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STRUCTURAL APPLICATION
BY
SYNOPSIS
This paper demonstrates an example of real weld application in a HSLA steel class
65 ksi and a HSLA steel class 50 ksi. It was possible to determine using thermal
simulations the recommended energy range of the weld more accurately, including
the need or not of preheating, and show that they were comparable with real welds.
The use of niobium HSLA steel shows benefits that include cost savings resulting
from the elimination of preheating, reduction in material use and increase in the
process speed.
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Introduction:
According to the World Steel association, about half of all steel produced worldwide
goes to the construction industry. An increase in industrial activities, infrastructure
projects driven by urbanization, population growth and replacement of aging
infrastructure will ensure that strong demand for steel will continue. Indeed, the world
steel consumption is expected to rise from 1500 million tons in 2000 to
approximately 2800 million tons by the year 2050.
The use of a higher strength steel can enable substantial savings in structural weight
and material costs. Although high strength steels are more expensive than
conventional structural steels, the price increase is less than the rate at which the
strength increases. The reduction in weight leads to cost savings related to
foundations, welding, fabrication, transportation and assembling in place. Due to this
reality, high strength structural steels are increasingly being applied in modern
construction.
High strength microalloyed steels are steels whose properties have been modified by
adding a small amount of an alloying element (usually less than 0.10%). Niobium is
the solution when both increased strength and improved toughness are required.
The economic benefits associated with using such small additions that confer
significant improvements to mechanical properties have led to the growing popularity
of microalloyed steels in the market. However, conservatisms in design codes often
hinder full exploitation of these steels. The following examples will help user to
recognize advantages, not only in terms of economic gain but also in terms of
sustainable and environmental friendly building. The latter becoming more and more
important for emerging countries with high growth rates.
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This already demonstrate the continuous pursue of more sustainable constructions,
being safer against fracture and generating lower costs while keeping up with
modern design developments. The process started, however requires more steps
and applications to convince designers worldwide.
A second work was presented in HSLA steel seminar in 2015 [3] applying ASTM
A572 grade 65 steel in combination with grade 50 as an optimized engineering
solution for CBMM’s new industrial building to house the company’s
dephosphorization plant in Araxá, Minas Gerais, Brazil. As a result, it was shown an
additional benefit of:
Weight savings = 10%.
Carbon dioxide emissions = 9% reduction.
Energy savings = no preheating welding process necessary.
Cost savings = 5% of the cost of the structure.
Most of the grade 65 (YS > 65 ksi) steel was applied in the main columns since it
delivers advantages related to high load levels and good interlocking provided by
platforms. In the platforms, calculations also demonstrated a benefit of using grade
65 in the main beams with sections up to 600 mm in height.
Figure 1: Microstructure of ASTM A572 grade 65, nital 4% and 500x magnification
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The benefits of Niobium in microalloyed steels:
Strengthening mechanism of niobium microalloying
Niobium effectively controls the microstructure of steel and small amounts of this
element can refine the grain size of hot rolled steels. The effects of niobium as a
microalloying element are schematically illustrated in Figure 2 [4] for reheating
temperatures up to 1200°C.
Fine grain size is an essential requirement for steels to obtain strength and
toughness properties. Figure 3 shows the strong effect that grain size (d) has on
mechanical yield strength (σy) in carbon-manganese steels.
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Figure 3: Relationship between grain size and yield strength. [5]
Reducing grain size generates a robust increase in strength for all carbon contents
considered. This is even stronger with niobium microalloying due to its effect of
preventing recrystallization during controlled rolling. Additionally, niobium precipitates
as very fine particles, further contributing to increased strength.
A study of ASTM 992 beam (S355) based on industrial heats led to the
commercialization of low-carbon niobium-bearing beam in place of a vanadium-
bearing beam [6]. The addition of niobium refines the grain and improves toughness.
Structural beams containing niobium microalloy exhibit double the impact strength at
room temperature compared to a vanadium microalloy system at similar condition
(carbon, sulfur, phosphorous and nitrogen levels and cooling rates) as illustrated in
Figure 4.
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Figure 4: Charpy V-notch impact strength comparison – niobium vs. vanadium. [6]
An important point in the welding standards is the need to group materials in classes
related to properties, especially according to different mechanical properties.
