Effect of Thermal Cutting Methods On The Fatigue Life of High Strength Structural Steel S690Q
Effect of Thermal Cutting Methods On The Fatigue Life of High Strength Structural Steel S690Q
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Article in American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP · July 2015
DOI: 10.1115/PVP2015-45174
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cut sheet components with very intricate geometries with high intended that the cut-edge quality should be as representative of
precision. real quality as possible, so the cutting parameters selected are
In spite of the advantages of using plasma and laser the ones used by the industry to cut the steel grade and
cutting processes, the current fatigue codes (i.e., BS 7608 [3]) thickness considered. The cutting parameters are summarized in
only take into account the fatigue performance of straight cut- Table 2.
edges made by flame cutting. Besides, some fabrication It should be noted that plasma cutting has used oxygen
standards, particularly North American codes (i.e., Alberta and air as plasma gas and as shielding gas, respectively, and
Specification for Bridge Construction [4]), define some laser cutting has used oxygen as assist gas. This election is very
extremely conservative limitations of cut-edge hardness, which common in carbon steels given that the heat of the oxidizing
cannot be reached by the two alternatives of cutting process or exothermic reaction allows the cutting speed to be increased by
even (in many occasions) by oxy-fuel cutting. 25%.
Regarding the fabrication of bolt holes, current fabrication Relating to the cutting speed, it is straightforward to
codes often state that holes shall only be made by drilling or notice that the cutting speed provided by both plasma cutting
punching. For example, the Specification for Structural Joints (2.2 m/min) and laser cutting (1 m/min) is considerably higher
Using High-Strength Bolts [5] defines that thermally cut holes than that provided by oxy-fuel cutting (0.5 m/min).
produced by mechanically guided means are permitted in
statically loaded joints and, for cyclically loaded joints,
thermally cut holes may be permitted if approved by the
Engineer of Record. However, many constructors choose not to
exercise this clause because there are no data to show how
these holes perform under fatigue loading. So far, steel structure
fabricators have had to perform multiple material-handling
steps to accommodate standard drilling and punching
operations. The validation of thermally cut holes for cyclically
loaded joints would allow multiple processes to be performed at
one time, reducing the amount of handling, thus leading to
reduced fabrication costs.
With all this, the aim of this research is, on the one hand,
to compare the fatigue performance of the three thermal cutting
methods concerning both straight cut-edges and cut holes; and,
on the other hand, to evaluate the possibility of extrapolating
the standard S-N curves to plasma and laser straight cut-edges
and thermally cut holes.
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TABLE 1. CHEMICAL COMPOSITION AND MECHANICAL EXPERIMENTAL PROGRAMME
PROPERTIES OF S690Q In order to achieve the conditions stated by ASTM E739-
CHEMICAL COMPOSITION (%) 10 [7], 10 specimens have been used to define each S-N curve.
C Si Mn P S Cr Mo Ni On the one hand, the specimen with tangentially blending fillets
between the uniform test section and the ends proposed by
0.15 0.40 1.42 0.005 0.001 0.02 0.002 0.16 ASTM E466-96 [8] has been selected to reproduce the real
Al Cu Nb N Sn Ti V CEV conditions of straight thermally cut-edges, which is shown in
0.048 0.01 0.029 0.006 0.002 0.003 0.058 0.43 Figure 3; it should be noted that the specimens were extracted
parallel to the rolling direction. On the other hand, a specimen
MECHANICAL PROPERTIES with a centered hole and mechanized straight edges has been
Young modulus Yield strength Tensile strength designed in order to simulate the presence of a bolt hole in a
(GPa) (MPa) (MPa) real component (Figure 4); due to the absence of this kind of
samples in the actual codes, it was necessary to adopt the
209.4 776.2 833.7 specimen drawing proposed by other authors [9]. Similar to the
straight specimens, the samples with a hole were also extracted
TABLE 2. CUTTING PARAMETERS parallel to the rolling direction. The finishing cut point is
located at the end of the hole diameter parallel to the load
OXY-FUEL CUTTING
direction, given that this is a singular point in which the
Parameter Value material disturbance is significantly higher.
