IBP1504_19

INFLUENCE OF THERMAL DISTRIBUTION

ON WELDING VERTEX IN CARBON STEEL
PIPE IN THE OCCURRENCE OF MATERIAL
MICROSTRUTURAL DEFECTS
Luiran do Nascimento Betfuer1

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

The development aims to evaluate the influence of the thermal distribution in the convergence
area of the welding vertex of pipes made of carbon steel in the occurrence of microstructural
defects. Characterizing: The deformation of the grains in relation to the conformation of the
edges. The identification of the heating regions of the welding vertex in function of the
equipments used. Microstructural variations along the surface and interior of the material and
the influence of the results on integrity of the weld. For this, the applied methodology
considered a relation of the process variables and samples of the welding vertex, point of
convergence, zone of heating and region of deformation of the grains, checking the results
through the tests of chemical composition, hardness, metallography and electron microscopy
by scanning. It was evidenced that the phenomena presented, such as the appearing of the
unidentified metallurgical structure in rosette form, formation of Iron Oxides, changes in the
composition of Carbon and grain deformations, can be manipulated in relation to their impact
on the property of the product, through parameterization of the process.

Keywords: Pipe. Electric Resistance Welding. Welding Vertex. Microstructural Defects

1. Introduction

Although it demonstrates several characteristics that facilitate its use in the most diverse
industrial areas, the selection of electric resistance welded pipes invariably presents several
competing items for the same applications. The welded region presents a defect generation
opportunity that cannot be tolerated in critical applications. Moreover, it exhibits various stress
concentrations, heterogeneous transformation zones, with the presence of the most diverse
metallurgical structures and the possibility of various morphological inconsistencies.
Improving the controls and providing the welded region with a reduction in the possibility of
defects, as well as optimizing the thermal distribution parameters, to give a better quality
assurance to the product, the electric resistance welded pipes may present technical grounds for
use in environments. increasingly restricted and provide greater technical and commercial
competitiveness compared to your competitors.
In the electric resistance welding process the high frequency current is transmitted to
the material surface through electrical contacts or induced by the use of induction coils
______________________________
1 Master, Materials Engineer - TUPER SA
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(NICHOLS, 1999). Due to the current transmission method, the welding process is classified
into high frequency by induction when using coils and high frequency by contact when using
electric contact parts. The energy required to heat the material is obtained by Joule effect.
The fusion that occurs only in the material area is provided by two effects of electric
current conduction in a conductor: skin effect and proximity effect (SAITO et al., 1986).
The conduction of direct and alternating electric current occurs differently in a specific
isolated conductor. While the continuous current flows evenly, the alternate will focus on the
material surface, with decreasing current density from the face to the center of the conductor.
This uneven distribution is called the skin effect (RUDNEV et al., 2003). Physically, the
penetration depth of alternating current in an isolated conductor is a function of the frequency
of the electric current and the resistive properties and relative magnetic permeability.
That way, it is concluded that the higher the frequency of the electric current, the lower
the depth of current penetration and the smaller the heated area. However, the current
penetration is inconstant throughout the material heating process, there is a relationship between
temperature and the current penetrability. Already, when two conductive materials are close
and have opposite currents, the magnetic field between them will add up and have greater
intensity, causing the current density to concentrate on the conductor surface that is in that
region. In the process of welding by electrical resistance, the edges of the material work as
conductors, presenting a current flow in opposite directions and causing the proximity effect to
affect the distribution of current density as a function of the distance between them. These
features make edge positioning geometry essential for proper weld fusion zone (DIAN, 2012).
This work aims to evaluate the influence of thermal distribution in the convergence areas of the
welding vertex of carbon steel pipes in the occurrence of microstructural defects. Associating
the mechanism of edge conformation with grain deformation and its relationship with the
heating and induction coil locations, besides analyzing the structural variations, hardness and
carbon percentage along the edge surface and interior of the material.

2. Materials and methods

The material used is a coil hot rolled carbon steel with 3.75mm of thickness and
specification SAE J403 1020, that have the chemical characteristics, shown in Table 1.
Table 1. Chemical composition (%) for carbono steel SAE J403 1020

C Si Mn P S Al Ni
0,19 0,012 0,489 0,019 0,005 0,043 0,009
Cr Mo N Sn As Ti Cu
0,026 0,002 0,004 0,002 0,002 0,001 0,019

Already, the tubular product was manufactured by cold forming and welded by high
frequency electrical resistance, following the specification ABNT NBR 5590 Grade B and with
external diameter of 168.30mm.

