Properties of HAZ in two-pass submerged arc welded

large-diameter pipe
Dr. Michael Grf
Europipe Deutschland GmbH, Mlheim, Germany
Dr. Kurt Niederhoff
Mannesmann Forschungsinstitut, Duisburg, Germany

EUROPIPE. The world trusts us.

PROPERTIES OF HAZ IN TWO-PASS SUBMERGED-ARC WELDED

LARGE-DIAMETER PIPE
- Means of Influencing, Specified and Necessary Tests Accompanying Pipe Production Dr. Michael Grf a and Dr. Kurt Niederhoff b
a
b

Europipe Deutschland GmbH, Mlheim, Germany

Mannesmann Forschungsinstitut, Duisburg, Germany

ABSTRACT
The paper presents results of further work on the effects of alloy modifications to improve the
HAZ toughness of the two-pass SAW weld in large-diameter pipe. This subject was dealt with for
the first time in ref. [1]. In addition to the reported results, especially the influence of Al and Si has
been studied.
On the one hand it could be demonstrated that the use of steels free of aluminium or silicon or
aluminium + silicon improves the statistical probability of meeting the specification requirements for
the individual impact energy values at low test temperatures to a certain extent. But, on the other
hand no significant rise in the lower bound curve of the scatterband for the individual values could be
observed and the slow cooling rate typical for two-pass SAW welding invariably led to the
development of predominantly upper bainitic microstructure in the grain-coarsened HAZ.
Therefore, in cases of increased wall thicknesses combined with low test temperatures (< - 30C)
it becomes increasingly difficult to fulfil comfortably the customers requirements, because of the
better testability of real thickwall two-pass welds in connection with an inevitably brittle HAZ
behaviour at such test temperatures. Independent on this, it could be demonstrated by wide plate
testing of defective welds that there is not really a detrimental effect on the in-service behaviour. The
HAZ is always tough enough to rule out brittle crack initiation during pipe laying and in service. All
linepipe grades applied today do not suffer any serious problems in this respect.
As has been proposed by Europipe since the publication of ref. [1], the best manufacturing
control is given by the use of steels in a well-defined and permitted range of chemical compositions.
In this case CVN and CTOD testing on the HAZ is unnecessary.
INTRODUCTION
Grain-coarsened HAZs (GCHAZs) possess reduced low-temperature toughness, a finding
which is well-known and hence will not be discussed here further. The GCHAZ that develops
particularly in low-alloy steels over a wide range of welding parameters, i.e. over a wide range of t8/5
values, transforms to upper bainite during cooling from the welding temperature. This upper bainite
contains MA constituent, which limits the toughness of the HAZ, particularly at low temperatures
(Figure 1). Large-diameter linepipe steels are typically affected by this problem. Only through nickel
additions in excess of about 2 to 3 % would it be possible to shift the upper bainitic transformation
range to longer cooling times, as a result
1

of which favourable transformation conditions would be achieved in the cooling time range typical of
the two-pass SAW seam weld in large-diameter linepipe (Figure 1).
This problem was discussed openly in ref. [1] where attention was drawn to the limited number of
alloying measures that can help achieve optimum toughness under the given practical conditions
(Figure 2). Reduction of carbon content plays a predominant role in this context. Restrictions on the
amount of microalloying elements added have also a significant effect (Figures 3 to 5). It could also
be demonstrated that different microalloying combinations entail different carbon contents (Figure 6).
Steels alloyed with boron have some disadvantages and therefore are not used as linepipe materials.
Ref. [2] introduced a modified steel killing practice which is claimed, for example in ref. [3], to
result in grain refinement (acicular ferrite formation) of the HAZ through the presence of finely
dispersed titanium oxide particles in the steel.
Such a beneficial phenomenon is well-known in arc welding practice. Fusion weld metals owe
their sufficient toughness to the presence of appropriate oxide particles (mostly mixed oxides from
the welding slag) in adequate number, size and distribution. The lattice structures of the oxide
particles and the associated sulphides are such that they act as nuclei for the formation of ferrite. If it
is assumed that the acicular ferrite grains are ideally 5 m cubes and that each grain would require
one oxide particle as the nucleus, the number of oxide particles needed would be incredibly high, at
8 million per cubic millimetre of weld metal.
Meanwhile, it has been recognised that attempts to make use of this effect in mass production of
steel have hardly any chance of success. Moreover, the necessary total oxygen content, at > 150 to
200 ppm, which reflects the necessary oxide content, would be excessively high. Consequently, an
other explanation of the mechanism in so-called titanium oxide steels was put forward in ref. [4].
The objective of the present work was to determine, among other things, the benefits that may be
achieved through alternative steel deoxidation practices (Al- and/or Si-free steels).
EXPERIMENTAL
The experiments were made both with laboratory-scale heats and mill-scale heats. In most cases,
the steels typically had low carbon contents and were made to low sulphur and phosphorous
steelmaking practices. Material grades X 60, X 65, X 80 and X 100 were studied. Steels with the
same basic composition but with the following characteristics were compared with each other.

