Technical Field
[0001] This invention relates to an ultrahigh strength UOE steel pipe having a strength
(TS) in the circumferential direction of the pipe of at least 750 MPa and at most
900 MPa, having a good balance of strength and toughness, and having improved resistance
to joint fracture and to a process for its manufacture.
Background Art
[0002] In recent years, there has been a strong demand for a reduction in the cost of pipelines.
For this purpose, as manufacturing techniques have progressed, there has been a marked
tendency to increase the strength of steel pipes themselves used to lay pipelines.
In the past, up to X80 grade of steel has been standardized by the American Petroleum
Institute (API) and is actually being used in pipelines.
[0003] At present, standardization and practical utilization of even higher strength X100
grade (corresponding to a strength in the circumferential direction of a pipe of at
least 750 MPa) are being actively investigated. When actually applying such an ultrahigh
strength steel to a steel pipe for a pipeline, taking safety from fracture into consideration,
a significantly higher level of toughness is demanded compared to the level which
is realized with conventional steel. Accordingly, there is a demand for a steel pipe
having both ultrahigh strength and ultrahigh toughness and a base metal steel which
can be used to manufacture such a steel pipe.
[0004] JP H08-209290-A and
JP H08-209291A disclose high strength steel pipes having a high Mn + high Mo composition. The former
discloses subjecting the pipe to tempering treatment, and the latter discloses carrying
out dual phase rolling.
[0005] Similarly,
JP H09-31536A discloses a high strength steel pipe having a Mn + high Mo composition, but disclosed
therein is an ultrahigh strength steel pipe corresponding to X120 grade with a base
metal strength of at least 950 MPa.
JP 2000-199036A discloses an ultrahigh strength steel pipe with a steel pipe strength of at least
900 MPa.
JP H08-199292A also discloses a high strength steel pipe in which the base metal structure has a
martensite fraction of at least 90%, and in the examples, an ultrahigh strength steel
having a base metal strength of at least 900 MPa is used.
[0006] The steel pipe strength and the base metal steel strength are the same. The steel
pipe strength is a value measured in the circumferential direction of a pipe, i.e.,
the pipe circumferential strength.
Disclosure of the Invention
[0007] The above-described prior art documents are each aimed primarily at increasing strength,
and they do not sufficiently disclose the toughness of the base metal and the toughness
of the heat affected zones (HAZ) of joints. Up to the present time, a high strength
steel which can adequately satisfy a balance between strength and toughness and resistance
to joint fracture which are particularly demanded in high strength steels of higher
than X80 grade, has not existed. In fact, in the above-described patent documents,
there is no mention of both joint fracture properties and toughness in the high strength
region which is the area of interest of the present invention.
[0008] According to the present invention, in order to increase resistance to joint fracture
in a UOE steel pipe, the carbon equivalent (Ceq) of steel is increased to a high range
which has not been utilized in the past. As a result, HAZ softening at the time of
welding, which is a phenomenon characteristic of UOE steel pipes which are welded
by submerged arc welding, can be markedly decreased.
[0009] On the other hand, taking into consideration the ability of on-site circumferential
welding which is performed at the time of laying of a pipeline in the field, there
is a demand for a balanced composition design which can realize a low weld cracking
parameter (Pcm).
[0010] As the strength of a steel increases, the level of toughness demanded of the HAZ
and the base metal increases. In this regard, it is essential to decrease Ti and N
in order to increase HAZ toughness, and at the same time it is necessary to decrease
S in order to increase the toughness of the base metal.
[0011] When a UOE steel pipe having its strength controlled to at least 750 MPa and at most
900 MPa (corresponding to X 100 grade) by composition design taking into consideration
the above points was manufactured, it was found to have extremely good resistance
to joint fracture and good toughness. At the time of manufacture, it was ascertained
that if the temperature at the completion of cooling by water cooling after hot rolling
was made 350° C or higher, an extremely high fracture toughness value of 150 J demanded
of X100 grade could be satisfied.