However, these methods bring a more complicated approach when working with
materials with different production methods like TMCP (Thermo-Mechanically
Controlled Processed) or QT (Quenched & Tempered) and same classification or
even with the variation of alloying elements levels. The differences can also impact
some manufacturing procedures needs in welding as preheating.
Borba et al. [7] showed some interesting results comparing two steels for wind tower
application - Sincron EN-10025-4 S355 M (TMCP) and ASTM A572 grade 50 (QT)
being welded for same process of high energy. It is showed that the microstructure
of a TMCP steel is much refined and has a lower carbon and alloying elements
content, without loss of the mechanical properties in the base metal. Once they were
welded, the impact Charpy-V results showed a big gap in the Heat Affected Zone
(HAZ) absorbing much more energy in the TMCP steel then in the QT steel as
showed in Figure 5. As explained by Borba et al. the result is related to a higher
heterogeneity in the tested samples and being the notch test with small opening less
sensitive to the different microstructure in the HAZ. The result is related to the region
with lower toughness when it has at least 30% of the notch.
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Figure 5: Hardness mapping in the region of Charpy-V notch samples and absorbed
energy in weld metal at -20°C (MS) and HAZ at -30°C (LF1 and LF5) [7]
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Figure 6: Crystallographic orientation map in evaluated steels HAZ by EBSD. [7]
Stalheim & Muralidharan [8] also showed in their different Continuous Cooling
Transformation (CCT) simulations how much the elements can affect the phase
transformation in steels. As an example, the carbon increase moves the ferrite,
perlite and bainite transformation areas to the right (increasing the time for these
transformations) allowing a higher amount of martensite to be formed. The addition
of elements as molybdenum, nickel and niobium reduce the kinetics of ferrite and
perlite formation allowing a higher amount of bainite to be formed. Each element
affects the CCT diagram in a different way, by nature or magnitude.
The H-beams section need to be produced using the submerged arc welding
process (SAW). The as-rolled sections had not previously been produced with grade
65 in the Brazilian market.
The joints of the SAW process (sections) and FCAW process (repair) were projected
and qualified on a Welding Procedure Specification (WPS) according to AWS D1.1 –
Structural Welding Code – Steel Standard. The welders were requalified according
to new consumables and materials, which are assumed as critical variables, and
which changed from groups into the welding standard. The consumables, for
example, shift from 70 ksi class in the grade 50 to 80 ksi class in the grade 65.
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A flux-cored arc welding (FCAW) process was used for the connections between
grade 65 and 50 at the base of the sections conform to the existing welding
procedures since the process for welding dissimilar materials follows the
requirements for the lower specification material that were currently performed.
The plate supplied by the Brazilian company was submitted to thermal simulations
using a dilatometer (DIL805A/D from TA Instruments) and a thermomechanical
simulation (Gleeble 3500 from Dynamic Systems Inc.) in order to understand the
possible problems during the production of the H-beams and real welds were also
performed. This bainitic steel present a very big welding range due to the low
carbon, low alloy and TMCP production process. No concern was raised after the
analysis, but two main questions need to be answered:
Table 1: Typical composition of low carbon low alloy grade 65 steel studied (wt %)
C (%) Si (%) Mn(%) P (%) S (%) Nb (%) Cu (%) N (%) V (%) Ti (%) CEV
0.09 0.25 1.50 0.014 0.002 0.030 0.143 0.004 0.004 0.013 0.35
Table 2: Mechanical properties of the low carbon low alloy grade 65 steel studied
YS (MPa) TS (MPa) El (%) Charpy-V @-50ºC (J)
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Figure 7: Granville diagram
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Table 4: Test results and conclusions of weldability tests in high strength steel
Test Result Conclusion
Reduction in area >60% Greater than 30%, no lamellar
(Through-thickness tearing susceptibility in the steel.
tensile test)
Tensile strength 570 MPa (SAW) Matches A572 Grade 65
600 MPa (FCAW) specification (minimum 550 MPa).
Hardness 203 HV The hardness results are below 350
(SAW HAZ) HV and do not indicate hard zones
and susceptibility to cracks from
213 HV martensitic formation.
(FCAW HAZ)
Bending test SAW and FCAW Even when bent, the welded joint
no fracture in the does not crack, qualifying the
weld welding procedure.
Impact test (at 23 ºC) 293 J While not a requirement in structural
(SAW HAZ) steels in Brazil, the result shows the
welded material has good
toughness at typical regional
temperatures (Araxá, Brazil).
