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Excellent abrasion resistance is required of pipes that are used in slurry transportation systems such as those for
transporting coal ash in pulverized-coal-firing boilers. We have developed an abrasion-resistant pipe named
NK-SL80 for transporting slurry. This paper reports properties and test results of the newly developed pipe.
NK-SL80 is a 0.15%C-1.5%Si-1.5%Mn-Fe steel pipe with dual-phase microstructure composed of ferrite and martensite. The martensite phase provides abrasion resistance and the ferrite phase provides workability. The newly developed pipe contains smaller amounts of elements such as C and Mn than conventional abrasion-resistant pipes,
and hence shows excellent field weldability compared with high-carbon abrasion-resistant pipes.
1.
Introduction
2. Outline of NK-SL80
2.1 Chemical compositions and mechanical properties of NK-SL80
Steel pipes used for slurry and waste transportation systems are required to have excellent abrasion resistance. As
abrasion resistance basically depends on the hardness of a
material, most conventional abrasion-resistant pipes
achieve their hardness by increasing the carbon content or
by adding alloying elements such as Ti and V. These approaches are effective for increasing abrasion resistance,
however weldability deteriorates as the resulting product
requires higher preheating temperatures for welding. These
approaches likewise deteriorate formability. The combination of poor weldability and poor formability leads to poor
field workability. Further, the addition of alloying elements increases manufacturing costs. NK-SL80 is an abrasion-resistant pipe that solves these problems and economically provides excellent field workability. Table 1
shows the ranges of chemical compositions of NK-SL80,
which is a carbon steel not containing expensive alloying
elements such as Ti and V.
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Table 1
C
NK-SL80
Si
Mn
1.20 ~ 1.60
0.20
1.20 ~ 1.60
0.040
0.040
Tensile strength
N/mm2
Yield strength
N/mm2
800
400
NK-SL80
Elongation
Hardness
Hv
10
250
JIS Z2201 No.5 specimen
Table 3
NK-SL80
Table 4
(Continuous) Casting
Hot working
Testing, inspection
Fig.1
Mn
0.15
1.43
1.50
0.010
0.004
Tensile strength
N/mm2
945
Yield strength
N/mm2
Elongation
%
Hardness
Hv
469
14
264
Si
NK-SL80
Melting
Product
Heating
Cooling
Ferrite + Austenite
Cooling quickly
Austenite is
transformed into
Martensite
Ferrite + Pearlite
0.05mm
Ferrite + Martensite
Photo 1
17
3. Practical properties
3.1 Abrasion resistance
3.1.1 Abrasion resistance of NK-SL80 and various
steel materials
General properties of abrasion resistance were evaluated
by specimen-rotating-type abrasion tests in wet environment. Fig.3 is a schematic drawing of the abrasion test
machine and the dimension of the specimens. The specimens were 10 mm in diameter and 60 mm in length, and
were moved in slurry at a speed of 4 m/sec. Abrasion resistance was evaluated by weight loss of the specimens
due to abrasion. In this test environment, the dominant
mode of abrasion was collision-type. Steel materials subjected to the rotating-type abrasion tests were carbon steel,
abrasion-resistant steel, and stainless steel. In total, 13
grades of steels shown in Table 5 were tested. Fig.4 shows
results of the tests. The specimens were rotated for four
hours in the environment that is composed of silica (JIS
Water+SiO2
150mm
NK-SL80
Mild steel (SS400, etc.)
