The Development of Ultra-High Strength Wire A joint development project by and.
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Transcript of The Development of Ultra-High Strength Wire A joint development project by and.
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The Development of Ultra-High Strength Wire
A joint development project by
and
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Application DemandsPermanent Mooring Cables
• Deepwater activities for long term fields.
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Application DemandsPermanent Mooring Cables
• High strength to weight ratio– Large diameter wire.
• Field life performance. – Corrosion Performance.
– Fatigue performance.
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Opportunities for Development
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Strength Progression
5000
7500
10000
12500
15000
17500
20000
22500
25000
100 110 120 130 140 150
Spiral Strand Diameter (mm)
MB
L (k
N)
1570 MPa Grade1770 MPa Grade1860 MPa Grade
Development Target – 1960 MPa
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Application DemandsProject Objective
• 5mm diameter final hot dip galvanised wire
• 1960MPa grade • Achieving a 10% improvement
in strand breaking strength• maintaining corrosion &
fatigue performance.
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The Development of Ultrahigh Strength Wire
Alloy Development Phase
Shaun Hobson
Corus RD&T – Swinden Technology Centre - UK
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ObjectiveObjective
To design a steel composition, capable of attaining a minimum UTS of 1960MPa in the hot dip galvanised wire(~5mm dia) condition, enabling a 10% improvement in cable strength.
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BackgroundBackground
(a) MICROSTRUCTURE
A fully pearlitic microstructure is required, to optimiseUTS / ductility / drawability.
When designing a new steel for rod/wire, the following need to be considered:-
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BackgroundBackground
As-Rolled Rod Microstructure
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BackgroundBackground
As-Rolled Rod Microstructure
Microstructure after 80% reductionfrom wire drawing Drawing Direction
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MicrostructureMicrostructure
Laying TemperatureControls austenite grain size
Forced Air Blast / Conveyor SpeedControls cooling rate, hence
transformation products
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Martensite
Bainite
Austenite
Tem
pera
ture
, °C
Pearlite
Time (Log Scale)
Interlamellar Spacing (S)
Cooling S (nm)
TS (N/mm²)
Rod Mill 130 1000
Patenting 5.5mm 50 1180
12mm 80 1100
Plain 0.7% C Steel
Microstructure : Lead Microstructure : Lead PatentingPatenting
Isothermal Transformation diagram
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BackgroundBackground
(a) MICROSTRUCTURE
A fully pearlitic microstructure is required, to optimiseUTS / ductility / drawability.
(b) WIRE PROPERTIES
Definition of the various ductility tests.
When designing a new steel, for rod/wire, the following need to be considered:-
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Wire PropertiesWire Properties
Torsional Ductility
Length of wire is gripped at one end, whilst theother end is rotated at a fixed speed. The numberof twists to fracture is recorded , along with thefracture type. A type is preferred ductile fracture.
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Wire PropertiesWire Properties
Torsional Ductility
Length of wire is gripped at one end, whilst theother end is rotated at a fixed speed. The numberof twists to fracture is recorded , along with thefracture type. A type is preferred ductile fracture.
A Type B Type C Type
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Wire PropertiesWire Properties
Torsional Ductility
Length of wire is gripped at one end, whilst theother end is rotated at a fixed speed. The numberof twists to fracture is recorded , along with thefracture type. A type is preferred ductile fracture.
Reverse Bend Ductility
Length of wire is repeatably bent through 90°over a specified radius in opposite directionsuntil fracture. The number of reverse bendsis recorded.
2nd bend 1st bend
A Type B Type C Type
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BackgroundBackground
(a) MICROSTRUCTURE
A fully pearlitic microstructure is required, to optimiseUTS / ductility / drawability.
(b) WIRE PROPERTIES
Definition of the various ductility tests.
(c) AGEING RESPONSE
Dynamic / static strain ageing of wire.
When designing a new steel, for rod/wire, the following need to be considered:-
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Immersion Time at Galv Temp, s
Tensi
le S
trength
Immersion Time at Galv Temp, s
Mean N
o o
f T
wis
ts t
o F
ail
ure
Ageing Response of Drawn WireAgeing Response of Drawn Wire
C Clustering & Pearlite Spheroidisation
Dislocation lockingby C migration
Delaminations (C type)
Recovery
A Type
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Immersion Time at Galv Temp
Tensi
le S
trength
Immersion Time at Galv Temp, s
Mean N
o o
f T
wis
ts t
o F
ail
ure
Ageing Response of Drawn WireAgeing Response of Drawn Wire
Increasing Temp
Increasing Temp
Drawing strain, scheduleand speed also influence theageing response duringgalvanising.
