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WO2008018980A2 - Utilisation de traitement par friction-malaxage et choc laser dans des applications pour pétrole et gaz et pétrochimiques - Google Patents

Utilisation de traitement par friction-malaxage et choc laser dans des applications pour pétrole et gaz et pétrochimiques Download PDF

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Publication number
WO2008018980A2
WO2008018980A2 PCT/US2007/016495 US2007016495W WO2008018980A2 WO 2008018980 A2 WO2008018980 A2 WO 2008018980A2 US 2007016495 W US2007016495 W US 2007016495W WO 2008018980 A2 WO2008018980 A2 WO 2008018980A2
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WIPO (PCT)
Prior art keywords
component
components
oil
structures
chosen
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PCT/US2007/016495
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English (en)
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WO2008018980A3 (fr
Inventor
Glen A. Vaughn
Narasimha-Rao Venkata Bangaru
Jayoung Koo
Raghavan Ayer
Danny Lee Beeson
Neeraj Srinivas Thirumalai
David Alan Baker
David Ashley Norman
Steven Jeffery Ford
Douglas Paul Fairchild
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Exxonmobil Research And Engineering Company
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Priority claimed from US11/499,800 external-priority patent/US20080032152A1/en
Application filed by Exxonmobil Research And Engineering Company filed Critical Exxonmobil Research And Engineering Company
Publication of WO2008018980A2 publication Critical patent/WO2008018980A2/fr
Publication of WO2008018980A3 publication Critical patent/WO2008018980A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
    • C21D10/005—Modifying the physical properties by methods other than heat treatment or deformation by laser shock processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding involving metallurgical change
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/009—Working by laser beam, e.g. welding, cutting or boring using a non-absorbing, e.g. transparent, reflective or refractive, layer on the workpiece

Definitions

  • the present invention relates generally to the field of friction stir and laser shock processing. More specifically, the present invention relates to the application of friction stir and laser shock processing to improve fatigue life of parts and structures used in the oil and gas and petrochemical industries. Still more specifically, the present invention relates to the application of combined friction stir and laser shock processing of welds, weld repairs and treatment of metal parts, particularly but not exclusively, ferrous and non-ferrous metal parts, to provide distinguished properties such as surface strength, high fatigue resistance, high toughness, surface hardness, stress corrosion resistance, environmental cracking resistance and the like.
  • CRA Corrosion resistant alloys. A specially formulated material used for completion components likely to present corrosion problems. Corrosion- resistant alloys may be formulated for a wide range of aggressive conditions.
  • HAZ Heat-affected-zone.
  • Heat-affected-zone Base metal that is adjacent to the weld line and that was affected by the heat of welding.
  • Toughness Resistance to fracture initiation.
  • Fatigue Failure under cyclic loading.
  • Fretting fatigue Fretting involves contact between surfaces undergoing small cyclic relative tangential motion. Fretting fatigue resistance is resistance to fracture in a notched metal parts or metal parts with holes.
  • Yield Strength Ability to bear load without deformation.
  • FSW Friction stir welding
  • Friction Stir Welding A solid state joining process for creating a welded joint between two work pieces in which the heat for joining the metal work pieces is generated by plunging a rotating pin of a tool between the work pieces.
  • FSP Friction stir processing
  • Friction stir processing The method of processing and conditioning the surface of a structure by pressing a FSW tool against the surface by partially plunging a pin into the structure.
  • Laser shock peening or processing Using a laser to generate shock waves at the surface of a metal part either to produce compressive stresses and/or to reduce tensile stresses near the surface to improve the fatigue life, stress corrosion cracking, and other properties of the metal part.
  • LSP Laser shock peening or processing.
  • Shot peening Bombarding metal parts with tiny metal or ceramic beads to reduce tensile residual stresses near the surface to improve the fatigue life of the metal part.
  • SCR Steel catenary riser. A deepwater steel riser suspended in a single catenary from a platform and connected horizontally on the seabed.
