Patent Application
20140175069
The present invention relates to a method of manufacturing a steel pipe (or tube, hereinafter referred to as a laser welded steel pipe) by welding longitudinal edges of an open pipe together using a laser beam, and particularly to a method of manufacturing a laser welded steel pipe appropriate for drilling and transporting oil or natural gas, such as oil country tubular goods or a line pipe.
Steel pipes used as oil country tubular goods or line pipes are broadly divided into welded steel pipes (for example, electric resistance welded steel pipes, UOE steel pipes, and other pipes) and seamless steel pipes. Among these steel pipes, electric resistance welded steel pipes are advantageous from an economical point of view because they can be manufactured at a low cost by using belt-like steel strips formed by hot rolling (so called hot rolled steel coils) as a starting material.
However, a typical electric resistance welded steel pipe inevitably includes a joint (a so-called seam) caused by welding because the electric resistance welded steel pipe is manufactured by forming a steel strip into a cylindrical shape using forming rolls to form an open pipe (here, an open pipe refers to a pipe-shaped strip formed by multiple forming rolls and having unwelded edges and such a pipe is referred to as an open pipe, below) and performing electric resistance welding (also referred to as high-frequency resistance welding) on edges of the open pipe (i.e., both side edges of the cylindrically formed steel strip) while pressing the open pipe with squeeze rolls. Such a seam has a problem of poor low-temperature toughness. Thus, oil country tubular goods or a line pipe employing an electric resistance welded steel pipe is difficult to use in a cold district. The reason why such a seam has poor low-temperature toughness is because, while edges are being welded together, the high-temperature molten metal reacts with atmospheric oxygen and forms an oxide, which is likely to remain in the seam.
The electric resistance welded steel pipe has another problem in that the corrosion resistance of the seam is likely to be deteriorated because an alloy element in the molten metal is likely to segregate while the edges are being welded together. Thus, oil country tubular goods or line pipes employing electric resistance welded steel pipes are difficult to use in a severe corrosion environment (for example, sour environment).
Meanwhile, welding with laser beams (hereinafter referred to as laser welding) has been receiving attention as a welding method with which the low-temperature toughness and the corrosion resistance of the seam are not deteriorated. With the laser welding, a heat source can have a small size and high-density heat energy can be converged. The laser welding thus can prevent an oxide from being formed in the molten metal or an alloy element from segregating in the molten metal. Thus, when the laser welding is employed in the manufacturing of welded steel pipes, the low-temperature toughness and the corrosion resistance of the seam can be prevented from being deteriorated.
Thus, a technology for manufacturing steel pipes (or steel tubes, i.e., laser welded steel pipes) by emitting laser beams onto the edges of open pipes to weld the edges together has been put into practice during manufacturing of welded steel pipes.
The laser welding, however, is performed by irradiating a weld portion with a laser beam, which is a high-energy density light beam, converged by an optical component and causes a metal to melt rapidly. Thus, the molten metal scatters from the formed molten weld pool as spatter. The scattered spatter adheres to welding equipment, thereby degrading the quality of the seam. Concurrently, the spatter also adheres to the optical component, making the welding operation unstable. Since laser welding is performed by converging high-density heat energy, a large amount of spatter is formed, causing welding defects such as occurrence of undercut or underfill (or depression). If underfill occurs in a weld portion, the strength of the weld portion is reduced.
In view of these problems, various technologies for preventing adherence of spatter or occurrence of spattering during laser welding have been studied. For example, a technology for preventing the occurrence of spattering by reducing laser power or by changing a focus position by a large degree (that is, by defocusing) has been put into practice. Reduction of laser power or defocusing, however, not only leads to reduction of welding speed (i.e., reduction of weld efficiency) but also involves a problem of making lack of penetration more likely to occur.
Patent Literature 1 discloses a technology for preventing occurrence of spattering by dividing a laser beam into multiple laser beam spots. However, the laser welding technology using multiple laser beam spots into which a laser beam is divided is similar to the laser welding technology with a lower laser power. Thus, such a technology involves not only reduction of weld efficiency but also a problem of making lack of penetration more likely to occur. Furthermore, since prisms that divide laser beams are expensive, the cost of the welding operation inevitably increases.
