4th Pipeline Technology Conference 2009

In 2006, CRC-Evans was first introduced to the Cold Metal Transfer (CMT)
process. At the time, CMT was a technology intended for use as a joining method
for thin gauged materials in the automotive industry. The idea of combining this
technology with a bug and band system for mechanized root pass deposition for
pipeline applications was conceived. Initial trials gave favorable results and
provided further justification to integrate the two individual systems to become a
single platform for pipeline girth welding.
CMT was originally packaged for robotic work cell applications. The necessary
components that make the system perform would need to be merged with the
most current bug and band technology. One of the early decisions regarding the
build process was driven by the capabilities of the components to allow digital
technology between the welding power supply and the bug itself. This digital
capability allows the system to react quickly and make adjustments to
compensate for changes during the deposition phase. As critical welds are made,
changes is joint geometry, variations in fit up and band misalignment, all have to
be taken into consideration.
The need for mounting the push-pull wire feed motor onto a conventional CRC
Evans P450 welding system was another necessary component in making the
conversion a success. The ability to mount this hardware would provide
significant challenges, however the result would be a system that could be used
in a production environment. Engineers from both CRC-Evans and Fronius had
to create a platform that would satisfy the need for robustness, ease of service,
mobility, and performance, especially in harsh environments. Figures 1 and 2
demonstrate the original configuration and the final modified platform.

Figure 1 Original Configuration

Figure 2 Modified configuration for Bug and Band System

The Process
Cold Metal Transfer is a modified Gas Metal Arc Welding (GMAW) process that
uses a new method of droplet detachment based on short circuit welding. The
moment the power source detects a short circuit, the welding current drops and
the filler wire starts to retract. Exactly one droplet is detached into the molten

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weld puddle. The filler wire then moves forwards again and the cycle is repeated.
The filler wire is constantly retracted at very short intervals. The precisely defined
retraction of the wire facilitates controlled droplet detachment to give a clean,
virtually spatter-free material transfer. Figure 3 demonstrates the droplet
detachment sequence.

wfs

Plasma phase

IS

Short circuit phase Boost phase

Arc phase

US

T
Figure 3 Droplet detachment sequence

When the combined platform had been developed laboratory trials commenced.
Through several months of development, a workable system was achieved and
mobilization for field qualifications and development programs was initiated.
Project Implementation
The first project for deployment of CMT was to be a spool base application where
welding of 345 mm diameter x 18.3 mm wall thickness (SAW 415 FPD + 316L
3mm layer) was required. The procedures were developed such that the root
pass deposition was completed by using a 309L Mo (ER309L Mo modified, AWS
A5.9-93) filler material, 1.2 mm diameter. The remaining procedure, consisting of

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the hot, fill, and cap passes were welded with Thermanit 625 (ERNiCrMo-3, AWS
A5.14) 1.0 mm diameter. The shielding gas was an Argon / CO2 balance and the
joint configuration was a closed gap J-bevel. The bevel angle measured 10
degrees.
Procedure welds were made and consistency trials were performed to ensure the
robustness of the procedure and the system. The root profile on the project
Corrosion Resistant Alloy (CRA) material exhibited more positive re-enforcement
than observed on carbon steel. This is partly due to the argon back-purge that is
used to shield the root from contamination during welding. The fusion area from
the parent material to weld bead were smooth and even however, and weld
surface chevrons were uniform. Figure 4 demonstrates a completed root pass
with internal and external profiles

Figure 4. Internal and External profiles

Mechanical testing was carried out both in the unstrained and strain aged
condition. For both scenarios, the mechanical performance met the acceptance
criteria for the project. A summary of the mechanical test results are listed below
in table 1.

Yield Strength
2
0.2% (N/mm )

Strained &
Aged

527

796

149J

228-252

Unstrained

515

753.5

132 J

193-222

Table 1 Mechanical Properties

CVN Toughness Typical Hardness

Ultimate Tensile
Properties WCL @ Ranges (HV10)
2
Strength (N/mm )
-46oC
Weld metal