[0012] According to one aspect, the present invention is a UOE steel pipe having a base
metal chemical composition comprising, in mass percent, C: 0.03 - 0.08%, Mn: 1.70
- 2.2%, S: at most 0.0020%, Ti: 0.005 - 0.025%, N: at most 0.0050%, optionally at
least one element selected from the following (i) through (iv), and a remainder of
iron and unavoidable impurities, wherein the below-defined carbon equivalent (Ceq)
is at least 0.50%, the weld cracking parameter (Pcm) is at most 0.24%, and the strength
of the pipe in the circumferential direction is at least 750 MPa and at most 900 MPa:

wherein Ceq = carbon equivalent, Pcm = weld cracking parameter, and the symbol for
each element in the above equations indicates the content of the element in mass percent,
- (i) one or two of Si: 0.05 - 0.50% and Al: at most 0.06%,
- (ii) one or more of Cu: at most 1.0%, Ni: at most 2.0%, Cr: at most 1.0%, Nb: at most
0.1 %, and V: at most 0.1 %,
- (iii) Mo: at most 1.0%, and
- (iv) Ca: at most 0.005%.
[0013] It is desired that a UOE steel pipe according to the present invention have a fracture
toughness such that the Charpy absorbed energy at -10° C is at least 150 J in both
the base metal and heat affected zone (HAZ).
[0014] From another aspect, the present invention is a process for manufacturing a UOE steel
pipe having a carbon equivalent (Ceq) of at least 0.50% and a weld cracking parameter
(Pcm) of at most 0.24% as defined above and a strength in the circumferential direction
of the pipe of at least 750 MPa and at most 900 MPa, the process comprising producing
a steel plate by hot rolling of a steel having the above-described chemical composition
followed by water cooling with a temperature at the completion of water cooling of
350° C or higher, applying U-pressing and O-pressing to the resulting steel plate,
and performing welding and pipe expanding to obtain a UOE steel pipe. Welding of the
UOE steel pipe is carried out by submerged (arc) welding according to a conventional
manner.
[0015] According to the present invention, by manufacturing a steel pipe which is controlled
so as to have a high carbon equivalent (Ceq) and a strength of at least 750 MPa and
at most 900 MPa, HAZ softening of the welded joint which is characteristic of UOE
steel pipes which are welded by submerged arc welding is diminished, and the resistance
to joint fracture of the UOE steel pipe is markedly improved. At the same time, by
decreasing the content of S, Ti, and N, the toughness of the base metal and HAZ can
be maintained.
[0016] A UOE steel pipe according to the present invention can be manufactured under the
same conditions as a conventional UOE steel pipe of X80 grade or below, thereby making
it possible to manufacture an ultrahigh strength UOE steel pipe while maintaining
productivity equivalent to that of a conventional UOE steel pipe. Accordingly, the
manufacturing costs of ultrahigh strength UOE steel pipes can be markedly decreased.
Brief Description of the Drawings
[0017] Figure 1 is a graph showing the relationship between the S content of steel and the
toughness of the base metal (the Charpy absorbed energy at -10° C).
Best Mode for Carrying Out the Invention
[0018] In order to apply an ultrahigh strength steel which is not prescribed by API standards
to an actual pipeline, it is necessary to provide a pipe having properties suited
for the environment of use while taking into consideration (1) safety from fracture
and (2) circumferential weldability.
[0019] Particularly in the case of a long distance pipeline for transporting natural gas
or oil, occurrence of fracture of a pipe leads to a serious accident. Modes of fracture
include brittle fracture and ductile fracture. In brittle fracture, fracture propagates
at an ultrahigh speed of at least 500 m/sec, while in ductile fracture, the speed
of propagation of fracture is lower and at most 300 m/sec. Accordingly, when steel
pipe is applied to an actual pipeline, it is essential that the base metal have a
toughness such that it undergoes ductile fracture in the environment of use.
[0020] Concerning the desired level of toughness, the HLP Committee (a Japanese organization
for fracture research) proposes that a higher fracture toughness value becomes necessary
as the strength of a steel increases in order to restrain the propagation of fracture
within a prescribed distance even when high speed ductile fracture occurs. The necessary
fracture toughness value (the Charpy absorbed energy at -10° C) depends upon the strength
grade of steel, the size of a steel pipe, the internal pressure, and other factors,
but with X 100 grade steel, it is not 40 to 50 J which is required of usual steel
(API X70 grade and below) but becomes at least 150 J. Accordingly, with X 100 grade
steel, in addition to high strength, a high fracture toughness value of this level
is required.