Patent Literature 2 discloses a technology for preventing underfill of deposit metal from occurring by using a filler wire during laser welding. With this technology, however, the components of the filler wire change the composition of the weld metal. Thus, an appropriate filler wire has to be selected in accordance with the components of open pipes, thereby increasing the burden of stock management of filler wires or production control of laser welding.
Patent Literature 3 discloses a technology for preventing welding defects by using laser welding and arc welding together. This technology, however, makes the structure of welding equipment complex, thereby increasing the burden of not only maintenance but also management of the welding operation.
[PTL 1] Japanese Unexamined Patent Application Publication No. 7-214361
[PTL 2] Japanese Unexamined Patent Application Publication No. 2004-330299
[PTL 3] Japanese Unexamined Patent Application Publication No. 2004-223543
The present invention provides a method of efficiently manufacturing a high-quality laser welded steel pipe at a high yield ratio while occurrence of undercut or underfill is prevented by appropriately arranging multiple portions (that is, spots) to be heated and melted by irradiation of multiple laser beams and appropriately keeping each spot diameter or each spot length on the upper surface (steel strip surface) of an open pipe so that the energy density on the outer surface of the open pipe is controlled during the manufacture of a laser welded steel pipe.
The inventors investigated and studied a stabilization technology for stabilizing a welding phenomenon during laser welding when a laser welded steel pipe is to be manufactured by performing laser welding on edges of an open pipe.
The keyhole 4 indicates a position at which the heat energy of a laser beam 3 converges the most. By positioning a junction between the edges within the keyhole 4, a laser welded steel pipe can be stably manufactured. However, a highly precise positioning technology is required to make the junction between the edges 2 coincide with the keyhole 4. If the processing state of the edges 2 or the butting state of the edges 2 is unstable, the molten metal 5 is made unstable. Consequently, spattering occurs frequently and welding defects such as undercut or underfill are more likely to occur. In view of these problems, the energy density of a laser beam with which the junction between the edges 2 is irradiated is adjusted. For energy density adjustment, the spot diameter, the spot shape, and the number of spots of the laser beam are appropriately maintained or the focus position of the laser beam is changed. In addition, the laser beam is emitted to a position out of the junction.
Adjusting forms of spots in this manner is a technique that can be executed by manufacturing an appropriate collection lens or collection mirror.
The present invention is made in view of these findings.
Specifically, the present invention provides a method of manufacturing a laser welded steel pipe by forming a steel strip into a cylindrical open pipe with forming rolls and performing welding on edges of the open pipe by emitting a laser beam onto the edges from an outer surface side of the open pipe while pressing the edges with squeeze rolls, the method comprising: performing welding using a plurality of laser beams each having a spot diameter 0.3 mm or larger on an upper surface of the open pipe (a surface of a steel strip), the plurality of laser beams being arranged such that the sum of spot diameters (hereinafter referred to as spot lengths) of the plurality of laser beams, the spot lengths extending perpendicularly to a welding line, on the surface of the steel strip is 0.5 mm or larger and such that a distance between spot centers of the plurality of laser beams in a direction of the welding line falls within 5 mm.
In the method of manufacturing a laser welded steel pipe according to the present invention, it is preferable that an energy density of each of the laser beams on an outer surface of the open pipe be 70 kW/mm2 or smaller. It is also preferable that a focus position of each of the laser beams be positioned 3T to −3T away from an outer surface of the open pipe where a thickness of the open pipe is denoted by T. It is also preferable that the sum of laser power of the plurality of laser beams be 15 kW or more and a welding speed be 7 m/min or more. It is preferable that each of the laser beams is emitted at a lead angle of 5 to 50° (an angle from a direction perpendicular to the pipe surface to a direction opposite to the welding direction is referred to as a lead direction). It is preferable that the open pipe have a thickness T exceeding 3 mm. It is preferable that an upset of 0.3 to 1.0 mm is applied to the edges of the open pipe when the edges are pressed with the squeeze rolls.
