Progress in Natural Science: Materials International 30 (2020) 110–117

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Original Research

Microstructure and properties of the interlayer heat-affected zone in X80 T

pipeline girth welds
Fang Baia,d, Hongsheng Dinga, Lige Tongb,⁎, Liqing Panc
a
School of Mathematics and Physics, University of Science and Technology Beijing, Beijing, 100083, China
b
School of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, China
c
College of Science, China Three Gorges University, Yichang, 443002, China
d
Pipeline Institute, China Petroleum Pipeline Engineering Co., Ltd., Langfang, 065000, China

ARTICLE INFO ABSTRACT

Keywords: The heat-affected zone between the layers of a weld metal is a sensitive and important component of girth welds
Girth weld in X80 pipelines. However, only a few studies have focused on the interlayer heat-affected zone (IHAZ). In this
Interlayer heat-affected zone work, thermal simulation was conducted to investigate the relationship between IHAZ microstructure and
Thermal simulation properties. Results showed that the toughness of the weld metal improved after a single welding thermal cycle
Granular bainite
but decreased after double welding thermal cycles, particularly when the weld metal was subjected to unaltered
Toughness
coarse grains of IHAZ. The relationship between the microstructure and properties of IHAZ was established to
present the correlation of toughness with granular bainite content, grain size, and high-angle grain boundary
content.

1. Introduction
Welding is crucially important for pipeline construction. The
heating process makes the girth weld the most sensitive and weakest
part of pipelines [1,2]. Multipass welding is commonly performed in
various pipeline constructions [3]. In this method, each welded joint
comprises two or more welding layers, and the interlayer heat-affected
zone (IHAZ) is formed between the welding layers. The low-tempera-
ture toughness of the welded joint is related to the microstructure of
IHAZ [4–6]. Therefore, the relationship between the microstructure and
properties of IHAZ should be studied to identify the key factors for
improving girth weld toughness.
However, research on IHAZ remains limited. Most studies have fo-
cused on the heat-affected zone (HAZ) between base and weld metals.
Several studies have shown that the impact performance of HAZ is
discretized due to the welding thermal cycling on HAZ [7], and the
coarse-grained HAZ (CGHAZ) is the weakest region in the girth weld
because of the large size of the prior austenite and the large amounts of
martensite–austenite (M–A) constituents in this zone [8,9]. Other stu-
dies have reported that a local brittle zone forms when CGHAZ is re-
heated to Ac1 and Ac3 [10], and the M–A constituents comprise the
major contributing factor to this brittle zone [11–15]. Moreover, a
decrease in prior austenite grain size and M–A constituent amount
improves Charpy impact energy [16,17], whereas the phases of
granular bainite (GB) and quasi-polygonal ferrite (QF), and grain size
may have a considerable effect on weld toughness [18,19].
The microstructure of HAZ between base and weld metals differs
fromthe IHAZ. However, few studies have been conducted on the IHAZ
of weld metals. The microstructural inhomogeneity of IHAZ is con-
sidered the primary reason for performance variation [20,21]. The
original microstructure of IHAZ exhibits a columnar morphology and
poor toughness [22,23]. By contrast, the microstructure of HAZ be-
tween base and weld metals comprises acicular ferrite (AF), which
demonstrates excellent toughness [24]. Wang et al. [25] reported that
the welding reheating process changes prior austenite morphology from
columnar to equiaxed structure. In addition, a brittle zone, called weld
metal subjected to intercritical coarse grains (WM–IC CG), is formed
during the welding reheating process. Moreover, “necklace” M–A con-
stituents distributed along austenite grain boundaries induce stress
concentration and reduce toughness. Wang et al. [26] showed that lath
ferrite or AF, bainite/martensite, and fine acicular-retained austenite
are beneficial for the weld metal toughness of IHAZ. There is, however,
no systematic research carried out for the microstructure and properties
of IHAZ, and the key factors that influence IHAZ toughness remain
unclear.
The microstructure and properties of IHAZ after single and double
welding thermal cycles were investigated in this study through thermal
simulation. The influences of different phase fractions, grain sizes, high-

⁎
Corresponding author.
E-mail addresses: bf851218@163.com (F. Bai), tonglige@me.ustb.edu.cn (L. Tong), lpan@ctgu.edu.cn (L. Pan).

https://doi.org/10.1016/j.pnsc.2019.08.010
Received 20 February 2019; Received in revised form 13 August 2019; Accepted 14 August 2019
Available online 27 February 2020
1002-0071/ © 2020 Chinese Materials Research Society. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/BY-NC-ND/4.0/).
F. Bai, et al. Progress in Natural Science: Materials International 30 (2020) 110–117