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Immersion Time at Galv Temp
Tensi
le S
trength
Immersion Time at Galv Temp, s
Mean N
o o
f T
wis
ts t
o F
ail
ure
Ageing Response of Drawn WireAgeing Response of Drawn Wire
Ideal position, just enough to recovertorsions, without too much loss of UTS
Torsional recoveryto type A fractures
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Three Stage Development Programme
(1)Laboratory assessment of experimental compositions
(2) Small scale production trial of most suitable steel
(3) Full scale trial cast, and cable manufacture
Development ProgrammeDevelopment Programme
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Stage 1 – Lab AssessmentStage 1 – Lab Assessment
60Kg Ingots
Rolled and Ground to 10mm Rod Samples
Patented (using a laboratory saltbath)
Drawn to 4.4mm Wire (single hole drawbench)
Simulated Galvanising (using laboratory saltbath)
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Stage 1 – Lab AssessmentStage 1 – Lab Assessment
Steel C Si Mn Cr
1 0.90 0.60 0.50 0.20
2 0.90 0.90 0.50 0.20
3 0.90 1.20 0.50 0.20
CMaximise strength, and refine pearlite.(need to avoid proeutectoid cementite / segregation)
SiSolid solution strengthening of pearlitic ferrite, suppressescementite formation and influences the ageing response during galvanising.
Mn / CrIncrease the hardenability, i.e. reduce the temperatureat which pearlite begins to transform from austenite, thus refining the pearlite and increasing the UTS.
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Stage 1 – Lab AssessmentStage 1 – Lab Assessment
1800
1850
1900
1950
2000
2050
2100
0 20 40 60 80 100 120
Immersion Time, s
Te
ns
ile
Str
en
gth
, M
Pa
0.6% Si
0.9% Si
1.2% Si
0
5
10
15
20
0 20 40 60 80 100 120
Immersion Time, s
Me
an
No
of
Tw
ists
to
Fa
ilu
re, n
0.6% Si
0.9% Si
1.2% Si
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Stage 1 – Lab AssessmentStage 1 – Lab Assessment
1800
1850
1900
1950
2000
2050
2100
0 20 40 60 80 100 120
Immersion Time, s
Te
ns
ile
Str
en
gth
, M
Pa
0.6% Si
0.9% Si
1.2% Si
0
5
10
15
20
0 20 40 60 80 100 120
Immersion Time, s
Me
an
No
of
Tw
ists
to
Fa
ilu
re, n
0.6% Si
0.9% Si
1.2% Si
Increasing Si
Increasing Si
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Stage 1 – Lab AssessmentStage 1 – Lab Assessment
SteelUTS, MPa
Tensile Ductility, %
Reverse Bends, n
Torsional Ductility, n (fracture type)
1 1835 39 11 18 (C)
2 1840 40 11 26 (A)
3 1905 45 13 28 (A)
Steel 3 was deemed the most promising composition and was progressedthrough to stage 2.
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Stage 2 – Small Scale ProductionStage 2 – Small Scale Production
Steel C Si Mn Cr
3 0.90 1.20 0.50 0.20
60kg Vac Melt
Forged and welded onto ‘carrier’ billets
Rolled to 12mm rods
Lead Patent
Wire Drawing (5.3mm)
Hot Dip Galvanise (5.4mm)
Corus RD&T
Corus ScunthorpeRod Mill
Bridon InternationalDoncaster
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Stage 2 – Small Scale ProductionStage 2 – Small Scale Production
Dia, mm
UTS, MpaTensile Ductility,
%Torsions, n
(fracture type)Reverse Bends, n
Patented Rod
12.0 1445 30 - -
Wire 5.30 2030 56 32 (A) 18
Galv Wire
5.40 1975 49 26 (A) 12
For an 80% drawing reduction, the target properties were met, without any processing difficulties. Therefore a full-scale commercial trial was recommended.
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
A full cast (300t) of steel 3 was successfully made at Scunthorpe Works.This was cast to bloom, rolled to billet and supplied to the rod mill.
8.0 – 13.5mm diameter rod was produced at Scunthorpe Rod Mill.All the rod was fully pearlitic.
