Patent Grant
11414733
This is the U.S. National Phase application of PCT/JP2018/044835, filed Dec. 6, 2018 which claims priority to Japanese Patent Application No. 2017-248909, filed Dec. 26, 2017, the disclosures of these applications being incorporated herein by reference in their entireties for all purposes.
The present invention relates to a high-strength seamless steel pipe for oil wells and gas wells (hereinafter, also referred to simply as “oil country tubular goods”), specifically, a low-alloy high-strength seamless steel pipe for oil country tubular goods having excellent sulfide stress corrosion cracking resistance (SSC) in a sour environment containing hydrogen sulfide. As used herein, “high strength” means strength with a yield strength of 862 MPa or more (125 ksi or more).
Increasing crude oil prices and an expected shortage of petroleum resources in the near future have prompted active development of oil country tubular goods for use in applications that were unthinkable in the past, for example, such as in deep oil fields, and in oil fields and gas oil fields of hydrogen sulfide-containing severe corrosive environments, or sour environments as they are also called. The material of steel pipes for oil country tubular goods intended for these environments requires high strength, and excellent corrosion resistance (sour resistance).
Out of such demands, for example, PTL 1 discloses a steel for oil country tubular goods having excellent toughness and excellent sulfide stress corrosion cracking resistance. The steel is a low-alloy steel containing, in weight %, C: 0.15 to 0.30%, Si: 0.05 to 0.5%, Mn: 0.05 to 1%, Al: 0.005 to 0.5%, Cr: 0.2 to 1.5%, Mo: 0.1 to 1%, V: 0.05 to 0.3%, and Nb: 0.003 to 0.1%, and the balance Fe and incidental impurities. The steel also contains P: 0.025% or less, S: 0.01% or less, N: 0.01% or less, and O (oxygen): 0.01% or less as impurities. The total amount of precipitated carbide is 1.5 to 4 mass %, the fraction of MC carbide in the total carbide amount is 5 to 45 mass %, and the fraction of M23C6 carbide is (200/t) mass % or less, where t is the wall thickness (mm) of the product.
PTL 2 discloses a steel pipe having excellent sulfide stress corrosion cracking resistance. The steel pipe contains, in mass %, C: 0.22 to 0.35%, Si: 0.05 to 0.5%, Mn: 0.1 to 1%, P: 0.025% or less, S: 0.01% or less, Cr: 0.1 to 1.08%, Mo: 0.1 to 1%, Al: 0.005 to 0.1%, B: 0.0001 to 0.01%, N: 0.005% or less, O (oxygen): 0.01% or less, Ni: 0.1% or less, Ti: 0.001 to 0.03% and 0.00008/N % or less, V: 0 to 0.5%, Zr: 0 to 0.1%, and Ca: 0 to 0.01%, and the balance Fe and impurities. In the steel pipe, the number of TiN having a diameter of 5 μm or more is 10 or less per square millimeter of a cross section. The yield strength is 758 to 862 MPa, and the crack generating critical stress (6th) is 85% or more of the standard minimum strength (SMYS) of the steel material.
PTL 3 discloses a low-alloy steel for oil country tubular goods having excellent sulfide stress corrosion cracking resistance, and a yield strength of 861 MPa or more. The steel contains, in mass %, C: 0.2 to 0.35%, Si: 0.05 to 0.5%, Mn: 0.05 to 1.0%, P: 0.025% or less, S: 0.01% or less, Al: 0.005 to 0.10%, Cr: 0.1 to 1.0%, Mo: 0.5 to 1.0%, Ti: 0.002 to 0.05%, V: 0.05 to 0.3%, B: 0.0001 to 0.005%, N: 0.01% or less, and O: 0.01% or less, and specifies a predetermined value for a formula relating the half value width of the [211] plane of the steel to hydrogen diffusion coefficient.
The sulfide stress corrosion cracking resistance of the steels in the techniques disclosed in PTL 1 to PTL 3 is based on the presence or absence of SSC after a round tensile test specimen is dipped for 720 hours under a load of a certain stress in a test bath saturated with hydrogen sulfide gas, according to NACE (National Association of Corrosion Engineering)™0177, Method A.
In PTL 1, the test bath used for evaluation in an SSC test is a 25° C. aqueous solution containing 0.5% acetic acid and 5% salt saturated with 0.05 atm (=0.005 MPa) hydrogen sulfide. In PTL 2, the SSC test conducted for evaluation uses a 25° C. aqueous solution of 0.5% acetic acid and 5% salt as a test bath under a hydrogen sulfide partial pressure of 1 atm (=0.1 MPa) for C110. For C125-C140, the partial pressure of hydrogen sulfide is 0.1 atm (=0.01 MPa) because a 1-atm test environment is too severe. In PTL 3, the test baths used for evaluation in an SSC test are an ordinary-temperature aqueous solution of 5 mass % common salt and 0.5 mass % acetic acid saturated with 0.1 atm (=0.01 MPa) hydrogen sulfide gas (the balance is carbon dioxide gas) (hereinafter, “bath A”), and an ordinary temperature aqueous solution of 5 mass % common salt and 0.5 mass % acetic acid saturated with 1 atm (=0.1 MPa) hydrogen sulfide gas (the balance is carbon dioxide gas) (hereinafter, “bath B”). In Examples in Table 4 of PTL 3, steels that had a yield strength of 944 MPa or more are all evaluated with bath A in an SSC test. As exemplified above, the criterion for high-strength steels to pass an SSC test, particularly steels with a yield strength of 862 MPa or more, is whether the steels survive a test in a test bath saturated with 0.05 atm (=0.005 MPa) or 0.1 atm (=0.01 MPa) hydrogen sulfide gas, because an SSC test conducted under a hydrogen sulfide gas partial pressure of 1 atm (=0.1 MPa) would be too severe. However, in light of today's oil country tubular goods facing more severe hydrogen sulfide environments, steel pipes used for oil country tubular goods in such environments are required to have high strength and sulfide stress corrosion cracking resistance even in a severe environment saturated with 0.2 atm (=0.02 MPa) of hydrogen sulfide gas. The foregoing related art techniques are not satisfactory in this regard.