  • TTR Top tension riser. A riser on offshore oil rigs which is placed in tension to maintain even pressure on marine riser pipe.
  • Weld joint A welded joint including the fused or thermo- mechanically altered metal and the base metal in the "near vicinity" of, but beyond the fused metal.
  • the portion of the base metal that is considered within the "near vicinity" of the fused metal varies depending on factors known to those in the welding art.
  • Weldment An assembly of component parts joined by welding.
  • Weldability The feasibility of welding a particular metal or alloy. A number of factors affect weldability including chemistry, surface finish, heat- treating tendencies and the like.
  • Hydrogen cracking Cracking that occurs in the weld subsequent to welding.
  • Stress corrosion cracking Cracking induced from the combined influence of tensile stress and a corrosive environment.
  • TMAZ Thermo-mechanically affected zone.
  • Thermo-mechanically affected zone Region of the joint that has experienced both temperature cycling and plastic deformation.
  • TMAZ-HZ The hardest region of a FSW joint.
  • LNG Liquefied natural gas. Gas, mainly methane, liquefied under atmospheric pressure and low temperature.
  • CNG Compressed natural gas. Natural gas in high-pressure surface containers that is highly compressed (though not to the point of liquefaction).
  • PLNG Pressurized liquefied natural gas. Gas, mainly methane, liquefied under moderate pressure and low temperature (higher temperature than LNG).
  • Invar An alloy of iron and nickel specifically designed to have low coefficient of thermal expansion
  • Duplex Steel consisting of two phases, specifically austenite and ferrite
  • Trees The assembly of valves, pipes, and fittings used to control the flow of oil and gas from a well.
  • BOP Blow Out Preventer. The equipment installed at the wellhead to control pressures in the annular space between the casing and drill pipe or tubing during drilling, completion, and work over operations.
  • OCTG Oil Country Tubular Goods. A term applied to casing, tubing, plain-end casing liners, pup joints, couplings, connectors and plain-end drill pipe.
  • Jack-up rigs Mobile drilling platform with retractable legs used in shallow waters less than 100 meters deep.
  • TLP Tension Leg Platform. A floating offshore structure held in position by a number of tension-maintaining cables anchored to seabed. Cables dampen wave action to keep platform stationary.
  • DDCV Deep Draft Caisson Vessel. Deep draft surface piercing cylinder type of floater, particularly well adapted to deepwater, which accommodates drilling, top tensioned risers and dry completions.
  • Compliant towers Narrow, flexible towers and a piled foundation supporting a conventional deck for drilling and production operations. Designed to sustain significant lateral deflections and forces, and are typically used in water depths ranging from 1,500 to 3,000 feet (450 to 900 m).
  • FPSO Floating Production Storage and Offloading vessel. A converted or custom-built ship-shaped floater, employed to process oil and gas and for temporary storage of the oil prior to transshipment.
  • FSO Floating Storage and Offloading vessel.
  • a floating storage device usually for oil, commonly used where it is not possible or efficient to lay a pipe-line to the shore.
  • the production platform will transfer the oil to the FSO where it will be stored until a tanker arrives and connects to the FSO to offload it
  • Tendons Tubular tethers that permanently moor a floating platform attached at each of the structure's corners.
  • Umbilicals An assembly of hydraulic hoses which can also include electrical cables or optic fibers, used to control a subsea structure or ROV from a platform or a vessel.
  • Tender vessels A support/supply ship for carrying passengers and supplies to and from facilities close to shore.
  • U.S. Patent Application No. 60/763,101 to Bangaru et al. discloses a novel method for welding and repairing cracks in metal parts by subjecting the metal parts to be welded to friction stir welding and the cracks to be repaired to friction stir processing. This method for rapidly welding high carbon steels minimizes grain coarsening in the HAZ and weldment cracking in the absence of an open flame as is utilized in conventional welding techniques. Friction stir welding and friction stir processing are conducted under conditions sufficient to provide a weld joint or crack repair having a preselected property or set of properties based upon the intended use of the weldment.