Table 1 thermal simulator to obtain different microstructures. Previous studies

Mechanical properties of the X80 pipeline steel. [27,28] have indicated that the reheated microstructure of weld metal
Material Yield strength Tensile Elongation (%) Impact energy subjected to coarse grains (WM–CG) always exhibits the poorest
(MPa) strength (MPa) −20 °C (J) toughness among the microstructure of weld metals. Hence, the heating
peak temperature (Tp,1) for a single thermal cycle was set to 1350 °C to
X80 555 715 27 130
obtain WM–CG, whereas the second heating peak temperature for the
double thermal cycles (Tp,2) was set to 1100 °C, 900 °C, and 750 °C.
Fig. 2 shows the typical thermal cycle curves used in this study [26].
angle grain boundaries, and M–A constituents on IHAZ toughness were
The microstructure and impact toughness of the thermal simulation
analyzed. Furthermore, the relationship between the microstructure
samples were tested. The Charpy impact test was conducted at −20 °C.
and properties of IHAZ was established.
The microstructures were characterized via optical microscopy (Zeiss
Upright Light Microscopes), scanning electron microscopy (JEOL-
2. Experiment 7000F), electron backscattered diffraction (EBSD), and transmission
electron microscopy (TEM; JEM-2200FS). The distribution and fraction
2.1. Materials and welding of M–A constituents were visualized by treating with LePera etchant
and analyzed using Image-Pro Plus 6.0 software. Microstructure grain
An X80 pipeline steel plate with a thickness of 18.4 mm was used in size was also analyzed with Image-Pro Plus 6.0.
this study. Table 1 provides the mechanical properties of the X80 pi-
peline steel.
The semiautomatic welding of a self-shielded flux-cored wire was 3. Results
adopted as the welding method in the experiment. The welding mate-
rials included a ϕ3.2 mm LB-52 welding rod for root welding and a 3.1. Impact toughness
ϕ2.0 mm self-shielded flux-cored JC-30 wire for filling and cap pass.
These materials have been commonly used in pipeline construction. Table 2 presents the impact toughness of different thermally simu-
Fig. 1(a) shows the welded joint during the thermal simulation test. The lated specimens. The original weld metal with columnar microstructure
thickness of the last welding pass was set to approximately 5 mm to has an average toughness value of 46.5 J. The WM–CG samples present
obtain the original microstructure of the weld metal with sufficient high toughness with an average value of 83.5 J. The toughness of the
thickness and uniform properties. Fig. 1(b) shows a thermal simulation weld metal decreased after double thermal cycles. The IHAZ obtained
specimen with dimensions of 5 mm × 10.5 mm × 71 mm that was when Tp,2 = 1100 °C was defined as weld metal subjected to unaltered
sampled from the welded joint. coarse grains (WM–UA CG) and had an average toughness of only 7.5 J.
The IHAZ obtained when Tp,2 = 900 °C was defined as weld metal
2.2. Experimental method subjected to supercritical coarse grains (WM–SC CG) and had an
average toughness of 45 J. The IHAZ obtained when Tp,2 = 750 °C was
Specific thermal cycles were performed by using a Gleeble-3500 defined as WM–IC CG and had an average toughness of 32.5 J. These

Fig. 1. Diagram of a sample for thermal simulation.

Fig. 2. Single and double thermal cycles.

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F. Bai, et al. Progress in Natural Science: Materials International 30 (2020) 110–117

Table 2 grain boundaries and coarse grains. The WM–CG obtained after a single
Comparison of the impact toughness of weld metal samples after different thermal cycle was coarse-grained. Fig. 4(b) shows that the micro-
thermal cycles. structure of WM–CG was dominated by GB, bainite ferrite (BF), and
Thermal cycle Test temperature Sample Impact energy (J) M–A constituents. Different microstructures were obtained after double
numbers (°C) thermal cycles at different Tp,2 values. Fig. 4(c) indicates that the mi-
Single Average crostructure of WM–UA CG remained coarse-grained. However, the
value value
average grain size of the microstructure of WM–UA CG was slightly
None −20 Original 56.5 46.5 smaller than that of the microstructure of WM–CG. The microstructure
31.5 was dominated by BF and GF with small amounts of QF and M–A
51.5 constituents. Fig. 4(d) shows that the microstructure of WM–SC CG was
Single WM-CG 77.5 83.5
characterized by non-uniform fine grains and mostly composed of GB,
76.5
97.0 BF, QF, polygonal ferrite (PF), and blocky M–A constituents. Fig. 4(e)
Double WM-UA CG 6.5 7.5 indicates that the microstructure of WM–IC CG was dominated by BF
9.0 and GB. The microstructure of WM–IC CG had a smaller average grain
7.0 size and thinner and denser laths than that of WM–CG. The M–A con-
WM-SC CG 59.5 45
stituents of WM–IC CG were distributed discontinuously along the grain
39.5
36.0 boundaries, and several M–A constituents outlined the grain bound-
WM-IC CG 31.0 32.5 aries.
36.5
30.0
3.3. EBSD