Aluminium-free and silicon-alloyed

Silicon-free and aluminium-alloyed
Aluminium-free and silicon-free
Both aluminium-alloyed and silicon-alloyed.

In addition to the specimens subjected to weld thermal cycle simulation, real welds were tested
and the number of specimens tested was statistically significant. Charpy V-notch impact tests
constituted the major part of the tests. Scattered CTOD tests were also made. The behaviour of
HAZ in full-section components was studied using wide plate tensile specimens. The specimens
contained artificial defects of different size and the defect tips were located in the grain-coarsened
HAZ adjacent to the fusion line.
2

RESULTS
INVESTIGATION OF THE EFFECT OF ALUMINIUM AND SILICON ON THE
CHARPY V-NOTCH IMPACT ENERGY OF THE HAZ IN THE LONGITUDINAL
SEAM WELD
Figures 7 to 9 show a few examples of the vast amount of data available now. The diagrams
show the scatter of the individual impact energy values. 60 to 120 specimens were tested at each test
temperature. For the sake of clarity, only the upper and lower bound curves for the scatter of the
individual values are shown in the diagrams. The data points (solid circles) in the diagrams represent
a typical customer requirement for an average value of 45 J minimum and an individual value of 37 J
minimum, which has to be considered as very severe because the test temperature specified is quite
low, at -30C. As can be seen from all figures, when a statistically significant number of specimens
are tested, it is not uncommon that a few scattered individual specimens fail to meet the specification.
In contrast, the average values determined for each set of three specimens as a rule meet the
specification. This test result, which can be considered as optimum in the present case and typical of
the longitudinal seam weld, is achieved in general only when the carbon content of the steel is
sufficiently low. The lower bound curve and especially the upper bound curve will be shifted
downwards at higher carbon contents.
The following can be read off the figures.
The data in Figure 7 refer to a steel that corresponds to that mentioned in ref. [2]. The grade
X 60 material, which was free of aluminium and silicon, contained only 0.06 % carbon and an
extremely low niobium content, which is not sufficient for the production of higher strength linepipe.
Although the alloying and microalloying measures adopted in this case were quite favourable, the
onset of heavy scatter of individual values could be noticed already at a test temperature of -10C.
The scatterband shown is applicable to both simulated and real weld HAZs. Because of the heavy
pipe wall, specimens could be taken with most critical orientation, i.e. inclined to the pipe wall. Thus,
the test conditions were made considerably severe, as result of which there was no difference in
toughness between the simulated HAZ and real weld HAZ. The results of both test methods
coincided largely. In respect of the test results on this weld, which can be considered as non-critical,
it should be noted that hardly any individual impact energy value below 20 J was measured at
temperatures down to -40C. Impact energies in the range of upper shelf energies (300 J) were
found on isolated specimens even at this low temperature.
In this respect, it should be mentioned that a few isolated individual values that fail to meet the
specification at test temperatures as low as about -30C are also known to occur in heavy wall
seamless linepipe (unaffected base material), which may exhibit mixed grain sizes (i.e. isolated coarse
grains of upper bainite in an otherwise fine grained microstructure). The above example, and many
other examples for that matter, show that even a few isolated coarse grains in a fine grain overall
microstructure can result in such individual low energy values at critically low test temperatures. It is
not known that such a microstructure is detrimental to the performance of a pipe in service.
For comparison with Figure 7, Figure 8 shows the data for a grade X 100 material. The data here
were obtained entirely from real welds. The wall thickness was 15 mm. The steel contained 0.08 %
carbon, 1.9 % manganese and 0.18 % molybdenum and was microalloyed with vanadium, niobium
and titanium. This example shows the effect of aluminium and silicon once again. As can be seen
from the figure, all the steels, except the steel free of aluminium and silicon, which were tested using a
3

