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Abstract
API 5L X80 steels are widely used in pipelines to transport oil and oil products under high pressure and where the
pipeline weight savings is important. The most common process in field for circumferential pipe-to-pipe welding is
shielded metal arc welding (SMAW), used in root, in the filling, and in finishing passes. It is a process used
successfully, but has the disadvantage of productivity and care for storage in the field. An alternative to productivity is
the process of gas metal arc welding (GMAW) with controlled transfer, such as the surface tension transfer (STT), for
welding of root passes and the filling and finished with flux cored arc welding (FCAW), which has high productivity and
quality comparable to welding with covered electrode.
In this work, two specimens of Brazilian API 5L X80 steel pipe were welded. One sample used one SMAW and the
other used GMAW-STT in the root pass and FCAW in the others passes. In SMAW were used in the root pass E6010
E9010-G filler metals with 3.25 mm in diameter, and all other passes with E9045 H4R-P2 consumable, with a diameter
of 4.0 mm. In GMAW-STT plus FCAW sample was welded with consumable ER80S-G, with 1.16 mm in diameter, in
the root pass and E101T1-GM-H8, with a diameter of 1.16 mm, for filling and finishing passes. In both cases were used
a argon-10% CO2 shielding gas. To compare the two welding the mechanical properties of the welds (hardness, tensile
strength, bending, nick-break and impact tests at 0oC) were compared, based on API 1104 standard.
The mechanical properties results showed that welding with controlled transfer and tubular electrode can be a good
substitute for welding with coated electrodes.
1. Introduction
High strength low alloy steels (HSLA) emerged in order to have superior mechanical properties when
compared to carbon steels [Bott,2005; Ratnapuli, 2008; Taiss, 2007]. HSLA steels have minimum yield strength from
275 MPa (40 Ksi) obtained by controlled rolling and heat treatments. They have low carbon and low amount of alloying
elements, which, in addition to specific thermo-mechanical processing routes, provided high mechanical strength and
good toughness [Ordoes, 2004; Bay, 2001]. HSLA steels are arranged in different grades on several standards,
according to their specific properties such as strength, toughness, plasticity, corrosion resistance and weldability [Bay,
2001]. One of its applications is for pipeline manufacturing for transporting oil and its products, such as gases, ruled by
API 5L and 1104 standards for material and for the welding of pipelines. In field, pipelines can be joined by different
welding processes [Wainer, 1992; Hillenbrand, 1997; Meyer, 1998; Rocha, 2010; Rocha, 2010a; Valim, 2005].
The GMAW-STT is a process variation on the usual GMAW, using shielding gases such as pure CO2, pure
argon or a mixture of both. GMAW-STT was designed to be applied to manufacture weld roots using a patented
technology called STT which means surface tension transfer [Waveform, 2006; Waveform, 2006a]. This GMAW
process variant was developed to generate low heat input, and small amount of fumes and spatters. To achieve these
objectives, the equipment operates with constant current curve, instead of constant voltage, which is typical for
conventional GMAW. Thus, the equipment can change the arc electrical current within a very short time. The welding
current wave shape is controlled to keep the arc opened and to transfer heat to weld pool. When the drop is formed at
the electrode tip, it will touch the weld pool, creating a short circuit. At this time, the equipment generates a drop in
______________________________
1
Engenheiro Mecnico, aluno do Curso de Especializao em Engenharia de Soldagem da Escola Politcnica da USP, aluno de Mestrado do
Departamento de Engenharia Metalrgica e de Materiais da EPUSP.
2
Mestre em Engenharia Metalrgica, Departamento de Engenharia Metalrgica e de Materiais da EPUSP Atualmente na Refinaria de Capuava
(RECAP) da Petrobrs, So Paulo.
3
Lincoln Electric do Brasil, Guarulhos, So Paulo.
4
Professor Associado, Departamento de Engenharia Metalrgica e de Materiais da EPUSP.