[0021] Safety from fracture can be evaluated by the location of fracture when a force is
applied in the circumferential direction of pipe. The location of fracture can be
classified as being the base metal, the weld metal, or the weld heat affected zone
(HAZ). When fracture occurs in the base metal, as stated above, if sufficient toughness
is provided, ductile fracture occurs. When fracture occurs in the weld metal, ductile
fracture occurs in some cases, but in the majority of cases, brittle fracture occurs.
Accordingly, it is absolutely necessary to avoid fracture in the weld metal. In general,
fracture in the weld metal is prevented by making the strength of the weld metal at
least as high as that of the base metal (performing overmatching). Fracture in the
HAZ is a phenomenon which is observed particularly in high strength steels with a
strength of at least 700 MPa.
[0022] A steel according to the present invention is particularly effective at preventing
HAZ fracture. The following are conceivable as means of preventing HAZ fracture:
- (1) making the strength of the weld metal at least as high as that of the base metal
(providing overmatching)
- (2) limiting the weld heat input as low as possible in order to reduce the area of
the HAZ,
- (3) increasing the strength of the HAZ,
- (4) controlling the shape of the weld, i.e., reducing stress concentrations in the
toe portion of the weld.
[0023] In the present invention, Ceq is increased in order to increase the strength of the
HAZ. The HAZ has a structure formed by melting due to the effect of heat followed
by resolidification or transformation. In order to increase the strength of the HAZ,
it is effective to make the composition rich (increase both Ceq and Pcm) or to decrease
the heat input. For this purpose, the heat input can be set to the lowest heat input
which can provide the desired shape of the weld. However, making the composition rich
has the problem that it leads to a decrease in circumferential weldability when joining
steel pipes to each other in the field.
[0024] In the present invention, a high strength is achieved by increasing Ceq so as to
suppress softening of the HAZ, while circumferential weldability is maintained at
a good level by limiting Pcm up to a certain value.
[0025] In order to increased HAZ toughness, control of the content of N and Ti is also important.
It was found that by optimizing the balance of content of these elements, a deterioration
in toughness accompanying an increase in strength can be prevented.
[0026] In the past, a TMCP (thermo-mechanical control process) was generally applied to
the manufacture of ultrahigh strength steel having a TS of 750 MPa or higher in such
a manner that the temperature at the completion of water cooling after hot rolling
was at most 200 °C (in many reports it is described to be room temperature). This
cooling condition was employed in order to provide the steel with basic properties
such as strength and toughness.
[0027] In the present invention, even though the steel has an ultrahigh strength of at least
750 MPa, taking into consideration safety from fracture, it has a chemical composition
for which Ceq ≥ 0.50% and manufactured with the temperature at the completion of water
cooling after hot rolling being 350° C or higher. As a result, fracture in the vicinity
of a joint is prevented at the time of occurrence of fracture, and at the same time
a high strength and high toughness can both be achieved.
[0028] By not employing an extremely low temperature for the temperature at the completion
of water cooling, the deformability of the base metal, i.e., uniform elongation thereof
can be greatly increased. Accordingly, a manufacturing process and a UOE steel pipe
according to the present invention are extremely effective from the standpoint of
safety from fracture.
[0029] Uniform elongation (degree of ultimate elongation) is the amount of plastic deformation
of a material occurring up to the maximum load in a tensile test. Accordingly, the
fact that a base metal has a large uniform elongation means that if the pressure abruptly
increases during operation of a pipeline, the amount of plastic deformation up to
the value of TS is large, and the safety from fracture is high. From this standpoint,
it is desirable that the uniform elongation of the base metal be at least 5.0%.
[0030] Figure 1 is a graph showing the relationship between the S content and the toughness
(the Charpy absorbed energy at -10 °C) of the base metal for X100 grade steels. From
Figure 1, it can be seen that the toughness of the base metal is markedly improved
by reducing the S content. From this result, it can be found that it is effective
to control the S content in an ultrahigh strength steel when a high fracture toughness
value is desired.