2.1. Work methodology

The variables were adjusted according to the values described in item 2.2.. With the
stabilized welding, the production was abruptly stopped in order to interrupt the transformations
present in the process and withdrawn a 520mm sample from the welding vertex region and
convergence zone (Figure 1).
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SAMPLE WITHDRAWN REGION

Figure 1. Sample withdrawn diagram

The sample was fractured in the weld region, obtaining two specimen segments (Figure
2), subsequently demarcated at 8 points for analysis (Figure 3).

EDGE

FIRST SAMPLE

SECOND SAMPLE

EDGE
CONVERGENCE POINT OF WELDING

Figure 2. Fractures sample diagram

Considering POINT 2 (0mm) as the convergence point, this is, welding start location
and and reference point. The other points are positioned as follows: POINT 1: -21mm; POINT
2: 0mm; POINT 3: + 26mm; POINT 4: + 100mm; POINT 5: + 173mm; POINT 6: + 207mm;
POINT 7: + 330mm and POINT 8: + 456mm (Figure 3).

POINT 1 POINT 7 EDGE

POINT 3 POINT 5

POINT 6 POINT 8
POINT 2 POINT 4

Figure 3. Positioning of points for analysis of the first sample

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All points of the first sample were cut transversely, generating 8 samples, respectively,
for metallographic analysis, scanning electron microscopy and Hardness test.
For chemical analysis, the second specimen was subdivided into three regions. The first
region covering points 1 to 4, the second region from points 4 to 7 and the third region from
point 7 onwards. The expectation of this test is to determine the percentage of carbon in the
surface layers and inside the material, relating the variation of the element regarding to the
structure formed or diffusion. Each region received a denomination, being milled at low rotation
and generating the chip for the necessary analyzes.

2.2. Equipment, machines and process parameters

For the tests were used: Forming with center line on the pipe axis in 8 cold forming
stages, inductor coil with internal diameter of 195mm and impeder with 125mm in diameter,
formed by solid ferrites. In turn, the parameters were adjusted as shown below and in Figure 4:
1) Welding speed: 15 meters / minute. 2) Welding power: 148 kW. 3) Frequency of welding
current: 197 kHz. 4) Heat input: 592 J. 5) External diameter of impeder: 125mm. 6) Distance
from face of impeder to inductor coil: 318,18mm.

Convergence point
Welding side roller

Inductor Coil

Figure 4. Diagram for welding parameters

The Vickers hardness test was used to evaluate the hardness change gradient along the
surface and inside of the material. For this, was used a load of 1kg, following the layout of 5
vertical and 11 horizontal measurements, totaling 55 points of analysis. The carbon content
along the described regions was obtained by a carbon and sulfur analyzer equipment. For
metallographic analysis, an optical microscope and a scanning electron microscope, were used.

3. Results and discussions

3.1. Metallographic analysis

In order to evaluate and analyze the microstructural characteristics present in the tests
executeds, metallographic test were performed in the eight samples of interest of the study. The
microstructure is analyzed from the sample farthest from the convergence vertex to the sample
already welded, and related to the diagram of welding phenomena visualized in Figure 5.

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Heating

Edge approximation

Liquid metal and material

expulsion

Figure 5. Heating sequence in the electric resistance welding process

The figure 6 shows the microstructure of sample N°8 (Region A - Figure 5).

EDGE

EDGE
A B

Figure 6. Sample N°8. (a) Visual aspect of the edge 50X. (b) Dimensional aspect of deformation 50X
EDGE

EDGE
A B

Figure 7. Sample N°7. (a) Visual aspect of the edge 50X. (b) Dimensional aspect of deformation 50X

Evidencing the structure of the material, formed of ferritic base with presence of small
perlite regions, confirmed the absence of microstructural alteration due to thermal effects. Note
the grain elongation in the region near the end edge (Figure 6), contributing to the visualization
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of the lamination effect of the edges, present in the Finn Pass stages, whose function is to adjust
the geometry of the edge to be welded. Due to the positioning chosen for the inductor coil and
the lamination application, the edge structure is as expected.
The micrographs of samples No. 7 to 5 (Region B - Figure 5) show a microstructure
very similar to that of sample No. 8, confirming that until point No. 05, the thermal input used
in the process was not sufficient to cause transformations. metallurgical (Figures 7 to 9).

