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INTRODUCTION
High strength and toughness American Petroleum Institute (API) grade steels have to fulfil increasingly challenging
structure property demands in modern pipeline applications. New projects might require an increase in plate thickness to
allow for an upgrade in the operating pressure or superior toughness to combat reduced design temperatures i.e. for
installations in sub- arctic regions. Besides general measures of quality assurance such as dimensional tolerances, the
production of these grades is focussed on achieving specific contract properties. The principal mechanical tests are
tensile, Charpy Impact or Charpy V- notch (CVN) and the DWT (Drop Weight Tear) test. Table I summarises the
acceptance criteria for Product Specification Level 2 X70 and X80 welded pipe from API Specification 5L. Canadian
line pipe standard CSA Z245.1 would also apply depending on the contract.
Table I Overview of the key performance indicators from API Specification 5L [1]
YS (Rt0.5) TS (Rm) Ratio CVNa DWTTb
Grade MPa (psi) MPa (psi) Rt0.5/Rm
J (ft. lbf) Min. area %
Min. Max. Min. Max. Max.
485 635 570 760 27 to 68
X70 0.93 ≥ 85
(70300) (92100) (82700) (110200) (20 to 50)
555 705 625 825 40 to 81
X80 0.93 ≥ 85
(80500) (102300) (90600) (119700) (30 to 60)
a
CVN conducted on full specimen at 0°C (32°F); range of energy values is dependent on the specified outside diameter.
b
The average shear fracture area in the DWTT shall be ≥ 85% based upon a test temperature of 0°C (32°F).
The measurements of CVN and DWT tests are to ensure that brittle fracture does not occur during service. The CVN
impact test measures the energy absorbed during fracture, whilst the DWT test uses a full thickness specimen and
assesses the toughness via the appearance of the fracture surface. This provides an additional safety factor to guarantee
operating above the ductile to brittle transition temperature. The DWT test is generally accepted to have the best
correlation with full scale behaviour; with 85% shear area an accepted minimum requirement to ensure that the fracture
propagation mode is ductile.
TARGET MICROSTRUCTURE
The phase transformation of austenite to ferrite during post rolling cooling can be used to develop different cooling
strategies to obtain a wide range of structure property relationships. A fine, uniform microstructure is the foundation for
a good combination of strength and toughness i.e. small grains or ‘packets’ of microstructure, small coherent precipitates
etc. [2, 3]. On cooling from austenite, the final microstructure can consist of a range of ferrite morphologies; ferrite,
pearlite (laminar ferrite + cementite), bainite and martensite. Each morphology can be associated with macro properties
that relate to the microstructure features; ranging from soft, but ductile ferrite to hard but brittle martensite.
For sub-arctic requirements, highly organised morphologies e.g. packets of ferrite plates that have the same
crystallographic orientation, may be deleterious to the mechanical properties. This is because in-service fracture or failure
processes can move readily through the microstructure, with individual plates within these packets, offering limited
resistance. One ferrite morphology rarely described as organised is acicular ferrite. This chaotic microstructure has a
‘basket weave’ appearance. ‘Acicular’ means shaped and pointed like a needle, which is the appearance when viewed
in two dimensions. The three dimensional grains have a thin, lenticular shape. The needle-like plates nucleate
heterogeneously on intragranular point nucleation sites, such as inclusions, and radiate in different directions. Cracks
propagating through the microstructure are believed to be frequently deflected. At a macro level, superior properties,
especially toughness are often realised.
The acicular ferrite transformation range is 400 to 600°C (750 to 1110°F) and in many respects is a similar
transformation to upper bainite. The microstructure morphologies differ because bainite sheaves grow from austenite
grain boundaries; whereas acicular ferrite platelets nucleate at intragranular nucleation (or point) sites, so that parallel
ferrite plates cannot readily form. Acicular ferrite is sometimes referred to as intragranular upper bainite [4].
To promote an acicular ferrite microstructure, the density of intragranular nucleation sites should be increased
compared to grain boundaries sites. This is not straightforward as inclusions or inhomogeneities are less effective in
nucleation compared to grain boundaries. A second option is to reduce the effectiveness of the austenite grain boundary
as a nucleation site either by alloying or by changing the finish rolling / cooling strategy to allow the nucleation of a
small amount of grain boundary ferrite. In both cases the aim is to disrupt significant grain boundary ferrite formation to
take advantage of the increased driving force for intragranular nucleation at lower temperatures. Given these
microstructure challenges, the likelihood of an acicular ferrite structure in the final plate material during production is
increased if the parameters summarised in Table II are considered.
Increase defects within the • This informs the rolling strategy that there should be significant
austenite grain structure. deformation below the non-recrystallisation temperature (TNR).
• This increases the dislocation density, shear bands and mismatch
within the crystal structure; all of which have the potential to act as
acicular ferrite nucleation sites.
