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To cite this article: Cleiton Carvalho Silva , Arlindo Braga de Souza Neto , Francisco Diego Araruna da Silva , Francisco Edval
Sampaio de Freitas Jnior & Jesualdo Pereira Farias (2010): Welding of the ASTM A106 Gr. B steel pipes for high-temperature
service part 2 microstructure and hardness, Welding International, 24:3, 231-240
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Welding International
Vol. 24, No. 3, March 2010, 231240
Selected from Soldagem & Inspecao 2008 13(3) 199 209
The first part of this work presented the results of the experimental determination of residual stresses along top joints in
pipes. The purpose of the second part will be to present a critical evaluation of the microstructure and hardness of the welded
joints for pipes with small diameter used in oil refineries, aiming to correlate the results with the residual stresses. The
methodology consists of welding pipes with a diameter of 2 in., using a manual TIG process. AWS ER70-S3 addition metal
with a 2.5 mm diameter was used. An electronic welding source and a data acquisition system for control were used to
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control the welding parameters. Metallographic samples were conventionally prepared and electropolished using chloride
acid solution. Optical microscopy and scanning electron microscopy were used to evaluate the microstructure.
Microhardness tests were made along the weld. The results show that the combination of heat cycles between the root and
the finish with low heat support caused significant reining of grains in the welded area and in the heat affected zone, as well
as promoting a reduction in the hardness values. The same behaviour was not reached for the samples welded with higher
welding heat input. None of the welded samples presented hardness values above the maximum established in the standards
(248 VH).
Keywords: residual stresses; welding; pipes; X-ray diffraction
4340 welded with coated electrode. Source: Ref. 1. properties of the pipes are shown in Table 2, along with
the limits established by ASTM standard A106 Gr. B27.
chlorates may potentially increase the risk of stress
The welds were made using the TIG process, produced
corrosion. Cooling et al.13 and Coudreuse et al.14 show in
manually by a qualified welder loaned from Petrobras. The
their work that the presence of chlorates, in moderate and
joints were produced by turning, using the geometry
high concentrations in formation and treatment water,
recommended in RQPS E-AC-260-012 (Figure 2), whose
increases the susceptibility to corrosion by pitting, which is
dimensions are shown in Table 2. Four test pieces were
the precursor to the formation of cracks in stress corrosion.
produced, all under the same conditions. The welding
Bagdasarian and Truax15 state that the combination of
parameters are shown in Table 3.
residual welding stresses, from the manufacture of the
The microstructural characterization of the welded
equipment, associated with stresses in service, and the
joints was extracted from metallographic exams. Samples
presence of an aqueous means containing chlorates, makes
were taken from the pipes, covering the region of the base
an extremely favourable condition for cracks to occur.
metal, heat-affected zone (HAZ), and weld metal. The
Corrosive methods containing hydrogen sulphate
analysis was carried out in the transverse section.
(H2S) are considered critical for stress corrosion or
Preparation consisted of bleaching, pre-polishing with a
weakening. This can be particularly associated with two
of 3 mm diameter diamond pasts, followed by an
types: hydrogen induced cracking (HIC) and sulphide
electrolyte polish with chloride acid, using a current
stress cracking. The first type occurs when the hydrogen
density of 3.75 A/cm2 and for a time of 10 s.
generated by the corrosive process is absorbed into the
Characterization of the microstructure was carried out
material, causing cracks along the direction of lamination,
using an optical microscope (OM) using a Jenaplan/Karl
regardless of the presence of stresses. The second type is a
Zeiss microscope with a coupled digital camera and
variant of HIC, and therefore necessitates the presence of
electron scan image acquisition system (Figure 3(a)).
applied or residual stresses. The second is more common
in welded joint and in steels with high resistance16,17.
The importance of this topic to the oil and gas sector Table 1. Chemical composition of the base metal and of the
can be evaluated by quantity of works on the subject in addition metal (% by mass).
recent years18 24. However, these works mostly cover Material C Mn Si P S
the theme by looking at the corrosive medium, which is
one of the factors in crack formation. Therefore, an Steel, ASTM A106 Gr.
analysis from the point of view of the residual stresses and B (pipe) 0.19 0.96 0.20 0.016 0.006
Addition metal
mechanical properties may provide important information AWS ER 70 S3 0.18 0.45 0.18 0.09 0.04
to minimize the occurrence of faults in welded joints,
where the residual stresses constitute a critical factor,
especially because the acceptance criteria for these joints Table 2. Dimensions of the test pieces and the joint geometry.