Aspects of the present invention have been made to provide a solution to the foregoing problems, and it is an object according to aspects of the present invention to provide a low-alloy high-strength seamless steel pipe for oil country tubular goods having high strength with a yield strength of 862 MPa or more, and excellent sulfide stress corrosion cracking resistance (SSC resistance) in an environment saturated with a high pressure of hydrogen sulfide gas, specifically, a sour environment with a hydrogen sulfide gas partial pressure of 0.02 MPa or less.
In order to find a solution to the foregoing problems, the present inventors conducted an SSC test according to NACE TM0177, method A, using seamless steel pipes of various chemical compositions having a yield strength of 862 MPa or more. Two types of 24° C. mixed aqueous solutions containing 0.5 mass % of CH3COOH and CH3COONa were used as test baths after saturating the solutions with 0.1 atm (=0.01 MPa) and 0.2 atm (=0.02 MPa) of hydrogen sulfide gas. Each test bath was adjusted so that it had a pH of 3.5 after the solution was saturated with hydrogen sulfide gas. The stress applied in the SSC test was 90% of the actual yield strength of the steel pipe. Three test specimens were tested in the SSC test of each steel pipe sample. The average time to failure for the three test specimens in an SSC test is shown in the graph of
In
None of the three test specimens broke at the time of 720 hours (solid circles)
At least one of the three test specimens broke, and the average time to failure was about 400 hours or more and less than 720 hours (solid triangles)
All of the three test specimens broke, and the average time to failure was about less than 400 hours (solid squares)
The present inventors conducted intensive studies of the differences observed in these SSC test results. The studies found that SSC initiated at different positions in steel pipes that had an average time to failure of 400 hours or more and less than 720 hours (solid triangles), and in steel pipes that had an average time to failure of less than 400 hours (solid squares). Specifically, observation of the fracture surface of the failure test specimen revealed that SSC initiated on the surface of the test specimen in steel pipes that had an average time to failure of 400 hours or more and less than 720 hours (solid triangles), whereas SSC initiated from inside of the test specimen in steel pipes that had an average time to break of less than 400 hours (solid squares).
Using these results, the present inventors conducted further studies, and found that these different behaviors of SSC vary with the distribution of inclusions in the steel. Specifically, for observation, a sample with a 15 mm×15 mm cross section across the longitudinal direction of the steel pipe was taken from a position in the wall thickness of the steel pipe from which an SSC test specimen had been taken for the test. After polishing the surface in mirror finish, the sample was observed for inclusions in a 10 mm×10 mm region using a scanning electron microscope (SEM), and the chemical composition of the inclusions was analyzed with a characteristic X-ray analyzer equipped in the SEM. The contents of the inclusions were calculated in mass %. It was found that most of the inclusions with a major diameter of 5 μm or more were oxides including Al2O3, CaO, and MgO, and a plot of the mass ratios of these inclusions on a ternary composition diagram of Al2O3, CaO, and MgO revealed that the oxide compositions were different for different behaviors of SSC.
From these results, a composition range was derived for inclusions that were abundant in the steel pipe that had an average time to break of 400 hours or more and less than 720 hours, and in which SSC occurred on a test piece surface, and for inclusions that were abundant in the steel pipe that had an average time to break of less than 400 hours, and in which SSC occurred from inside of the test piece. These were compared with the number of inclusions in the composition observed for the steel pipe in which SSC did not occur in 720 hours, and the upper limit was determined for the number of inclusions of interest.
Aspects of the present invention were completed on the basis of these findings, and are as follows.
[1] A low-alloy high-strength seamless steel pipe for oil country tubular goods,
the steel pipe having a yield strength of 862 MPa or more, and having a composition that contains, in mass %, C: 0.25 to 0.50%, Si: 0.01 to 0.40%, Mn: 0.45 to 0.90%, P: 0.010% or less, S: 0.001% or less, O: 0.0015% or less, Al: 0.015 to 0.080%, Cu: 0.02 to 0.09%, Cr: 0.9 to 1.5%, Mo: 1.4 to 2.0%, Nb: 0.005 to 0.05%, B: 0.0005 to 0.0040%, Ca: 0.0010 to 0.0020%, Mg: 0.001% or less, and N: 0.005% or less, and in which the balance is Fe and incidental impurities,
the steel pipe having a microstructure in which the number of oxide-base nonmetallic inclusions including CaO, Al2O3, and MgO and having a major diameter of 5 μm or more in the steel, and satisfying the composition ratios represented by the following formulae (1) and (2) is 5 or less per 100 mm2, and in which the number of oxide-base nonmetallic inclusions including CaO, Al2O3, and MgO and having a major diameter of 5 μm or more in the steel, and satisfying the composition ratios represented by the following formulae (3) and (4) is 20 or less per 100 mm2,
(CaO)/(Al2O3)≤0.25 (1)
1.0≤(Al2O3)/(MgO)≤9.0 (2)
(CaO)/(Al2O3)≥2.33 (3)
(CaO)/(MgO)≥1.0 (4)
wherein (CaO), (Al2O3), and (MgO) represent the contents of CaO, Al2O3, and MgO, respectively, in the oxide-base nonmetallic inclusions in the steel, in mass %.
[2] The low-alloy high-strength seamless steel pipe for oil country tubular goods according to item [1], wherein the composition further contains, in mass %, one or more selected from V: 0.02 to 0.3%, W: 0.03 to 0.2%, and Ta: 0.03 to 0.3%.
[3] The low-alloy high-strength seamless steel pipe for oil country tubular goods according to item [1] or [2], wherein the composition further contains, in mass %, one or two selected from Ti: 0.003 to 0.050%, and Zr: 0.005 to 0.10%.
As used herein, “high strength” means having strength with a yield strength of 862 MPa or more (125 ksi or more). As used herein, “excellent sulfide stress corrosion cracking resistance (SSC resistance)” means that three steel pipes subjected to an SSC test conducted according to NACE TM0177, method A all have a time to failure of 720 hours or more in a test bath, specifically, a 24° C. mixed aqueous solution of 0.5 mass % CH3COOH and CH3COONa saturated with 0.2 atm (=0.02 MPa) hydrogen sulfide gas.