Hardness mapping indicated that there was no hard zone formation after SAW and
FCAW (Figures 8-10).
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Macro and microstructural analyses were performed in SAW and FCAW specimens,
Figures 11 and 12, showing that no segregation or martensitic formation was found
in the weld.
Figure 11: Macro and microanalysis Figure 12: Macro and microanalysis
of the SAW welded regions of the FCAW welded regions
To answer this question two coupons with ASTM A572 grade 65 with 25.4 mm
thickness were prepared and welded with SAW butt joint process (described in table
3) in the same environmental conditions. The only difference was the preheating
performed till 150ºC in one of the plates. The result is presented in the table 5.
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Table 5: Microstructure and mechanical results in welds of ASTM A572 grade 65
with and without preheating
Microstructure Mechanical results
The expected difference in the two procedures is the change in the cooling time due
to a higher heat already existing in the sample. This heat change and impact tend to
be higher in a real beam situation as the dimensions and heat transfer will be bigger
but due to the high heat input and speed of the SAW weld it can still be comparable.
The results are aligned with the thermal simulation results where the material
preheated presented in the end bigger ferritic grain size in the CGHAZ and also
more perlite volume due to a slower cooling and more time for the austenitic grain
growth. The TS and hardness are not changed due to the high weldability of the
steel due to the low carbon and carbon equivalent content, but is important to note
the big drop in the toughness and transition temperature. This result shows that not
only the preheating does not seem appropriate in terms of process efficiency (there
was no change in the possibility of excessive softening or MA formation), but can
also be deleterious if the structure is later submitted to cyclic efforts or low
temperature environment.
The preheating procedure for this steel is therefore not necessary even if indicated in
the AWS D1.1 standard in the preapproved tables. It is also important to remark that
the Annex I of AWS D1.1 has a methodology to identify preheating needs according
to the real carbon content and procedures variables that confirm the results of this
study.
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ASTM A572 grade 65/50
A weld joint using both steels grade 65 and grade 50 was also performed in order to
understand possible effects in the weldability of both steels (25.4 mm plate). The
grade 50 has a higher carbon content as it is a QT steel comparing to the TMCP
steel grade 65. The chemical composition is showed in the table 6 and 7.
Table 6: Composition of low carbon low alloy grade 50 steel studied (wt %)
C (%) Si (%) Mn(%) P (%) S (%) Nb (%) Cu (%) V (%) Ti (%) CEV
0.15 0.25 1.40 0.017 0.005 0.033 0.01 ND 0.015 0.35
Table 7: Composition of low carbon low alloy grade 65 steel studied (wt %)
C (%) Si (%) Mn(%) P (%) S (%) Nb (%) Cu (%) V (%) Ti (%) CEV
0.07 0.29 1.53 0.017 0.003 0.019 0.14 ND 0.013 0.35
The most important point in this case is to understand that having a lower grade
does not mean an easier weld or a steel that can support better high heat inputs.
Conclusion:
The correct use of welding procedures is very important in the project and fabrication
of structures. It has been shown how the material technology has changed in the
past few years and how the new niobium steels can allow advantages in terms of
leaner structures and easy welded joints.
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As a comparison in the project described by Leonardo et al. [3] and using as a
reference the steel structure manufacturing data and IPCC guidelines, in a project of
roughly 450 tonnes of welded beams, the non-use of preheating procedure when
using SAW for the H beans of ASTM A572 Grade 65 steel reduced the consumption
of 233,030 m3 of oxygen and 146 tonnes of LPG resulting process economy of
roughly US$ 250,000.00, reduction in beam welding time and a non-emission of
427.6 ton of CO2e (carbon dioxide equivalent) increasing the sustainable value of the
building in addition to all points already described in the introduction as the 7% total
material cost reduction comparting with a ASTM A572 Grade 50 structure.
Much has to be done and the correct knowledge coming to all levels in the structural
supply chain is one of the challenges to be overcome in the next years. The
technologies already exist and in some levels are just not being used in the most
effective way.
References:
1. P. Langenberg, “Quality matters – material requirements in Eurocode 3
(EN1993) in view of component safety”, Value-added Niobium
microalloyed
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Transmission Pipeline Steels”. Proceedings of IPC 2006, 6th International
Pipeline Conference, Calgary. 2006
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