Failure Mechanisms and Solutions for Fin-Pass Rolls Repair-Ring at an Electric Resistance Welding Pipe Plant

Laribaghal, Mahammad; Torfi, Mehdi; Khorasanian, Mehdi; Alavi Zaree, Seyyed Reza

doi:10.22050/ijogst.2021.302007.1609

Document Type : Research Paper

Authors

¹ Assistant Professor, Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, 61357-83151, Iran

² Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, 61357-83151, Iran

https://doi.org/10.22050/ijogst.2021.302007.1609

Abstract

Fin-pass rolls are the latest series of rolls in electric resistance welding (ERW) pipe production lines that form the sheets to tubular shape and adjust the edges of the sheet for welding. The rolls (made of AISI 8622 steel) lose their proper function after about 10 years of operation due to severe wear and change of their original surface profile. The worn portions were removed by grinding and replaced by an AISI D2 high carbon steel ring to repair these rolls. After a short time of service (about one year), the edge of the repair ring was exposed to severe spalling and fracture. The present study investigated the causes of the rapid failure of the AISI D2 repair ring and proposed a solution to the problem. The surface morphology, hardness, and wear resistance were studied. Moreover, the stress analysis of fin-pass rolls was studied using ABAQUS 6.14 finite element software for the closer investigation of the failure mechanism. The leading cause of spalling was the inherent brittleness of the AISI D2 steel and the presence of a high-stress concentration at the edges of the repair ring. To overcome this problem, carburized AISI P20 steel, case hardened AISI 4140 steel, and hard chromium electroplated AISI 4140 steel were replaced, and the resulting properties were studied. The highest resistance to spalling and wear occurred with carburized AISI P20 steel because of the high surface hardness and the gradual increase of toughness from the surface to the depth in the carburizing process, increasing the wear resistance and retarding the growth of fatigue cracks.

Highlights

The repair of the fin-pass roller using repair rings and its failure mechanism are investigated;
The stresses on fin-pass rollers are studied using the finite element simulation method;
The optimization of repair ring materials and their wear behavior is studied.

Keywords

Main Subjects

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Iranian Journal of Oil and Gas Science and Technology

Failure Mechanisms and Solutions for Fin-Pass Rolls Repair-Ring at an Electric Resistance Welding Pipe Plant

References

References

Volume 10, Issue 4 - Serial Number 37
October 2021
Pages 31-42

Failure Mechanisms and Solutions for Fin-Pass Rolls Repair-Ring at an Electric Resistance Welding Pipe Plant

References

References

Volume 10, Issue 4 - Serial Number 37October 2021Pages 31-42

Volume 10, Issue 4 - Serial Number 37
October 2021
Pages 31-42