• This also helps breakdown the prominent recrystallised austenite
texture, and increase the likelihood of different orientations in the final
microstructure.
Increase the number and size of • It has been shown that inclusions rich in titanium are effective in
inclusions. producing acicular ferrite [4]. A specific titanium compound has not
been reported as the microanalysis is difficult and the data accuracy a
consideration.
• The heterogeneous nature of non-metallic inclusions is one of the
reasons why there is a lack of clarity in the nucleation mechanism for
acicular ferrite.
Tailoring the chemistry; must • Consider an increase in Nb; this solute is well known to have an effect
remain within the limits set by on the recrystallisation of austenite, raising TNR and providing
the API 5L Specification. inclusions (precipitates).
Figure 1Schematic diagram of a finishing stand on Plate Mill and a Steckel Mill.
As shown in Figure 1, Plate Mills are typically single or two stand reversing mills whilst Steckel Mills are reversing
mills with the addition of heated coil furnaces on the entry and exit sides of the mill. This enables the effects of
temperature run down to be lessened and the production of products with similar lengths to those on a Hot Strip Mill is
possible. Coils up to 25.4mm (1”) thick are now routinely produced. The mill layout itself acts as one constraint on the
development of time temperature strain paths for new products. One of the benefits of a Steckel Mill compared to a
Plate Mill is the single piece weight that can be rolled by producing coiled product. However unlike a Hot Strip Mill,
where the finishing sequence occurs in a single rolling direction, a Steckel Mill involves reversing and coiling as the
product thickness is reduced. This leads to an increase in processing time. Compared to a Plate Mill, typical finishing
times maybe greater than twice as long in a Steckel Mill for products of comparable thickness and width. In addition, the
increased product length leads to inhomogeneity in the time temperature strain paths from the head to tail. The
implication of this characteristic of Steckel Mill rolling on the final product performance must also be considered by the
steel producer.
Figure 2a Figure 2b
0 10 20 30 40 0 10 20 30 40
Figure 2 A comparison of the grain size distribution from two API coiled plates; Figure 2a with higher RHF temperature
and Figure 2b with a lower RHF temperature.
Table III Summary of the Key Through Process Parameters for coiled API Steckel plate.
Process Overview
Parameter
1) Alloy Design • A C-Mn-Si based composition is a nominal starting point for alloy design.
• Solid solution strengthening (Mn, Ni and Mo) and micro-alloying (Nb, V and Ti).
• Nb is an important element in designing the rolling strategy i.e. determining TNR
which in turn determines the temperature ranges for roughing, finishing and the
hold period.
• Nb(CN) to precipitate during the hold, finish rolling and cooling to the aid the
nucleation of a fine final microstructure.
• Due to the longer finish rolling times, coiled API Steckel plate is expected to
require a richer composition with increased micro-alloying. The longer time at
temperature coarsens precipitates which reduces their effectiveness. 30 to 50% more
Nb is expected than in plate chemistries.
• Ti (an element with a higher affinity for N than Nb) is added to fix N and potentially
allow a greater Nb % to dissolve during reheating. Potential to aid formation of
acicular ferrite.
2) As-cast Slab/ • For API high strength with good low toughness, a total reduction ratio (slab to
Structure plate thickness) of 10:1 is recognised as a minimum requirement.
• The other main targets are tight and consistent chemistry control, good internal
cleanliness and minimisation of downstream influence of the centreline.
• Good slab surface quality and dimensional control promote more efficient
downstream processing.
5) Hold Period • Pause in the rolling to allow cooling to below TNR and TST (recrystallisation stop
temperature).
• Nb(CN) precipitates form, pinning the austenite grain boundaries to prevent
recrystallisation on the resumption of rolling.
6) Finishing • The restart temperature will depend on mill capability (force, torque) for the given
Sequence product dimensions. Aim for the lowest temperature possible.
• Maximum deformations will also depend on mill capability (force, torque) for the
given product dimensions and temperature range.
• This should be designed to achieve good reductions per pass; > 15%.
• Deform and pancake the pinned austenite grains; creating dislocations and shear
bands in conjunction with precipitates, within the austenite grains to provide
nucleation sites for acicular ferrite.
• Typically expect > 70% reduction in Finishing.
7) Cooling • To target preferred acicular ferrite. A fine or very fine form of the ferrite with
Strategy small α- ferrite laths between carbon rich partitions.
• Target cooling rate will depend on composition and thickness.
• Expected to be between 20 and 30 °C/s.
(2)
Figure 3 Prediction of non – recrystallisation (TNR) and stop – recrystallisation (TST) temperatures to target the end
roughing temperature; strain 0.25, strain rate 3s-1.
