PROCESSING of THERMOMECHANICAL ROLLED STEEL With Respect of Welding and Cutting

Processing of thermomechanical rolled steel with respect of welding and cutting
Jrgen Schtz, EWE Welding Laboratory, Dillinger Htte
12.01.2010 ADVANCED STEEL FOR THE FUTURE
Verfasser/Dokument
z Different delivery conditions of fine grained steel z Processing of thermo-mechanical rolled steel
) Flame cutting ) Forming ) Welding ) Flame straightening
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) Post weld heat treatment
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Oxygen cutting, plasma cutting, laser cutting
no preheat required no scale on the surface
Verfasser/Dokument
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flame cutting material is combusted with oxygen and oxides are blown out plasma-cutting material is melted by ionized gas and blown out by gas jet (oxygen / nitrogen) laser-cutting material is vaporized (minor thickness) or combusted with oxygen
Verfasser/Dokument
material suiteable for gas cutting :

ignition temperature lower than melting temperature melting temperature of oxides lower than melt temperature of base material positive energy balance to keep material above ignition temperature
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liquidus-temperature ignition-temperature
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Combustion of the plate ?

1. combustion of gas (acetylene, propane, 0.5 bar) 2. heating of subsurface to ignition temperature 3. combustion of iron within the oxygen (7 bar) jet, oxides are blown out in the jet, (exothermic process ,autogenous)
1. nozzle 2. gas -oxygen (heating) 3. oxygen -jet (cutting) 4. plate to be cut 5. heating flame
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10
In brief
Oxy acetylene flame preheats the metal to the ignition point at the place to be cut. It also provides a protective shield between the cutting oxygen stream and the atmosphere.
Cutting oxygen combines with iron to form iron oxide.
11
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Cutting oxygen jet blows away molten iron and iron oxide thereby cutting a narrow slit or kerf in the metal object.
Datum und Veranstaltung eintragen
12
too fast
o.k
too slow
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14
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Oxy-cutting rapid heating and cooling at the flame cut edge martensitique microstructure :
maximum hardness is only a function of carbon content Hv = f(C) ; 800*C(%) +294
16
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90 section, 50 mm plate thickness
15 section, for hardness measurement
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19
straining of outer surface :
= t / (2r + t)
r t : mandrel (bending) radius : plate thickness
Verfasser/Dokument
approximate value : 2r >> t
= t/2r
or..
= thickness / diameter
20
21
Verfasser/Dokument
Influence of edge preparation for technical bending specimen

4,0 3,5
bending (180) without cracking crack initiation at subsurface crack initiation at edge
non grinded edge
r/t technical bending specimen
3,0 2,5 2,0 1,5 1,0 0,5 0,0 S460M 0.11%C
non grinded edge
grinded edge
grinded edge non grinded edge grinded edge

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S460M 0.10%C
S460N 0.18%C
S460N 0.15%C
S460N 0.13%C
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23
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Hot forming
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Hot forming
25
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Effect of cold forming on steel properties
increase of yield strength higher yield to tensile ratio reduction of residual elongation shift of transition from brittle - ductile
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27
Cold forming
impact energy after 5% strain staining + ageing
initial
Tstrain Tageing
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test temperature
12.01.2010 ADVANCED STEEL FOR THE FUTURE 28
Cold forming
impact energy
S+A+ initial PWHT staining + ageing
test temperature
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S420M - 40mm (CMnNb) influence of straining, ageing and tempering on TT (1/4 thickness) 150 delivery condition 10 % strain 10 % strain + aged (250/30min) 10 % strain + 580C/30min
impact energy, average [joules]
125
100
75
50
25
Verfasser/Dokument
0 -100
-80
-60
-40
-20
test temperature [C]

z Different delivery conditions of fine grained steel
z Processing of thermo-mechanical rolled steel

