Abstract This work investigates the performance of high strength cast steel welded joints to confirm their feasibility for application in mooring components. Three welded joints, with ultimate tensile strength in the range of 700 to 900 MPa, were obtained by the shielded metal arc welding process, the most applied in repair operation. After welding, a post welding heat treatment was performed to relieve the residual stresses. The results obtained in tension, impact Charpy-V, and hardness tests, at different positions of the heat affected zone were compared with equivalent welded joints performed with rolled steels currently applied in mooring chain links. These results showed that cast steels can obtain results equivalent to the rolled steels. Furthermore, the composition of cast steels for more stringent requirements (UTS > 860 MPa) is adjusted with higher nickel contents, while rolled and forged steels show increased C, Cr, and Mo contents. As a consequence, a refined microstructure with excellent impact toughness was obtained. Thus, these steels present a high potential to be used in this application contributing to reduce manufacturing costs.

API 5L X80 steels are widely used in welded pipes in the petroleum industry. However, microstructural changes in the heat affected zone are a concern when welding such pipes due to the potential formation of regions with low toughness. Despite all the research concerning mechanical properties of welded joints, the acceptance criteria for the qualification of welding procedures are still limited. Welded joints do not always guarantee the safe operation of industrial equipment, because the current Standards adopted are not able to evaluate the properties at some critical regions of the welded joint. This work studied the characteristics of a girth welded joint and showed evidences of low toughness at 0.5 mm from the fusion line due to the micro-phases necklacing the prior austenite grain boundaries. As this feature is not considered by the current Standards for approval of welding procedures, this work proposes an alternative approach to improve the safety of welded structures.

RESUMO O presente trabalho apresenta os resultados de um programa de pesquisa cujo objetivo principal é o desenvolvimento de consumíveis adequados para a soldagem de componentes de ancoragem fabricados em aços de alta resistência. Após avaliação de diferentes composições químicas, com base no balanço de Mn e Ni é feita uma análise detalhada das propriedades mecânicas e microestruturais da composição química que propiciou os melhores resultados para permitir uma conclusão decisiva. Foram soldadas juntas pelo processo eletrodo revestido utilizando consumíveis de 4,0 mm de diâmetro, com preaquecimento de 200 ºC, corrente contínua, posição plana e energia de soldagem nominal de 1,5 kJ / mm. Após a soldagem, foram realizados ensaios mecânicos (tensão, impacto Charpy-V, dureza) e metalográficos por microscopia ótica, microscopia eletrônica de varredura e EBSD em amostras removidas integralmente do metal de solda, tanto na condição de como soldado quanto após tratamento térmico pós-soldagem (TTPS) realizado a 600 ºC. Os resultados mostram que os metais de solda obtiveram propriedades mecânicas satisfatórias após o TTPS, sendo adequados para aplicação em componentes de ancoragem de acordo com a especificação IACS W22. Além disso, observou-se que a tenacidade ao impacto experimentou uma melhoria com o aumento do tempo de TTPS, o que é crucial para componentes com maiores espessuras.

ABSTRACT The present work show the results of an extensive working program whose the main goal is the development of consumables suitable for welding of mooring components manufactured in high strength steels. After an exhaustive evaluation of different chemical compositions, based on a balance of Mn and Ni, a detailed analysis of the mechanical and microstructural properties is done for the heat which proposed the best results in order to allow a decisive conclusion. Welded joints were produced by using 4,0 mm diameter covered electrodes, with preheat of 200 ºC, direct current, flat position and nominal heat input of 1.5 kJ/mm. After welding, mechanical tests (tension, impact Charpy-V, hardness) and metallographic examination (optical microscopy and scanning electron microscopy, electron back scattering diffraction) were performed in specimens removed integrally from the weld metal both in the as welded condition and post weld heat treatment at 600 º C. The results show that the weld metals obtained satisfactory mechanical properties after PWHT, being adequate for application on high strength steel mooring components with several grades according to the IACS W22 specification. In addition, it was noted that impact Charpy-V results were improved with increasing the time of PWHT, which is crucial for larger components.