As used herein, “oxides including CaO, Al2O3, and MgO” mean CaO, Al2O3, and MgO that remain in the solidified steel in the form of an aggregate or a composite formed at the time of casting such as continuous casting and ingot casting. Here, CaO is an oxide that generates by a reaction of the oxygen contained in a molten steel with calcium added for the purpose of, for example, controlling the shape of MnS in the steel. Al2O3 is an oxide that generates by a reaction of the oxygen contained in a molten steel with the deoxidizing material Al added when tapping the molten steel into a ladle after refinement by a method such as a converter process, or added after tapping the molten steel. MgO is an oxide that dissolves into a molten steel during a desulfurization treatment of the molten steel as a result of a reaction between a refractory having the MgO—C composition of a ladle, and a CaO—Al2O3—SiO2-base slug used for desulfurization.
Aspects of the present invention can provide a low-alloy high-strength seamless steel pipe for oil country tubular goods having high strength with a yield strength of 862 MPa or more, and excellent sulfide stress corrosion cracking resistance (SSC resistance) in an environment saturated with a high pressure of hydrogen sulfide gas, specifically, a sour environment having a hydrogen sulfide gas partial pressure of 0.02 MPa or less.
Embodiments of the present invention are described below in detail.
A low-alloy high-strength seamless steel pipe for oil country tubular goods according to aspects of the present invention has a yield strength of 862 MPa or more,
the steel pipe having a composition that contains, in mass %, C: 0.25 to 0.50%, Si: 0.01 to 0.40%, Mn: 0.45 to 0.90%, P: 0.010% or less, S: 0.001% or less, O: 0.0015% or less, Al: 0.015 to 0.080%, Cu: 0.02 to 0.09%, Cr: 0.9 to 1.5%, Mo: 1.4 to 2.0%, Nb: 0.005 to 0.05%, B: 0.0005 to 0.0040%, Ca: 0.0010 to 0.0020%, Mg: 0.001% or less, and N: 0.005% or less, and in which the balance is Fe and incidental impurities,
the steel pipe having a microstructure in which the number of oxide-base nonmetallic inclusions including CaO, Al2O3, and MgO and having a major diameter of 5 μm or more in the steel, and satisfying the composition ratios represented by the following formulae (1) and (2) is 5 or less per 100 mm2, and in which the number of oxide-base nonmetallic inclusions including CaO, Al2O3, and MgO and having a major diameter of 5 μm or more in the steel, and satisfying the composition ratios represented by the following formulae (3) and (4) is 20 or less per 100 mm2.
The composition may further contain, in mass %, one or more selected from V: 0.02 to 0.3%, W: 0.03 to 0.2%, and Ta: 0.03 to 0.3%. The composition may further contain, in mass %, one or two selected from Ti: 0.003 to 0.050%, and Zr: 0.005 to 0.10%.
(CaO)/(Al2O3)≤0.25 (1)
1.0≤(Al2O3)/(MgO)≤9.0 (2)
(CaO)/(Al2O3)≥2.33 (3)
(CaO)/(MgO)≥1.0 (4)
In the formulae, (CaO), (Al2O3), and (MgO) represent the contents of CaO, Al2O3, and MgO, respectively, in the oxide-base nonmetallic inclusions in the steel, in mass %.
The following describe the reasons for specifying the chemical composition of a steel pipe according to aspects of the present invention. In the following, “%” means percent by mass, unless otherwise specifically stated.
C: 0.25 to 0.50%
C acts to increase steel strength, and is an important element for providing the desired high strength. C needs to be contained in an amount of 0.25% or more to achieve the high strength with a yield strength of 862 MPa or more in accordance with aspects of the present invention. With C content of more than 0.50%, the hardness does not decrease even after high-temperature tempering, and sensitivity to sulfide stress corrosion cracking resistance greatly decreases. For this reason, the C content is 0.25 to 0.50%. The C content is preferably 0.26% or more, more preferably 0.27% or more. The C content is preferably 0.40% or less, more preferably 0.30% or less.
Si: 0.01 to 0.40%
Si acts as a deoxidizing agent, and increases steel strength by forming a solid solution in the steel. Si is an element that reduces rapid softening during tempering. Si needs to be contained in an amount of 0.01% or more to obtain these effects. With Si content of more than 0.40%, formation of coarse oxide-base inclusions occurs, and these inclusions become initiation points of SSC. For this reason, the Si content is 0.01 to 0.40%. The Si content is preferably 0.02% or more. The Si content is preferably 0.15% or less, more preferably 0.04% or less.
Mn: 0.45 to 0.90%
Mn is an element that increases steel strength by improving hardenability, and prevents sulfur-induced embrittlement at grain boundaries by binding and fixing sulfur in the form of MnS. In accordance with aspects of the present invention, Mn content of 0.45% or more is required. When contained in an amount of more than 0.90%, Mn seriously increases the hardness of the steel, and the hardness does not decrease even after high-temperature tempering. This seriously impairs the sensitivity to sulfide stress corrosion cracking resistance. For this reason, the Mn content is 0.45 to 0.90%. The Mn content is preferably 0.55% or more, more preferably 0.60% or more. The Mn content is preferably 0.85% or less, more preferably 0.80% or less.
P: 0.010% or Less
P segregates at grain boundaries and other parts of the steel in a solid solution state, and tends to cause defects such as cracking due to grain boundary embrittlement. In accordance with aspects of the present invention, P is contained desirably as small as possible. However, P content of at most 0.010% is acceptable. For these reasons, the P content is 0.010% or less. The P content is preferably 0.009% or less, more preferably 0.008% or less.
S: 0.001% or Less
Most of the sulfur elements exist as sulfide-base inclusions in the steel, and impair ductility, toughness, and corrosion resistance, including sulfide stress corrosion cracking resistance. Some of the sulfur may exist in the form of a solid solution. However, in this case, S segregates at grain boundaries and other parts of the steel, and tends to cause defects such as cracking due to grain boundary embrittlement. For this reason, S is contained desirably as small as possible in accordance with aspects of the present invention. However, excessively small sulfur amounts increase the refining cost. For these reasons, the S content in accordance with aspects of the present invention is 0.001% or less, an amount with which the adverse effects of sulfur are tolerable.