Verfasser/Dokument
31
Consumables for welding TM-rolled steels :
Consunables have to be selected in a way that they fulfill the required

mechanical properties ( i.e yield, tensile, toughness)
Welding position may be respected Any subsequent PWHT has to be taken into account But no difference to normalized steel
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DIN EN 499
E 46 6 1Ni B 4 2 H5
electrode 460 MPa Reh TT 47 J, -60C 0.6-1.2 % Ni
5 ml H2 /100g all welding positions DC current, >105% efficiency basic covered

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33
z Welding
)HAZ hardness )Hydrogen induced cracking - preheating )Toughness in the HAZ )Working range
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temperature
1600
melt
fusion line
1400
CGWEZ
1200
austenite
A3 lin e
fine grained WEZ partly aust. WEZ temp. WEZ Weld metal WEZ Base material
200
A1-line
0.15 %
%C
35
Verfasser/Dokument
400
S420M 100mm HAZ hardness as a function of distance from fusion line
hardness HV 10
275
275
hardness HV 10
250
S420M - 100mm SAW 0,7 kJ/mm
upper lower
250
S420M - 100mm SAW 5.0 kJ/mm
upper lower
225
225
200
200
175
175
150 -4 -2 2 4
150 -4 -2 2 4
distance from fusion line [mm]
distance from fusion line [mm]
36
Verfasser/Dokument
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HAZ hardness tests on bead on plate welds
10
20
39
cooling time t8/5 s

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1400 1300 1200 1100 Tmax (fusion line) 1350C
temperature [C]
1000 900 800 700 600 500

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40s
20s
400 300 200
10s
time [sec]
heat input [kJ/mm]

5
40 s
4
30 s
20 s
2
10 s
1
3-dimensional heat flow
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0 50 100 150 200 250

41
interpass temperature [C]

WEZ-Hrte
450 400 350 300 250 200
C,Si,Mn,Cr,Mo,Ni,Cu,V,Nb
C
C,Si,Mn,Cr,Mo,Ni,B
Ti
C,Si,Mn,Cr,Mo,Ni,Cu,B
150 1 10 100
t8/5 Zeit
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Verfasser/Dokument
HAZ hardness tests on bead on plate welds

500
HAZ hardness (HV10)
400
S 460 N
300
10
20
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cooling time t8/5 s

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200
S 460 M
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Hydrogen induced crack parallel to fusione line in the CG-HAZ
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Hydrogen induced crack In the HAZ of a multi-pass weld
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Verfasser/Dokument
Calculation of minimum preheating temperature (EN 1011)

CET = C + (Mn + Mo)/10 + (Cr + Cu)/20 + Ni/40 To = 700 CET + 160 tanh (t/35) + 62 HD exp 0.35 + (53 CET - 32) Q - 330 t HD Q = Blechdicke (mm) = Wasserstoff-Eintrag (ml/100 g - DIN 8572) = Wrmeeinbringen ( kJ/cm)
Tekken Test :
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Tp (C)
150 125 100 75 50 25 0 0,2
Tp(C)
200 175
C 0,07 0,12 0,18
Mn 1,55 1,55 1,45
Mo 0 0 0
CET Q d HD
Cr 0,03 0,03 0,03
Cu 0,2 0,2 0,05
Ni 0,2 0,25 0,05
200 175 150 125 100 75 50 25 0 0 5 10 15 hydrogen ml/100g deposit metal
0,24 % 0,29 % 0,33 % 1,5 1,5 1,5 50 50 50 5 5 5
0,25
CET = C + (Mn+Mo)/10 + (Cu+Cr)/20 + Ni/40 (%)
0,3
0,35
0,4
0,45
0,5
75 50 25 0
25
50
75 100 plate thickness (mm)
3 4 5 welding heat input (kJ/mm)
49
Verfasser/Dokument
200 175 150 125 100 75 50 25 0
200 175 150 125 100
Tp (C)
Tp (C)
50
Verfasser/Dokument
Preheating temperature EN1011