EDGE
EDGE
A B

Figure 8. Sample N°6. (a) Visual aspect of the edge 50X. (b) Dimensional aspect of deformation 50X

EDGE

EDGE
A B

Figure 9. Sample N°5. (a) Visual aspect of the edge 50X. (b) Dimensional aspect of deformation 50X
BORDA

BORDA

A B

Figure 10. Sample N°4. (a) Edge microstructure 100X. (b) Transition microstructure 100X

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On approaching the convergence point, the samples of points N° 4 (Region C - Figure

5) and N° 3 (Region D - Figure 5) are analyzed. At regions farthest from the edge, described as
the base material, the structure is predominantly ferritic with small perlite regions. Already in
the transition sections, there is the formation of a structure of rosettes in the midst of a ferritic
matrix (Figures 10 to 12). This feature is most present in regions nearest the ends and can be
characterized through the principles of formation graphite.

A B

DETAIL B
EDGE

Figure 11. Sample N°4. (a) Edge region 50X. (b) Edge region and transition zone 200X

A B
EDGE

EDGE

Figure 12. Sample N°3. (a) Edge region 100X. (b) Edge region and transition zone 50X
BORDA

BORDA

Figure 13. Sample N°2. (a) Edge region 50X. (b) Edge region and transition zone 50X

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The sample N°2 (Figures 13) represents the region exactly over the welding vertex
(Steps E up to G - Figure 5). At this point, closer to the edge, the change in microstructure
relative to the base material is visible. In the transition region, a darker phase is noted, also
evidenced in samples No. 4 and No. 3 and characterized as a rosette structure in the middle of
a ferritic and / or perlite matrix. However, it is noteworthy that to increase the amount of perlite
it is necessary to have a carbon enrichment in the place. The sample N° 1, representimg the
welded region (Steps H and I - Figure 5), looks similar to that seen in point 2, with an increase
in the amount of the 'dark' phase near the edge, compared to the base material ( Figure 14-b).
Looking at the weld region (Figure 14-a), an aspect of martensitic structure is noted.

A B

EDGE
Figure 14. Sample N°1. (a) Welding with martensite structure 500X. (b) Edge region and transition zone 50X

The scanning electron microscopy technique was performed only on sample N° 3. In

the other samples, the microstructure was very similar and within the expected. This sample
exposes micrographs of the edge and transition region, being visualized acicular structures and
ferritic grains everywhere the analyzed. The edge reports no significant differences from the
rest of the material. However, Figure 15 shows micrographs of sample N° 3 with oxidation
points in the edge regions, across the surface, and in some sub-surface locations. Chemical
analysis (Figure 16) shows the presence of Fe and O and proves the oxidation of the material,
besides characterizing the occurrence and influence of the mechanisms of Skin Effect,
Proximity Effect and oxide formation in the edge regions, determining the impacts, defect
generation and product quality assurance.

A B

Figure 15. Edge Region and EDS Analysis Points

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3.2. Carbon determination

Carbon determination was performed in 9 locations. Do not view the differences

between the results presented for surface, intermediate and material localities in the sample
from point 7 onwards, with carbon percentage valued at 0.194% in the 3 regions. For test N°
01 - Region 4 to 7, carbon percentage varied approximately 9% from material region to
intermediate and surface locations, while for test N° 02 – Region 1 to 4, the carbon percentage
varied approximately 7,5% from material region to intermediate location, and 1% from
intermediate region to surface location. Under both conditions, the carbon content was higher
in the regions near the edge, followed by a reduction in the intermediate and material points.
There was an approximately 8.5% increase in carbon content.
The data confirm the hypothesis of increased carbon content and consequent increase in
perlite content in the edge regions to the locations near the vertex. As the intermediate region
and material did not suffer reduction of carbon content, in relation to the chemical composition
of the raw material, it can be discarded that there has been diffusion from the interior towards
the edge. Also, there would not be enough time due to the dynamics of the process.

