OAK RIDGE NATIONAL LABORATORY

U. S. DEPARTMENT OF ENERGY
Fr i c t i on St i r Wel di ng of API
Gr ade X65 St eel Pi pes
Zhili Feng*, Russell Steel**, Scott Packer**
and Stan A. David*
* Oak Ridge National Laboratory, Oak Ridge, TN
** MegaStir Technologies, Provo, UT
April, 2005
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Ac k now l edgement
Research was sponsored in part by the
U.S. Department of Energy, Office of
Energy Efficiency and Renewable Energy,
Industrial Technologies Program under
contact DE-AC05-00OR22725 with UT
Battelle, LLC.
Technical and financial support of
MegaStir Technologies.
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Why FSW of Pi pel i ne St eel s
Ultra high-strength steels
Properties
Productivities?
Hydrogen issue
Weld metal property matching the base
metal
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Mat er i al
API 5L Grade X-65 steel
Common in oil and gas industry for pipelines
0.08C-1.0Mn-0.235Si-0.04Al-0.016Nb
C
eq
= 0.14
ERW Line Pipe
OD: 12.75 (324 mm)
Wall thickness: 0.25 (6.35 mm)
Base metal properties per mill specification
Yield: 67 ksi
Ultimate tensile: 77 ksi
Elongation: 33%
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Wel di ng
Polycrystalline cubic boron nitride
(PCBN) tool
Shoulder diameter: 1
Pin length: 0.22
Girth weld
Square butt joint configuration
No special groove preparation
Surface ground before welding
Single pass full penetration from
OD
Welding parameters
500 - 600 rpm
4 - 6 in/min
Welding forge force: 6500 lbf
Special run-off tab to eliminate the
exit hole on the pipe
Argon shielding gas from the tool
to protect weld from oxidation
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U. S. DEPARTMENT OF ENERGY
Fi el d depl oyabl e FSW syst em
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U. S. DEPARTMENT OF ENERGY
Hydr aul i c i nt er nal suppor t /f i x t ur e
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U. S. DEPARTMENT OF ENERGY
Wel di ng movi e
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U. S. DEPARTMENT OF ENERGY
Fi ni shed pi pe
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Fi ni shed pi pe
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Mi c r ost r uc t ur e and Mec hani c al
Eval uat i on
Scale: 1:5
12x3.14=37.7 Each section: 9 long after metallography samples
9
Weld
start
1 (OD weld width)
Exit tab
0 0 270 180 90
3

c
r
o
s
s
-
w
e
l
d

t
e
n
s
i
l
e
:
4

w
i
d
e
3 BM tensile:
4wide
9 HAZ Charpy:
4.5x3
18 WM Charpy:
9x3
(4) Metallographic samples
Face for Metallography
9 BM Charpy:
5x3
Tool rotation:
CCW
Advancing Side
Retrieving Side
Scale: 1:5
12x3.14=37.7 Each section: 9 long after metallography samples
9
Weld
start
1 (OD weld width)
Exit tab
0 0 270 180 90
3

c
r
o
s
s
-
w
e
l
d

t
e
n
s
i
l
e
:
4

w
i
d
e
3 BM tensile:
4wide
9 HAZ Charpy:
4.5x3
18 WM Charpy:
9x3
(4) Metallographic samples
Face for Metallography
9 BM Charpy:
5x3
Tool rotation:
CCW
Advancing Side
Retrieving Side
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Mec hani c al Test i ng
Tensile
Room temperature
3 cross-weld tensile: (1-in wide strip) API 1104
3 Base metal at room temperature
Orientation: Axial
ASTM E8, rectangular flat
Full stress strain curve. Yield stress at 0.2% offset plastic strain and at 0.5%
total strain
Charpy V notch: ASTM E23, 10x5x50 (sub-sized due to wall thickness)
side V-notch through thickness
3 repeats at each temperature.
Base metal: axial orientation @ -50, 0, 20C
HAZ: @ -50, 0, 20C
Weld: @ -50, -30, -20,-10, 0, and 20C
Weld
Notch
Location
HAZ
Notch
Location
~0.3
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U. S. DEPARTMENT OF ENERGY
Tensi l e pr oper t i es
Base Metal
Cross-weld
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Sampl es f ai l ed out si de t he w el d and HAZ
dur i ng c r oss-w el d t ensi l e t est
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Char py V-Not c h I mpac t Test
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Char py V-Not c h I mpac t Test
ASTM E23
10x5x50 mm, sub-sized
All samples showed 100% shear
0
20
40
60
80
100
120
140
-60 -50 -40 -30 -20 -10 0 10 20 30
Temp, C
E
n
e
r
g
y
,

J
Weld
HAZ
Base Metal
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Wel d Cr oss-Sec t i on Mac r o
2mm
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
The i nt er f ac e i s not easi l y
di st i ngui shabl e under hi gh magni f i c at i on
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Evi denc e of l ac k of bondi ng on t he
r oot f ac e
Relative small ~ 0.15 mm
Oxide layer
Did not affect the mechanical
tensile and impact properties
0.15mm
0.07mm
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U. S. DEPARTMENT OF ENERGY
Mi c r ost r uc t ur e
Base Metal
TMAZ
Stir zone
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Cr oss-w el d sec t i on mi c r o-har dness
pr of i l e
0 2 4 6 8 10 12 14 16 18 20 22
0
0.8
1.6
2.4
3.2
4
4.8
Postion (mm)
P
o
s
i
t
i
o
n

(
m
m
)
160-170 170-180 180-190 190-200 200-210 210-220
50
100
150
200
250
H
v

@

2
0
0
g
1/2t
1/4t
3/4t
OAK RIDGE NATIONAL LABORATORY
U. S. DEPARTMENT OF ENERGY
Summar y
A portable, field deployable FSW system
has been developed for successful
welding of X65 pipe
Fully consolidated weld joint can be
obtained in a single pass
Welding speed
Microstructure/microhardness
The girth show superior tensile and
impact properties