take into account not the level of the residual stresses, but
rather the hardness values25,26. D (mm) d (mm) e (mm) L (mm) r (mm)
The first part of this work presents the results of the 60.3 52.5 3.9 410.4 4
experimental determination of the residual stresses along
Welding International 233
Test piece Pass Effective current (A) Effective voltage (V) Weld speed (cm/min) Weld energy (kj/cm)
C1 Root 136 12.4 7.8 8.5
Finish 137 12.3 7.8 8.4
C2 Root 136 11.6 7.3 8.5
Finish 136 11.9 8.1 7.8
C3 Root 133 12.1 7.1 8.9
Finish 135 11.5 7.8 7.8
C4 Root 133 11.3 8.1 7.3
Finish 133 11.3 7.8 7.5
D1 Root 104 11.4 4.6 10.1
Finish 104 12.0 4.8 10.2
D2 Root 103 11.1 4.9 9.0
Finish 103 11.7 4.5 10.4
D3 Root 102 11.1 4.7 9.4
Finish 102 11.2 4.6 9.6
D4 Root 104 11.0 4.6 9.7
Finish 104 11.2 4.5 10.0
A Phillips XL electron scan microscope was also used highlight that the choice of sample D4 was based on the
coupled with an analysis system of dispersive X-ray maximum residual stress found in this test piece, which
energy (Figure 3(b)). constitutes a critical condition, as in the result presented in
Vickers microhardness profiles were taken of the the first part of this work28. For the samples in group C, in
welded joints in the external and internal surfaces of the terms of the residual stresses, there was no significant
pipe. The analysis covered the region of the fused zone variation between the four test pieces evaluated.
(FZ), HAZ, and base metal, with the aim of verifying the Figure 4(a) presents the macrography of the welded
effect of the heat cycle on hardness and whether the levels joint from sample C4. The HAZ regions for the internal
are within acceptable limits, established by ASME and external surface are shown in Figure 4(b),(c),
standard VIII25 and by API standard 51026 as 248 VH. respectively. For the internal region of the pipe, more
The microhardness test was carried out using a Shimadzu refined grains were seen, both in the FZ and HAZ.
microhardness meter (Figure 3(c)). The microstructure of the weld metal in sample C4 is
shown in Figure 5(a). Note the great predominance of
primary ferrite of the grain boundary PF(G), which follows
3. Results and discussion the direction of equiaxial columnar growth of the weld
The results for the microstructure presented below refer to metal due to solidification, formed by grains of primary
samples C4 and D4, since samples 1 3 of the two groups ferrite. Among the columns formed by primary ferrite
(C and D) were intended for hydrostatic tests to obtain grains, note that more refined regions of acicular ferrite
other results, giving continuity to the studies about AF and intragranular polygonal ferrite PF(I). Also note
residual stresses in small diameter pipes. It is important to that between the grains of ferrite PF(G) in the columnar
234 C.C. Silva et al.
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Figure 7. Electron scan microscopy result of the constituents. (a) and (b) Weld metal. (c) and (d) HAZ-GG. (e) and (f) HAZ-GF.
allowing better characterization of its micro-constituents. second phase aligned (indication 2), which is very similar
In the weld metal, there were carbonates finely dispersed to upper bainite and granular bainite.
in the ferritic matrix, as shown in Figure 7(a),(b). Figure 7(e) shows the microstructure of the HAZ-GF,
Figure 7(c) shows a scan of the HAZ-GG, in which it is illustrating the presence of polygonal grains of ferrite and
possible to see ferrite with lateral plates (indication 1), perlite, as well as lateral plates of ferrite intermixed with
illustrating that in between the boards there was a perlite. Figure 7(f) shows an expanded detail from the
formation of a ferrite carbonate aggregate, probably fine previous figure, which shows the distribution of carbonates
perlite. In Figure 7(c),(d), note the ferritic phase with inside the perlite that intermixes with the ferrite boards.
Welding International 237
Figure 11. Microstructure of the internal surface of sample D4. (a) Weld metal and (b) HAZ-GG, refined by a later pass. Attack: Nital
2%; Magnification: 75X.
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Neither of the two welding conditions analysed was 12. Delafosse D, Magnin T. Hydrogen induced plasticity in
able to promote microstructural alterations that would stress corrosion cracking of engineering systems. Eng Fract
raise the hardness values above the maximum established Mech. 2001;68(6):693 729.
13. Cooling PJ, Kennani MB, Martin JW, Nice PI. The
by the standard, which is 248 VH, showing that the fact application limits of alloyed 13 Cr tubular steels for down
that a joint has low hardness does not necessarily indicate a hole duties. Corrosion 98. Houston (TX): NACE. Paper No.
condition of low level of residual stresses. 94; 1998.
14. Coudreuse L, Verneau M, Dufrane JJ. Sulphide stress
cracking resistance of weldable super-martensitic stainless
Acknowledgements steels. Super Martensitic Stainless Steels 99. Brussels,
Belgium; 1999. p. 299 306
The authors would like to thank professor Joaquim Teixeira de 15. Bagdasarian AJ, Truax DJ. Chloride stress corrosion
Assis and professor Vladimir Monin of IPRJ-UERJ (Nova cracking of austenitic stainless steels in hydro processing
Friburgo) for their laboratory support to ANP-PRH31 for units. Corrosion 97. Houston (TX): NACE. Paper No. 501;
awarding the grant, the staff of PETROBRAS/LUBNOR/MI, 1997.
especially Engineer Danudio I.S. de Souza; Engineer Gerardo
16. Albarran JL, Martinez L, Lopez HF. Effect of heat treatment
J.A. Perez, and maintenance technician Joao Cesar Matias da
on the stress corrosion resistance of a micro alloyed pipeline
Silva, and to the technical teams of the research Centre of
steel. Corros Sci. 1999;41(6):1037 1049.
PETROBRAS/CENPES, and the development bodies of FINEP
17. Bruno TV, Christensen C, Hill RT. History and development
and CNPq for their financial support.
of TM0284. Corrosion 99. Houston (TX): NACE. Paper No.
422; 1999.
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