  • U.S. Patent Application No. 60/763,101 is incorporated herein by reference in its entirety.
  • fusion welding of high strength pipeline steels and other ferrous components used in the oil & gas and petrochemical industry invariably introduces residual tensile stresses and softening in a narrow zone in the heat- affected-zone. These factors degrade both the toughness and the fatigue resistance of the welded joints because residual tensile stresses increase the propensity for surface-initiated cracks. Due to residual tensile stresses, the welded joints in steels and corrosion resistant alloys are also susceptible to environmental cracking in corrosive environments. In off shore oil drilling platforms, conventional welding of steel catenary risers (SCRs) and top tension risers (TTRs) result in high tensile residual stresses.
  • SCRs steel catenary risers
  • TTRs top tension risers
  • liquefied natural gas (LNG) and pressurized liquefied natural gas (PLNG) containers also include high integrity weldments that have residual tensile stresses that negatively affect the fatigue resistance and toughness in the weld areas.
  • an advantageous method of treating ferrous or non-ferrous alloy components comprises the steps of providing an opaque overlay on said component and a transparent overlay on top of said opaque overlay to form a coated component, laser shock processing said coated component to produce a coated and treated component having at least one laser shock processed component region having compressive residual stress, removing said opaque overlay and said transparent overlay from said coated and treated component to form a treated component, and employing said treated component in oil/gas and/or petrochemical applications.
  • Another aspect of the present disclosure relates to an advantageous oil/gas and/or petrochemical ferrous or non-ferrous material component comprising two or more segments of ferrous or non-ferrous material components, friction stir weldments bonding adjacent segments of said components together, and laser shock peened surfaces having compressive residual stress surrounding the friction stir weldments.
  • Another aspect of the present disclosure relates to an advantageous oil/gas and/or petrochemical ferrous or non-ferrous material component comprising two or more segments of ferrous or non-ferrous material components, fusion weldments bonding adjacent segments of the components together, and laser shock peened surfaces having compressive residual stress surrounding the fusion weldments.
  • a further aspect of the present disclosure relates to an advantageous oil/gas and/or petrochemical ferrous or non-ferrous material component comprising one or more segments of ferrous or non-ferrous material components, and at least one laser shock processed component region having compressive residual stress on the surface of the one or more segments of the components.
  • a further aspect of the present disclosure relates to an advantageous oil/gas and/or petrochemical ferrous or non-ferrous material component comprising two or more segments of ferrous or non-ferrous material components, a combination of friction and fusion weldments bonding adjacent segments of said components together, and laser shock peened surfaces having compressive residual stress surrounding the combination of friction and fusion weldments.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications results in compressive residual stresses near the surface of the treated part.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications results in decreased grain thickness near the surface of the treated part relative to the bulk structure.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications exhibits improved fatigue life.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications exhibits improved stress corrosion cracking resistance and environmental cracking resistance.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications is effective in arresting pre-existing cracks.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications is effective in improving surface strength and surface hardening properties of the component.
  • the disclosed use of LSP in steel and corrosion resistant alloy structures for oil and gas exploration, producing, and petrochemical applications provides for lower grades of steel and corrosion resistant alloy materials to be qualified for service and/or a decrease in the structural thickness of treated regions.
  • Figure 1 depicts a plot of compressive residual stresses as a function of depth after laser shock peening A656 grade 1 steel.
  • Figure 2 depicts electron back scattered diffraction (EBSD) images of the microstructure of A656 steel (a) in the bulk region (unpeened) and (b) in the surface region (LSP treated).
  • EBSD electron back scattered diffraction
  • Figure 3 depicts the surface hardness of A656 steel before and after laser shock peening.
  • the present disclosure relates to the use of friction stir and laser shock processing in oil and gas exploration, producing, and petrochemical applications to improve the fatigue life, stress corrosion resistance, environmental cracking resistance and other properties of critical regions of steels and corrosion resistant alloys subjected to FSP/LSP treatment.