ABSTRACT Nickel-based weld overlays (cladding) are commonly used in oil & gas industry to extend the life of equipment under corrosive environment, as it improves the corrosion resistance without a significant increase in the manufacturing cost, when compared to a full nickel-based alloy equipment. Although there are extensive literature involving overlays applied by SMAW, GMAW or GTAW processes, works about the use of FCAW process are limited. Consequently, an investigation of the performance of the overlays deposited by this process, which provides a higher productivity in comparison to the processes usually used, can be an interesting option for this application. The present work evaluates the mechanical and microstructural properties of the nickel-based superalloy 625 weld overlay deposited on a ASTM A516 Grade 70 carbon steel plate by the flux cored arc welding process (FCAW), both in as welded and heat treated conditions. Bending and microhardness tests were performed in order to verify possible effects of welding thermal cycles on the mechanical properties. The microstructure was evaluated through both optical (OM) and scanning electron microscopy (SEM), with the use of electron backscatter diffraction (EBSD) technique. Corrosion tests were conducted on samples removed from the top layer of the weld overlay according to ASTM G 48 Method A. All results obtained with this welding process, in both as welded and heat treated samples, were considered satisfactory.

Resumo O presente trabalho tem como objetivo estudar o comportamento de juntas soldadas obtidas pelo processo GMAW com eletrodo rotativo (GMAW-RE), de modo a permitir uma análise comparativa de produtividade e propriedades mecânicas com o processo GMAW convencional (GMAW). Foram realizadas soldagens multipasse pelos dois processos GMAW com preaquecimento de 100 °C em chapas de dimensões 500 × 150 × 10 mm em aço ASTM A36, na posição plana e energia de soldagem média de 2,30 kJ/mm. Após a soldagem, foram realizados ensaios de impacto Charpy-V, microdureza e metalográficos em corpos-de-prova removidos transversalmente ao cordão de solda. Adicionalmente, foi realizada uma análise comparativa de produtividade entre os processos. Os resultados mostram que o processo GMAW-RE propicia um aumento de produtividade e redução de custos significativos em relação ao processo GMAW. Adicionalmente, foram observados valores equivalentes de tenacidade ao impacto para o metal de solda, mas uma redução nesta propriedade na zona termicamente afetada. Embora a literatura disponível destaque o elevado potencial deste processo para substituição do processo GMAW convencional em aplicações industriais, verifica-se a necessidade de mais evidências experimentais para um maior suporte a esta indicação.

Abstract The main goal of the present work is to evaluate the behavior of welded joints obtained by the GMAW with rotating electrode process (GMAW-RE) in comparison to the Conventional GMAW process (GMAW). Multipass welding by both processes were performed in ASTM A36 steel plates with dimensions of 500 × 150 × 10 mm, preheating of 100 °C in the flat position and average welding energy of 2.30kJ/mm. After welding, Charpy-V notch and microhardness tests and metallographic examination were performed in samples removed transversally to the weld bead. Additionally, a comparative analysis of productivity and costs between processes were done. The results show that the GMAW-RE promotes higher productivity and reduction of costs in comparison to GMAW. Additionally, similar impact toughness results were observed in weld metals and a reduction on this property at the HAZ. Although the literature states the high potential of the GMAW-RE for replacement of the conventional GMAW in industrial applications, it was concluded that other experimental results are still necessary before the final conclusion.

AbstractThe main goal this work is to evaluate the occurrence of the constituents and microphases observed in as-received API X80 pipe through the microstructures transformed from rich-carbon remaining austenite obtained via heat treatments. These heat treatments comprised austenitization at 1000 °C for 30 minutes, followed by annealing at 700 °C, 623 °C, 542 °C and 462 °C for 15, 60 and 300 minutes and then cooling in water or still air. The effects of the increase in annealing parameters were: 1) the increase of microhardness values of the MA constituents and martensite islands, 2) the grain size of both ferritic phase and the martensite islands were increased, 3) the rise in the mean free path of ferrite and 4) the microstrains of samples were decreased. The cooling rates influenced significantly the transformation of carbon-rich remaining austenite to hard constituents and several microphases. After annealing at 700 °C during 60 min followed by quenching, the morphology of the MA constituents and its microhardness values were compatible for both heat-treated and as-received conditions.