150 125 100
heat input hydrogen hydrogen Heat input GSMAW kJ/mm GMAW 1.0 0.7 kJ/mm 2 ml/100g 2 DM ml/100g SMAW DM SMAW 2.2 2.0kJ/mm kJ/mm 4 ml/100g 4 ml/100g SAW 3.3 DM SAW 3.3kJ/mm kJ/mm 7 ml/100g 7 ml/100g
S460 (N) S355J2G3 (N) S460N
S355G8+N Offshore
75 50 25
S500M
S420G2+M S460M S355G8+M
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20
40
60
80
100
plate thickness plate thickness

HAZ toughness of S355N and S355M

350 300
S355M (Nb) S355N Offshore S355N standard S355N old 0,08% C, 0,001% S 0,12% C, 0.001% S 0,20% C, 0,003% S 0,20% C, 0,028% S
impact energy [joules]
250 200 150 100
0 -80
-60
-40
-20
20
40
52
temperature [C]
Verfasser/Dokument
50
Advantages of TM-steel - Processing
TM
350 300 250
High toughness / High safety

S355J2+N S460ML S690QL
Welding leads to toughness reduction High toughness in the base material reduces the risk of brittle fracture and gives saftey!
Charpy-V [J]
200 150 100 50 0
-120
-100
-80
-60
-40
-20
20
Temperature [C]
Verfasser/Dokument
Impact testing of thick welds for the approval of offshore steels
54
Verfasser/Dokument
GRD 450 TMCP plate thickness 60-100mm

300
mean impact energy at -40C [J]
250
200
150
100
50
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FL
0 0 1 2
FL+2mm
3
FL+5mm
4 5
heat input [kJ/mm]
55
Working range
Temperature [C]
250 200 150 100 50 S355J2G3 70 mm
higher heat input max. interpass temp.
min. preheat and interpass temp.

Verfasser/Dokument
S355M - 100mm 1 2 3 4 5
56
Heat input [kJ/mm]


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57
58
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The flame straightening of a plate is based in principle on a local heating of the area to be shortened in combination with the hindrance of thermal expansion by the cold vicinity. This causes a bulging of the heated zone. When cooling down to ambient temperature the resulting tensile stresses will lead to the required deformation.
59
Verfasser/Dokument
The efficiency of the process depends on :

thermal field wall thickness heating rate very narrow located heating restraint and stiffness of the construction
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Lower limit of applicable temperature At peak temperature the area to be straightened must undergo plastic deformation. During subsequent cooling the compressive stresses turn into tensile stresses. The final tensile stresses are producing the effect on geometry. Thus the temperature must be increased above the temperature where sufficiently high compression stress are built up so that the yielding occurs The yield strength at elevated temperature is lowered to such an extent that the compressive stress will lead to sufficient bulging of the area to be straightened. For S355 / 420M steel both conditions are fulfilled for temperatures exceeding approximately 450C. So any lower temperatures are ineffective for shaping.
61
Verfasser/Dokument
Upper limit of applicable temperature The upper limit of the temperature range is shall not be exceeded in order to regain the mechanical properties of the plate after subsequent cooling. Two different flame straightening procedures have to be distinguished because they require different temperature limits.
62
Verfasser/Dokument
In the first case the plate is only superficially heated. The heat input related to the plate thickness is small. Due to the steep temperature gradients in the through thickness direction cooling is very fast. Cooling speed is in the range of high heat input welding. Due to the fast transformation again a fine grained microstructure is achieved which is very similar to the initial microstructure. So are the mechanical properties. Temperatures above 925C shall not be permitted to avoid grain growth. (examples: line heating)
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Verfasser/Dokument
Surface heating rapid cooling peak temperature max. 900-950C
In the second case the entire cross section of the plate is heated. The heat input related to the plate thickness is high. The heated area cools down slower than in the first case. The larger the heated area the slower the cooling. Air cooling represents the very extreme of such procedure. To avoid softening of the steel temperatures exceeding 600C are not permitted. For a short period 650C may still be acceptable, but clearly below 700C so that a partial transformation to austenite can be excluded. (examples: wedge heating, triangular heating)
64
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Full section heating rather slow cooling peak temperature max. 600-650C
Zusammenstellung der Glhfarben beim Flammrichten
65
Verfasser/Dokument