O (oxygen): 0.0015% or Less
O (oxygen) exists as incidental impurities in the form of oxides of elements such as Al, Si, Mg, and Ca. When the number of oxides having a major diameter of 5 μm or more and satisfying the composition ratios represented by (CaO)/(Al2O3)≤0.25, and 1.0≤(Al2O3)/(MgO)≤9.0 is more than 5 per 100 mm2, these oxides become initiation points of SSC that occurs on a test specimen surface, and breaks the specimen after extended time periods in an SSC test, as will be described later. When the number of oxides having a major diameter of 5 μm or more and satisfying the composition ratios represented by (CaO)/(Al2O3)≥2.33, and (CaO)/(MgO)≥1.0 is more than 20 per 100 mm2, these oxides become initiation points of SSC that occurs from inside of a test specimen, and breaks the specimen in a short time period in an SSC test. For this reason, the O (oxygen) content is 0.0015% or less, an amount with which the adverse effects of oxygen are tolerable. The O (oxygen) content is preferably 0.0012% or less, more preferably 0.0010% or less.
Al: 0.015 to 0.080%
Al acts as a deoxidizing agent, and contributes to reducing the solid solution nitrogen by forming AlN with N. Al needs to be contained in an amount of 0.015% or more to obtain these effects. With Al content of more than 0.080%, the cleanliness of the steel decreases, and, when the number of oxides having a major diameter of 5 μm or more and satisfying the composition ratios represented by (CaO)/(Al2O3)≤0.25, and 1.0≤(Al2O3)/(MgO)≤9.0 is more than 5 per 100 mm2, these oxides become initiation points of SSC that occurs on a test specimen surface, and breaks the specimen after extended time periods in an SSC test, as will be described later. For this reason, the Al content is 0.015 to 0.080%, an amount with which the adverse effects of Al are tolerable. The Al content is preferably 0.025% or more, more preferably 0.050% or more. The Al content is preferably 0.075% or less, more preferably 0.070% or less.
Cu: 0.02 to 0.09%
Cu is an element that acts to improve corrosion resistance. When contained in trace amounts, Cu forms a dense corrosion product, and reduces generation and growth of pits, which become initiation points of SSC. This greatly improves the sulfide stress corrosion cracking resistance. For this reason, the required amount of Cu is 0.02% or more in accordance with aspects of the present invention. Cu content of more than 0.09% impairs hot workability in manufacture of a seamless steel pipe. For this reason, the Cu content is 0.02 to 0.09%. The Cu content is preferably 0.07% or less, more preferably 0.04% or less.
Cr: 0.9 to 1.5%
Cr is an element that contributes to increasing steel strength by way of improving hardenability, and improves corrosion resistance. Cr also forms carbides such as M3C, M7C3, and M23C6 by binding to carbon during tempering. Particularly, the M3C-base carbide improves resistance to softening in tempering, reduces strength changes in tempering, and contributes to the improvement of yield strength. In this way, Cr contributes to improving yield strength. Cr content of 0.9% or more is required to achieve the yield strength of 862 MPa or more in accordance with aspects of the present invention. When contained in an amount of more than 1.5%, Cr seriously increases the hardness of the steel, and the hardness does not decrease even after high-temperature tempering. This seriously impairs the sensitivity to sulfide stress corrosion cracking resistance. For this reason, the Cr content is 0.9 to 1.5%. The Cr content is preferably 1.0% or more. The Cr content is preferably 1.3% or less.
Mo: 1.4 to 2.0%
Mo is an element that contributes to increasing steel strength by way of improving hardenability, and improves corrosion resistance. Particularly, Mo2C carbide, which is formed by secondary precipitation after tempering, improves resistance to softening in tempering, reduces strength changes in tempering, and contributes to the improvement of yield strength. In this way, Mo contributes to improving yield strength. Adding a specific amount of Mo in a steel having the yield strength of 862 MPa or more in accordance with aspects of the present invention also improves crack propagation resistance in sulfide stress corrosion cracking, particularly in a sour environment having a hydrogen sulfide gas partial pressure of 0.2 atm (0.02 MPa) or more, and provides high yield strength and high sulfide stress corrosion cracking resistance at the same time. The required Mo content for obtaining these effects is 1.4% or more. With Mo content of more than 2.0%, the Mo2C carbide coarsens, and causes SSC by creating initiation points of sulfide stress corrosion cracking. For this reason, the Mo content is 1.4 to 2.0%. The Mo content is preferably 1.5% or more. The Mo content is preferably 1.8% or less.
Nb: 0.005 to 0.05%
Nb is an element that delays recrystallization in the austenite (γ) temperature region, and contributes to refining γ grains. This makes niobium highly effective for refining of the lower microstructure (for example, packet, block, and lath) of steel immediately after quenching. Nb content of 0.005% or more is necessary for obtaining these effects. When contained in an amount of more than 0.05%, Nb seriously increases the hardness of the steel, and the hardness does not decrease even after high-temperature tempering. This seriously impairs the sensitivity to sulfide stress corrosion cracking resistance. For this reason, the Nb content is 0.005 to 0.05%. The Nb content is preferably 0.006% or more, more preferably 0.007% or more. The Nb content is preferably 0.030% or less, more preferably 0.010% or less.
B: 0.0005 to 0.0040%
B is an element that contributes to improving hardenability when contained in trace amounts. The required B content in accordance with aspects of the present invention is 0.0005% or more. B content of more than 0.0040% is economically disadvantageous because, in this case, the effect becomes saturated, or the expected effect may not be obtained because of formation of an iron borate (Fe—B). For this reason, the B content is 0.0005 to 0.0040%. The B content is preferably 0.0010% or more, more preferably 0.0015% or more. The B content is preferably 0.0030% or less, more preferably 0.0025% or less.