  • FSP/LSP treatment in oil and gas exploration, producing, and petrochemical applications is distinguishable over the prior art in providing for conventional and friction stir welds, conventional and friction stir weld repairs, and treatment of critical regions of structures to yield improved properties and performance.
  • LSP Laser shock peening or processing
  • a high-energy, pulsed Neodymium-glass laser or yttrium aluminum garnet (YAG) crystal lasing rod producing a very short pulse (from about 14 to 30 nanoseconds long) and a wavelength of about 1.06 ⁇ m with an energy per pulse of about 50 joules or more is directed from the laser through a chain of mirrors and lenses onto the surface of the part being treated.
  • the surface of the metal part to be treated via LSP is first covered with two types of overlays.
  • the first type of overlay on the surface of the part is an opaque overlay which is opaque to the laser beam.
  • the opaque overlay may be, but is not limited to, a black coating, black paint, lead, aluminum, copper, and zinc.
  • the type of opaque overlay may be used to tailor the shape and amplitude of the stress waves generated via LSP.
  • Black paint is a particularly preferred opaque overlay.
  • the second type of overlay is positioned on top of the opaque overlay, and may be any material that is transparent to the laser beam.
  • the transparent overlay may be, but is not limited to, water, quartz and K7 glass. The surface area of the metal part to be treated with LSP is first coated with an opaque overlay, and then coated with the transparent overlay.
  • the laser beam is then directed onto the surface of the metal part and passes through the transparent overlay and strikes the opaque overlay where it immediately vaporizes the opaque overlay.
  • the vapor or plasma generated from the opaque overlay then absorbs the incoming laser energy and rapidly heats and expands against the surface of the metal part to be treated and the transparent overlay.
  • the transparent overlay functions to trap the thermally expanding vapor or plasma against the surface of the metal part to be treated, and results in the pressure rising to a much higher level than if the transparent overlay were not present.
  • the trapped vapor or plasma builds to a pressure of up to 100,000 atmospheres.
  • the sudden, high pressure against the surface of the metal part to be treated causes a shock wave to propagate into the metal part to be treated, and if the peak stress of the shock wave is above the dynamic yield strength of the material, the metal part yields and plastically deforms. As the stress wave propagates deeper into the metal, the peak stress of the wave decreases, but deformation of the metal continues until the peak stress falls below the dynamic yield strength of the metal.
  • the shock wave generated by the laser and the coated metal part gives rise to compressive residual stresses at the surface of the metal part to be treated.
  • the peak pressure generated during LSP treatment may be controlled by changing the power density of the laser beam.
  • the peak pressure generated is proportional to the square root of the peak power density.
  • the power density may range from 0.1 to IXlO 4 depending upon the laser type, the treated material type and the depth of residual compressive stresses desired.
  • LSP variable parameters include, but are not limited to, laser power density, spot size, and pulse width.
  • the shape of the spot treated on the metal part with the laser is generally round, but other shapes may be used to provide more efficient and effective processing conditions.
  • the size of the area of the metal part to be treated with LSP with one pulse depends on number of material, laser and processing factors.
  • the spot size may range from about 0.1 inch to about 1 inch in diameter.
  • a typical spot size is generally from about 0.24 to about 0.35 inches in diameter.
  • a single laser beam is directed onto the area of the metal part to be treated.
  • the laser beam may be split into two beams of equal intensity, and these beams are used to strike opposite sides of the part simultaneously.
  • thin sections of metal parts to be treated may be treated from one side only by using a back-up support for the side of the metal part not being treated.
  • the size of the area of the metal part to be treated depends on the part design and the service conditions.
  • a metal part may require that only a small area be LSP treated and a single treated spot may be sufficient, for example around small oil, pin, or bolt holes, or at the root of a notch in the side of a thin section.
  • the metal part may require that a large area be LSP treated, for example around the circumference of a weld line joining two pipes or a weld line joining two shafts of deep water oil drill bit. In these cases, successive spots are overlapped until the circumference has been completely treated with LSP. Generally in treating areas larger than 1 centimeter (0.39 inches) in diameter, overlapping spots are needed.
