strip type tensile test results. Indentation test is particularly useful to evaluate stress- strain curve of HAZ in which tensile test cannot be conducted, and that of large strain region, in other words, necking stage of the tensile test. In this study, the stress - strain curves (S-S curve) of weld metal and base material were constructed by connecting S-S curve obtained from the indentation test to S-S curve obtained from the strip type tensile test smoothly at necking point. ABAQUS Ver. 6.5 was used for FE analysis and the minimum element size at notch tip was set to 0.025mm x 0.025mm x 0.5mm. Figure 6 shows mesh division of the wide plate test specimen. In the FE model, the relationship between equivalent plastic strain at notch tip and global strain is obtained. This global strain will be used to evaluate ductile crack initiation at notch tip of wide plate test specimen and to express the strain capacity of the girth-welded pipe.

150

600

150 Surface notch R102 Load 2c

400
Load 300 GL1 GL2 B B GL4 GL3

100

1350

GL1-GL2 remote strain GL2-GL3 global strain

B-B cross section base material 23.7 HAZ 2 a weld metal 14 2 HAZ Surface notch weld metal Notch tip 4 element HAZ

0.025 0.025 minimum element size at notch tip: 0.025mm x 0.025mm x 0.5mm

Fig.5 FE model for the wide plate test specimen

1/2 symmetry model Initial notch size a = 1mm or 3mm, 2c = 25mm Surface notch

Fig.6 Mesh division of the wide plate test specimen

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Elongation%)

RESULTS AND DISCUSSION Transverse weld tensile test Figure 7 shows fracture appearances of the test specimen with 5mm pitch grid pattern after transverse weld tensile test. Final failure occurs apart from weld metal.

80 70 60 50 40 30 20 10 0 0 5 10 El (%); GL=50mm
HAZ B.M.-2 W.M. B.M.-1 B.M.-3

B.M.-3 B.M.-2 B.M.-1 HAZ W.M.

weld metal

15

5mm

5mm

Fig.7 Fracture appearances of test specimens

Figure 8 shows elongation increment behavior measured by deformed grid patterned on the specimen surfaces. Elongation measurement position is also shown in the Figure 8. Overall deformation behavior including final stage can be seen by this figure. Elongation at weld metal denoted by red line increases prior to base material, probably because 0.5%PS of the weld metal is not so high and it is almost even-matching. However, soon after that elongation at HAZ softening region and base material adjacent to HAZ catch up with the elongation at weld metal as indicated by arrows and finally deformation concentrates at the HAZ softening region before final fracture. It is clearly observed that localized deformations at weld metal are prevented and final failure occurred at the HAZ, even if weld metal yields initially during early stages of the tensile test. This is one of the most important outcomes in this fundamental study. On the other hand, the tensile strain capacity of a pipeline is usually characterized using uniaxial tests so-called curved wide plate test. Deformation at HAZ softening region is suppressed due to plastic restraint of base material in this case. In order to simulate local deformation behavior around the notch tip in the wide plate tests, FE analysis were performed.

weld metal GL=50mm

Fig.8 Elongation increment behavior measured by deformed grid patterned on the specimens

Finite element analysis In order to simulate local deformation behavior around the notch tip in the wide plate test of the examined weld joint, FE analysis were performed using a 3-dimensional model. Figure 9 shows equivalent plastic strain distribution around the notch tip obtained by FE analysis. Plastic strain at the notch tip is likely to extend toward the HAZ softening region. Then, ductile crack would initiate and propagate in the HAZ side. Figure 10 shows nominal stress and equivalent plastic strain at notch tip versus global strain relationship in the case of a=1mm, 2c=25mm, which is the object of this study. Equivalent plastic strain at notch tip is that of the 0.05mm x 0.05mm area having maximum strain. Equivalent plastic strain at notch tip increased with global strain and it reached around 0.9 at global strain of 7%, at which tensile stress reaches the maximum in the strip type tensile test of base material. Supposing the critical equivalent strain for ductile crack initiation of base material and HAZ of X80 is around 1.1 [9], ductile crack would not initiate before the base material started to neck in this particular weld joint.

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Stress[MPa]

Figure 11 shows nominal stress and equivalent plastic strain at notch tip versus global strain relationship in the case of a=3mm, 2c=25mm. In this case of severe defect size, equivalent plastic strain at notch tip increased to over 1.5 at global strain of 7% and ductile cracking would initiate before base material necking.

Equivalent plastic strain at notch tip Equivalent plastic strain at notch tip

800 700 600 500 400 300 200 100 0 0 1 2 3 4 5 6 Global strain[%] 7 8

3.5 3 2.5 2 1.5 1 0.5 0

WM

HAZ

BM

Fig.11 Nominal stress and equivalent plastic strain at notch tip versus global strain relationship in the case of a=3mm, 2c=25mm

Thus, ductile cracking would not initiate before initiation of base material necking in this particular TS over-matching weld joint in which the defect size is 1mm of notch depth and 25mm of notch length, which is supposed to be allowable defect size for undercut of SAW used for double jointing inside shops. To verify obtained FE analysis results, wide plate test experiment will be conducted and discussed. Fig.9 Equivalent plastic strain distribution at the notch tip (1mm of notch depth and 25mm of notch length) CONCLUSIONS In this study, a submerged arc weld joint was produced using TS over-matching welding consumable and transverse weld tensile test was conducted. Deformation behavior of the joint was analyzed to verify applicability to double jointing girth welds for strain-based design. Obtained results are as follows. (1) Elongation at weld metal increases prior to base material, but soon after that elongation at the HAZ softening region and base material adjacent to HAZ catch up with the elongation at weld metal and finally, deformation concentrates at the HAZ softening region before final fracture, in the case of API standard type transverse weld tension test. (2) In order to simulate local deformation behavior around the notch tip in the 300mm wide plate tests, FE analysis were performed. Initial notch size is set 1mm of notch depth and 25mm of notch length. Equivalent plastic strain at notch tip increased with global strain and it reached around 0.9 at global strain of 7%, at which tensile stress

Equivalent plastic strain at notch tip

800 700 600 Stress[MPa] 500 400 300 200 100 0 0 1 2 3 4 5 6 Global strain [%] 7 8

3.5 3 2.5 2 1.5 1 0.5 0

Fig.10 Nominal stress and equivalent plastic strain at notch tip versus global strain relationship in the case of a=1mm, 2c=25mm

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reaches maximum. Supposing critical equivalent strain for ductile crack initiation of base material and HAZ of X80 is around 1.1, ductile crack would not initiate in this particular weld joint. (3) Thus, this particular weld joint would be applicable for double jointing girth welds based on strain-based design.

ACKNOWLEDGMENTS The authors would like to thank Dr. T. Kubo of JFE Techno-Research Corporation for local strain measurement of transverse weld tensile tests.

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