Ca: 0.0010 to 0.0020%
Ca is actively added to control the shape of oxide-base inclusions in the steel. As mentioned above, when the number of composite oxides having a major diameter of 5 μm or more and satisfying primarily Al2O3—MgO with a (Al2O3)/(MgO) ratio of 1.0 to 9.0 is more than 5 per 100 mm2, these oxides become initiation points of SSC that occurs on a test specimen surface, and breaks the specimen after extended time periods in an SSC test. In order to reduce generation of composite oxides of primarily Al2O3—MgO, aspects of the present invention require Ca content of 0.0010% or more. Ca content of more than 0.0020% causes increase in the number of oxides having a major diameter of 5 μm or more and satisfying the composition ratios represented by (CaO)/(Al2O3)≥2.33, and (CaO)/(MgO)≥1.0. These oxides become initiation points of SSC that occurs from inside of the test specimen, and breaks the specimen in a short time period in an SSC test. For this reason, the Ca content is 0.0010 to 0.0020%. The Ca content is preferably 0.0012% or more. The Ca content is preferably 0.0017% or less.
Mg: 0.001% or Less
Mg is not an actively added element. However, when reducing the S content in a desulfurization treatment using, for example, a ladle furnace (LF), Mg comes to be included as Mg component in the molten steel as a result of a reaction between a refractory having the MgO—C composition of a ladle, and CaO—Al2O3—SiO2-base slug used for desulfurization. As mentioned above, when the number of composite oxides having a major diameter of 5 μm or more and satisfying primarily Al2O3—MgO with an (Al2O3)/(MgO) ratio of 1.0 to 9.0 is more than 5 per 100 mm2, these oxides become initiation points of SSC that occurs on a test specimen surface, and breaks the specimen after extended time periods in an SSC test. For this reason, the Mg content is 0.001% or less, an amount with which the adverse effects of Mg is tolerable. The Mg content is preferably 0.0008% or less, more preferably 0.0005% or less.
N: 0.005% or Less
N is contained as incidental impurities in the steel, and forms MN-type precipitate by binding to nitride-forming elements such as Ti, Nb, and Al. The excess nitrogen after the formation of these nitrides also forms BN precipitates by binding to boron. Here, it is desirable to reduce the excess nitrogen as much as possible because the excess nitrogen takes away the hardenability improved by adding boron. For this reason, the N content is 0.005% or less. The N content is preferably 0.004% or less.
The balance is Fe and incidental impurities in the composition above.
In accordance with aspects of the present invention, one or more selected from V: 0.02 to 0.3%, W: 0.03 to 0.2%, and Ta: 0.03 to 0.3% may be contained in the basic composition above for the purposes described below. The basic composition may also contain, in mass %, one or two selected from Ti: 0.003 to 0.050%, and Zr: 0.005 to 0.10%.
V: 0.02 to 0.3%
V is an element that contributes to strengthening the steel by forming carbides or nitrides. V is contained in an amount of preferably 0.02% or more to obtain this effect. When the V content is more than 0.3%, the V-base carbides may coarsen, and cause SSC by forming initiation points of sulfide stress corrosion cracking. For this reason, vanadium, when contained, is contained in an amount of preferably 0.02 to 0.3%. The V content is more preferably 0.03% or more, further preferably 0.04% or more. The V content is more preferably 0.1% or less, further preferably 0.06% or less.
W: 0.03 to 0.2%
W is also an element that contributes to strengthening the steel by forming carbides or nitrides. W is contained in an amount of preferably 0.03% or more to obtain this effect. When the W content is more than 0.2%, the W-base carbides may coarsen, and cause SSC by forming initiation points of sulfide stress corrosion cracking. For this reason, tungsten, when contained, is contained in an amount of preferably 0.03 to 0.2%. The W content is more preferably 0.07% or more. The W content is more preferably 0.1% or less.
Ta: 0.03 to 0.3%
Ta is also an element that contributes to strengthening the steel by forming carbides or nitrides. Ta is contained in an amount of preferably 0.03% or more to obtain this effect. When the Ta content is more than 0.3%, the Ta-base carbides may coarsen, and cause SSC by forming initiation points of sulfide stress corrosion cracking. For this reason, tantalum, when contained, is contained in an amount of preferably 0.03 to 0.3%. The Ta content is more preferably 0.08% or more. The Ta content is more preferably 0.2% or less.
Ti: 0.003 to 0.050%
Ti is an element that forms nitrides, and that contributes to preventing coarsening due to the pinning effect of austenite grains during quenching of the steel. Ti also improves sensitivity to hydrogen sulfide cracking resistance by making austenite grains smaller. Particularly, the austenite grains can have the required fineness without repeating quenching (Q) and tempering (T) two to three times, as will be described later. Ti is contained in an amount of preferably 0.003% or more to obtain these effects. When the Ti content is more than 0.050%, the coarsened Ti-base nitrides may cause SSC by forming initiation points of sulfide stress corrosion cracking. For this reason, titanium, when contained, is contained in an amount of preferably 0.003 to 0.050%. The Ti content is more preferably 0.005% or more, further preferably 0.010% or more. The Ti content is more preferably 0.025% or less, further preferably 0.018% or less.
Zr: 0.005 to 0.10%
As with titanium, Zr forms nitrides, and improves sensitivity to hydrogen sulfide cracking resistance by preventing coarsening due to the pinning effect of austenite grains during quenching of the steel. This effect becomes more prominent when Zr is added with titanium. Zr is contained in an amount of preferably 0.005% or more to obtain these effects. When the Zr content is more than 0.10%, the coarsened Zr-base nitrides or Ti—Zr composite nitrides may cause SSC by forming initiation points of sulfide stress corrosion cracking. For this reason, zirconium, when contained, is contained in an amount of preferably 0.005 to 0.10%. The Zr content is more preferably 0.013% or more. The Zr content is more preferably 0.026% or less.
The following describes the inclusions in the steel with regard to the microstructure of the steel pipe according to aspects of the present invention.
Number of Oxide-Base nonmetallic inclusions including CaO, Al2O3, and MgO and having major diameter of 5 μm or more in the steel, and satisfying composition ratios represented by the following formulae (1) and (2) is 5 or less per 100 mm2
(CaO)/(Al2O3)≤0.25 (1)
1.0≤(Al2O3)/(MgO)≤9.0 (2)
In the formulae, (CaO), (Al2O3), and (MgO) represent the contents of CaO, Al2O3, and MgO, respectively, in the oxide-base nonmetallic inclusions in the steel, in mass %.