Fig. 1 - GMAW-STT schematic current wave shape and the correspondent metal transfer type [Waveform, 2006a].
When compared to SMAW, GMAW-STT has advantages especially in relation to productivity, because there
is no need to stop production for supplies exchange and root pass grinding, because weld bead profile is flat. On the
other hand, the root bead profile made with a cellulosic electrode is convex, which leads to greater loss of time with the
root pass grinding operation [Waveform, 2006a].
The filling and finishing welding passes can be done by SMAW or FCAW process. The FCAW welding
process uses the same equipment as in GMAW process that generates a higher productivity, when compared to SMAW.
The advantages and disadvantages of each this process is a good subject to research.
The objective of this work is to compare mechanical properties of pipeline circumferential welded joint made
with SMAW and GMAW-STT/FCAW.
2. Experimental procedure
The API 5L X80 pipe in this experiment had a diameter of 20 inches and 19 mm thick. For the experiments,
four samples with 300 mm width were cut to form a weld joint. Table 1 shows the pipe chemical composition compared
to API 5L X80 standard classification.
Table 1 - Base metal chemical composition compared to API 5L X80 standard classification.
Elements
w%
API 5L
C
0,063
0.20
Mn
1,813
1,5
Si
0,159
-
P
0,019
0.025
S
0,005
0.015
Cr
0,015
-
Ni
0,014
-
Mo
0,207
-
Al
0,028
-
Ti
0,013
V
0,022
Nb
0,062
0.15
The SMAW welding were done with three electrodes types. It was utilized in the root pass two electrodes type,
E7018 in the first root pass and E9010 in the second root pass. The filling and finishing passes were done with an E9045
P2 H4R coated electrode [Lincoln, 2003], with 4 mm diameter, voltage of 28 V, welding current of 190 A, a welding
speed of 3.0 mm/s; and a preheating temperature of 150oC and interpass temperature of 200oC.
In the SMAW-STT/FCAW processes combinations, welding of root pass was made with the GMAW-STT
process using ER80S-G with pure CO2 as shielding gas. The wire diameter was 1.2 mm, a voltage of 19 V, welding
current of 55 (base current) and 400 A (peak current), welding speed of 8.3 mm/s and a gas flow of 14 l/min. The filler
2
700
600
500
400
300
706
668
706
693
707
692
100
712
200
695
800
0
1
2
SMAW
GMAW-STT / FCAW
Figure 2: Tensile strength of each four sectors for both welding procedures.
3.2. Bending test
Results of bending tests for each sector of both procedures are presented in table 2. Besides the indications on
SMAW samples, all were according to acceptance criteria. All samples made with GMAW-STT presented results with
no indications of discontinuities. These results can be related to the process characteristics. In the case of SMAW, slag is
generated and the deposition is discontinuous compared to FCAW.
Table 2 - Base metal chemical composition compared to API 5L X80 standard classification.
Sector
1
2
3
4
1
2
3
4
Specimen
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
Process
SMAW
SMAW
SMAW
SMAW
SMAW
SMAW
SMAW
SMAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
GMAW-STT / FCAW
Observed
No discontinuity.
1.1 mm of open in the fusion line
No discontinuity.
0.7 mm of open in the fusion line
1.2 mm of open in the fusion line
1.2 mm of open in the fusion line
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
No discontinuity.
Result
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Approved
Results of Vickers hardness test (HV5) are depicted in figure 3 for both welding procedures
and four sectors.
