Abstract. Due to the good mechanical properties of forged parts, the forging process plays a decisive role in the manufacturing of seamless stainless steel pipes for oil country tubular goods (OCTG) lines. Tough competition between manufacturers gives them plenty of incentive to make their processes in raw material and energy usage more and more efficient. In this context the expansion process is one of the critical production steps in the manufacturing of seamless stainless steel pipes. This work presents a sensitivity analysis of a finite element method (FEM) for the simulation of the expansion of the alloy UNS N08028. The input parameters ram speed, tool angle, initial ID and final ID of the billet as well as temperature were used to describe responses like tool wear and material loss. With the aim to minimize the tool wear and to reduce the material waste, a study of influence of the input parameters on the mentioned responses were performed. This development is supported by experimental work in order to validate the simulation model. The sector demand for new materials with specific properties and the cost-intensive experimental trials justifies the use of such simulation tools and opens great opportunities for the industry.

Abstract. Due to the good mechanical properties of forged parts, the forging process plays a decisive role in the manufacturing of seamless stainless steel pipes for oil country tubular goods (OCTG) lines. Tough competition between manufacturers gives them plenty of incentive to make their processes in raw material and energy usage more and more efficient. In this context the expansion process is one of the critical production steps in the manufacturing of seamless stainless steel pipes. This work presents a sensitivity analysis of a finite element method (FEM) for the simulation of the expansion of the alloy UNS N08028. The input parameters ram speed, tool angle, initial ID and final ID of the billet as well as temperature were used to describe responses like tool wear and material loss. With the aim to minimize the tool wear and to reduce the material waste, a study of influence of the input parameters on the mentioned responses were performed. This development is supported by experimental work in order to validate the simulation model. The sector demand for new materials with specific properties and the cost-intensive experimental trials justifies the use of such simulation tools and opens great opportunities for the industry.

The use of high nickel content austenitic stainless steels (SASS) has significantly increased in the last decade. The corrosion and high fatigue resistance of these materials make them suitable for manufacturing oil country tubular goods (OCTG). SASS are processing by forging from casting conditions. Dynamic recovery (DRV) and recrystallization (DRX) of as-cast super austenitic stainless steel, N08028 Alloy, is investigated to study the refining effect from the as-cast grain structure to fully recrystallized austenite due to hot deformation. Both the critical stress and strain for the initiation of DRX are determined using the flow curves. To perform this analysis, hot compression tests are performed at temperatures between 900°C and 1250°C, and strain rates between 0.1 s-1 and 10 s-1, up to 0,8 final strain using a Gleeble®3800 thermomechanical simulator. Subsequently, the Johnson-Avrami-Mehl-Kolmogorow (JMAK) model is used to numerically fit the flow curves and consequently determine the critical strain. No critical points are seen for temperatures under 1100°C. Above this temperature, the JMAK model proves to be valid in all studied strain rates.

The machining of a central axial hole in a duplex stainless steel 2205 bar is sufficient to optimize cooling and thus to achieve the toughness requirements of the most demanding international standards. The cooling rates are obtained by finite element methodology simulation. The increased cooling rate in the central zone of the bar is directly related to the improvement of the Charpy impact toughness. Microstructure at different bar locations is characterized by optical microscopy, scanning electron microscopy, and energy‐dispersive X‐ray spectrometry. In the absence of sigma phase precipitation, an austenite spacing over 45 μ provokes a decrease in absorbed energy close to 40 J. Moreover, the pierced bar complies with the international standards requirements in tensile with yield strength higher than 450 MPa and Rockwell hardness lower than 31 (HRC) over the section and along the bar. Finally, the resistance to pitting corrosion required is also satisfactory due to the absence of chromium nitrides.