  • the high-energy, pulsed Neodymium-glass laser for use in LSP may be positioned in close proximity to the work station where the metal parts to be treated are held and manipulated during LSP.
  • a metal part is placed in a work station by loading it into a fixture, and then the part and fixture are moved into the proper position relative to the laser for LSP.
  • the laser beam is directed into the work station, treating the desired spot on the metal part.
  • the metal part is then either moved to the next position for the following spot to be treated or is removed from the work station and replaced with the next part to be treated.
  • the steps of part pick-up, positioning, LSP, and part removal may be performed automatically, for example, via robotic means.
  • the laser may be transported to a field area, for example to pipeline or drilling platform areas where it may be used to treat the weld area after joining two pieces of pipeline or two pieces of drill shafts.
  • the laser as opposed to the part to be treated may be repositioned following the LSP of a spot on the metal part.
  • the circumference of a weld line in a pipeline or drill shaft may be treated via LSP by rotating the laser around the circumference of the circular part. Spot overlap is again utilized to provide for complete treatment of the weld area.
  • Laser peening treatment decreases the grain size/thickness of the steel or corrosion resistant alloy near the surface region which induces a plastic strain relative to the bulk of the structure.
  • the relative deformation of the surface region relative to the bulk region of the structure results in the generation of residual compressive stresses near the surface of the metal part.
  • These residual stresses may be measured using x-ray diffraction techniques by measuring the spacing of the crystallographic lattice planes at the surface of the metal part relative to the unstressed crystal lattice of the same materials not subjected to LSP. Tension increases the spacing between the lattice planes and compression decreases the spacing between the lattice planes.
  • the distribution of the residual stress below the metal surface is determined by successively removing a thin layer from the surface by electropolishing and then making x-ray measurements of the new surface. This incremental process is continued down to the maximum depth of interest, generally from about 0.020 to about 0.050 inches in depth.
  • the actual depths of the LSP-induced compressive stresses will vary depending on the type and intensity of the laser processing conditions and the properties of the metal to be treated. With LSP, the residual compressive stresses are generally highest at the surface and decrease gradually with increasing
  • the distribution of the residual stresses below the surface is generally much deeper for LSP than it is for shot peening.
  • the depth of compressive stresses induced with shot peening is generally less than 0.010 inches as opposed to 0.10 inches with LSP or an order of magnitude deeper with LSP.
  • the properties improved by the introduction of residual compressive stresses induced by LSP treatment include, but are not limited to, surface strength, fatigue life, fretting fatigue resistance, stress corrosion resistance, fatigue cracking resistance, environmental/corrosion cracking resistance, and surface hardness.
  • the compressive residual stresses imparted by LSP prevent cracks from growing in metal structures, and hence improve the part's fatigue life.
  • the compressive residual stresses are effective for reducing both fatigue cracks, environmental/corrosion cracks.
  • LSP is useful in treating critical regions of ferrous materials, preferably for treating the critical regions of steels and cast irons, and more preferably for treating high carbon steels having a CE equal to or greater than 0.48.
  • Exemplary, but not limiting, plain carbon and alloy steels include, AISI 1010, 1020, 1040, 1080, 1095, A36, A516, A440, A633, A656, 4063, 4340, and 6150.
  • high carbon steels include, AISI WI, SI, 01, A2, D2, Ml, and API L80.
  • LSP is useful in treating ferrous corrosion resistant alloys, including but not limited to, stainless steel.
  • Exemplary, but not limiting, stainless steels include, AISI 409, 446, 304, 316L, 410, 440A, 17-7PH and duplex s.s.
  • LSP is useful in treating non-ferrous alloys, including but not limited to, titanium alloys, cobalt alloys, iron-nickel alloys, and nickel alloys.
  • the critical regions of ferrous or non-ferrous material components include, but are not limited to, notch areas, areas surrounding bolt and pin holes, and at the root of a notch in the side of a thin sections.