As described above, an SSC test was conducted for three test specimens from each steel pipe sample in each test bath for which a 24° C. mixed aqueous solution of 0.5 mass % CH3COOH and CH3COONa saturated with 0.02 MPa hydrogen sulfide gas was used, and that had an adjusted pH of 3.5 after the solution was saturated with the target pressure of hydrogen sulfide gas. The stress applied in the SSC test was 90% of the actual yield strength of the steel pipe. As shown in
Number of Oxide-Base nonmetallic inclusions including CaO, Al2O3, and MgO and having major diameter of 5 μm or more in the Steel, and satisfying composition ratios represented by the following formulae (3) and (4) is 20 or less per 100 mm2
(CaO)/(Al2O3)≥2.33 (3)
(CaO)/(MgO)≥1.0 (4)
In the formulae, (CaO), (Al2O3), and (MgO) represent the contents of CaO, Al2O3, and MgO, respectively, in the oxide-base nonmetallic inclusions in the steel, in mass %.
As described above, an SSC test was conducted for three test specimens from each steel pipe sample in each test bath for which a 24° C. mixed aqueous solution of 0.5 mass % CH3COOH and CH3COONa saturated with 0.02 MPa hydrogen sulfide gas was used, and that had an adjusted pH of 3.5 after the solution was saturated with the target pressure of hydrogen sulfide gas. The stress applied in the SSC test was 90% of the actual yield strength of the steel pipe. As shown in
The following describes a method for manufacturing the low-alloy high-strength seamless steel pipe for oil country tubular goods having excellent sulfide stress corrosion cracking resistance (SSC resistance).
In accordance with aspects of the present invention, the method of production of a steel pipe material of the composition above is not particularly limited. For example, a molten steel of the foregoing composition is made into steel using an ordinary steel making process such as by using a converter, an electric furnace, and a vacuum melting furnace, and formed into a steel pipe material, for example, a billet, using an ordinary method such as continuous casting, and ingot casting-blooming.
In order to achieve the specified number of oxide-base nonmetallic inclusions including CaO, Al2O3, and MgO and having a major diameter of 5 μm or more and the two compositions above in the steel, it is preferable to perform a deoxidation treatment using Al, immediately after making a steel using a commonly known steel making process such as by using a converter, an electric furnace, or a vacuum melting furnace. In order to reduce S (sulfur) in the molten steel, it is preferable that the deoxidation treatment be followed by a desulfurization treatment such as by using a ladle furnace (LF), and that the N and O (oxygen) in the molten steel be reduced with a degassing device, before adding Ca, and finally casting the steel. It is preferable that the concentration of the impurity including Ca in the raw material alloy used for the LF and degassing process be controlled and reduced as much as possible so that the Ca concentration in the molten steel after degassing and before addition of Ca falls in a range of 0.0004 mass % or less. When the Ca concentration in the molten steel before addition of Ca is more than 0.0004 mass %, the Ca concentration in the molten steel undesirably increases when Ca is added in the appropriate amount [% Ca*] in the Ca adding process described below. This increases the number of CaO—Al2O3—MgO composite oxides having a high CaO ratio, and a (CaO)/(MgO) ratio of 1.0 or more. These oxides become initiation points of SSC, and SSC occurs from inside of the test specimen in a short time period, and breaks the specimen in an SSC test. When adding Ca in the Ca adding process after degassing, it is preferable to add Ca in an appropriate concentration (an amount relative to the weight of the molten steel; [% Ca*]) according to the oxygen [% T.O] value of the molten steel. For example, an appropriate Ca concentration [% Ca*] can be decided according to the oxygen [% T.O] value of molten steel derived after an analysis performed immediately after degassing, using the following formula (5).
0.63≤[% Ca*]/[% T.O]≤0.91 (5)
Here, when the [% Ca*]/[% T.O] ratio is less than 0.63, it means that the added amount of Ca is too small, and, accordingly, there will be an increased number of composite oxides of primarily Al2O3—MgO having a small CaO ratio, and a (Al2O3)/(MgO) ratio of 1.0 to 9.0, even when the Ca value in the steel pipe falls within the range according to aspects of the present invention. These oxides become initiation points of SSC, and SSC occurs on a test specimen surface after extended time periods, and breaks the specimen in an SSC test. When the [% Ca*]/[% T.O] ratio is more than 0.91, there will be an increased number of CaO—Al2O3—MgO composite oxides having a high CaO ratio, and a (CaO)/(MgO) ratio of 1.0 or more. These oxides become initiation points of SSC, and SSC occurs from inside of the test specimen in a short time period, and breaks the specimen in an SSC test.
The resulting steel pipe material is formed into a seamless steel pipe by hot forming. A commonly known method may be used for hot forming. In exemplary hot forming, the steel pipe material is heated, and, after being pierced with a piercer, formed into a predetermined wall thickness by mandrel mill rolling or plug mill rolling, before being hot rolled into an appropriately reduced diameter. Here, the heating temperature of the steel pipe material is preferably 1,150 to 1,280° C. With a heating temperature of less than 1,150° C., the deformation resistance of the heated steel pipe material increases, and the steel pipe material cannot be properly pierced. When the heating temperature is more than 1,280° C., the microstructure seriously coarsens, and it becomes difficult to produce fine grains during quenching (described later). The heating temperature is preferably 1,150° C. or more, and is preferably 1,280° C. or less. The heating temperature is more preferably 1,200° C. or more. The rolling stop temperature is preferably 750 to 1, 100° C. When the rolling stop temperature is less than 750° C., the applied load of the reduction rolling increases, and the steel pipe material cannot be properly formed. When the rolling stop temperature is more than 1,100° C., the rolling recrystallization fails to produce sufficiently fine grains, and it becomes difficult to produce fine grains during quenching (described later). The rolling stop temperature is preferably 900° C. or more, and is preferably 1,080° C. or less. From the viewpoint of producing fine grains, it is preferable in accordance with aspects of the present invention that the hot rolling be followed by direct quenching (DQ).