[0031] In the present invention, the necessary least fracture toughness value is 150 J,
so the S content is made at most 20 ppm. When a still higher fracture toughness value
such as 200 J or greater is desired, the S content can be made 14 ppm or less.
[0032] The present invention can provide a UOE steel pipe which can satisfy all of prevention
of HAZ fracture of a joint, a high uniform elongation of a base metal, and good circumferential
weldability required at the time of laying of a pipeline, which could not be achieved
by conventional manufacturing processes.
[0033] According to the present invention, with a UOE steel pipe manufactured by TMCP with
the temperature at the completion of water cooling-being 350° C or higher which is
the same as for usual steel of API X80 grade or below, a strength corresponding to
API X100 grade is satisfied by increasing the carbon equivalent (Ceq) to 0.50% or
greater, and circumferential weldability can be provided by limiting the weld cracking
parameter (Pcm) to 0.24% or lower.
[0034] The chemical composition of the base metal in the present invention is as follows.
C: 0.03 - 0.08%
[0035] C is an element which is effective at increasing strength of steel. In order to impart
a strength of X100 grade to steel, its content is made at least 0.03%. However, if
the C content exceeds 0.08%, it leads to a marked decreases in toughness so that it
has an adverse effect on the mechanical properties of the base metal, and at the same
time it promotes formation of surface defects on a slab. A preferred C content is
0.03 - 0.05%.
Mn: 1.70 - 2.2%
[0036] Mn is an element which is effective at increasing the strength and toughness of steel,
and its content is made at least 1.70% in order to impart sufficient strength and
toughness. However, if the Mn content exceeds 2.2%, the toughness of a weld deteriorates.
A preferred Mn content is 1.8 - 2.0%.
S: at most 0.0020%
[0037] S is one of the elements which it is necessary to limit their content in order to
achieve the necessary toughness of a base metal. If the S content exceeds 0.0020%,
the fracture toughness value necessary for the base metal cannot be achieved. As previously
explained with respect to Figure 1, the S content may be further limited in accordance
with the fracture toughness value required of the base metal, such as to at most 0.0014%.
Ti: 0.005 - 0.025%
[0038] Ti has an effect of suppressing grain growth in a HAZ by forming TiN and thus increasing
the toughness of the HAZ. For this purpose, it is necessary for the Ti content to
be at least 0.005%. However, if the Ti content exceeds 0.025%, the amount of dissolved
N increases, and HAZ toughness deteriorates. A preferred Ti content is 0.005 - 0.018%.
N: at most 0.0050%
[0039] N forms nitrides with V, Ti, and the like and thus has the effect of increasing high
temperature strength of steel. However, if the content of N exceeds 0.0050%, it forms
carbonitrides with Nb, V, and Ti, thereby causing a decrease in the toughness of the
base metal and the HAZ. When a high level of HAZ toughness is desired, N is preferably
controlled at an extremely low value of at most 0.0035%.
[0040] In addition to the above-described basic components of composition, the carbon equivalent
(Ceq) and weld cracking parameter (Pcm) of the base metal are extremely important
factors in order to achieve a high strength of at least X100 grade and high toughness
in the base metal and HAZ.
Ceq of the base metal: at least 0.50%
[0041] In order to ensure that a base metal strength of at least X100 grade is achieved
by TMCP in which the temperature at the completion of water cooling is set to 350°
C or higher, the carbon equivalent (Ceq) of the base metal is made at least 0.50%.
As long as a base metal strength of X100 grade or higher can be achieved, there is
no particular upper limit on the Ceq, but Ceq is preferably at most 0.55%. Ceq is
given by the following equation (the symbols for elements in the equation indicate
the content of those elements in mass percent):

Pcm of the base metal: at most 0.24%
[0042] The steel composition is designed such that the weld cracking parameter (Pcm) of
the base metal is at most 0.24% in order to achieve high strength and high toughness
even at the time of circumferential welding. There is no particular lower limit for
Pcm, but normally it is at least 0.16%. Pcm is given by the following equation (the
symbols for elements in the equation indicate the content of those elements in mass
percent):

[0043] In a UOE steel pipe according to the present invention, there are no particular restrictions
on the Ceq and Pcm of the weld metal.