  • LSP is used following conventional fusion welding methods in the weldment area to improve the aforementioned properties in the surface region of the weld, and hence improve the integrity and fatigue properties of the fusion weld.
  • LSP is used following friction stir welding methods in the weldment area to improve the aforementioned properties in the surface region of the weld, and hence improve the integrity and fatigue properties of the friction stir weld.
  • FSW and LSP are used in combination to improve the service life of welded structures used in the oil and gas exploration, production, and refining industries, as well as the petrochemical industry. More particularly, FSW is used to make the weld followed by LSP being used to treat the weld area to reduce residual tensile stresses by creating residual compressive stresses near the surface of the friction stir weld area.
  • the benefits of FSW and FSP are primarily derived from the following characteristics: (1) lower temperatures required to perform the joining and lower temperatures in the joint cause less detrimental effects in the adjoining base metal (e.g. coarse grains); (2) high degree of plastic deformation resulting from the rotation of the tool which results in fine grain size which is conducive to improved strength and toughness; and (3) avoidance of hydrogen embrittlement in weldments as compared to fusion welds, which are often prone to hydrogen embrittlement from the decomposition of the residual moisture in the arc.
  • FSW and FSP friction stir processing methods described herein may be used to form welds, for example as spot welds and butt welds, as well as to repair weld areas. More particularly, FSW and FSP may be used to join and repair/treat respectively structures and structural components associated with the oil and gas industry.
  • the joining via FSW may be performed either in a manufacturing facility such as a steel mill where the components are made or in the -field of fabrication yard where the components are assembled.
  • the repair and treatment via FSP is generally made in the field.
  • the resultant structures exhibit superior mechanical integrity and, in many instances, may be joined and repaired/treated at a lower cost.
  • FSW in combination with LSP may be used in the welding of duplex stainless steels (duplex s.s. or DSS).
  • Duplex s.s. derives its strength and corrosion resistance from a controlled balance of ferrite and austenite phases.
  • the desired mixture of phases in the bulk duplex s.s. may be achieved by controlled hot working and /or a combination of cold working and annealing treatments.
  • the steel is heated to a very high temperature in a single phase ferrite region and cools to the duplex phase upon cooling to room temperature.
  • the cooling rate of the weld has to be controlled.
  • FSW of duplex s.s. may provide a more consistent phase balance since the temperature of the joints may be more precisely controlled, and in particular may be done at a lower temperature in the two phase region, thus consistently yielding an acceptable microstructure and resultant properties.
  • the weldment is subjected to LSP to further enhance the aforementioned surface properties of the weld area.
  • LSP is used following friction stir repair of cracks in the repair area to improve the aforementioned properties in the surface region of the repair, and therefore improve the integrity and fatigue properties of the repair area.
  • LSP is used following a combination of friction stir and fusion welding methods in the weldment area to improve the aforementioned properties in the surface region of the weld, and hence improve the integrity and fatigue properties of the friction stir weld. More particularly, the steel is welded first using fusion welding or other conventional welding method known to have a high rate of productivity. Following high throughput fusion welding, the fusion line and HAZ of the welds may be processed by FSW. This reduces and potentially eliminates the HAZ and the tensile residual stresses in the near surface regions.
  • the combination of fusion welding and friction stir welding enhances the integrity of the joint with regard to resistance to hydrogen embrittlement, fatigue, etc. without sacrificing productivity since bulk of the welding is performed by conventional methods and only the critical subsurface regions are processed by FSW. Following the combination of fusion welding and friction stir welding of the weldment, it is subjected to LSP to further enhance the aforementioned surface properties of the weld area.
  • LSP is used to treat critical regions of ferrous and non-ferrous material structures used in the oil and gas exploration, production, and transport industries, as well as the petrochemical industry.
  • Exemplary, but non-limiting, structures in the oil and gas exploration, production, refining industry where LSP treatment is useful by itself or in combination with conventional fusion welding or friction stir welding joining and repair techniques are high strength pipeline weld areas, SCR and TTR weld areas, threaded components, oil drilling equipment weld areas (i.e. two sections of a deep water oil drill string), LNG and PLNG container weld areas, riser/casing joints, and well head equipment.