It is also preferable that, when a trailing beam of the laser beams is arranged in the direction of the welding line, a lead angle of the trailing beam be smaller than a lead angle of a leading beam of the laser beams.
According to the present invention, a laser welded steel pipe can be stably manufactured at a high yield ratio while occurrence of undercut or underfill is prevented by appropriately arranging multiple portions (that is, spots) to be heated and melted by irradiation of multiple laser beams and appropriately keeping each spot diameter or each spot length on the upper surface (steel strip surface) of an open pipe so that the energy density on the outer surface of the open pipe is controlled during the manufacture of a laser welded steel pipe. The obtained laser welded steel pipe has a seam that is excellent in terms of low-temperature toughness and corrosion resistance and is thus appropriate for oil country tubular goods or a line pipe used in a cold district or corrosion environment.
In the present invention, a laser welded steel pipe is manufactured by using multiple laser beams.
(1) Positions on Open Pipe Upper Surface (Steel Strip Surface) to which Laser Beams are Emitted and Position of Edges
a) illustrates positions to which two laser beams are emitted, specifically, laser beams 3-1 and 3-2 having the same spot diameter are arranged on both sides of the edges 2.
b) illustrates positions to which three laser beams are emitted, specifically, a laser beam 3-1 having a small spot diameter is used for preheating and laser beams 3-2 and 3-3 having the same spot diameter are arranged on both sides of the edges 2.
c) illustrates positions to which four laser beams are emitted, specifically, laser beams 3-1, 3-2, 3-3, and 3-4 having the same spot diameter are arranged on both sides of the edges 2, two beams on each side.
d) illustrates positions to which two laser beams are emitted, specifically, laser beams 3-1 and 3-2 having different spot diameters are arranged on both sides of the edges 2. In this example, since the laser beam 3-1 has a small spot diameter, the laser beam 3-1 is positioned closer to the edges 2 than the laser beam 3-2 is.
e) illustrates positions to which two laser beams are emitted, where laser beams 3-1 and 3-2 are arranged along the edges 2. In this example, the laser beam 3-2 has a small spot diameter
Arrangement of laser beams in the case of using multiple laser beams is not limited to the examples illustrated in
It is preferable to use multiple laser beams each having a spot diameter 0.3 mm or larger on the upper surface of an open pipe (steel strip surface). This is because, if the spot diameter is smaller than 0.3 mm, it is difficult to stably maintain a keyhole. The upper limit of the spot diameter on the open pipe upper surface (steel strip surface) is 1.0 mm.
As illustrated in
It is preferable that the energy density of each laser beam 3 on the outer surface of the open pipe 1 be 70 kW/mm2 or lower. The lower limit of the energy density is set to be 1 kW/mm2 or more to prevent the penetration property from being reduced because the penetration property would be reduced if a laser beam 3 is simply defocused. However, if the energy density exceeds 70 kW/mm2, the amount of spatter generated from the outer surface of the open pipe 1 increases. Here, the energy density of each laser beam 3 is adjusted by controlling the laser power and the spot diameter.
(5) Distance from Upper Surface of Open Pipe (Steel Strip Surface) to Focus Position
The distance from the upper surface of the open pipe to the focus position is denoted by t (mm) and the thickness of the steel strip of the open pipe is denoted by T (mm). If the distance t from the upper surface of the open pipe to the focus exceeds 3×T (specifically, 3T upward from the upper surface), the position of the focus is too high, making it difficult to stably maintain the keyhole. On the other hand, if the distance t exceeds −3×T (specifically, 3T downward from the upper surface), the position of the focus is too low, making spatter more likely to be generated from the back surface of the steel strip (i.e., the inner side of the open pipe). Thus, the distance t from the upper surface of the open pipe to the focus is preferably set within the range from −3×T to 3×T. Here, it is preferable that the distance from the upper surface of the steel strip to the focus for the leading laser beam 3a and the distance from the upper surface of the steel strip to the focus for the trailing laser beam 3b coincide with each other in terms of the stability of a keyhole.