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66
Response of tensile properties on PWHT (S420 M)

yield strength MPa
tensile strength MPa

560
440
540
420
520
400
20mm 25mm 50mm
500
20mm 25mm 50mm
380 16,8 17,0 17,2 17,4 17,6 17,8 18,0 18,2 18,4 18,6 18,8
480 16,8 17,0 17,2 17,4 17,6 17,8 18,0 18,2 18,4 18,6 18,8
Verfasser/Dokument
Hollomon Parameter
Holding temperature 600C 600C 600C 630C 630C Holding time 60 min 240 min 480 min 60 min 240 min HP-Factor 17,00 17,53 18,05 18,15 18,25
Hollomon Parameter
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For post weld heat treatment recommended parameters 530C - 580C 1-2 hours
Verfasser/Dokument
68
Summary and conclusion

No hot forming allowed No heat treatment above ~600C Processing temperatures up to ~600C are acceptable warm-forming, PWHT, Good initial toughness allows considerable cold deformation Excellent weldability as a result of the optimised chemical composition, benefits: the omission of preheating, the application of higher weld deposition rates omission of post weld heat treatment
Weight reduction in the construction without a drawback for processing

69
Verfasser/Dokument
Distortion caused by residual stress : Yield strength will lower with increasing temperature Tensile stress occurs when material shrinks Transformation constituents (martensite/perlite) have higher volume than
austenite, this creates compressive stress
Expanding material will be plastically deformed due to colder vincinity

Verfasser/Dokument
(flame straightening)
70
Entstehung von Schrumpf- und Umwandlungsspannungen
tensile
300
thermal shrinkage austenite
temperature
300
martensit formation
500
700
900
ferrite / bainite formation
300
compressive
Yield point = f(T)
71
Verfasser/Dokument

PROCESSING of THERMOMECHANICAL ROLLED STEEL With Respect of Welding and Cutting - Presentation Jurgen Schutz

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PROCESSING of THERMOMECHANICAL ROLLED STEEL With Respect of Welding and Cutting - Presentation Jurgen Schutz

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Jrgen Schtz, EWE Welding Laboratory, Dillinger Htte

12.01.2010 ADVANCED STEEL FOR THE FUTURE

) Post weld heat treatment

12.01.2010 ADVANCED STEEL FOR THE FUTURE

) Post weld heat treatment

12.01.2010 ADVANCED STEEL FOR THE FUTURE

) Post weld heat treatment

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Oxygen cutting, plasma cutting, laser cutting

no preheat required no scale on the surface

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

material suiteable for gas cutting :

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Combustion of the plate ?

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Cutting oxygen combines with iron to form iron oxide.

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Datum und Veranstaltung eintragen

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

90 section, 50 mm plate thickness

15 section, for hardness measurement

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

) Post weld heat treatment

12.01.2010 ADVANCED STEEL FOR THE FUTURE

straining of outer surface :

approximate value : 2r >> t

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Influence of edge preparation for technical bending specimen

non grinded edge

r/t technical bending specimen

3,0 2,5 2,0 1,5 1,0 0,5 0,0 S460M 0.11%C

non grinded edge

grinded edge non grinded edge grinded edge

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Effect of cold forming on steel properties

12.01.2010 ADVANCED STEEL FOR THE FUTURE

impact energy after 5% strain staining + ageing

S+A+ initial PWHT staining + ageing

impact energy, average [joules]

test temperature [C]

z Different delivery conditions of fine grained steel

z Processing of thermo-mechanical rolled steel

) Post weld heat treatment

12.01.2010 ADVANCED STEEL FOR THE FUTURE

Consumables for welding TM-rolled steels :

Consunables have to be selected in a way that they fulfill the required

12.01.2010 ADVANCED STEEL FOR THE FUTURE

electrode 460 MPa Reh TT 47 J, -60C 0.6-1.2 % Ni

5 ml H2 /100g all welding positions DC current, >105% efficiency basic covered

12.01.2010 ADVANCED STEEL FOR THE FUTURE

12.01.2010 ADVANCED STEEL FOR THE FUTURE