Note: Descriptions are shown in the official language in which they were submitted.
CA 02279580 1999-08-13
METHOD FOR PRODUCING A STEEL PIPE USING A HIGH DENSITY
ENERGY BEAM
This is a divisional application of Canadian Patent Application Serial No.
2,175,169, filed April 26, 1996, and entitled "Method for Producing a Steel
Pipe Using a High Density Energy Beam" .
BACKGROUND OF THE INVENTION
l0 1. Field of the Invention
The present invention relates to a method for producing an electric-
resistance-welded steel pipe, and more particularly to a method for
producing an electric-resistance-welded steel pipe using a high density
energy beam.
2. Description of the Related Arts
In conventional methods, a steel strip is formed into a cylindrical shape
while transferring the steel strip so that both edges of the steel strip face
each other. The both edges of the steel strip are welded to produce a steel
pipe. Among the conventional methods, an electric-resistance-welding
2o method is the most efficient. In the electric-resistance-welding method,
a butt joint portion is heated and fused to form a fusion zone by using
induction heating of high frequency electric current or applying a high
frequency electric current to the butt joint portion from a contact chip. The
fusion zone is pressed by squeeze rolls to remove impurities and oxides which
exist in the fusion zone, thus the welding being done. However, oxides having
high melting point are not removed and remain in a weld zone by oxygen in air
during the heating and the fusion of the edges of the steel strip. The oxides
comprise alloying elements such as Mn, Si, and Cr. The remained oxides
may result in a weld defect called the "penetrator" . To
1
CA 02279580 1999-08-13
suppress oxidization and to obtain a high quality welded steel pipe, gas
shielding is applied. The gas shielding, however, gives not sufficient effect.
A pipe-producing method using high density energy beam such as laser
beam has been developed on the background described above. The method
is a welding method to fuse the edges of a steel strip under irradiation of
high density energy beam. It is known that since the method avoids
exposing the fused metal to atmospheric air, weld defects such as oxide
inclusion are hard to generate, and high quality welded steel pipe is
obtained.
The method using high density energy beam is disclosed in JP-A-3-
291176 which is published on December 20, 1991 and JP-B-4-18954 which
is published March 30, 1992 (the terms "JP-A-" and "JP-B" referred to
herein signify "unexamined Japanese patent publication" and "examined
Japanese patent publication", respectively). Fig. 4 shows a pipe-producing
method disclosed in JP-A-3-291176. A steel strip 1 is formed into an open
pipe having edges la and lb. The edges la and lb are heated to a
temperature of from 200 to 600 °C using a heat source 2 of a high
frequency
induction method or a high frequency resistance method. Then a high
density energy beam as the second heat source 3 is irradiated to a portion lc
2 0 adjacent to squeeze rolls 4a and 4b to weld the portion. The method is a
complex welding method which increases the welding speed by preheating
the steel strip edges using the first heat source to make up the insufficient
energy of the second heat source.
The above-mentioned method aims to produce ferritic or austenitic
2 5 stainless steel pipe. But secondary operation properties such as cutting,
2
CA 02279580 1999-08-13
bending, press forming and forging deteriorate owing to coarsening of
crystal grains in the ferritic stainless steel. Quality of the steel pipe
deteriorates owing to weld decay in the austenitic stainless steel. For the
above-mentioned problems, the preheating by the high frequency heat
source 2 is limited to a temperature of from 200 to 600 °C. If,
however, a
size of steel pipe or a wall thickness of steel pipe increases, the increase
of
the welding speed cannot be expected by the preheating of a temperature of
around 600 °C.
Fig. 5 shows a pipe-producing method disclosed in JP-B-4-18954.
According to the pipe-producing method, preheating is carried out by using
the induction heating coil 2 as the first heat source. Upstream of a V-
converging point ld where both edges la and lb of the steel strip firstly
contact each other is preheated to a degree that very little fusion occurs at
the edges 1 a and 1 b of the steel strip. The joint face 1 c of the steel
strip at
downstream of the V-converging point 1 d is welded by irradiating high
density energy beam 3 as a second heat source. In a portion between the
V-converging point 1 d and the fusion zone by the high density energy beam,
and in a portion downstream of the fusion zone, a clamping force is applied
to both edges of the steel strip to a degree that both edges simply touch each
2 0 other.