3.3. Hardness test

280,0
260,0
TEST N°1
240,0
HARDNESS HV10

TEST N°2
220,0
TEST N°3
200,0
TEST N°4
180,0
TEST N°5
160,0
TEST N°6
140,0
TEST N°7
120,0
TEST N°8
0,25 0,50 0,75 1,00 1,25 1,50 1,75 2,00 2,25 2,50 2,75
PROGRESS ON MATERIAL INSERTION (MM)

Figure 16. Average hardness distribution in relation to edge distance

Tests N° 08, 07, 06 and 05, performed on samples whose structure did not show thermal
performance characteristics, but, grain deformations and elongations, presented similar
variations of hardness decline and stability. In both cases, the highest hardness point is located
in the edge regions, with gradual and constant reduction over the distance. Test N° 04, the first
to have an unidentified microstructure seen in figure 11-b, reports a longer continuity of the
hardness standard for further gradual decline. Due to the thermal distributions caused by the
positioning of the welding induction coil, a higher initial hardness standard is observed in
relation to the previous samples. Test N° 03, the last one before the welding convergence point,
shows the hardness apex in the region near the edge and the constant drop during the distance.
Already the samples N° 02 and 01, from welded regions, have similar hardness variation
characteristics, with the highest values close and the constant fall. All hardness results
demonstrate full consistency with the parameters of grain deformation, thermal input, welding
and carbon distribution throughout the material. Note, total symmetry with the data visualized
by the chemical composition test, because the increase of hardness is totally related to the
increase of the carbon percentage near the edge.
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4. Conclusion

It is evident the presence of deformed grains in the regions near the edge of the material
(samples not affected by high temperature). Such phenomenon is a result of the edge lamination
process, occurred during the forming stage and necessary for the correction of the steel coil
cutting morphology. The process is characterized as a mechanical hardening, which, the
occurrence of plastic deformations performed below the steel recrystallization temperature, will
result in a volumetric increase of disagreements in the crystal structure, and in the increase of
the metal resistance. Such concepts are proven by the Hardness results, where the values
presented for the end regions are higher than in the rest of the material. In the regions with
thermal influence, there is a microstructural change gradient of the material to the end of the
edge, and in the extent without temperature interference, the presence of a predominantly
ferritic structure with small perlitic nucleus. In the transition and edge sections, a structure
similar to rosettes or graphite clusters is visualized in a ferritic matrix. Through the
determination of carbon and sulfur, in addition to the hardness test, it was possible to verify that
these regions present a higher carbon concentration and more severe hardness, compared to the
base material. Evidence of the formation of oxides in regions with incidence of thermal
influence. Iron oxides formed in the end regions of the edges of the material and were remand
during the welding process, that is, they were not completely expelled after the stage of
compression. Among other types of defects, such indications may result in “Penetrators”. Such
failures can be characterized as non-metallic oxide inclusions, mainly FeO, MnO, SiO2, which
were remand in the weld line during tube fabrication and critically affect the mechanical
properties, notably the ductility of the weld line (CAVALHEIRO, 2004). This fragility,
associated with stresses characteristic of heat treatment processes or tubular product
conformation tends to cause rupture of the welded region and provide catastrophic failures. By
characterizing the various regions of the welding vertex, it becomes possible to determine the
starting point of the heating and to relate it to the distance of the welding induction coil. Thus,
it is concluded that by means of a complete parameterization, it is possible to determine the
generating moment of the presented phenomena, such as the emergence of the unidentified
rosette metallurgical structure, formation of iron oxides, carbon composition alterations and
deformations of grains by, manipulating the impact on the property of the final product.
Considering the characteristics applicable to the pipe, object of the study, it is understood that
better quality levels are obtained by delaying the appearance of the structures visualized in the
study, by positioning, closer to the welding vertex, the inductor coil.

4. References

DIAN, Gustavo Henrique. Influência do aporte de calor e da velocidade de soldagem na

tenacidade da solda HF-ERW. 2012. 93 f. Dissertação (Mestrado) - Curso de Mestrado
Engenharia Mecânica na área de Materiais, Universidade Estadual Paulista, Guaratinguetá,
2012.
NICHOLS, Robert K.. High frequency welding - the process and applications. Thermatool
Corp.. East Haven, p. 1-8. 1999.
RUDNEV,V. et al.. Handbook of Induction Heating. New York: Marcel Dekker. 2003. 800p.
SAITO, M. et al.. Theoretical Analysis of Current Distribution in Electric Resistance Welding.
Transactions ISIJ, 1986. Vol. 26. p. 461-467.
CAVALHEIRO, Benedito C. Tratamento térmico – Trinca na solda, tubos API 5CT P110.
Tenaris Confab, p. 1-20. 2004.

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