Preferably, the thickness T of the open pipe 1 exceeds 3 mm. If the thickness T is 3 mm or smaller, burn-through is likely to occur.
Generally, the amount of spatter that is formed during laser welding decreases as the laser power is reduced and as the welding speed is reduced. However, adjusting the laser power and the welding speed for the purpose of preventing spattering from occurring leads to reduction in productivity of laser welded steel pipes. This adjustment also makes it more likely that blowholes will occur. Thus, from the view points of improvement in productivity and reduction of blowholes, it is preferable that the sum of the laser power of multiple laser beams 3 be set to be 15 kW or more and the welding speed be set at 7 m/min or higher. If the sum of the laser power is less than 15 kW, the welding speed is reduced to less than 7 m/min, thereby leading to reduction in productivity and occurrence of blowholes.
Preferably, the distance between the focuses of the laser beams 3 is 200 mm or larger. If the distance between the focuses is smaller than 200 mm, laser welding is performed unstably because the focus positions fluctuate in the Z axis direction of the edges 2 of the open pipe 1 (i.e., the direction of the optical axes of the laser beams).
As illustrated in
It is preferable to apply an upset of 0.3 to 1.0 mm to edge portions 2 in order to prevent occurrence of undercut or underfill because it is difficult to completely prevent occurrence of spattering due to laser welding. If the upset length is below 0.3 mm, undercut or underfill cannot be prevented from occurring. On the other hand, if the upset length exceeds 1.0 mm, it takes a long time to maintain the seam 6.
The junction between the edges 2 in the traveling direction A of the open pipe 1 may be formed at any position at which an average distance between the edges 2 is reduced to 0.5 mm or smaller by using squeeze rolls (not illustrated).
Any of various forms of oscillators can be used as a laser beam oscillator used in the present invention. Preferable examples of the oscillator include a gas laser using a gas (for example, carbon dioxide gas, helium-neon, argon, nitrogen, and iodine) as a medium; a solid laser using a solid (for example, YAG into which a rare earth element is doped) as a medium; a fiber laser using a fiber as a laser medium instead of bulk; and a disk laser. Alternatively, a semiconductor laser may be used.
An auxiliary heat source may be used to heat the open pipe 1 from an outer side of the open pipe 1. The configuration of the auxiliary heat source is not particularly limited as long as the heat source can heat and melt the outer surface of the open pipe 1. For example, means operated with a burner melting method, a plasma melting method, a tungsten inert gas melting method, an electron beam melting method, a laser beam melting method, and other methods are appropriate for the auxiliary heat source.
Nevertheless, it is most preferable to use an arc as the auxiliary heat source. A device that can apply an electromagnetic force (that is, an electromagnetic force occurring from a magnetic field of welding currents) to a molten metal 5 in such a direction as to prevent burn-through of the molten metal 5 is used as an arc producer. For example, technologies known to date such as a tungsten inert gas welding or plasma arc welding can be used. Preferably, an arc producer is disposed so as to be integrated with a laser beam. The reason for this disposition is to effectively exert an influence of the magnetic field, occurring around the welding currents that produce an arc, on a molten metal 5. It is more preferable that the arc producer be positioned so as to be ahead of the laser beams 3. This is because this positioning allows moisture or oil content to be removed from the edges 2.
Even in the case where an auxiliary heat source other than an arc is used, it is preferable that the auxiliary heat source be disposed so as to be integrated with an oscillator of the laser beams 3. This is because, if the auxiliary heat source and a laser are not integrally disposed, a large amount of heat is required to obtain an effect of the auxiliary heat source, thereby making reduction of welding defects (such as undercut) very difficult. It is more preferable that the auxiliary heat source be positioned so as to be ahead of the oscillator of the laser beams 3. This is because this positioning allows moisture or oil content to be removed from the edges 2.