In this method, the place of irradiation of high density energy beam 3 is
carried out at downstream of the V-converging point 1 d where both edges
of the steel strip contact each other for the first time. As shown in Fig. 5,
however, the joint portion may open owing to spring back at downstream of
2 5 the squeeze rolls 4a and 4b to induce undercut at the weld zone, or a
3
CA 02279580 1999-08-13
solidification cracks may generate depending on the
composition of the material. The squeeze rolls 4a, 4b and
the squeeze rolls 5a, 5b clamp both edges of the steel
strip to a degree that both edges simply touch each other.
Such clamp of both edges, however, has been hard to
technologically attain, since there appears a gap between
the squeeze rolls 4a and 4b and the squeeze rolls 5a and 5b
caused by spring back.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a
method for producing a steel pipe using a high density
energy beam to provide a pipe of high quality with high
efficiency and without weld defects.
To attain the object, the present invention provides a
method for producing a steel pipe, comprising the steps of:
(a) forming a steel strip having two edges into a
cylindrical form so that the two edges face each other;
(b) preheating the two edges of the steel strip to a
temperature of a melting point or less by applying a high
frequency electric current to the two edges;
(c) pressing the two edges of the steel strip against
each other by using squeeze rolls to form a joint portion
including a joint line;
(d) irradiating a high density energy beam sufficient
to fuse a full thickness of the steel strip at a portion
adjacent to a squeeze point to weld the joint portion, the
squeeze point being a crossing point of a hypothetical line
extending across centers of squeeze roll shafts and the
joint line; and
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CA 02279580 1999-08-13
(e) controlling an upset using the squeeze rolls
enough to reduce a weld defect simultaneously with the step
(d), the upset being a difference between a coil width (mm)
before pipe forming and a circumferential length of pipe
(mm) .
In the step (d), the high density energy beam can be
irradiated on the joint line at an upstream side of the
squeeze point by 0 to 5 mm.
In the step (e), the upset is preferably from 0.1 to
1 mm.
Furthermore, the present invention provides a method
for producing a steel pipe, comprising the steps of:
(a) forming a steel strip into an open pipe having
two edges;
(b) joining the two edges of the open pipe to form a
joint portion; and
(c) irradiating a high density energy beam to the
joint portion to weld the joint portion, the high density
energy beam having a beam axis and an irradiation point,
the beam axis being inclined toward a welded portion.
The high density energy beam has an inclination of 5
to '20 degrees. The inclination is an angle formed by the
beam axis and a vertical line at the irradiation point.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic view of an apparatus which is
used in the embodiment-1.
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CA 02279580 1999-08-13
Fig. 2 is a graph showing a relation of preheating temperature, maximum
welding velocity for full penetration, and quality of weld zone according to
the embodiment-1.
Fig. 3 is a graph showing a relation of upset and quality of weld zone
according to the embodiment-1.
Fig. 4 is an explanatory view of a prior art.
Fig. 5 is another explanatory view of another prior art.
Fig. 6 is a schematic view of the embodiment-2.
Fig. 7 is a graph showing a relations of a beam inclination to generated
weld defects in number and to penetration depth according to the
embodiment-2.
DESCRIPTION OF THE EMBODIMENT
Embodiment-1
In the embodiment-l, a steel strip having two edges is formed into a
cylindrical form so that the two edges face each other. The two edges of the
steel strip are preheated to a temperature of a melting point or less by
applying a high frequency electric current to the two edges. The preheated
two edges are pressed each other by using squeeze rolls to form a joint
2 0 portion including a joint line. A high density energy beam sufficient to
fuse
a full thickness of the steel strip is irradiated to a portion adjacent to a
squeeze point to weld the the joint portion. The squeeze point is a crossing
point of a hypothetical line extending across centers of squeeze roll shafts
and the joint line. An upset is controlled by using the squeeze rolls to
reduce
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CA 02279580 1999-08-13
a weld defect. The upset is a difference between a coil width (mm) before
pipe forming and a circumferencial length of pipe (mm).
The preheating temperature of the edges of the steel strip is preferably
from 600 to 1200 °C. The joint portion has "I" shape and the gap of
joint is
preferably 0 to 0.20 mm. The high density energy beam can be irradiated
on the joint lice at an upstream side of the squeeze point by 0 to 5 mm. The
joint portion of the edges of steel strip is welded by laser and the upset
given
by the squeeze rolls is preferably 0.1 to 1 mm. The preheating zone and the
adjacent portion of irradiation of the high density energy beam are shielded
by a gas.