SMAW - Sector 1
Finishing
Filling
Root
Finishing
280
260
240
220
200
180
280
260
240
220
200
11
13
15
SMAW - Sector 2
Finishing
Filling
Root
10
13
Finishing
Filling
Root
300
Vickers Hardness (HV5)
300
280
260
240
220
200
180
280
260
240
220
200
180
SMAW - Sector 3
Finishing
Filling
11
13
15
Root
10
13
300
Filling
Root
300
Vickers Hardness (HV5)
Root
180
1
280
260
240
220
200
180
280
260
240
220
200
180
11
13
15
SMAW - Sector 4
Finishing
10
13
Filling
Root
Finishing
300
Filling
Root
300
Vickers Hardness (HV5)
Filling
300
Vickers Hardness (HV5)
300
280
260
240
220
200
180
280
260
240
220
200
180
11
13
15
10
13
Figure 3: Hardness test for both welding procedures and four sectors. The hardness profiles
were measured in the root pass, filling pass and finishing pass.
Analyzing GMAW hardness results one can conclude the HAZ hardness presents a trend to
higher values than root and filling passes. This result is asymmetric regarding both sides HAZ. This
fact can be due to the coated electrode work angle, which is different from 90o. On the other hand,
4
GMAW-STT presented more uniform hardness values than SMAW, but he values for both
welding procedures are comparable, except SMAW finishing pass. It is important to notice the
difference in chemical composition in the fusion zone, due to different consumables used in each
welding procedure.
3.4. Chemical composition
Chemical compositions of weld metal in the root and face of weld joint in each position for
two welding procedures are presented in table 3.
Table 3 - Chemical compositions of weld metal in the root and face of weld joint in each position.
Process
Sector
1
2
SMAW
3
4
1
GMAWSTT /
FCAW
2
3
4
Specimen
Face
Root
Face
Root
Face
Root
Face
Root
Face
Root
Face
Root
Face
Root
Face
Root
C
0,053
0,084
0,056
0,078
0,053
0,087
0,064
0,100
0,044
0,060
0,044
0,063
0,044
0,073
0,043
0,064
Mn
1,244
1,180
1,237
1,256
1,231
1,196
1,237
1,093
2,111
1,864
2,144
1,826
2,145
1,789
2,142
1,790
Si
0,503
0,399
0,473
0,466
0,495
0,398
0,482
0,374
0,247
0,240
0,240
0,240
0,233
0,223
0,254
0,239
P
0,009
0,012
0,009
0,010
0,009
0,011
0,009
0,011
0,011
0,012
0,011
0,012
0,011
0,012
0,012
0,013
S
0,010
0,010
0,009
0,009
0,009
0,011
0,011
0,011
0,003
0,003
0,003
0,004
0,003
0,004
0,004
0,004
Cr
0,042
0,045
0,039
0,052
0,043
0,047
0,042
0,044
0,040
0,058
0,043
0,057
0,039
0,061
0,042
0,057
Ni
0,892
0,818
0,939
0,835
0,880
0,836
0,928
0,815
0,818
0,645
0,860
0,527
0,855
0,487
0,848
0,480
Mo
0,218
0,199
0,221
0,220
0,218
0,202
0,223
0,191
0,021
0,107
0,018
0,131
0,017
0,152
0,018
0,149
Al
0,002
0,002
0,002
0,004
0,003
0,003
0,002
0,002
0,804
0,643
0,712
0,557
0,697
0,473
0,794
0,630
Cu
0,022
0,019
0,023
0,020
0,022
0,018
0,023
0,017
0,010
0,032
0,010
0,039
0,008
0,040
0,009
0,050
Ti
0,012
0,013
0,012
0,016
0,012
0,015
0,012
0,014
0,003
0,003
0,002
0,003
0,002
0,003
0,003
0,003
V
0,012
0,010
0,012
0,011
0,012
0,010
0,011
0,009
0,003
0,006
0,002
0,006
0,002
0,006
0,003
0,007
Nb CEiiw (2)
0,006 0,376
0,007 0,387
0,005 0,381
0,009 0,401
0,006 0,373
0,007 0,395
0,005 0,389
0,004 0,386
0,017 0,464
0,022 0,450
0,015 0,472
0,020 0,444
0,015 0,471
0,019 0,450
0,016 0,470
0,020 0,440
Pcm (3)
0,166
0,187
0,168
0,190
0,165
0,192
0,177
0,197
0,176
0,184
0,178
0,185
0,177
0,194
0,177
0,185
Figure 4 depicts IIW carbon equivalent (CEiiw) and carbon equivalent parameter (Pcm) for
each position and welding procedure. The dashed lines represent CEiiw and Pcm of base metal,
respectively 0.413 and 0.175 .