After being formed, the seamless steel pipe is subjected to quenching (Q) and tempering (T) to achieve the yield strength of 862 MPa or more in accordance with aspects of the present invention. From the viewpoint of producing fine grains, the quenching temperature is preferably 930° C. or less. When the quenching temperature is less than 860° C., secondary precipitation hardening elements such as Mo, V, W, and Ta fail to sufficiently form solid solutions, and the amount of secondary precipitates becomes insufficient after tempering. For this reason, the quenching temperature is preferably 860 to 930° C. The tempering temperature needs to be equal to or less than the Ac1 temperature to avoid austenite retransformation. However, the carbides of Mo, V, W, or Ta fail to precipitate in sufficient amounts in secondary precipitation when the tempering temperature is less than 600° C. For this reason, the tempering temperature is preferably 600° C. or more. Particularly, the final tempering temperature is preferably 630° C. or more, more preferably 650° C. or more. In order to improve sensitivity to hydrogen sulfide cracking resistance through formation of fine grains, it is preferable to repeat quenching (Q) and tempering (T) at least two times. Quenching (Q) and tempering (T) is repeated preferably at least three times when Ti and Zr are not added. When DQ is not applicable after hot rolling, it is preferable to produce the effect of DQ by compound addition of Ti and Zr, or by repeating quenching (Q) and tempering (T) at least three times with a quenching temperature of 950° C. or more, particularly for the first quenching.
Aspects of the present invention are described below in greater detail through Examples. It should be noted that the present invention is not limited by the following Examples.
The steels of the compositions shown in Table 1 were prepared using a converter process. Immediately after Al deoxidation, the steels were subjected to secondary refining in order of LF and degassing, and Ca was added. Finally, the steels were continuously cast to produce steel pipe materials. Here, high-purity raw material alloys containing no impurities including Ca were used for Al deoxidation, LF, and degassing, with some exceptions. After degassing, molten steel samples were taken, and analyzed for Ca in the molten steel. The analysis results are presented in Tables 2-1 and 2-2. With regard to the Ca adding process, a [% Ca*]/[% T.O] ratio was calculated, where [% T.O] is the analyzed value of oxygen in the molten steel, and [% Ca*] is the amount of Ca added with respect to the weight of molten steel. The results are presented in Tables 2-1 and 2-2.
The steels were subjected to two types of continuous casting: round billet continuous casting that produces a round cast piece having a circular cross section, and bloom continuous casting that produces a cast piece having a rectangular cross section. The cast piece produced by bloom continuous casting was reheated at 1,200° C., and rolled into a round billet. In Tables 2-1 and 2-2, the round billet continuous casting is denoted as “directly cast billet”, and a round billet obtained after rolling is denoted as “rolled billet”. These round billet materials were hot rolled into seamless steel pipes with the billet heating temperatures and the rolling stop temperatures shown in Tables 2-1 and 2-2. The seamless steel pipes were then subjected to heat treatment at the quenching (Q) temperatures and the tempering (T) temperatures shown in Tables 2-1 and 2-2. Some of the seamless steel pipes were directly quenched (DQ), whereas other seamless steel pipes were subjected to heat treatment after being air cooled.
After the final tempering, a sample having a 15 mm×15 mm surface for investigation of inclusions was obtained from the center in the wall thickness of the steel pipe at an arbitrarily chosen circumferential location at an end of the steel pipe. A tensile test specimen and an SSC test specimen were also taken. For the SSC test, three test specimens were taken from each steel pipe sample. These were evaluated as follows.
The sample for investigating inclusions was mirror polished, and observed for inclusions in a 10 mm×10 mm region, using a scanning electron microscope (SEM). The chemical composition of the inclusions was analyzed with a characteristic X-ray analyzer equipped in the SEM, and the contents were calculated in mass %. Inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (1) and (2), and inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (3) and (4) were counted. The results are presented in Tables 2-1 and 2-2.
The tensile test specimen was subjected to a JIS Z2241 tensile test, and the yield strength was measured. The yield strengths of the steel pipes tested are presented in Tables 2-1 and 2-2. Steel pipes that had a yield strength of 862 MPa or more were determined as being acceptable.
The SSC test specimen was subjected to an SSC test according to NACE TM0177, method A. A 24° C. mixed aqueous solution of 0.5 mass % CH3COOH and CH3COONa saturated with 0.2 atm (=0.02 MPa) hydrogen sulfide gas was used as a test bath. The test bath was adjusted so that it had a pH of 3.5 after the solution was saturated with hydrogen sulfide gas. The stress applied in the SSC test was 90% of the actual yield strength of the steel pipe. The test was conducted for 720 hours. For samples that did not break at the time of 720 hours, the test was continued until the pipe broke, or 900 hours. The time to failure for the three SSC test specimens of each steel pipe is presented in Tables 2-1 and 2-2. Steels were determined as being acceptable when all of the three test pieces had a time to break of 720 hours or more in the SSC test.
0.52
0.23
0.91
0.42
0.011
0.0018
0.0018
0.087
1.8
0.7
0.0022
0.0003
2.1
0.9
0.061
0.0002
0.0018
0.0055
B
E
O
38
132
181
22
245
6
698
13
688
631
594
397
419
446
P
Q
R
S
T
U
V
W
X
Y
Z
AA
AB
AC
AD
773
442
497
554
788
121
294
447
622
668
21
54
117
181
7
681
688
705
389
403
466
764
297
488
541
187
203
244
503
517
633
749
11
671
688
761
The yield strength was 862 MPa or more, and the time to failure for all the three test specimens tested in the SSC test was 720 hours or more in the present examples (steel pipe No. 1-1, and steel pipe Nos. 1-6 to 1-14) that had the chemical compositions within the range of the present invention, and in which the number of inclusions having a major diameter of 5 μm or more and a composition satisfying the formulae (1) and (2), and the number of inclusions having a major diameter of 5 μm or more and a composition satisfying the formulae (3) and (4) fell within the ranges of the present invention.
In contrast, at least two of the three test specimens tested in the SSC test broke within 720 hours in Comparative Example (steel pipe No. 1-2) in which the Ca in the chemical composition was above the range of the present invention, and in Comparative Example (steel pipe No. 1-3) in which the number of inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (3) and (4) fell outside the range of the present invention because of the high Ca concentration in the molten steel after degassing, and the [% Ca*]/[% T.O] ratio of more than 0.91 after the addition of calcium.