According to the embodiment-1, a steel strip which is continuously
supplied is formed into a cylindrical shape. Both edges of the steel strip are
preheated to the melting point of the material or less, preferably to a
temperature ranging from 600 to 1200 °C, using high frequency induction
method or high frequency resistance method. A high density energy beam
sufficient to fuse a full thickness of the steel strip is irradiated to a
portion
adjacent to a squeeze point to weld the the joint portion. The high density
energy beam can be irradiated on the joint line at an upstream side of the
squeeze point by 0 to 5 mm. An upset is controlled by using the squeeze
2 0 rolls simultaneously with irradiating the high density energy beam. A
preferable upset is from 0.1 to 1.0 mm.
The above described method provides the following advantages.
A maximum welding velocity for full penetration increases and the
range of allowable welding speed is widened. A high quality welded steel
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CA 02279580 1999-08-13
pipe is produced without generating weld defects such as undercut,
blowhole and longitudinal crack.
Detection of a welding position is carried out by CCD camera which is
placed just before the location where the both edges of the steel strip
converge each other. The position of the joint portion of the both edges is
taken of by the CCD camera and a welding torch is moved, synchronized
with movement of the joint line. Thereafter, an excess portion of the weld
zone is cut off. Subsequently, a portion adjacent to the weld zone is
subjected to a quenching treatment by heating to a predetermined
temperature using a high frequency induction power source and water-
cooling. After the quenching treatment, tempering is perfomed by heating
to a predetermined temperature. Alternatively, the portion adjacent to the
weld zone is heated to a predetermined temperature and is air-cooled.
Now preferable individual constitutions of the present embodiment will
be described.
( 1 ) Preheat temperature at the edges of steel strip
An effect of the preheating temperature on the welding temperature was
investigated. The preheating temperature was changed from room
2 0 temperature to the melting point of the steel strip. Welding was conducted
using a carbon dioxide gas laser with 20 kW of output. The maximum
welding velocity for full penetration and the quality of weld zone were
studied. Fig. 2 shows the results of the case that a electric-resistance-
welded
steel pipe was producd by using an ordinary pipe-forming mill in which the
2 5 steel strip is continuously supplied and cylindrically formed. The
electric-
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CA 02279580 1999-08-13
resistance-welded steel pipe comprises carbon steel and has a size of 508 mm
of outer diameter and 12.7 mm of wall thickness. The hatched area in Fig. 2
indicates the area to provide satisfactory welding bead.
As seen in Fig. 2, the maximum welding speed increases with the
preheating. It is well possible to weld in the preheating temperature of less
than 600 °C. The preheating temperature of less than 600 °C,
however,
deteriorates productivity because increase rate of welding speed becomes
1.5 or less. The increase rate of welding speed is defined by the ratio of the
maximum welding speed at that temperature when the operation is presently
performed to that at the room temperature.
Accordingly, to obtain the increase rate of 1.5 or more, the preheating
temperature is preferably 600 °C or more.
When the preheating temperature is over melting point, the increase rate
of welding speed is about 3.5, but a burn through bead appears which invites
failure in obtaining satisfactory welding bead.
when the preheating temperature is over 1200 °C and below the melting
point, the increase rate of welding speed is 3 or more. An improvement of
productivity is obtained. In that range of temperature, however, the
allowable range O V ( which is an adequate welding speed range to give
2 0 satisfactory welding bead) between the maximum welding speed resulting
in melt down bead and the maximum welding speed for full penetration
significantly narrows compared with the case of preheat temperature of
1200°C or less.
Therefore, the preheating temperature is melting point of the material or
less, preferably from 600 to 1200°C.
9
CA 02279580 1999-08-13
(2) Place of irradiation of high density energy beam
Both edges of the steel strip formed into cylindrical shape opens owing to
spring back at downstream of the crossing point of the hypothetical line
extending across centers of squeeze roll shafts and the butt joint line.
The crossing point is hereinafter referred to simply as "squeezing point".
Accordingly, when welding is conducted under irradiation of high density
energy beam to a place downstream of the squeezing point, a tensile stress
occurs during the solidification of fused metal to induce weld defects such as
undercut and solidification cracks depending on the chemical composition
of the material. On the other hand, at upstream of the squeezing point, both
edges of the cylindrical steel strip come close each other when they
approach to the squeezing point, so the weld defects such as solidification
cracks which occur at downstream of the squeezing point are avoided.
Consequently, it is important to carry out welding by irradiating high
density energy beam to a portion adjacent to the squeezing point.