Test Condition

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In January of 2009 the first field weld production was attempted. As with most
pipeline project kick offs, challenges were present early and the installation of
new technology only made such challenges greater. There were unknowns about
how the system would perform in the field, and just how operators would take to
the new system.
For a total of 8 days, 84 welds were completed for an average of 10.5 welds per
day.
Although the production achieved was less than the desired target,
improvements in the production process and welding procedure could be made
to realize significant gains. Implementation of CMT as a field production welding
method was considered a success, but further use in production environments
would be required to increase the productivity of the system.
Carbon Steel
Additional work has been carried out to qualify the mechanized CMT process for
carbon steel applications. For carbon steel, the root pass welding procedure is
mostly transparent, in that the same parameters can be used for different
applications. The joint design is a closed gap J-Bevel, with a 5 degree bevel
angle. The shielding gas is an Argon / CO2 mixture, with travel speeds ranging
from 355 mm/min to 508 mm/min and wire feed speeds from 4.5 m/min to 6.5
m/min. The welding consumable diameter is 1.0 mm and trials with ER90S-G,
ER80S-G, and ER70S-6 wire variations have all yielded good results.
A technically significant carbon steel application that involved the use of CMT
was the single sided welding of the root pass on a closure weld for a pressure
vessel. The project material was 42 x 19.1mm Gr. 550 and the intended
application for this project was the transportation of compressed natural gas
(CNG in a fatigue sensitive environment). Low service temperature requirements
dictated the need for good toughness properties at -40oC and the use of a solid
wire procedure could deliver the required properties.
As internal clamping was not an option, mechanized CMT was a natural choice.
The advantages of using CMT for the root pass were two fold. The first was
maintaining a narrow bevel. As the narrow bevel reduces weld deposit volume
and allows for use of mechanized fill and cap passes. This meant productivity
could be increased and mechanical properties achieved. The second advantage
was the need for the root pass to be flush with the ID surface of the parent
material. The specification requirement was to remove all internal excess
penetration upon completion. The root profile with CMT eliminated concern for
this major requirement because of its flat profile.
By using the mechanized CMT process with the narrow groove J-Bevel,
mechanized fill pass welding could be implemented. The fill and cap passes were

4th Pipeline Technology Conference 2009

welded using Pulsed GMAW with an ER70S-6 wire. Overmatching of the Gr 550
pipe material was achieved and the toughness requirements were met. Table 2
demonstrates the mechanical properties of the qualified procedure.

Test Condition

Yield Strength
2
0.2% (N/mm )

5G Girth Weld

620

CVN Toughness CTOD Toughness

Ultimate Tensile
Properties WCL @ Properties WCL @
2
Strength (N/mm )
o
o
-50 C
-40 C (ave)

727

106 J

0.34mm

Table 2 Mechanical Properties

Additional procedures for a separate project that involved the transportation of

compressed natural gas were qualified on 6 x 0.250 Gr 485 pipe material. The
project application was to weld pipes spooled horizontally and made into a
coselle arrangement (see figure 5). The fatigue effects exhibited on these welds
required careful consideration as the loading would be different than a typical
offshore Steel Cantenary Riser (SCR). As the coselle is pumped full of CNG,
pressure is exerted internally on the weld in the hoop direction. Subsequent
depressurized during offloading created cyclic loading that had to be taken into
consideration.

Figure 5 Horizontal Spooling of 6 pipe

One of the most important advantages of CMT as a root pass welding technology
for carbon steel is the finished profile of the internal weld bead. For fatigue
applications CMT provides a root profile that is uniform and has a shallow
reentrant angle. The shallow reentrant angle reduces stress concentration and
subsequently increases fatigue life. Preliminary fatigue testing of strip type
specimens demonstrated increased fatigue life over welds using traditional root
pass welding technology. This meant that using CMT for root pass would extend
the life of the coselle.

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Another carbon steel project using CMT that should be highlighted involves
double jointing small diameter flow lines. For double joint applications, CMT
offers significant advances in productivity, especially considering that the
technology does not require the use of an internal alignment tool. The platform
versatility allows CMT to be deployed in project locations that traditional
mechanized welding processes may not be ideal, such as offshore tie ins.
SCR qualification requirements for double jointing pipe are also considered a
major target for this technology. Fatigue properties of the root bead have shown
that the weld can be carried out without the need to remove the internal
reinforcement, while still meeting the stringent requirements required for such
critical service. The ability of the system to adapt to small diameter pipeline
applications offers significant benefits for welding of fatigue critical pipelines,
which is worthy of note.
Upcoming work is also scheduled for examining the use of mechanized CMT root
passes and Pulsed GMAW fill and cap passes for welding high strength pipeline
tie-ins
Conclusion
The CMT process is an up and coming mechanized root pass welding
technology for pipeline girth welds. The technology is just now entering the
market and has the potential to increase quality, productivity, and expand
capability. Field trials on Inconel clad material in a production environment have
demonstrated the potential capabilities of the system.
In addition to welding CRA materials, welding qualifications and development
projects have been conducted on carbon steel pipe materials. Pressure vessels
with stringent requirements for fatigue life and low temperature toughness
welded with CMT root passes have been carried out with proven quality and
mechanical performance. Double jointing and welding of SCR quality welds are
additional applications where CMT may be applied.
For welding cross country pipelines with HSLA steels grades X-80 and above,
mechanized CMT and GMAW-P tie-in welding provides the low hydrogen
solution that meets the need for elevated mechanical properties requirements.
The CMT Process can also provide the following benefits:

Faster travel speeds when compared to conventional root pass welding

processes can significantly improve productivity.

Elimination of copper backing saves on consumable costs

Deposition thicknesses of approximately 5mm

4th Pipeline Technology Conference 2009

Accommodation of mismatch up to 3.0mm

Low heat inputs, minimized bevel volume, accommodation of mismatch, fatigue

performance and root profile are the drivers for continued implementation of this
technology into the pipeline industry.