Cutting speed 0.45-0.5 m/min
Propane pressure 0.4 bar
pre 1.2 bar
Oxygen pressure
working 6 bar
PLASMA CUTTING
Parameter Value
Plasma arc current 200 A
Plasma arc voltage 131V
FIG 3. DRAWING OF SPECIMEN WITH STRAIGHT CUT-
Cutting speed 2.2 m/min EDGE (DIMENSIONS IN MM)
Torch standoff 4.1 mm
Plasma gas: pre 24 l/min
Oxygen flow rate working 69 l/min
Shielding gas: pre 65 l/min
Air flow rate working 28 l/min
Piercing time 0.6 s
Piercing standoff 8.2 mm
LASER CUTTING FIG 4. DRAWING OF SPECIMEN WITH HOLE (DIMENSIONS
IN MM)
Parameter Value
Beam power 3600 W As a summary, 60 fatigue tests have been carried out. The
specimen distribution is shown in Table 3.
Cutting speed 1 m/min
TABLE 3. SPECIMEN DISTRIBUTION
Nozzle diameter 1.7 mm Straight edge With hole
Nozzle distance 0.5-0.8 mm OXY-FUEL CUTTING 10 10
Focus diameter 0.2 mm PLASMA CUTTING 10 10
Focus position On the top surface LASER CUTTING 10 10
Assist gas Oxygen
Both S-N curves and fatigue limit are the parameters
Assist gas pressure 0.6 bar selected to evaluate the fatigue behavior. Fatigue tests were
conducted using a high frequency testing machine with a
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400KN capacity, which can carry out fatigue tests at the fatigue category corresponding to the flame cut edges should be
specimen resonance frequency. This frequency oscillates adopted, because BS7608 [3] does not take into account the
between 77 and 79 Hz for the two types of specimens selected. fatigue quality of plasma or laser cut-edges:
Referring to the definition of the rest of the fatigue test
- Class B: “Any flame cut edges subsequently machined
parameters, the stress ratio (R) selected is equal to 0.1, which is
or ground smooth. All visible signs of draglines should
adopted by most of the references found in the bibliography
be removed from the flame cut-edge by grinding or
(i.e., [2]). The stress ranges have been defined taking into
machining”.
account that the maximum stress of the sinusoidal cycle cannot
be higher than the steel yield stress. Finally, a number of cycles - Class C: “Any cutting of edges by planning or
equal to 107 has been adopted to define the fatigue strength in machine flame cutting with controlled procedure.
the infinite fatigue life [10]. Thermal cut quality in accordance with EN 9013 [13]
with mean height of the profile range 2”.
COMPARISON WITH THE STANDARDS
If it were necessary to evaluate the fatigue performance of
The nominal stress approach is an established approach
a component with thermally cut bolt holes, a situation
for fatigue design and assessment of steel components adopted
represented here by the specimens with the hole, this would not
by most standards. The nominal stress approach is based on S-
be possible, because BS7608 [3] does not include this fatigue
N curves. Structural details are designed based on the nominal
detail. For this reason, the fatigue category used to evaluate
stress range in the connecting members rather than on the local
drilled holes is adopted to compare with the experimental
concentrated stress. The fatigue design procedure is based on
results:
associating the detail under consideration with a specific
- Class D: “Small hole (may contain bolt for minor
category.
fixtures). Hole drilled or reamed. Minimum distance
Around the world, there are numerous fatigue standards
between center of hole and plate edge: 1.5 x hole
which provide their own fatigue S-N curves (i.e. BS7608 [3],
diameter”.
ASSHTO LRFD Bridge Design Specifications [11], Eurocode 3
[12]). They present some differences given that they have been CUT-EDGE CHARACTERIZATION
obtained in base on their own experimental fatigue programme. Figure 5 show the typical physical appearance of the three
With a view to validating the present research, the standard thermally cut-edges.
BS7608 [3] has been selected. This is one of the most up-to-
date fatigue codes in the world and it is used in many areas of
industrial application. Besides, the steel grade (S690Q) and TOP
plate thickness (15 mm) selected here are covered by this code. DROSS ADHERENCE
One of the main advantages of this standard is that each
design class is characterized by a mean and a design S-N curve BOTTOM
corresponding to the selected nominal probability of failure.