Downstream of the squeezing point is, however, not preferable for the
portion of irradiation of high density energy beam, where tensile stress is
applied to the weld portion, and upstream of the squeezing point is
preferable. Even in upstream of the squeezing point, joint gap of above
2 0 0.20 mm induces undercut defect owing to the excessive gap. The joint gap
of 0.20 mm corresponds to the point of about 5 mm upstream from the
squeezing point.
Conclusively, the high density energy beam is irradiated to adjacent area
of the squeezing point, and more preferably to a place by 0 to 0.5 mm
CA 02279580 1999-08-13
upstream of the squeezing point. The place of irradiation corresponds to the
point giving a joint gap of 0 to 0.20 mm.
(3) Upset
In a pipe-producing welding method which uses high density energy
beam, fused metal having a narrow width is produced at a high speed, so the
solidification rapidly occurs, undercut occurs on the bead portion at rear
side and solidification cracks likely occur depending on chemical
composition of the material. Furthermore, gas and metallic vapor are likely
entrapped to generate blow holes. Application of upsetting using squeeze
rolls is a means for preventing those type of defects. That is, undercut is
prevented by push-out of fused weld metal toward the plate thickness
direction by upsetting. Upsetting pushes out the welding metal, and the
push-out action collapses blow holes. On the other hand, solidification
cracks of welding metal is prevented by applying compression force to the
weld metal by upsetting.
The preventive effect against the generation of weld defects using
upsetting was experimentally confirmed. Steel pipes were produced by
continuously forming a steel strip, electric-resistance-welding and using .
carbon dioxide gas laser with 20 kW of output. . The steel pipes comprise
2 0 carbon steel and have the size of 508 mm of outer diameter and 7.5 mm of
wall thickness. using carbon dioxide gas laser with 20 kW of output. Fig. 3
shows the result of test in which squeeze rolls clamped the external
periphery of welding steel pipe to give compression deflection to the weld
metal portion to a range of from 0 to 2.0 mm. When the upset is less than 0.1
2 5 mm, the push-out of weld metal and the compression force are too small, so
11
CA 02279580 1999-08-13
the preventive effect against weld defects is small to result in the
generation
of undercut and to remain weld defects. When the upset exceeds 1.0 mm,
then the width of weld metal is narrow to a range of from 0.5 to 2 mm, and
most of the weld metal are pushed out, and the heat-affecting zone swells by
metal flow. Hook cracks have generated attributably to the inclusion and to
segregation of component after the swollen portion including bead was
machined.
Therefore, upsetting of fused metal is essential for welding by high
density energy beam, more preferably the upset length should be set in a
range of from 0.1 to 1.0 mm.
(4) Shield gas
During the pipe-producing process, the preheating zone at the edges of
the steel pipe using high frequency current, the weld zone, and the adjacent
portion to the weld zone is preferably shielded by inert gas such as helium.
The role of shielding is to suppress the remaining of oxide film and oxide
generated during the preheating on the butt face of steel strip in the weld
zone.
2 0 Example
Fig. 1 shows a schematic view of an apparatus for producing an
electric-resistance-welded steel pipe which is used in the embodiment-1.
According to the example, a steel strip 1 is continuously supplied and
formed into a cylindrical shape. Both edges la and lb of the steel strip
2 5 facing each other were preheated to a temperature of melting point of the
12
CA 02279580 1999-08-13
material or less by using a high frequency resistance heating device 6. The
contacts 6a and 6b of the high frequency resistance heating device 6 are
arranged at upstream of the V-converging point 1 d with a specified spacing.
At an adjacent portion of the squeezing point 9, which is a crossing point of
the hypothetical line 7 extending across the centers of squeeze roll shafts 4a
and 4b and a butt joint line 8 between the edges la and lb of the steel strip,
a high energy density laser beam 10 is irradiated to fuse the full thickness
of
the steel strip 1 to weld a butt joint portion lc, and simultaneously, the
butt
joint portion is pressed to a specified upset to join together. The reference
numbers l la and l lb are top rolls which are installed to suppress the
misalignment of butt joint portion lc, at need.
The following are the results of production of electric-resistance-
welded steel pipes comprising carbon steel and having the size of 304 to 508
mm of outer diameter and 5.0 to 12.7 mm of wall thickness using the
above-described manufacturing equipment.
The chemical composition of starting material was 0.05 wt.% C, 0.15
wt.% Si, 1.20 wt.% Mn, 0.010 wt.% P, 0.001 wt.% S, O.OSwt.% Nb, and
0.03wt.% V.
