The use of duplex stainless steel (DSS) in various fields is promising due to its excellent anti-corrosion properties, but traditional welding can lead to the formation of unfavorable phases that deteriorate its quality. This study aimed to use the rotary friction weld (RFW) technique to prevent the formation of harmful phases in the welding of an S32205 alloy pipe. The welding parameters used included a rotating speed of 20 m/s, a friction pressure of 10 MPa, a friction time of 30 s, and a forging pressure of 30 MPa. The microstructure and mechanical properties of the resulting RFWed joint were investigated. The results revealed that the weld zone exhibited a microstructure consisting of ferrite and austenite phases, with no deleterious phase detected. The ferrite content was measured to be 53.3%, 54.5%, and 68.7% in the base metal, thermomechanical affected zone (TMAZ), and weld, respectively, owing to the rapid cooling rate in the RFW process, which prevented any harmful phase formation in the weld zone. Furthermore, the RFW process successfully produced an ultrafine grain with a ferrite/austenite grain size of 0.40 μm and 0.41 μm, respectively. The weld zone and TMAZ contained more low-angle grain boundaries (LAGBs) compared to the base metal, which was attributed to the dynamic recovery (DRV) within a grain. The high heating and cooling rates and short welding time of the RFW process did not allow sufficient time for the dynamic recrystallization of the microstructure in the weld zone. However, a slight increase in the ferrite content in the weld zone resulted in grain refinement and an increase in the dislocation density, resulting in a slight increase in the 358 HV0.2 hardness and 823 MPa tensile strength of the weld zone. This study offers a novel approach for obtaining ultrafine grain duplex stainless steel pipes with exceptional mechanical properties through the application of RFW.

A 5000m³ single deck floating roof crude oil storage tank was found to have a cracked Q345R bottom plate during an open tank inspection. To analyze the cause of the failure, a series of experiments were carried out. The results showed that the chemical composition of the failed crude oil storage tank bottom plate material Q345R had a slight excess of S, V, and Ti which causes the material to form a bainite structure, resulting in a hard and brittle material with poor toughness. Q345R is susceptive to H₂S stress corrosion cracking according to SCC test. Based on the working condition investigation, the cracked plate was subjected to the local settlement and H₂S contained corrosive medium. With the stress concentration induced by local settlement, the bottom plate cracked. In order to avoid such incidents, Q345R material should be avoided in H₂S containing environment, and online monitoring should be carried out regularly to assess the overall condition of the tanks.

T-joint welding is a key manufacturing process of large storage tanks. However, complex residual stresses are generated and have a great effect on the structural integrity of storage tanks. The high residual stress caused by welding and the discontinuous structure may result in tank cracking and failure. In this work, the residual stress distributions on the inner surface, outer surface, and thickness direction of the T-joint were investigated by using the finite element method and indentation test method. The effect of local PWHT with different heating temperatures, heating rates, and heating widths on the residual stress distribution was also discussed. Results show that the residual stress of the T-shaped joint is high due to the serious structure discontinuity, multi-layer welding, and high strength. Among all the stresses, the circumferential residual stress is the highest and most concentrated in the outer weld connected with the annular plate. The residual stress gradually decreases with the increase in the heat treatment temperature. When the heating rate is less than 106 °C/h, the residual stress gradually decreases with the decrease in the heating rate. The large thermal deformation caused by heat treatment can be simultaneously avoided by heating the inside and outside of the T-joint. The residual stress decreases with the decrease in the width of the heating zone. The residual stress can be regulated by using a smaller width in the heating zone. An optimized heat treatment scheme with a heating temperature of 700 °C, heating rate of 56 °C/h, and heating width of 200 mm was proposed, which has a good ability to control residual stresses and improve the quality of the T-joint. It also has a good application in engineering.

Girth welds are weak points in pipelines, and failures occur frequently. In a gas transmission pipeline, a girth weld experienced cracking, prompting a failure analysis using experimental methods and finite element analysis (FEA). Experimental results showed that X-ray non-destructive testing (NDT) revealed cracks, porosity, and lack of fusion in the girth weld. However, the hardness and microstructure of the material showed no abnormalities. During operation, the pipeline experienced an increase in soil cover and was subjected to ground subsidence and vehicle loads. Finite element analysis was conducted on the defective girth weld under different conditions, including varying soil cover depths, different levels of subsidence, and varying vehicle loads, to examine the pipeline’s stress response. The results indicated that the combination of soil cover, subsidence, and vehicle loads led to pipeline failure, whereas none of these factors alone was sufficient to cause girth weld failure. To prevent such failures from occurring again, the following measures are recommended: strengthen on-site welding quality control of girth welds, conduct inspections for defects in girth welds of in-service pipelines, and promptly address any defects that exceed acceptable limits.

X80 steel pipelines are widely used in oil and gas transportation, and the quality and fracture behavior of the girth weld have an important influence on the safety and performance of the pipeline. This study presents a comprehensive investigation into the microstructure, mechanical properties, and fracture characteristics of X80 steel welded joints. Through microstructure analysis and mechanical testing, the hardness, impact, and tensile properties of the base metal, heat-affected zone, and weld zone are evaluated. Digital Image Correlation (DIC) technology is employed to scrutinize the strain behavior under quasi-static tensile tests for both smooth and notched round bar specimens, providing a detailed strain distribution analysis. The findings indicate that, while X80 welded joints are well-formed without significant defects, the hardness and impact properties vary across different zones, with the base metal exhibiting the highest impact toughness and the weld zone the lowest. Notched tensile tests reveal that the presence and geometry of notches significantly alter the stress state and deformation characteristics, influencing the fracture mode. The DIC analysis further elucidates the strain concentration and localization behavior in the weld zone, highlighting the importance of notch size in determining the load-bearing capacity and ductility of the welded joints. This study contributes to a deeper understanding of the fracture mechanics in X80 pipeline girth welds and offers valuable insights for the optimization of welding practices and the assessment of pipeline integrity.

Light hydrocarbon fuels are widely utilized in industrial production and transportation due to their high calorific value and clean combustion characteristics. Compared to traditional oil tanker transportation, pipelines not only reduce transportation costs but also minimize environmental impact. To understand the leakage and diffusion law of light hydrocarbon pipelines, this paper takes light hydrocarbon pipelines as the research object, establishes the conceptual model of the process of light hydrocarbon leakage and diffusion, divides the four major processes of leakage and diffusion, analyzes the relevant theory, and deduces a formula. The numerical model of pipeline–air–soil leakage and diffusion was established to analyze the whole process of light hydrocarbon leakage and diffusion. The diffusion behavior of individual hydrocarbon components is examined, along with a comparative analysis between multi-component and single-component leakage scenarios. Simulation results reveal that the leakage process comprises three stages: an initial rapid diffusion phase, a transitional phase where a stable region begins to form, and a final stage where the diffusion pattern stabilizes around 800 s. C3 and C5 exhibit the largest diffusion ranges among gaseous and liquid hydrocarbons, respectively. In multi-component systems, the vaporization sequence suppresses the overall diffusion range compared to single-component cases, though gas-phase hydrocarbons tend to accumulate near the leakage source. Understanding the leakage and diffusion behavior of light hydrocarbon pipelines is crucial for energy security. By accurately modeling these processes, we can determine the impact zones of potential pipeline failures and establish appropriate safety buffers. This proactive approach not only safeguards human life and the environment but also ensures the reliable and uninterrupted delivery of energy resources. Consequently, such research is instrumental in fortifying the resilience and dependability of energy infrastructure.