  • LSP treatment reduces residual tensile stresses and softening in the HAZ for fusion welded high strength pipelines used to transport oil and gas. LSP improves the integrity of the weld or joint which correspondingly increases the toughness and fatigue resistance of the welded joints.
  • the LSP and FSW/FSP methods disclosed herein are suitable for forming and repairing/treating structures in oil and gas exploration, production and refining applications.
  • FSW is particularly advantageous for forming spot welds and butt welds of tubular components in these types of applications.
  • the LSP and FSW/FSP methods disclosed herein are suitable for joining and repairing structures and components used in natural gas transportation and storage type applications.
  • the LSP and FSW/FSP methods disclosed herein may be utilized to enable gas transportation technologies ranging from pipelines, compressed natural gas (CNG), pressurized liquefied natural gas (PLNG), liquefied natural gas (LNG) and other storage/transportation technologies.
  • the LSP and FSW/FSP methods disclosed herein may be used for the joining/processing of pipelines, flow lines, gathering lines, transmission lines, expansion loops, and other transmission lines.
  • the LSP and FSW/FSP methods disclosed herein may be used for joining / processing of materials made of carbon steels, cast irons, structural steels, or corrosion resistant alloys comprising steels, cast irons, stainless steels, duplex stainless steels, nickel or cobalt base based alloys, other Fe-Ni alloys (e.g. Invar) or joining of other dissimilar metals (e.g. steel and nickel).
  • the LSP and FSW/FSP methods disclosed herein may be used for the joining / processing of LNG, CNG, and PLNG storage and/or transportation structures. This includes modular LNG structures, shipping vessels, transferring components and pipelines, and related technologies (e.g. Al tanks, 9% Ni tanks, Invar tanks).
  • LSP and FSW/FSP methods disclosed herein also may be utilized for joining and repairing various structures used for oil and gas well completion and production.
  • These structures include, but are not limited to, offshore and onshore production structures, oil pipelines, oil storage tanks, casing/tubing, completion and production components, cast structure to flow line connections, subsea components, downhole tubular products (OCTG), topsides and related structures, umbilicals, tender and supply vessels, and flare towers.
  • exemplary offshore production structures include jacketed platforms, mobile offshore drilling units and related production components like casings, tendons, risers, and subsea facilities.
  • Mobile offshore drilling units include, but are not limited to, semi-submersibles and jack-up rigs, TLPs, DDCVs, compliant towers, FPSO, FSO, ships, tankers and the like.
  • Exemplary subsea components include, but are not limited to, duplex, manifold systems, trees, and BOPs.
  • Exemplary topsides and related structures include deck superstructures, drilling rigs, living quarters, helidecks, and related structures. It should be understood that LSP/FSW may be used to form the welds comprising such structures and components and LSP/FSP may be used to repair and treat the welds or joints comprising such structures.
  • the LSP and FSW/FSP methods disclosed herein are suitable for joining and repairing structures and components used in- refining and chemical plants.
  • the LSP and FSW/FSP methods provide advantages in the refining and chemicals plant applications through, inter alia, repair of components/structures, dissimilar metal joining, joining of steel structures and joining of difficult to weld materials, such as cast iron.
  • These applications include, but are not limited to, cast iron, heat exchanger tubes and low and high-temperature process and pressure vessels.
  • Exemplary low and high-temperature process and pressure vessels include steam cracker tubes, steam reforming tubes, and refinery structures and components.
  • FIG. 1 is a plot of the compressive residual stresses induced by LSP treatment as a function of depth from the surface for A656 grade 1 steel for laser power densities of 8 and 10 GW/cm 2 . Residual stresses were measured using the 3D-Energy Dispersive X-ray Diffraction (3D-EDXRD) method. The residual compressive stresses increase as a function of the laser power density utilized.
