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Fractographic Analysis of Weld Metal and HAZ Regions of API X-80 Steel Subjected to Simulation of the Reel-Lay Method

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Abstract

The reel-lay method is a process commonly used for rigid riser installation. During this process, riser materials are subjected to high strain levels and associated plastic damage which can affect their structural integrity. The aim of this work was to evaluate the fracture surfaces at weld metal and heat-affected zone regions of API X-80 steel three-point bend specimens, SE(B), subjected to reel-lay method simulations. The pre-existence of circumferential planar defects at 12 o’clock position was considered and the J-integral was used to simulate the reel-lay condition at the defects. Different strain levels considering conditions less and more severe than the real one were also studied. The results showed a great influence of J magnitude on fracture surface morphology. The increase of J magnitude led to a greater local surface damage on the specimens and stable crack growth during reel-lay simulation. High loading conditions should be avoided in the operation in order to prevent further structural damage of the materials.

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Abbreviations

a :

Crack length/crack size (mm)

a ef :

Effective crack size (Irwin’s first order correction) (mm)

a n :

Machined notch length (mm)

b :

Uncracked ligament (mm)

B :

Specimen thickness (mm)

BM:

Base material

BM(L):

Tensile test specimen of base material (longitudinal to rolling direction)

BM(T):

Tensile test specimen of base material (transversal to rolling direction)

da/dN :

Fatigue crack propagation rate (mm/cycle)

E′ :

Elastic modulus for plane stress (GPa)

EPRI:

Electric Power Research Institute

GTAW:

Gas tungsten arc welding

h :

Notch height (mm)

h 1 :

Function for J p according to EPRI procedure

HAZ:

Heat-affected zone

J :

Fracture resistance in terms of J-integral

J e :

Elastic component of J (kJ/m2)

J p :

Plastic component of J (kJ/m2)

J tot :

Sum of elastic and plastic components of J (kJ/m2)

K :

Strain hardening exponent from Ramberg-Osgood equation

K I :

Stress intensity factor in mode I of loading (MPa m1/2)

n :

Strain hardening coefficient from Ramberg-Osgood equation

P :

Load (N)

P 0 :

Reference load (N)

R :

Stress ratio

S :

Distance between specimen rollers equal to 4W (mm)

SMAW:

Shielded metal arc welding

SE(B):

Three-point bending specimen

SEM:

Scanning electron microscopy

W :

Specimen width (mm)

WM:

Weld metal

WM(L):

Tensile test specimen of weld metal region (longitudinal to weld direction)

WM(T):

Tensile test specimen of weld metal region (transversal to weld direction)

α:

Constant of Ramberg-Osgood equation

ΔK :

Stress intensity factor range (MPa m1/2)

εfracture :

Strain at fracture

ε0 :

Strain at yield point

σYS(upper) :

Upper yield strength (MPa)

σYS(lower) :

Lower yield strength (MPa)

σTS(upper) :

Tensile strength (MPa)

σ0 :

Stress at yield point (MPa)

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Acknowledgments

The authors would like to thank PETROBRAS especially Dr. Guilherme Donato and Dr. Eduardo Hippert, the Fracture Mechanics and Structural Integrity group of University of São Paulo especially Prof. Claudio Ruggieri and Gustavo Donato, Dr. Marcelo Moraes from NUCLEP and CNPq and FAPERJ.

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Author notes

  1. M. A. N. Beltrão

    Present address: Welding Technology Center of SENAI-RJ, Rua São Francisco Xavier 601, Rio de Janeiro, CEP 20550-011, Brazil

Authors and Affiliations

  1. Laboratory of Fracture Mechanics, Metallurgical and Materials Engineering Program (PEMM)/COPPE, Federal University of Rio de Janeiro, Center of Technology, I-222, Rio de Janeiro, RJ, CEP 21941-972, Brazil

    M. A. N. Beltrão & F. L. Bastian

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Correspondence to M. A. N. Beltrão.

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Beltrão, M.A.N., Bastian, F.L. Fractographic Analysis of Weld Metal and HAZ Regions of API X-80 Steel Subjected to Simulation of the Reel-Lay Method. J. of Materi Eng and Perform 23, 3523–3533 (2014). https://doi.org/10.1007/s11665-014-1158-6

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  • DOI: https://doi.org/10.1007/s11665-014-1158-6

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