A soldagem de aços de alta resistência representa um desafio constante devido a grande variedade de ligas disponíveis, que necessitam associar requisitos rigorosos de elevada resistência mecânica e tenacidade simultaneamente. Neste contexto, os aços da classe HY-80 amplamente utilizados na Marinha Brasileira, são ainda preferencialmente soldados pelo processo eletrodo revestido apesar das limitações deste processo em comparação com outros processos de soldagem. Com o objetivo de avaliar a possibilidade de uma melhoria de produtividade na soldagem manual deste aço, o presente trabalho apresenta uma análise comparativa entre as propriedades mecânicas de juntas soldadas do aço HY-80 realizadas pelos processos eletrodo revestido e GMAW. Foram realizadas soldagem multipasses pelos processos eletrodo revestido e GMAW com preaquecimento de 90°C e temperatura interpasses máxima de 150°C em chapas de dimensões 850X150X30mm em aço HY-80, na posição plana e energia de soldagem média de 1,29 e 1,36 kJ/mm, respectivamente. Posteriormente, realizou-se tratamento térmico pós-soldagem a 600°C por 1 hora, sendo esta condição comparada com a condição de como soldada. Foram realizados ensaios de tração, impacto Charpy-V, dureza e metalográficos para caracterização microestrutural por microscopia eletrônica de varredura. Adicionalmente, foi realizada uma análise comparativa de produtividade entre os processos. Os resultados mostraram ser possível obter propriedades mecânicas adequadas para todas as condições de análise. Além disso, verificou-se que a produtividade propiciada pelo processo GMAW foi muito superior à do processo eletrodo revestido.

The welding of high strength steels represents a continuous challenge taking into account the great variety of alloys systems, which present stringent requirements of high strength and toughness. Into this context the HY-80 steels largely employed in the Naval Industry are still welded preferentially by the SMAW process, despite its limitations when compared with other welding processes. In order to promote an improvement on productivity, the present work presents a comparative analysis between the mechanical properties of the HY-80 welded joints performed by the GMAW and SMAW processes. Multipass welding by shielded metal(SMAW) arc and gas metal arc welding (GMAW) processes were performed with preheating and inter-pass temperatures of 90°C and 150°C respectively in plates of dimensions 850X150X30 mm in HY-80 steel, in the flat position and average energy welding of 1.29 for SMAW and 1.36kJ/mm for GMAW process. After welding a post weld heat treatment at 600°C for 1 hour was performed, this condition being compared with the as welded condition. Tensile, Charpy-V notch and hardness tests and metallographic examination by scanning electron microscopy were performed for mechanical and microstructural characterization. Additionally, it was carried out a comparative analysis between processes. The results show that it is possible to achieve adequate mechanical properties for all analyzed conditions. Furthermore, it was observed that the productivity provided by the gas metal arc welding process was greater than shield metal arc welding.

Realizou-se a avaliação de metal de solda com resistência a tração superior à 860MPa, para utilização na soldagem de aço grau R4 da norma IACS W22. Para tanto, foram soldadas juntas multipasse com preaquecimentos realizados à 200 e 250ºC pelo processo eletrodo revestido, utilizando um consumível com 4,0mm de diâmetro e cuja composição base é C-0,06%, Mn-1,89%, e Ni-2,95%. Após a soldagem foram realizados ensaios mecânicos e metalográficos em corpos-de-prova retirados integralmente do metal depositado nas condições de como soldado e após tratamento térmico pós-soldagem realizados à 600ºC por 2 horas. Os resultados mostraram que os metais de solda obtidos apresentaram propriedades mecânicas adequadas para todas as condições de análise, propiciando resultados superiores aos mínimos requeridos para a utilização na soldagem do aço grau R4 utilizados em equipamentos de ancoragem de plataformas de petróleo. A análise metalográfica permitiu clarificar a microestrutura presente e explicar o comportamento das propriedades mecânicas após o tratamento térmico.

A weld metal with tensile strength higher than 860 MPa for the welding of a IACS W22 R4 Grade Steel was evaluated. Welded joints with preheat of 200 and 250ºC were produced by SMAW process using 4.0 mm diameter covered electrodes in multipass technique whose basic composition was: C-0,06%, Mn-1,89%, e Ni-2,95%. After welding, mechanical and metallographic tests were done in all-weld metal samples in both as-welded and post welded heat treatment conditions performed at600ºC for 2 hours. The results show that the obtained weld metals have mechanical properties higher than the minimum required for the welding of a IACS W22 R4 Grade steel in all condition analysis, which makes possible to attain an adequate strength/toughness relationship for high strength steel applied in mooring equipments. The metallographic analysis allowed the identification of microstructure and, consequently, the behavior of the mechanical properties after post weld heat treatment.