At least one of the three test specimens tested in the SSC test broke within 720 hours in Comparative Example (steel pipe No. 1-4) in which the number of inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (1) and (2) fell outside the range of the present invention because of the [% Ca*]/[% T.O] ratio of less than 0.63 after the addition of calcium, and in Comparative Example (steel pipe No. 1-5) in which Ca was below the range of the present invention.
All of the three test specimens tested in the SSC test broke within 720 hours in Comparative Examples (steel pipe Nos. 1-15, 1-17, 1-23, 1-25, and 1-27) in which C, Mn, Cr, Mo, and Nb in the chemical composition were above the ranges of the present invention, and, as a result, the steel pipes maintained their high strength even after high-temperature tempering.
Comparative Examples (steel pipes No. 1-16, 1-18, 1-24, and 1-28) in which C, Mn, Cr, and B in the chemical composition were below the ranges of the present invention failed to achieve the target yield strength.
In Comparative Example (steel pipe No. 1-26) in which Mo was below the ranges of the present invention, the steel had insufficient crack propagation resistance against sulfide stress corrosion cracking, and all of the three test specimens tested in the SSC test broke within 720 hours.
At least two of the three test specimens tested in the SSC test broke within 720 hours in Comparative Examples (steel pipe Nos. 1-19 and 1-20) in which P and S in the chemical composition were above the ranges of the present invention.
All of the three test specimens tested in the SSC test broke within 720 hours in Comparative Example (steel pipe No. 1-21) in which O (oxygen) in the chemical composition was above the range of the present invention, and in which the number of inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (1) and (2), and the number of inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (3) and (4) fell outside the ranges of the present invention.
All of the three test specimens tested in the SSC test broke within 720 hours in Comparative Example (steel pipe No. 1-22) in which Al in the chemical composition was above the range of the present invention, and in which the number of inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (1) and (2) fell outside the range of the present invention.
Two of the three test specimens tested in the SSC test broke within 720 hours in Comparative Example (steel pipe No. 1-29) in which Mg in the chemical composition was above the range of the present invention, and in which number of inclusions having a major diameter of 5 μm or more and a composition satisfying formulae (1) and (2) fell outside the range of the present invention.
In Comparative Example (steel pipe No. 1-30) in which N in the chemical composition was above the range of the present invention, the excess nitrogen formed BN with boron, and the hardenability was poor due to an insufficient amount of solid solution boron. Accordingly, this steel pipe failed to achieve the target yield strength.
The steels of the compositions shown in Table 3 were prepared using a converter process. Immediately after Al deoxidation, the steels were subjected to secondary refining in order of LF and degassing, and Ca was added. Finally, the steels were continuously cast to produce steel pipe materials. Here, high-purity raw material alloys containing no impurities including Ca were used for Al deoxidation, LF, and degassing, with some exceptions. After degassing, molten steel samples were taken, and analyzed for Ca in the molten steel. The analysis results are presented in Tables 4-1 and 4-2. With regard to the Ca adding process, a [% Ca*]/[% T.O] ratio was calculated, where [% T.O] is the analyzed value of oxygen in the molten steel, and [% Ca*] is the amount of Ca added with respect to the weight of molten steel. The results are presented in Tables 4-1 and 4-2.
The steels were cast by round billet continuous casting that produces a round cast piece having a circular cross section. The round billet materials were hot rolled into seamless steel pipes with the billet heating temperatures and the rolling stop temperatures shown in Tables 4-1 and 4-2. The seamless steel pipes were then subjected to heat treatment at the quenching (Q) temperatures and the tempering (T) temperatures shown in Tables 4-1 and 4-2. Some of the seamless steel pipes were directly quenched (DQ), whereas other seamless steel pipes were subjected to heat treatment after being air cooled.
After the final tempering, a sample having a 15 mm×15 mm surface for investigation of inclusions was obtained from the center in the wall thickness of the steel pipe at an arbitrarily chosen circumferential location at an end of the steel pipe. A tensile test specimen and an SSC test specimen were also taken. For the SSC test, three test specimens were taken from each steel pipe sample. These were evaluated as follows.
The sample for investigating inclusions was mirror polished, and observed for inclusions in a 10 mm×10 mm region, using a scanning electron microscope (SEM). The chemical composition of the inclusions was analyzed with a characteristic X-ray analyzer equipped in the SEM, and the contents were calculated in mass %. Inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (1) and (2), and inclusions having a major diameter of 5 μm or more and satisfying the composition ratios of formulae (3) and (4) were counted. The results are presented in Tables 4-1 and 4-2.
The tensile test specimen was subjected to a JIS Z2241 tensile test, and the yield strength was measured. The yield strengths of the steel pipes tested are presented in Tables 4-1 and 4-2. Steel pipes having a yield strength of 862 MPa or more were determined as being acceptable.
The SSC test specimen was subjected to an SSC test according to NACE TM0177, method A. A 24° C. mixed aqueous solution of 0.5 mass % CH3COOH and CH3COONa saturated with 0.2 atm (=0.02 MPa) hydrogen sulfide gas was used as a test bath. The test bath was adjusted so that it had a pH of 3.5 after the solution was saturated with the target pressure of hydrogen sulfide gas. The stress applied in the SSC test was 90% of the actual yield strength of the steel pipe. The test was conducted for 720 hours. For samples that did not break in 720 hours, the test was continued until the pipe broke, or 900 hours. The time to failure for the three SSC test specimens of each steel pipe is presented in Tables 4-1 and 4-2. Steels were determined as being acceptable when all of the three test specimens had a time to break of 720 hours or more in the SSC test.
The yield strength was 862 MPa or more, and the time to failure for all the three test specimens tested in the SSC test was 720 hours or more in the present examples (steel pipes No. 2-1 to 2-20) that had the chemical compositions within the range of the present invention, and in which the number of inclusions having a major diameter of 5 μm or more and a composition satisfying the formulae (1) and (2), and the number of inclusions having a major diameter of 5 μm or more and a composition satisfying the formulae (3) and (4) fell within the ranges of the present invention, and thus, the steel pipes (No. 2-1 to 2-20) were acceptable.
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| PCT/JP2018/044835 | 12/6/2018 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2019/131035 | 7/4/2019 | WO | A |
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