No production problems with :-
(a) Mill loads / hot stiffness(b) Increased hardenability(c) Scale / descalability (high Si)
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
7 8 9 10 11 12 13 14
Rod Dia., mm
UT
S, M
Pa
Plain 0.90C
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
7 8 9 10 11 12 13 14
Rod Dia., mm
UT
S, M
Pa V-Microalloy
Plain 0.90C
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
7 8 9 10 11 12 13 14
Rod Dia., mm
UT
S, M
Pa
UHC-Si-Cr (steel 3)
V-Microalloy
Plain 0.90C
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1250
1500
1750
2000
2250
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
True Strain
Ten
sile
Str
engt
h, M
Pa
Work Hardening Curves
Plain 0.90C
Direct drawn
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1250
1500
1750
2000
2250
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
True Strain
Ten
sile
Str
engt
h, M
Pa
Work Hardening Curves
V-Microalloy
Plain 0.90CDirect drawn
Patented
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
1000
1250
1500
1750
2000
2250
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
True Strain
Ten
sile
Str
engt
h, M
Pa
Work Hardening Curves
UHC-Si-Cr
V-Microalloy
Plain 0.90C Direct DrawnPatented
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
Wire Size,Mm
ConditionUTS, Mpa
Torsions, n (fracture type)
Elong to Fracture, %
Reverse Bends, n
5.204.90
As-drawn20952100
33 (A)29 (A)
--
--
5.305.00
Galvanised20402070
11 (C)8 (C)
8.18.3
-10
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale Production
Wire Size,Mm
ConditionUTS, Mpa
Torsions, n (fracture type)
Elong to Fracture, %
Reverse Bends, n
5.204.90
As-drawn20952100
33 (A)29 (A)
--
--
5.305.00
Galvanised20402070
11 (C)8 (C)
8.18.3
-10
5.0Galvanised
Non-Std2025 26 (A) 10.0 9
Ageing response at galvanising is influenced by :-Microstructure, Drawing Strain, Drawing Speed, Galvanising Times/Temps
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Stage 3 – Full-Scale ProductionStage 3 – Full-Scale ProductionFatigue Testing of Single Wires (Fatigue limits at 2 x 106 cycles)
Tests were conducted to BS 5896 for 2 x 106 cycles. Industry standard uses max. stress = 45% of grade UTS, with min. stress changed until a fatigue limit is reached
Fatigue limit increases with strength, but reduces as % of grade
200
400
600
1500 1600 1700 1800 1900 2000
Grade
Str
ess
ran
ge,
Ds
, MP
a
21
22
23
24
1500 1600 1700 1800 1900 2000
Tensile Grade
Fat
igu
e lim
it, D
s, %
of
gra
de
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Summary of Steel DevelopmentSummary of Steel Development
1000
1250
1500
1750
2000
2250
12mm Rod PatentedRod
5mm GalvWire
UTS
, MPa
Plain C
V-Microalloy
UHC-Si-Cr
The galvanised wire was supplied to the ropery at Bridon, where it was spirally spun to a full sized mooring cable.
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Opportunities for Development
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Strength to Weight
5000
7500
10000
12500
15000
17500
20000
22500
25000
100 110 120 130 140 150
Spiral Strand Diameter (mm)
MB
L (
kN)
DNV CN 2.5Bridon SPR2Bridon SPR2plusBridon Xtreme10% targettest resulttest resulttest result
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Fatigue Performance
-1.60
-1.40
-1.20
-1.00
-0.80
-0.60
-0.40
-0.20
0.00
2.00 3.00 4.00 5.00 6.00 7.00 8.00
Number of Cycles (log)
Rat
io o
f ten
sion
rang
e to
refe
renc
e br
eaki
ng s
treng
th (l
og) Spiral Strand
Six Strand Wire Rope
Common Chain Links
NRM = K
Where Log K = a – b.Lm
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Fatigue Performance
Test 1 Test 2
Conditions 30% ± 10% 20% ± 10%
Achieved N 384,650 808,279
Expected:
Spiral Strand 562,220 1,239,595
Six Strand Wire Rope
166,878 316,418
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Mode of Fatigue Failure
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Fatigue Performance
-1.60
-1.40
-1.20
-1.00
-0.80
-0.60
-0.40
-0.20
0.00
2.00 3.00 4.00 5.00 6.00 7.00 8.00
Number of Cycles (log)
Ra
tio o
f te
nsi
on
ra
ng
e to
re
fere
nce
bre
aki
ng
str
en
gth
(lo
g)
Spiral Strand
Six Strand Wire Rope
Common Chain Links
Xtreme Spiral Strand estimate
NRM = K
Where Log K = a – b.Lm
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Fatigue Performance
Conventional Grade
Spiral Strand
UHC-Si-Cr Grade Spiral
Strand
Six Strand Wire Rope
Fittings / Common
Chain
Life Span
1.8 x 106 yrs 1.2 x 106 yrs2.2 x 105
yrs9.45 x 104 yrs
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Commercial Application
• Three full scale mooring systems manufactured.
• Assessment of alternative applications.– Bridges– Structures
• Next stage of strength improvement initiated.
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The Development of Ultra-High Strength Wire
A joint development project by
and