Carbon dioxide gas laser with 20 kW of maximum output was used.
2 0 Regarding the producing condition, the shield gas was He or N2 applied to
the preheating area on edges of the steel strip and to the adjacent portion of
the weld zone. Welded steel pipe was prepared by changing welding speed,
preheating temperature, gap of butt joint, place of laser irradiation, and
upset. When the weld zone swollen by upsetting, cutter or the like was
2 5 applied to remove the build up.
13
CA 02279580 1999-08-13
The expression of the place of laser irradiation was "-" for upstream of
the squeezing point and "+" for downstream thereof.
The quality of thus prepared welded steel pipe was evaluated by the
criteria given below.
As for the bead shape, appearance inspection was given to observe the
bead penetration across the full thickness, the undercut on the bead surface,
the presence of burn through, and the generation of hook cracks after bead
machined.
For the weld defects inside of the weld zone, nondestructive inspection
was applied to check the number of blow holes and inclusions and the
presence of solidification cracks.
The impact property of the weld zone of the steel pipe produced by the
present invention was evaluated by the fracture appearance transition
temperature vTs (the temperature that the ductile fracture percentage
becomes 50%) which was determined by Charpy impact test.
These evaluation tests were applied to the weld zone which was treated by
quenching and tempering ( heating to 950°C ~ water quenching ~1
tempering at 600 °C).
2 0 Table 1 and Table 2 show the manufacturing conditions and the quality
evaluation of Examples and Comparative Examples.
14
CA 02279580 1999-08-13
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CA 02279580 1999-08-13
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16
CA 02279580 1999-08-13
The effect of preheating was investigated in Examples No.l through
No.l 1 and Comparative Examples No.l through No.lO.
Comparative Example No. l showed the results of welding without
preheating , using 2.0 m/min. of welding speed for full penetration. On the
other hand, Examples No.l through No.6 which were subjected to preheat
ranging from 300 to 1000 °C showed increase of welding speed for full
penetration, and that for 600 °C of preheat was approximately 1.5 times
the
speed at room temperature.
In the case that the preheat was carried out at 1200 °C,
Comparative
Example No.3 which used the welding speed of 3.0 m/min. resulted in a
burn through bead, and Comparative Example No.4 which used the welding
speed of 7.5 m/min. resulted in an incomplete penetration. Examples No.7
and No.8 which used the welding speed of 4.0 m/min. and 7.0 m/min.,
respectively, provided a satisfactory bead.
For the case of 1300 °C of preheat, Examples No.9 and No.10 which
used
the welding speed of 6.0 m/min. and 7.0 m/min., respectively, provided the
satisfactory bead. Comparative Examples No.5 through No.7 which used
the welding speed of 4.0 m/min. and 5.5 m/min., respectively, resulted in
the burn through bead, and Comparative Example No.8 which used the
2 0 welding speed of 7.5 m/min. resulted in the incomplete penetration.
As described above, the allowable range of welding speed for the
satisfactory bead is wide so as to be 3 m/min. for the case of 1200 °C
of
preheating temperature, and the allowable range significantly narrowed to
about 1 m/min. for the case of 1300 °C of preheating temperature.
17
CA 02279580 1999-08-13
In the case of 1400 °C of preheating temperature, Comparative
Example
No.9 which used 6.5 m/min. of welding speed resulted in the burn through
bead, as in the case of 1300 °C of preheating temperature. Example No.
l l
provided the satisfactory bead at 7.0 m/min. of welding speed.
Accordingly, the allowable welding speed range to obtain the satisfactory
bead further narrowed. In the case that the burn through bead or the
incomplete penetration bead are formed, the solidification of fused metal
became unstable, and weld defects such as oxide inclusion and blow hole
remained in the weld zone, and gave high Charpy transition temperature
(vTs) as high as -40 °C or more.
In this manner, the preheat of both edges of the steel strip increased the
welding speed for full penetration and improved the productivity compared
with the case of the room temperature processing. However, preheating up
to the melting point of the material results in the burn through bead, so the
preheat temperature is preferably not to exceed the melting point of the
material. When the productivity is taken into account, the lower limit of
preheat temperature is preferably to set at 600 °C or less. When the
allowable welding speed range for the satisfactory bead, the upper limit
thereof is preferably to set at 1200 °C or less.
2 0 The effect of upsetting was investigated in Examples No. l2 through
No. l4 and Comparative Examples No.l l through No.l6.
