Bilat, Anne-Sophie (2007) Estimation du risque de rupture fragile de soudures de pipelines en aciers à haut grade : caractérisation et modélisation. PhD thesis Sciences et génie des matériaux, Centre des Matériaux P.M. Fourt, ENSMP p.300.

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Abstract

As a consequence to reduction of gas transportation costs, pressure inside pipe will tend to increase. To achieve it, ferritic‐bainitic steel with high strength, such as X100 (yield strength above 100 ksi, or 690 MPa) were developed.

Girth welds of modern line pipe steel X100, issued from a pulsed automatic gas metal arc welding, were tested to check their performance in artic temperature conditions. It is shown that an impact specimen at ‐20 °C with a notch placed in the middle of the fusion line could break at low energy (<40 J). The brittle zone is located in the coarse‐grained heat‐affected

zone of the weld. The reproduction of two heat‐affected zones with a thermal‐mechanical simulator, Gleeble 1500, allows determining the mechanical behavior of representative microstructures of the welded joint. Tension tests with or without notch, bend tests and impact tests are performed between ‐196°C and 20 °C. This experimental database is used to fit materials constitutive equations

which are used in a finite element code to predict the fracture of the welded joint. Results obtained by local approach are compared with those obtained by the usual dimensioning rules used by exploiters (Failure Assessment Diagrams).

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Table of content

CHAPITRE I ‐ BIBLIOGRAPHIE - 21



I.1. LES ACIERS A HAUTS GRADES POUR PIPELINES ... 22

I.1.1. Des pipelines d’hier aux pipelines d’aujourd’hui - 22

I.1.2. L’obtention des aciers à hauts grades - 26

I.1.3. De la plaque vers le tube - 32

I.1.4. La mise au point du grade X100 - 33

I.2. LE SOUDAGE DES PIPELINES ET SES FAIBLESSES - 38

I.2.1. Le soudage automatique - 38

I.2.2. La soudure longitudinale et la soudure de raboutage

I.2.3. La formation de la zone affectée thermiquement (ZAT)

I.2.4. Les zones d’amorçage de la rupture fragile dans la ZAT



CHAPITRE II ‐ MATERIAUX DE LA SOUDURE ET CHOIX D’UN ASSEMBLAGE - 53



II.1. LES SIX ASSEMBLAGES ET LEUR SOUDAGE - 54

II.2. LE METAL DE BASE : UN ACIER X100 POUR PIPELINES

II.2.1. La microstructure de l’acier X100 étudié - 56

II.2.2. Les mesures de la composition chimique - 58

II.2.3. Les mesures d’austénite résiduelle - 60

II.2.4. La cartographie EBSD du métal de base - 61

II.3. LA ZONE AFFECTEE THERMIQUEMENT - 63

II.3.1. La ZAT de la soudure longitudinale W(L) – 2B50 63

II.3.2. La ZAT de la soudure en T – tube 2B50 - 66

II.3.3. La ZAT de la soudure de raboutage - 68

II.3.4. Les composés M‐A martensite‐austénite 72

II.3.5. Les inclusions - 73

II.4. LE METAL FONDU - 74

II.4.1. La microstructure du métal fondu - 74

II.4.2. Les mesures de la composition chimique - 74

II.5. LE CHOIX DU TUBE - 77

II.5.1. Les spécifications sur les soudures - 77

II.5.2. Les mesures de dureté - 78

II.5.3. Le comportement mécanique et l’écrouissage des assemblages - 79



CHAPITRE III ‐ IDENTIFICATION DES ZONES CRITIQUES VIS‐A‐VIS DE LA RUPTURE FRAGILE - 83



III.1. LE DELAMINAGE DANS LE PLAN LT DU METAL DE BASE - 84

III.2. LES ESSAIS DE TRACTION DU JOINT REEL ENTRE ‐196 ET 20 °C - 86

III.3. LES ESSAIS CHARPY DANS LA ZAT ET LE METAL DE BASE - 90

III.3.1. Le prélèvement et le placement des éprouvettes. 90

III.3.2. Le protocole d’essai - 91

III.3.3. Le mouton Charpy instrumenté de 300 J - 92

III.3.4. L’exploitation et choix des éprouvettes à expertiser

III.3.5. L’identification de la zone de rupture fragile dans le 2B50 - 97

III.4. LA COMPARAISON ENTRE LES PROCEDES BITORCHES

III.5. LA COMPARAISON ENTRE LES ESSAIS ET LES RESULTATS DE LA LITTERATURE - 102



CHAPITRE IV ‐ REPRODUCTION DE LA ZAT - 105

IV.1. SOUDAGE INSTRUMENTE - 106

IV.1.1. Données sur l’instrumentation et les cycles de soudage - 106

IV.1.2. Exploitation des relevés de températures - 108

IV.2. PRESENTATION DE LA MACHINE GLEEBLE - 112

IV.2.1. Présentation du dispositif - 112

IV.2.2. Ebauches Φ5 et 􀀀11 - 113

IV.2.3. Réglages de l’asservissement - 113

IV.2.4. Vitesse de refroidissement et homogénéité de chauffe

IV.3. MISE AU POINT ET VALIDATION DES CYCLES - 117

IV.3.1. Cycles existant dans la littérature ... 117

IV.3.2. Influence de la vitesse de refroidissement et de la température maximale sur la taille des grains et la dureté

IV.3.3. Essais de cycles : influence du nombre de cycles et de la température maximale atteinte.. 120

IV.3.4. Cycles créés pour simuler les ZAT réelles - 121

IV.3.5. Températures de transformation de l’acier X100 à l’étude - 123



CHAPITRE V ‐ ANALYSE LOCALE EN VUE DE LA PREDICTION DE LA RUPTURE. 129

V.1. INTRODUCTION A L’APPROCHE LOCALE DE LA RUPTURE - 130

V.1.1. Méthodologie de l’approche locale - 130

V.1.2. Application de l’approche locale à la soudure . 131

V.2. ESSAIS MECANIQUES SPECIFIQUES - 132

V.2.1. Description des essais : éprouvettes et matériaux .

V.2.2. Résultats des essais de traction avec éprouvettes entaillées - 134

V.2.3. Résultats des essais de flexion lente avec des éprouvettes Charpy - 135

V.3. ETUDE DES MECANISMES DE RUPTURE PAR FRACTOGRAPHIE - 137

V.3.1. Les éprouvettes de traction entaillées dans la ZAT Cs

V.3.2. Les éprouvettes de flexion lente entaillées dans la ZAT Cs - 141

V.3.3. Les éprouvettes entaillées dans le joint réel en ligne de fusion - 144

V.4. MODELISATION DU COMPORTEMENT PLASTIQUE - 147

V.4.1. Anisotropies en contrainte et en déformation du métal de base - 147

V.4.2. Modélisation du comportement - 148

V.4.3. Stratégie d’identification des paramètres du modèle

V.4.4. Les dimensions du joint et des ZAT - 152

V.4.5. Technique de maillage - 153

V.4.6. Résultats de l’identification sur les courbes macroscopiques - 154

V.4.7. Validation de l’optimisation des paramètres sur joint réel - 158

V.5. MODELISATION DE LA RUPTURE - 159

V.5.1. Introduction des critères de rupture - 159

V.5.2. Techniques de simulation pour prédire la rupture... 161

V.5.3. Bilan de la démarche et résultats - 171

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