0,386
0,389
0,373
0,395
CEiiw
0,401
0,381
0,387
0,376
0,3
0,197
0,177
0,192
0,165
0,168
0,1
0,190
0,2
0,187
(a)
0,4
0,166
Percentage (w%)
0,5
Pcm
0,0
Face
Root
Fa ce
Root
Fa ce
Root
Fa ce
Root
4
Sector / Specimen
CEiiw
Pcm
CEiiw
0,440
0,470
0,450
0,471
0,444
0,472
0,450
0,464
0,3
0,185
0,177
0,194
0,177
0,178
0,1
0,185
0,2
0,184
(b)
0,4
0,176
Percentage (w%)
0,5
Pcm
0,0
Face
Root
1
Face
Root
Face
Root
3
Face
Root
4
Sector / Specimen
CEiiw
Pcm
Figure 4: IIW carbon equivalent (CEiiw) and carbon equivalent parameter (Pcm) for each
position. (a) SMAW welding procedure and (b) GMAW-STT
/FCAW welding procedure.
5
Analyzing figure 4, SMAW presents CEiiw and Pcm lower than GMAW-STT/FCAW.
Comparing these results to hardness results there is no difference between welding sectors and
welding procedures. This result can be related to the effect of welding heat input of both welding
procedures.
3.5. Nick break test
Table 4 shows results of nick break for each welding sector and welding procedure;
Table 4 - Nick break test result for each welding sector and welding procedure.
Process
Sector
SMAW
GMAW-STT / FCAW
Problem
Result
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
No discontinuity. Approved
200
110
112
230
248
128
149
116
91
206
236
127
115
112
83
209
246
137
106
90
70
209
243
100
133
73
300
Weld
Root
HAZ
Weld
Root
HAZ
Weld
Root
HAZ
Weld
Root
HAZ
0
1
3
SMAW
Figure 5: IIW carbon equivalent (CEiiw) and carbon equivalent parameter (Pcm) for each
position. (a) SMAW welding procedure, and (b) GMAW-STT
/FCAW welding procedure.
Analyzing figure 5, root passes presented a lower absorbed energy than weld joint and HAZ.
Comparing both welding procedure, SMAW presented a higher absorbed energy than GMAWSTT/FCAW. The same trend is observed for weld metal. On the other hand, HAZ absorbed
6
energy was lower in HAZ for SMAW than GMAW-STT/FCAW. These results are related to weld
metal chemical composition and heat input. All results are higher than the specified by API 5L.
4. Conclusions
Based on materials and welding procedures one can conclude:
a) results of tensile test showed no difference in tensile strength.
b) bending and nick break test results are similar for both welding procedure.
c) HAZ hardness test result of SMAW welding procedure is higher than other joint regions for
each sector. GMAW-STT/FCAW presents almost same hardness result for each sector.
d) Absorbed energy is lower for root than for weld metal and HAZ.
5. Acknowledgements
The authors would like to acknowledge Lincoln Electric for funding this research.
6. References
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BOTT, I. S. et Al. High-strength steel development for pipelines: A Brazilian perspective. Metallurgical and Materials
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HILLENBRAND, H. G. et Al. Procedures, Considerations for Welding X80 Line Pipe Established. Oil & Gas Journal,
v. 37, p. 47 - 56, Set., 1997.
MEYER, D. W. Flux cored arc welding. Welding Brazing and Soldering - Metals Handbook. American Society of
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2003.
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(Mestrado) - Departamento de Cincia dos Materiais e Metalurgia, Pontifcia Universidade Catlica do Rio de Janeiro.
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