Comparative Example No.l l did not apply upsetting, and generated
solidification cracks in the welded portion. Since the application of
upsetting prevented the generation of solidification cracks, upsetting is
2 5 essential. Comparative Examples No.12 and No.15 which applied upset less
18
CA 02279580 1999-08-13
than 0.10 mm resulted in an undercut bead because of insufficient upsetting.
Comparative Examples No.13, 14, and 16 which applied upset above 1.00
mm generated hook cracks owing to excessive upsetting. On the other hand,
Examples No. l2, 13, and 14 which applied upset in a range of from 0.10 to
1.00 mm provided satisfactory bead.
Consequently, upsetting is essential to obtain the satisfactory bead, and
preferably the upset is preferably from 0.10 to 1.00 mm.
The effect of place of laser irradiation was investigated in Examples
No.lS through No.21 and Comparative Examples No.l7 through No.23.
Comparative Examples No.l8, 19, 22, and 23 which received the
irradiation of laser at downstream of the squeezing point generated
solidification cracks within bead. When the place of laser irradiation was
selected at upstream of the squeezing point, generation of solidification
crack was avoided. Comparative Examples No.17, 20, and 21 which
received the irradiation of laser at more than 5 mm distant from the
squeezing point, the gap of the butt joint became excessive and undercut
generated. On the other hand, when the place of laser irradiation was
selected to a range of from 0.0 to 5.0 mm upstream of the squeezing point,
satisfactory bead was obtained.
2 0 Accordingly, the place of laser irradiation is preferably set to a range
of
from 0.0 to 5.0 mm upstream from the squeezing point.
The effect of shield gas was investigated in Comparative Examples No.24
and 25.
Comparative Examples No.24 and 25 did not use shield gas. Lots of
2 5 oxide inclusion and blow holes appeared in the welded portion, and vTs
19
CA 02279580 1999-08-13
degraded. On the other hand, Examples No.l through No.21 used shield
gas, and provided the satisfactory bead.
Therefore, shield gas is preferably important.
As described above, in Comparative Examples which were processed at
outside of the scope of the present embodiment, when the material is
preheated to the melting point or more thereof, when upsetting is not
applied to the fused metal portion to press it against squeeze rolls, or when
no shield gas is used, bead shape degraded and weld defects generated. Also
vTs became -40 °C or above.
To the contrary, in Examples No. l through No.21 which used the
condition for manufacturing welded steel pipe of the present embodiment,
bead shape was satisfactory, weld defect was not generated, and satisfactory
vTs value was obtained.
According to the present embodiment, a steel strip which was
continuously supplied is formed into cylindrical shape; both edges of the
steel strip are preheated to the melting point of the material or less than
thereof, preferably to a temperature ranging from 600 to 1200 °C, using
high frequency induction method or high frequency resistance method
2 0 while irradiating high density energy beam, which beam enables to fuse
full
thickness of the steel strip, to a place adjacent to the crossing point of a
hypothetical line extending across the centers of squeeze roll shafts and the
butting line, more preferably at 0 to 5.0 mm upstream of the crossing point,
under application of a compression force to a predetermined upset length to
2 5 conduct welding; simultaneously the squeeze rolls apply compression of
CA 02279580 1999-08-13
preferably 0.1 to 1.0 mm. With the procedure, a high quality welded steel
pipe is produced at a high efficiency without having weld defects such as
undercut, blowhole, longitudinal crack.
EMBODIMENT-2
A method for producing a electric-resistance-welded steel pipe of the
present embodiment comprises: forming a steel strip into an open pipe;
joining both edges of the steel strip together; irradiating high density
energy
beam to the joint portion with an inclination toward the welded portion
along the welding line to weld the joint portion.
The present embodiment applies the inclination, 8 , of the high density
energy beam in a range of from 5 to 20 degrees. As shown in Fig.6, the
beam inclination, B , is an angle formed by the beam axis 14 and the normal
line 15 to the base pipe at the beam irradiation point.
The present embodiment comprises: forming a steel strip into an open
pipe; preheating both edges of the steel strip to a temperature ranging from
300 to 1200 °C using an electric resistance method or an induction
heating
method; joining the edges each other; and irradiating a high density energy
beam to the joint portion to weld thereof.