significantly large number of specimens, exhibit almost identical lower bound curves. The steel free of
aluminium and silicon shows on the other hand a slight advantage in terms of a raised position of the
lower bound curve of the scatterband. This advantage is however only at test temperatures above 25C, i.e. at temperatures at which the compliance with usual specifications is still not very difficult.
In comparison, there is a relatively large difference in the positions of the upper bound curves. In this
respect, the variant that is aluminium-silicon-free and the variant that is silicon-free but aluminiumalloyed have advantages over the other variants. But, the fulfilment of the usual mean impact energy
requirements for sets of three specimens is not a problem even in the case of the latter variants.
The following figure (Figure 9) shows once again the detrimental effect of niobium, which has to
be invariably present as the most important microalloying element in high strength linepipe steels, on
the impact toughness of HAZ. This detrimental effect cannot be fully compensated for even by the
use of aluminium-silicon-free steels. In this example, niobium-bearing and niobium-free steels with the
basic composition corresponding to that of grade X 80 are compared with each other. The carbon
content was low, at 0.06 %. Variant A, which was a so-called titanium-oxide steel, did not contain
aluminium and was microalloyed with sufficient amount of niobium. This heat could attain the strength
level of grade X 80. Variant B contained aluminium, but no niobium. As a result, this steel could only
attain a strength level of grade X 60.
Also this figure shows again that when a statistically significant number of specimens are tested,
the requirement for the minimum individual value of 37 J at -30C cannot always be met by niobium
microalloyed linepipe steels. This finding is also confirmed by the statistical assessments of the data
on production pipe, presented in Figures 10 and 11. Only in the case of sour service pipe with
extremely low carbon contents, as shown in the figures, is it possible to fulfil comfortably the
requirements of the specification used as an example here.
EFFECT ON SERVICE PERFORMANCE OF LINE PIPE
Figure 12 shows the HAZ toughness properties for two 20 mm thick grade X 80 plates, which
were differently alloyed. The materials were used for determining the behaviour of longitudinal seam
welds in wide plate tests. CTOD specimens taken at the critical HAZ location were also tested here.
As the number of specimens tested was too small, the scatterbands shown do not have statistical
significance, i.e. they do not represent the probable full scatter of the individual values. The objective
of the tests was only to provide some rough orientation in view of the wide plate tests, which were
the actual objective of the investigation.
The results of the wide plate tests are shown in Figure 13. The estimation of the advantage of
using aluminium-silicon-free steels is only indirectly possible from the data, because grade X 80
materials with and without aluminium and silicon, but with exactly the same carbon content and the
same basic composition, were not available at the time of this investigation. When comparing the two
steels, it should be borne in mind that the aluminium-silicon-free steel had also the advantage of the
favourably low carbon content of 0.06 %, compared to the aluminium-silicon-bearing steel with a
carbon content of 0.10 %.
It is not difficult to conclude from the results that the effect of carbon content was more significant
than that of aluminium and silicon (compare the results on both steels for the large defect 86.0 mm
long and 5.0 mm deep). Furthermore, it is clear from the data that the defect size has a more

predominant effect on the test results (compare only the specimens from the aluminium-siliconbearing steel (0.10 % C) with large and small defects).
All in all, a fully non-critical full-scale specimen behaviour was noticed for both steels at test
temperatures down to -50C. As expected, none of the specimens showed a brittle low-stress
fracture initiation. Sufficiently large crack opening and gross section yielding occurred before the
specimens failed by unstable brittle crack growth. Thus, it is clear that even a relatively brittle HAZ,
as present in the 0.10 % carbon variant, possesses sufficient margin of safety against unstable crack
initiation. It should be noted that the defects incorporated into the wide-plate test specimens had
such a large size that is not encountered in practice. The presence of such large defects in the
longitudinal seam weld would also be ruled out by means of highly developed non-destructive
inspection techniques. Moreover, weld defects of critical nature and size have not been encountered
so far (Figure 14). Even if small defects escaped detection or were not repaired, they would not be
present, as a rule, in the weld surface regions, which are considered as most critical from the fracture
mechanics point of view.
SUMMARY
The continuation of the work reported in ref. [1] has shown that the development potential of
large-diameter linepipe steels has been adequately exploited to the extent that the alloying measures
listed in Figure 2 have been fully adopted. Major attention has to be drawn to the benefit of reducing
the carbon content of the steel. The benefit that can be derived by the use of the so-called titanium
oxide steels is limited in that it only helps increase the statistical probability of fulfilling the impact
toughness requirements for the individual value. The use of these steels do not really improve the
performance of the linepipe in service. This contention was confirmed by the results of the fracture
mechanics tests (wide-plate tests).
It was already suggested in ref. [1] that the use of impact tests for the purpose of quality control
of production pipe can be largely or fully dispensed with. An effective alternative to the use of impact
tests is the adoption of adequately narrow ranges for the individual elements of the chemical
composition of the steel. Therefore, impact tests may be used as an additional checking measure
when the chemical composition deviates inadvertently from the specified ranges.
REFERENCES
[ 1 ] Grf, M. and K. Niederhoff: Toughness behaviour of the Heat-affected zone
(HAZ) in double submerged-arc welded large-diameter pipe; Pipeline
Technology Conference, 15-18 October 1990, Oostende, Belgium
[2 ] NSC patent on Ti-oxide treated structural steels (EP 0177851)
[ 3 ] Nakasugi, H.; Tamehiro, H.; Nishioka, K.; Ogata, Y. and Kawada, Y.:
Recent development of X80 grade line pipe, International Conference
Welding -90 , on welding technology, materials and fracture;
22-24 October 1990, Geesthacht, Germany
[ 4 ] Terada, Y.; Tamehiro, H.; Ishikawa, H.; Sugiyama, M.; Chijiiwa, R. and N.
Ayukawa: Sour Resistant X65 UOE Line Pipe for Low-temperature Service;
7th International Offshore and Polar Engineering Conference,
Honolulu, Hawaii, May 1997
5

10

11

12

13

14