The expression proposed to define both S-N curves is shown in a)
equation (1): 5 mm
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Analyzing Figure 5, the cut-edge surfaces generated by absence of defects and very shallow draglines. The oxy-fuel cut
the three thermal cutting methods are observed to have very hole also displays a smooth surface. Nevertheless, it should be
different characteristic features. It should be noted that the noted that the presence of some dross adhered to the cut surface
specimens have been tested without any machining or polishing and the bottom edge has been rounded. The quality of the laser
step after the cutting operation. cut surface is the worst and it is characterized by the presence
of predominant surface draglines, particularly near the top of
- The oxy-fuel cut-edge surface is considerably smooth
the cut edge.
and is covered by an oxide layer which is very difficult
to remove. The formation of surface dross at the OXY-FUEL CUTTING
bottom of the oxy-fuel cut-edge is also clearly visible. FINISHING CUT POINT
The plasma cut-edge surface is the smoothest of the
three thermally cut-edge surfaces. The presence of
very shallow draglines is noticeable.
- The laser cut-edge surface is characterized by the
presence of irregular surface disruptions. The causes
of these surface features could be determined to an
increased molten flow of steel overlapping [14]. 5 mm 5 mm
600
ALBERTA SPECIFICATION EN 1090
500
kg/mm2)
400
300
200
5 mm 5 mm
100
5
FATIGUE EVALUATION OF SPECIMENS WITH strength at the run out level in comparison with the other two
STRAIGHT CUT-EDGE cutting processes: oxy-fuel cutting decreases plasma cutting
The fatigue test results corresponding to specimens with a and laser cutting fatigue strength by 84 MPa and 63 MPa,
straight edge and mean S-N curves of different cutting respectively. After comparing fatigue results and surface
processes are shown in Figure 9. The run-out points are quality, a correlation between them cannot be found in this
represented with an arrow. case. This can be explained by the fact that all oxy-fuel cut
600
specimens show the crack initiation at the bottom edge where
the surface dross actuates as a stress concentrator; it would
seem to reduce the fatigue resistance at the run out level.
Although the laser cut surfaces display disruptions, the fatigue
performance of laser cut specimens is slightly better than that
shown by plasma cut specimens. Thus, other parameters (i.e.
residual stresses or HAZ microstructures) could significantly
affect the final fatigue performance
Figure 10 compares the experimental results with both
∆σ (MPa)
OXY-FUEL RESULTS
PLASMA RESULTS
LASER RESULTS
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FATIGUE EVALUATION OF SPECIMENS WITH A CUT (Figure 8b). In contrast, the presence of predominant draglines
HOLE in the laser cut holes (Figure 8c) could have a considerably
The fatigue test results obtained in the specimens with a negative impact on the fatigue strength at the run out level. The
thermally cut hole are presented in Figure 11. The run-out oxy-fuel cut holes also display a high quality surface as shown
points are represented with an arrow. in Figure 8a, but the presence of dross adherence (particularly
600
near the bottom of the cut-edge) could assist crack initiation.
Finally, Figure 12 compares the S-N curves provided by
the design class D of BS7608 [3] with the experimental results
obtained in specimens with a thermally cut hole. The aim is to
determine whether or not it is possible to apply this design class
(proposed for hole drilled or reamed) to steel holed components
that have been thermally cut. After analyzing design class D, it
can be stated that the fatigue design values are safe enough in
the finite life region and the amplitude fatigue limit is
∆σ (MPa)
PLASMA RESULTS
LASER RESULTS
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for oxy-fuel cut straight edges (without machining), and it is [12] EN 1993-1-9, “Eurocode 3: Design of steel structural -
rather conservative for plasma and laser cut straight edges in Part 1-9”, European Committee for Standardization, Brussels,
the steel grade S690Q. 2005.
Finally, it has also been demonstrated that the fatigue [13] EN ISO 9013, “Thermal cutting – Classification of thermal
categories proposed by BS7608 for drilled and reamed holes cut – Geometrical product specification and quality tolerances”,
(design class D) could also be used for thermally cut holes in European Committee for Standardization, Brussels, 2004.
the steel grade S690Q. [14] Thomas D.J. Characterisation of steel cut edges for
improved fatigue property data estimations and enhanced CAE
ACKNOWLEDGMENTS durability. PhD Thesis, Materials Research Centre, School of
The authors of this work would like to express their Engineering, University of Wales, 2002.
gratitude to the European Union for the financial support of the [15] EN 1090-2:2011, “Execution of steel structures and
project HIPERCUT: “High Performance Cut Edges in aluminium structures - Part 2: Technical requirements for steel
Structural Steel Plates for Demanding Applications” (RSFR- structures”, European Committee for Standardization, Brussels,
CT- 2012-00027), on the results of which this paper is based. 2011.
[16] Schneider C.R.A., Maddox S. J. IIW-XIII-WG1-121r3-06,
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