The present embodiment is characterized in that the applied beam of the
high density energy irradiating to the joint portion of the open pipe is
inclined toward the welded portion along the welding line. The reason why
the beam inclined toward the welded portion along the welding line
2 5 suppresses the above-described weld defects is the following. Generally, a
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CA 02279580 1999-08-13
beam which is converged to a point of welding has a small converged
diameter ranging from 50 to 500 ~c m and is irradiated normal to the open
pipe. Accordingly, the key hole formed during the welding gives small
diameter thereof, and likely collapses due to a gravity sagging of fused
metal at rear side of the fused basin, which tends to generate weld defects
such as blow hole.
On the other hand, when the beam is inclined toward the welded portion
along the weld line, as in the case of the present embodiment , the key hole
area becomes wide owing to the gravity action to the fused metal at rear side
of the fused basin. Consequently, the sagging of fused metal does not fill the
key hole, thus the generation of weld defects such as key hole is avoided.
Experiment proved that the optimum inclination, 8 , of the beam is in a
range of from 5 to 20 degrees toward the welded portion along the welding
line. The experiment was conducted using a carbon steel strip having 12
mm of thickness, a carbon dioxide gas laser with 20 kW of output, and with
varied beam inclinations and welding speeds. The result is shown in Fig. 7.
Fig. 7 shows the evaluation of a generated number of weld defects and
penetration depth by the expression of relation between the beam inclination
and the welding speed. The line "A" shows the relation between the beam
2 0 ~ inclination and the generated number of weld defects. The line "B" shows
the relation between the beam inclination and the penetration depth.
In Fig.7, vertical irradiation of beam onto the open pipe is taken as
"0°".
The beam inclined toward the welded portion is taken as "+", and the beam
inclined toward the not yet welded portion is taken as "-". Regarding the
2 5 number of generated blow holes in relation to the beam inclination, the
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CA 02279580 1999-08-13
generation of blow holes was suppressed when the inclination became +5°
o r
more independent of the welding speed. Within a beam inclination range of
from -20 to +20°, the penetration depth at the weld bead portion gave
about ,
0.8 times or more to the penetration depth at beam inclination of 0°
(or the
penetration depth ratio) where the depth reached to maximum level. Thus
the beam inclination range of from -20 to +20° does not impair
productivity. In the case that the beam inclination is outside of the range of
-20 to +20°, however, the ratio of penetration depth became 0.8 or less
to
degrade the productivity. Therefore, the beam inclination is set to a range
of from +5 to +20° toward the welded portion along the welding line.
Fig. 6 is a schematic view of the method of the present embodiment.
As seen in Fig. 6, a steel strip 1 is formed into an open pipe while joining
both edges thereof, and a laser beam 13 which was converged by a
processing lens (not shown) is irradiated onto a joint portion 12 of the steel
strip I at a beam inclination, 8 , toward the welded portion along the
welding line to perform the welding of the joint portion 12. The beam
inclination, 8 , is an angle between the beam axis 14 of the laser beam 13
and the normal line 15 to the open pipe at the beam irradiation point. Only
2 0 the inclination within a specific range toward the welded portion along
the
welding line gives satisfactory result as described below. Experiment
proved that the range of inclination, 8 , is from 5 to 20°.
The effect of the present invention will be described below referring to
the embodiment.
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CA 02279580 1999-08-13
The base material was a hot-rolled steel strips having thickness range of
from 4.8 to 16 mm. These steel strip were formed into pipe having
diameter of from 75 to 508 mm. The joint portion of each pipe was welded
under irradiation of above-described laser beam 13.
The welding wad conducted at the laser beam inclination ranging from
-30 to +30° along the welding line. The welding condition was 20 kW of
laser output, 40 to 290 mm/sec. of welding speed, and helium as shield gas.
The joint portion of the open pipe was heated to 600 °C or 1000
°C by an
electric resistance method, and the pipe -welding was performed under the
above-described condition.
The welded pipe was obtained under the condition, and the presence of
blow holes and the penetration depth at the welded portion were checked.
Table 3 and Table 4 show the pipe size, the welding condition, and the
evaluation of the weld bead.