The grain boundary misorientations of the thermally simulated

results show that the toughness of the weld metal improved after a
single thermal cycle but decreased after double thermal cycles, parti-
cularly when Tp,2 = 1100 °C.
Fig. 3 shows the fracture surfaces of the samples. The fracture sur-
face of the sample WM–CG (Fig. 3(b)) displays typical ductile fracture
characteristics with many dimples. The other fracture surfaces ex-
hibited brittle cleavage fracture manner with small areas of dimples.
3.2. Microstructure
Fig. 4(a) shows that the microstructure of the original weld metal
was columnar with AF and GB. This microstructure demonstrated clear
samples were analyzed through EBSD, as presented in Fig. 5.
Fig. 5(a)–5(d) show the Euler maps of the thermally simulated samples.
The high-angle grain boundaries are marked in yellow and black in the
pictures, whereas the low-angle grain boundaries are marked in red.
Fig. 5(e) provides a comparison of the grain boundaries in the simulated
samples at different angles. In this study, high-angle grain boundaries
were defined as grain boundary angles greater than 15°, whereas grain
boundary angles within the range of 5–15° were defined as low-angle
grain boundaries [29]. The WM–SC CG and WM–UA CG samples had
the highest (28.8%) and lowest (9.7%) contents of high-angle grain
boundaries, respectively. The WM–CG sample had the highest content
of low-angle grain boundaries (17.1%), and the WM–UA CG sample had

Fig. 3. Impact fracture surfaces of the simulated samples: (a) original, (b) WM–CG, (c) WM–UA CG, (d) WM–SC CG, and (e) WM–IC CG.

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Fig. 4. Optical micrographs of the simulated samples: (a) original, (b) WM–CG, (c) WM–UA CG, (d) WM–SC CG, and (e) WM–IC CG.

Fig. 5. EBSD analysis of grain boundary misorientations: (a)–(d) Euler maps of WM–CG, WM–UA CG, WM–SC CG, and WM–IC CG, respectively; and (e) comparison
of grain boundaries at different angles in the simulated samples.

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Table 3
Average grain size of different simulated samples.
Samples Microstructure grain Original WM–CG WM–UA CG WM–SC CG WM–IC CG

Average grain diameter (μm) 106 75 49 32 51

Optical picture

the highest content of grains with boundary angles between 0° and 5°
(80.6%).
3.4. Grain size
Table 3 provides the average grain size of each simulated sample.
The original sample had an average grain diameter of approximately
106 μm due to its coarse columnar microstructure, whereas the average
grain diameter of the WM–CG sample was 75 μm. The microstructure of
the WM–UA CG sample remained coarse-grained, with an average grain
diameter of 49 μm. The average grain diameters of WM–SC CG and
WM–IC CG were 32 μm and 51 μm, respectively. WM–SC CG had the
lowest average grain diameter among all the samples.
3.5. M–A constituents
The size and morphology of the M–A constituents of the samples
subjected to different thermal cycles were analyzed. Fig. 6 presents the
observed features of M–A constituents in the weld metal. TEM ob-
servation showed that several M–A constituents were in blocky and
sharp-angled shape (Fig. 6(a)), whereas others were in the form of a
stringer film (Fig. 6(b)). M–A constituents were typically in the hard
brittle phase and had a high carbon content; stress concentration can
form around M–A constituents in sharp-angled forms [26].
Fig. 7(a) presents the M–A constituent contents of the different si-
mulated samples. The WM–CG and WM–UA CG samples had the highest
(2.8%) and lowest (1.86%) M–A constituent contents, respectively.
Morphology analysis was performed to further understand the effect of
M–A constituents. M–A constituents with a length longer than 2 μm
were defined as large, and those with a length-to-width ratio lower than
3 were considered as blocky. Fig. 7(b) shows the stringer and blocky
M–A constituent contents of the different samples. The WM–IC CG
sample exhibited the highest average stringer M–A constituent content
(20.9%), and the WM–SC CG sample had the highest average blocky
M–A constituent content (70.9%). Fig. 7(c) provides a comparison of
the large and large blocky M–A constituent contents of the different

Fig. 6. Morphology of M–A constituents: (a) blocky and sharp-angled and (b) stringer film.

Fig. 7. Statistics for the M–A constituents of the simulated samples: contents of (a) M–A, (b) M–A with different morphologies, and (c) large and large blocky M–A.