[0044] In this specification, when Ceq and Pcm appear by themselves, they refer to the Ceq
and Pcm of the base metal including the HAZ, i.e., that of the entire steel pipe except
for the weld metal.
[0045] The strength in the circumferential direction of a UOE steel pipe according to the
present invention is at least 750 MPa and at most 900 MPa. This strength level of
a steel pipe is defined to indicate that it is the level of X 100 grade. In the present
invention, by controlling the chemical composition of steel as described above, an
ultrahigh strength UOE steel pipe of X 100 grade strength can be manufactured by the
same process as for a conventional low strength UOE steel pipe in which the temperature
at the completion of water cooling after hot rolling is 350° C or higher, and the
pipe can be provided with the fracture toughness value required in the base metal
and HAZ.
[0046] The base metal of a UOE steel pipe according to the present invention may further
contain one or more optional elements selected from the group listed below as (i)
- (iv).
- (i) Si: 0.05 - 0.50%, Al: at most 0.060%
Si and Al both have a deoxidizing effect, and preferably at least one of them is included.
Si is effective not only as a deoxidizing agent but also at increasing the strength
of steel. If the Si content is less than 0.05%, deoxidization is inadequate. If the
Si content exceeds 0.5%, a large amount of martensite-austenite constituent is formed
in the HAZ, thereby causing the toughness of the HAZ to deteriorate extremely and
thus leading to a decrease in the mechanical properties of a steel pipe. The Si content
can be selected within the range of 0.05 - 0.50% taking into consideration a balance
with the plate thickness of the steel plate.
Like Si, Al functions as a deoxidizing agent. Its effects can be adequately attained
when its content is at most 0.06%. Addition in excess of this amount adversely affects
circumferential weldability in the field and is also not desirable from the standpoint
of economy.
- (ii) Cu: at most 1.0%, Ni: at most 2.0%, Cr: at most 1.0%, Nb: at most 0.1 %, V: at
most 0.1 %
These elements serve to improve hardenability of steel when added in a small amount
and thus have an effect of improving various properties.
Cu can increase strength without significantly impairing toughness as a result of
a change in microstructure due to solid solution strengthening and the effect of increasing
hardenability. If Cu exceeds 1.0%, the Cu checking phenomenon which is harmful in
that it causes the formation of slab surface defects may occur. In order to prevent
such defects, it becomes necessary for the slab to be heated at a low temperature,
thereby imposing limitations on the range in which manufacture can be performed.
In the same manner as Cu, Ni also can increase strength without significantly impairing
toughness by a microstructural change due to solid solution strengthening and the
effect of increasing hardenability. At the same time, it serves to suppress a deterioration
in the toughness of the base metal and HAZ after hot bending. However, addition of
more than 2.0% of Ni increases costs so is not practical, and it also adversely affects
ability of on-site circumferential welding.
Like Cu and Ni, Cr also can increase strength without significantly deteriorating
toughness by a microstructural change due to solid solution hardening and the effect
of increasing hardenability. However, if Cr exceeds 1.0%, the toughness of the HAZ
decreases.
Nb and V have a great effect on increasing strength by precipitation strengthening
and the effect of increasing hardenability, or on improving toughness by crystal grain
refinement. However, if either is added in excess of 0.1%, it causes a decrease in
the toughness of HAZ.
When at least one of these elements is added, a more preferred content is Cu: at most
0.50%, Ni: at most 0.80%, Cr: at most 0.40%, Nb: at most 0.06%, and V: at most 0.06%.
- (iii) Mo: at most 1.0%
Mo is effective at increasing the strength of the base metal and of welds. If too
much Mo is added, it causes a deterioration in ability of on-site circumferential
welding and the toughness of the HAZ. Therefore, its upper limit is made 1.0%. When
Mo is added, a more preferred content is at most 0.50%.
- (iv) Ca: at most 0.005%
Ca has an effect on shape control and specifically spheroidizing of inclusions in
steel, thereby preventing hydrogen-induced cracking or lamellar tears. However, these
effects saturate at a Ca content of 0.005%.