20
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CA 02279580 1999-08-13
Table 3
No. Pipe LaserWeldingBeam Number Penetration
dimensions outputvelocityinclinationof depth
DiameterWall v generated
thickness weld
(mm) (kW) {mm/sec)(deg) defects(%)
(mm) (- /m)
1 75 4.8 20 160 -30 35 75
2 75 4.8 20 160 +30 0 70
Comparative3 168 7 . 20 160 -5 5 100
5
Example 4 168 7.5 20 160 +25 0 75
5 168 7.5 15 125 +30 0 70
6 273 12.7 20 80 -30 40 70
7 273 12.7 20 80 -15 22 100
8 273 12.7 20 80 +25 0 75
9 508 16.0 20 40 -25 19 75
10508 16.0 20 40 +30 0 70
1175 4.8 20 160 +20 0 100
1275 . 4.8 20 16 +5 0 100
0
This 13168 7.5 20 _ +20 0 100
160
invention14168 7.5 20 125 +15 0 100
15168 7.5 15 125 +5 0 100
16273 12.7 20 80 +20 0 100
17273 12.7 20 80 +5 0 100
18273 12.7 20 80 +15 0 100
19508 16.0 20 40 +20 0 100
20508 16.0 20 40 +5 0 100
CA 02279580 1999-08-13
Table 4
No. Pipe PreheatLaserWeldingBeam Number Penetration
dimensions temperaoutputvelocityinclinationof depth
DiameterWall ture v generated
thickness weld
(mm) (C) (kW) (mm/sec)(deg) defects(90)
(mm) (- /m)
1 16s 7.5 600 20 210 -5 s loo
2 168 7.5 600 20 210 +25 0 75
Comparative3 168 7.5 600 15 160 +30 0 70
Example 4 168 7.5 1000 20 290 -5 7 100
5 168 7.5 1000 20 290 +25 0 75
6 168 7.5 1000 15 225 +30 0 70
7 508 16.0 600 20 55 -25 21 75
8 508 16.0 600 20 55 +30 0 70
9 508 16.0 1000 20 75 -25 19 75
10 508 16.0 1000 20 75 +30 0 70
11 168 7.5 600 20 210 +20 0 100
12 168 7.5 600 20 160 +15 0 100
This 13 168 7.5 600 15 160 +5 0 100
invention14 168 7.5 1000 20 290 +20 0 100
15 168 7.5 1000 20 225 +15 0 100
16 168 7.5 1000 15 225 +5 0 100
17 508 16.0 600 20 55 +20 0 100
18 508 16.0 600 20 55 +5 0 100
19 508 16.0 1000 20 75 +20 0 100
20 508 16.0 1000 20 75 +5 0 100
26
CA 02279580 1999-08-13
The criterion of evaluation for blow hole generation at the welded
portion was that 3 or more of blow holes per 1 m of weld length is "bad" and
that less than 3 of blow holes is "good". The penetration depth was
expressed by the ratio to the strip thickness. The criterion of evaluation of
penetration depth was that the full penetration bead t is essential, or that
the
penetration depth ratio of 100 is evaluated as "good" and that the ratio of
less than 100 is evaluated as "bad".
In Table 3, Comparative Examples No. 2, 4, 5, 8, and 10 used the beam
inclination of +25° or more, and generated no weld defect. These
Comparative Examples, however, failed to penetrate the weld bead into the
strip thickness, and the penetration depth ratio was less than 100.
Comparative Examples No. 1, 3, 6, 7, and 9' used the beam inclination of
-5° or less, and many weld defects occurred.
In Table 4, Comparative Examples No. 2, 3, 5, 6, 8, and 10 used the beam
inclination of +25° or more; and generated no weld defect. These
Comparative Examples, however, did not show full penetration, and the
penetration depth ratio was less than 100.
Comparative Examples No. 1, 4, .7, and 9 used the beam inclination of -
5°
or less, and many weld defects occurred.
2 0 As described above, the welding condition that was out of the range of the
present embodiment generated weld defects or resulted in an incomplete
penetration. On the other hand, only the beam inclination that satisfies the
whole range of the present invention provided satisfactory weld beads
without generating weld defect.
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CA 02279580 1999-08-13
Consequently, a welding condition outside of the range of the present
embodiment degraded bead shape or generated weld defects. To the
contrary, it is understood that only the case where the whole welding
conditions of the present embodiment are satisfied provides satisfactory
bead shape without containing weld defect.
The present embodiment is applicable not only for producing a
electric-resistance-welded steel pipe but also for butt welding of general
work. The sectional shape of an open pipe is arbitrarily selected, for
example, as a circular or rectangular shape.
As described above, the present embodiment conducts welding by
irradiating high density energy beam inclining to a specified angle toward
the welded portion along the weld line. The welding is stably performed in
a penetrating welding. Thus the weld defects such as undercut, blow hole,
burn through, which have been inherent defects of laser welding process,
are completely prevented. In addition, the welding provides satisfactory
bead shape on both inside and outside of the steel pipe. Furthermore, the
method of the present invention further improves the features of high
efficiency of laser welding to increase the productivity.
25
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