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Fig. 8. Relationships between IHAZ microstructure and toughness: (a) GB content, (b) average grain diameter, (c) high-angle grain boundaries, (d) M–A constituents,
and (e) large blocky M–A constituents.
samples. The WM–CG sample presented the highest average large M–A
constituent content (12.1%), whereas the WM–SC CG sample had the
highest content of large blocky M–A constituents (7.7%).
4. Analysis and discussion
Fig. 8 shows the relationships between IHAZ microstructure and
toughness. IHAZ microstructure is mostly composed of AF, GB, BF, M–A
constituents, and small amounts of PF and QF. The presence of large
blocky GB reduces toughness, whereas lath BF improves toughness.
Fig. 8(a) presents the relationship between the GB content and impact
toughness of the simulated samples. The WM–UA CG sample exhibited
the worst low-temperature toughness and the highest GB content of
75%. In the other samples, GB content was inversely related to tough-
ness. The toughness decreases as the GB content increases. The GB
morphology of the samples was also observed via TEM. The WM–UA CG
sample with the worst toughness had the highest GB content and a GB
lath width of approximately 1.1 μm (Fig. 9(a)). The GB lath width of the
WM–CG sample was approximately 0.55 μm (Fig. 9(b)). GB lath width
Fig. 9. Morphologies of GB: (a) WM–CG and (b) WM–UA CG
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Progress in Natural Science: Materials International 30 (2020) 110–117
was affected when the WM–CG sample was reheated to temperature
above Ac3, and increments in GB lath width reduced the impact
toughness of the samples.
Fig. 8(b) illustrates the relationship between grain size and impact
toughness. With the exception of the WM–CG sample, the toughness of
the WM–UA CG, WM–SC CG, and WM–IC CG samples was inversely
proportional to microstructure grain size.
Fig. 8(c) shows the relationship between high-angle grain boundary
contents and impact toughness. With the exception of the WM–CG
sample, the toughness of the WM–UA CG, WM–SC CG, and WM–IC CG
samples was proportional to the contents of high-angle grain bound-
aries. The WM–UA CG sample exhibited low toughness due to its low
content of high-angle grain boundaries. The low high-angle grain
boundary content of the WM–UA CG sample may be attributed to the
presence of a large amount of GB, which has no high-angle grain
boundary. The most effective barrier for crack propagation was high-
angle misorientation boundaries, which were advantageous for tough-
ness [30].
Fig. 8(d)–(e) presents the relationship between M–A constituents
F. Bai, et al.
and impact toughness. The contents of the M–A constituents exerted a
complex effect on toughness. Fig. 8(d) shows that toughness was en-
hanced by the high total contents of M–A constituents. However,
toughness and the content of large blocky M–A constituents were un-
related primarily because the effect of M–A constituents depends on
their shape and distribution. The shape of M–A constituents was re-
markably affected by the crystallography of surrounding bainite [31].
M–A constituents do not decrease microstructure toughness but im-
prove toughness, particularly stringer M–A constituents that enhance
the toughness of CGHAZ [32–34]. However, Luo et al. [35] suggested
that stringer M–A constituents are more harmful to toughness compared
with blocky M–A constituents. Studies showed that a decrease in crack
initiation absorbed energy is mostly attributed to coarse M–A con-
stituents [36–38]. M–A constituents cause the brittle behavior of hard
zones [39]. Lan et al. [40] reported that stress concentration is present
around M–A constituents and is primarily responsible for the reduction
in toughness. Accordingly, the effect of M–A constituents on toughness
remains debatable. In the current study, the effect of the M–A con-
stituents on toughness are not analyzed because clear evidence for this
issue remains unavailable.
The preceding discussion shows that girth weld toughness is related
to many factors. The reciprocal of the square root of grain size was also
used in this study to consider the expression of material strength and
grain size in the Hall–Pech relation. The relationship of IHAZ toughness
with the reciprocal of the square root of grain size, GB content, and
large-angle grain boundary content can be expressed as
1 of prior austenite grain size on martensite–austenite constituent and toughness in
IE = 313.89 860.81 × d 2 2.79 × CGB + 1.95 × CHA.
where IE denotes the impact energy (J), d refers to the grain diameter
(μm), CGB is the GB content (%), and. CHA denotes the content of high-
angle grain boundaries (%).
Eq. (1) shows that IHAZ toughness is proportional to the reciprocal
of the square root of grain size, whereas the content of large-angle grain
boundaries is inversely proportional to GB content.
5. Conclusions
The microstructures and properties of IHAZ were studied through a
thermal simulation test. The following major conclusions were drawn.
(1) The weld metal after a single thermal cycle (referred to as WM-CG
in this paper) exhibited high impact energy. The toughness of weld
metal decreased after double thermal cycles, particularly that of
WM–UA CG.
(2) The corresponding relationship between the microstructure and
properties of IHAZ was established. The toughness of IHAZ was
related to many factors. Toughness was primarily affected by GB
content. The smaller the grain size, the higher the content of high-
angle grain boundaries, and the better the toughness of weld metal.
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