[0047] A UOE steel pipe according to the present invention can be manufactured by subjecting
a steel slab which is adjusted to have the above-described chemical composition to
hot rolling, and after the completion of finish rolling, water cooling is performed
thereon such that the temperature at the completion of water cooling is 350° C or
higher. The resulting hot rolled steel plate is formed into a tubular shape by usual
U-pressing and O-pressing, and then the abutting edges are bonded by welding on the
inner and outer surfaces. This welding is carried out by submerged arc welding. After
the welded pipe is formed, it is subjected to pipe expanding so as to increase the
roundness. Pipe expanding can be carried out by mechanical pipe expanding or hydraulic
pipe expanding.
[0048] There are no particular restrictions on the steps of manufacture of a UOE steel pipe
in a manufacturing process for a UOE steel pipe according to the present invention
except for the water cooling conditions after hot rolling. Manufacture may be carried
out in the same manner as for the manufacture of a conventional UOE steel pipe of
X80 grade or below. Nevertheless, a UOE steel pipe having an ultrahigh strength of
X100 grade (a strength in the pipe circumferential direction of at least 750 MPa and
at most 900 MPa) and at the same time having improved resistance to fracture can be
manufactured.
[0049] The following example is intended to illustrate the present invention more specifically,
but it is merely for illustration purpose and does not restrict the invention in any
way.
Example
[0050] Hot rolled steel plates for use as a base metal was prepared from steel slabs having
the chemical compositions shown in Table 1 by heating and retaining them at a temperature
of 1100 - 1200° C, then subjecting them to hot rolling with a finish rolling temperature
in the range of 700 - 850° C so as to give a plate thickness of 20 mm. The hot-rolled
plates were water cooled with the temperatures at the completion of water cooling
shown in Table 1 and then air cooled to room temperature. The base metal steel plates
were formed into a tubular shape by U-pressing and then O-pressing in cold conditions.
Then, the abutting edges of the shapes were welded by usual submerged arc welding,
and the resulting pipes were subjected to mechanical pipe expanding. In this manner,
UOE steel pipes having an outer diameter of 910 mm (36 inches), a wall thickness of
20 mm, and a length of 1200 mm were manufactured.
[0051] Table 1 also shows the strength and toughness of the base metal, the tensile properties
of the joint, and results of a circumferential welding test performed on the resulting
UOE steel pipes. The base metal strength and the position at which joint tensile fracture
occurs are particularly important parameters for ascertaining the effects of the present
invention.
[0052] The toughness and strength of a base metal were evaluated by taking an impact test
piece (JIS No. 4) and a tensile test piece (an ASTM rod-shaped test piece with a diameter
of 6.35 mm) from the circumferential direction of each UOE steel pipe so as not to
include the weld or the HAZ and determining the Charpy absorbed energy at -10° C (indicated
as VE-10° C), the tensile strength (TS), and the uniform elongation (degree of ultimate
elongation).
[0053] A tensile test of the joint was carried out by taking a tensile test piece in the
circumferential direction such that the weld of each UOE steel pipe was in the center
of the test piece, and performing a tensile test on the test piece having the reinforcement
of weld as it was to determine the tensile strength and ascertain the location of
fracture. An impact test piece (JIS No. 4) was taken from the HAZ (weld heat affected
zone) of each UOE steel pipe and used to determine the Charpy absorbed energy at -10°
C (VE-10° C). Weldability was evaluated by actually performing circumferential welding
of the UOE steel pipes and determining whether cracking occurred at -10° C in y slit
cracking test. Cases in which cracking was observed are indicated by an X and cases
in which it were not observed are indicated by an O.

[0054] In Nos. 1 and 20 - 24 which are working examples of the present invention, the strength
and toughness of the base metal satisfy the prescribed conditions, and at the same
time, due to optimization of the chemical composition, the resistance to joint fracture
was excellent as evidenced by the fact that fracture at the base metal could be achieved
in the joint tensile test. In addition, circumferential weldability was also excellent.
[0055] In contrast, in the comparative examples, appropriate level of strength or toughness
or other properties could not be achieved. In particular, in Nos. 10, 12, and 16 -
18, there was an extreme decrease in the toughness of the HAZ.