For a good uniform final microstructure from all micro-alloyed rolling strategies, it is generally recommended that the
final deformation temperature in the roughing sequence is greater than TNR whilst the entry temperature for the finishing
sequence (i.e. after the hold period) is below TST. This avoids the mixed microstructure region if deformations occur
between TNR and TST, which is potentially detrimental to final mechanical properties. For superior low temperature
toughness, the last roughing pass should be as close to TNR as is practically possible. This allows full recrystallisation,
but due to subsequent Nb precipitation, the extent of austenite grain growth in the hold period is reduced. From Figure
3 a target last pass roughing temperature would be in the range 1020 to 1050°C (1870 to 1920°F).
A further practical consideration is that Figure 3 reports isothermal conditions. After drop out from the RHF, the
workpiece develops a thermal gradient as the surface is cooled during contact with the rolls and surrounding
environment. Due to the large hold ratio (> 70% reduction expected in finishing) the thermal gradient from surface to
centre is likely to be greater than 50°C (90°F). With a good, fine, uniform structure integral to low temperature
toughness, the steel producer should consider the thermal gradient when designing the temperature range of the
roughing sequence.
Figure 4a Figure 4b
Figure 4 Comparison of DWTT results from a) Trials 1 and 2 and b) Trials 2 and 3. The effects of processing temperature
and composition can be identified.
Detailed microscopy from the first two production trials found that centreline segregation was potentially an issue; the
hardness of the centreline was approximately 20 points harder than at a ¼ thickness. A new trial was planned with a
modified X70 composition, one that was designed to reduce the effect of the centreline segregation. The ‘Low’
temperature parameters known to achieve the improvement in Figure 4a were retained. Figure 4b reports percentage
shear fraction with decreasing DWTT temperature for the new trial. The results show improvements in the percentage
shear fraction at all test temperatures and increase the average percentage shear fraction at -45°C (-49°F) to
approximately 70%. From these trials there was improved product consistency, with greater than 90% shear fraction
reported with more consistency at temperatures down to -30°C (-22°F).
In reviewing the trial process data the roughing sequence was identified as an area for possible improvement. This was
an increase to the final pass reduction to 25%. Due to potentially coming close to the limits of the Roughing Mill, a
product with a narrower width was trialled. The results are shown in Figure 5, which also includes the DWTT curves
for the earlier production trials for comparison. Similarly to the previous trials with the modified X70 composition, an
improvement was reported at all DWTT temperatures. The greatest improvement is shown at -45°C (-49°F), with the
shear fracture percentage around 90%. This indicates that the energy shelf has been moved to lower test temperatures.
Future trials are being planned to increase the final product dimensions and further improve mechanical property
performance.
CONCLUSIONS
Targeting sub-arctic toughness performance from coiled 19.1mm (¾”) API X70 Steckel Plate represents a challenge for
the steel producer. It represents an example of a premium product where the through process metallurgical
understanding is paramount, both in selecting the target structure property relationships but then in delivering this
outcome from a complex multi-stage processing route. The final pipe performance can be traced upstream through all
stages to the initial steel making and casting. Once a slab is cast, the remaining process parameters need to be tightly
controlled and repeatable throughout a production run. The production trials were designed and performed by Evraz
Regina Steel with support from Primetals Technologies UK Ltd. The results in the final section show a clear
chronological improvement in product performance with consistent DWTT performance at a test temperature of -30°C
and clear progress towards the target of -45°C (-49°F). This represents a development in the capability of the installed
equipment base, the process consistency and in the understanding of the key through process metallurgical parameters.
REFERENCES
1. API Specification 5L, 45th Edition, API Publishing Services, Washington DC, 2012, pp32.
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3. N.J. Petch, “The cleavage strength of polycrystals”, Journal of Iron and Steel Institute, Vol. 174, 1953, pp. 25 – 28.
4. R.W.K Honeycombe and H.K.D.H Bhadeshia, “Acicular Ferrite”, Steels; Microstructure and Properties, 3rd edition,
Elsevier, Oxford, UK, 2006, pp155.
5. G.E. Dieter, Mechanical Metallurgy, 3rd edition, McGraw – Hill Book Co., New York 1986, pp236.
6. C.W. Choi, H.J. Koh and S. Lee, “Analysis and Prevention of Yield Strength Drop during Spiral Piping of Two
High-Strength API-X70 Steels”, Metallurgical and Materials Transactions A, Vol. 31A, 2000, pp2669.
7. S.S. Sohn, S.Y. Han, J. Bae, H.S. Kim and S. Lee, “Effects of microstructure and pipe forming strain on yield
strength before and after spiral pipe forming of APIX70 and X80 linepipe steel sheets”, Materials Science &
Engineering A, Vol. 573A, 2013, pp. 18 – 25.
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Control and Precipitate Size in Structural Steels”, ISIJ International, 1999, Vol. 39, No. 9, pp. 930 – 936.