  • 3D-EDXRD 3D-Energy Dispersive X-ray Diffraction
  • FIG. 1 shows the electron back scattered diffraction (EBSD) images of the microstructure of bulk A656 steel (a) in the bulk region (nonpeened) and (b) the surface region (after laser shock peening). From an examination of the microstructure of bulk A656 in figure (a), the average grain thickness was 3.4 micrometers. In contrast, the microstructure of the laser peened surface region (50 micrometers from the surface) of (b) depicts an average grain thickness of 1.8 micrometers. This shows that due to LSP treatment, the grains near the surface were deformed to a plastic strain of approximately 50%.
  • EBSD electron back scattered diffraction
  • Figure 3 depicts the surface hardness of A656 steel before and after laser shock peening. It shows that the surface region has work hardened and has a higher hardness with respect to the bulk due to LSP treatment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
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Abstract

L'invention concerne l'utilisation du traitement par friction-malaxage et choc laser dans des applications pour pétrole et gaz et/ou pétrochimiques. L'utilisation comprend l'opération consistant à soumettre des assemblages soudés par friction-malaxage, des assemblages soudés par fusion, et d'autres régions critiques de composants d'alliage ferreux et non ferreux utilisés dans des applications pour pétrole et gaz et pétrochimiques à un traitement par choc laser pour créer des contraintes de compression résiduelles près de la surface de la zone traitée. Les forces de compression résiduelles dans les composants ferreux ou non ferreux améliorent des propriétés comprenant, entre autres, la résistance superficielle, l'endurance, la dureté superficielle, la résistance à la corrosion par contrainte, la résistance à la fatigue et la résistance à la fissuration en milieu corrosif. Le traitement par friction-malaxage et choc laser trouve une application particulière dans des pipelines haute résistance, des colonnes montantes à caténaire en acier, des colonnes montantes à tension supérieure, des composants filetés, des contenants pour gaz naturel liquéfié, des contenants pour gaz naturel liquéfié sous pression, des trains de tiges pour pétrole en eaux profondes, des joints pour colonnes montantes/boîtiers, et équipement de tête de puits.
PCT/US2007/016495 2006-08-04 2007-07-20 Utilisation de traitement par friction-malaxage et choc laser dans des applications pour pétrole et gaz et pétrochimiques WO2008018980A2 (fr)

Applications Claiming Priority (4)

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US11/499,800 US20080032152A1 (en) 2006-08-04 2006-08-04 Use of laser shock processing in oil & gas and petrochemical applications
US11/499,800 2006-08-04
US11/643,526 US20080032153A1 (en) 2006-08-04 2006-12-21 Use of friction stir and laser shock processing in oil & gas and petrochemical applications
US11/643,526 2006-12-21

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Cited By (4)

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CN110284084A (zh) * 2019-06-28 2019-09-27 江苏理工学院 一种高强耐磨铝合金板塑性成形方法
US20220162723A1 (en) * 2019-03-27 2022-05-26 Osaka University Surface-modifying method for steel material and steel structure
CN115026431A (zh) * 2022-07-05 2022-09-09 山东科技大学 一种高抗腐蚀疲劳镍铝青铜表面微纳多尺度梯度结构的构建方法
US20240100624A1 (en) * 2018-08-28 2024-03-28 MELD Manufacturing Corporation Solid-state joining of features to cast parts

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20240100624A1 (en) * 2018-08-28 2024-03-28 MELD Manufacturing Corporation Solid-state joining of features to cast parts
US20220162723A1 (en) * 2019-03-27 2022-05-26 Osaka University Surface-modifying method for steel material and steel structure
CN110284084A (zh) * 2019-06-28 2019-09-27 江苏理工学院 一种高强耐磨铝合金板塑性成形方法
CN110284084B (zh) * 2019-06-28 2021-09-28 江苏理工学院 一种高强耐磨铝合金板塑性成形方法
CN115026431A (zh) * 2022-07-05 2022-09-09 山东科技大学 一种高抗腐蚀疲劳镍铝青铜表面微纳多尺度梯度结构的构建方法

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