PH-SUS
NK Everhard
SUS
TMCP-SUS
High Mn steel
1.2
60mm
10mm
Specimen
Specimen
Ferritic steels
0.8
0.6
0.4
NK-SL80
0.2
Austenitic steels
0
100
200
300
400
500
600
Hardness HV98MPa
Test condition : SiO2 + Water, Time : 4h
Fig.3
Fig.4
Grade
Hardness Hv/98N
Si
NK-SL80
260
0.15
1.43
1.50
C-steel
STPY400
125
0.10
0.29
0.56
X52
160
0.12
0.28
1.30
Nb
Alloy-steel
9 Cr
220
0.08
0.23
0.44
0.14
8.35
0.90
Nb,V
360A
440
0.16
0.25
0.96
0.20
0.63
0.21
V,Ti,B
500A
520
0.27
0.31
0.96
0.61
0.22
V,Ti,B
17Cr-5Ni
290
0.01
0.57
0.47
0.45
5.11
17.5
0.25
Nb
15Cr-5Ni
360
0.01
0.50
0.67
3.70
4.91
14.8
Nb,Ti
NK Ever Hard
PH-SUS
High Mn-steel
Mn
Cu
Ni
Cr
Mo
(mass %)
Others
Material
12Mn
320
0.95
0.30
12.8
SUS304
150
0.04
1.02
0.36
8.13
18.2
0.23
SUS304N
220
0.06
1.69
0.14
8.10
18.4
0.08
TMCP-SUS
SUS317
265
0.01
0.33
1.60
13.8
18.2
3.40
Dual-SUS
SUS329J1
230
0.02
0.47
0.98
5.79
22.5
3.16
SUS
18
3.1.2
Condition 1 (clinker-39kg,water-80kg)
Condition 2 (clinker-50kg,water-70kg)
1.2
SS400
Fig.6
NK-SL80
S50C
1
0.8
0.6
0.4
0.2
0
Fig.5
0.4
1.2
NK-SL80
0.6
0.2
SS400
0.8
S50C
Air nozzle
3.1.3
Fly ash
Fig.7
40m
Photo 2
19
10m
NK-SL80
S50C (0.50C)
Grain size , m
Fig.8
Fig.9
by 3-dimension method
S50C(0.50C)
15
15
0.20
0.83
0.23
0.90
0.20
0.53
0.20
0.50
As-pickled surface
0.20
0.58
0.20
0.60
3.2 Weldability
3.2.1 Weldability
NK-SL80 is characterized by its excellent weldability.
S50C conventionally used for ash conveying pipes has a
high (0.5%) carbon content, and requires preheating to
20
Table 8
Welding
process
NK-SL80
Photo 3
S50C (0.5C)
0.1mm
Welding
consumables
*
0.1mm
Automatic welding:
TIG welding
Welding condition
50
100
No crack
No crack
No crack
R.T. (25)
*As for the welding material, the joint tensile strength is made the welding
material of 420N/mm2 or more as shown in the table.
**When the shielded metal arc welding is used, with a welding rod of
low-hydrogen type like the table. And moreover , please use that have to
dry immediately before the welding, and note the cold crack prevention
about the covered electrode.
Pre-heat temperature
Welding
condition
Table 7
Semi-automatic
Welding:
gas-shielded metal
arc welding
4.
60
17
17
1417
3 pass
Flange
2 pass
1 pass 1012
Pipe
3 pass
2 pass
1 pass
318.5
[mm]
Fig.10
21
PipeNK-SL80
Nominal dia.
A
B
25
1
32
11/4
40
11/2
50
2
65
21/2
80
3
90
31/2
100
4
125
5
150
6
200
8
250
10
300
12
350
14
400
16
450
18
500
20
550
22
600
24
650
26
700
28
750
30
800
32
850
34
900
36
950
38
1000
40
318.517.0t5500L (mm)
60
5 pass
4 pass
6 pass
2 pass
3 pass
1 pass
Thickness (mm)
2mm
Fig.11
5.
34.0
42.7
48.6
60.5
76.3
89.1
101.6
114.3
139.8
165.2
216.3
267.4
318.5
355.6
406.4
457.2
508.0
558.8
609.6
660.4
711.2
762.0
812.8
863.6
914.4
965.2
1016.0
Fig.12
Seamless
length : max. 13.5m
UOE pipe
length : max. 12.0m
Conclusion
Outside dia.
(mm)
References
1) Shima. Karyoku Genshiryoku Hatsuden (The Thermal and Nuclear
Power). Vol. 50 (1999).
2) Maruta et al. Karyoku Genshiryoku Hatsuden (The Thermal and Nuclear Power). Vol. 50 (1999).
3) Shibata et al. Karyoku Genshiryoku Hatsuden (The Thermal and Nuclear Power). Vol. 49 (1998).
4) Nagae et al. NKK Giho(NKK Technical Bulletin). No. 144 (1993).
5) Furukawa et al. Tokushukou (Special Steel). No. 48 (1999).
6) Sato et al. Yosetsu Kogaku (Welding Technology). No. 106.
<Please refer to>
Akira Toyama
Product Design & Technical Services, NKKTUBES
Tel. 044 (322) 1666
E-mail address : Akira_Toyama@ntsgw.keihin.nkk.co.jp
Toshihiko Fukui
Heavy Steel Products Research Dept., Materials & Processing Research Center
Tel. 044 (322) 1735
E-mail address : Toshihiko_Fukui@ntsgw.heihin.nkk.co.jp
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