In the present invention, laser welding can be performed even on a thick open pipe 1 (for example, having a thickness of 4 mm or larger) without preheating the edges 2 by high-frequency induction heating or by other means. Nevertheless, preheating the edges 2 brings about effects such as improvement in productivity of laser welded steel pipes.
As described above, according to the present invention, a laser welded steel pipe is manufactured by laser welding with a high energy. Thus, occurrence of undercut or underfill is reduced and a high-quality laser welded steel pipe can be manufactured at a high yield ratio without reducing weld efficiency. The obtained laser welded steel pipe has a seam 6 that is excellent in terms of low-temperature toughness or corrosion resistance and is appropriate for oil country tubular goods or a line pipe used in a cold district or a corrosion environment.
Laser welded steel pipes were manufactured by forming belt-like steel strips into cylindrical open pipes using forming rolls, pressing the edges of the open pipes with squeeze rolls, and emitting laser beams from the outer surface side of the open pipes. Components of the steel strips are shown in Table 1.
Laser welding was performed using two fiber laser oscillators of 10 kW. The power of the oscillators and the welding speed were set as shown in Table 2.
Examples of the invention illustrated in Table 2 are examples that satisfy conditions essential for the present invention. Among the examples of the invention, steel pipe No. 10 is an example in which the welding speed falls outside the preferable range of the invention, steel pipe No. 11 is an example in which the laser power falls outside the preferable range of the invention, steel pipe No. 12 is an example in which the upset length falls outside the preferable range of the invention, and steel pipe No. 13 is an example in which the energy density falls outside the preferable range of the present invention. All of these examples are regarded as examples of the invention since they satisfy conditions essential for the present invention.
Among comparative examples, steel pipe No. 7 is an example in which the spot diameter falls outside the preferable range of the present invention, steel pipe Nos. 7 and 8 are examples in which the spot length falls outside the preferable range of the present invention, and steel pipe No. 9 is an example in which the distance between spot centers falls outside the preferable range of the present invention, and steel pipe Nos. 14 and 15 are examples for which a single laser beam is used.
Obtained laser welded steel pipes were subjected to the ultrasonic inspection test, and the seam of each pipe was inspected for a length of 20 m in accordance with JIS G0582. The results of inspection are shown in Table 2. In Table 2, regarding an artificial defect of an N5 inner/outer surface notch serving as a reference, when an indication of the peak level is 10% or lower, the steel pipe is evaluated as being excellent (double circle mark). When the indication of the peak level is higher than 10% but not higher than 25%, the steel pipe is evaluated as being good (circle mark). When the indication of the peak level is higher than 25% but not higher than 50%, the steel pipe is evaluated as being fair (triangle mark). When the indication of the peak level exceeds 50%, the steel pipe is evaluated as being poor (cross mark).
As is clear from Table 2, the examples of the invention were evaluated as being either excellent (double circle mark), good (circle mark), or fair (triangle mark) in the ultrasonic inspection. Welding defects such as undercut or underfill due to occurrence of spattering were not observed. On the other hand, the comparative examples were evaluated as being poor (cross mark) in the ultrasonic inspection. Moreover, welding defects such as undercut or underfill were observed. In steel pipe No. 13, which is one of the examples of the present invention, welding defects such as undercut or underfill were slightly observed.
The present invention is remarkably effective from the industrial point of view because the present invention allows laser welded steel pipes to be stably manufactured at a high yield ratio and the obtained laser welded steel pipes have a seam that is excellent in terms of low-temperature toughness and corrosion resistance and are thus appropriate for oil country tubular goods or a line pipe used in a cold district or corrosion environment.
1 open pipe
2 edge
3 laser beam
4 keyhole
5 molten metal
6 seam
This application is the U.S. National Phase application of PCT International Application No. PCT/JP2011/060805, filed Apr. 28, 2011, the disclosure of which is incorporated herein by reference in its entirety for all purposes.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/060805 | 4/28/2011 | WO | 00 | 1/2/2014 |
