Aluminum Drill Pipes: Material and Design Developments

2008 ◽  
Author(s):  
Marcelo Igor Lourenc¸o ◽  
Theodoro A. Netto ◽  
Joa˜o Carlos Ribeiro Pla´cido
Keyword(s):  
Mechanical Design ◽  
Fatigue Behavior ◽  
Axial Stress ◽  
Drill Pipe ◽  
Element Model ◽  
Fatigue Tests ◽  
Small Scale ◽  
Physical Experiments ◽  
Drill Pipes ◽  
Tool Joint

An extensive research program on the structural strength of aluminum drill-pipes is being conducted at COPPE/UFRJ. The main objective is to improve the fatigue performance of these components by selecting the appropriate aluminum alloy and by enhancing the mechanical design of the threaded steel connector. This paper presents the experimental test program and numerical analyses conducted on a drill-pipe of different materials (Al-Zn-Mg alloy) and geometries from those previously presented [1,2]. Small-scale specimens were tested to determine its uni-axial stress-strain and fatigue behavior. Full-scale fatigue test results are also presented. A finite element model of the drill pipe, including the tool-joint region, was developed. The model simulates, through different load steps, the tool-joint hot assembly, and then reproduces the physical experiments numerically in order to obtain the actual stress distribution. The correlation between full and small-scale fatigue tests is performed via multi-axial fatigue models. The weak points of the current practice design are highlighted for further development.

Experimental and Numerical Evaluations of Aluminum Drill Pipes Under Cyclic Loads

2006 ◽  
Author(s):  
Marcelo Igor Lourenc¸o ◽  
Theodoro A. Netto ◽  
Neilon S. Silva ◽  
Paulo Emi´lio Valada˜o de Miranda ◽  
Joa˜o Carloes Ribeiro Pla´cido
Keyword(s):  
Drill Pipe ◽  
Fatigue Tests ◽  
Full Scale ◽  
Experimental Program ◽  
Small Scale ◽  
Strain Stress ◽  
Drill Pipes ◽  
Aluminum Pipe ◽  
Tool Joint ◽  
Joint Assembly

Experimental program and numerical analyses were carried out to investigate the fatigue mechanisms of aluminum drill pipes designed and manufactured in compliance with ISO 15546. Material mechanical properties, including S-N curve, were determined through small-scale tests on specimens cut from actual drill pipes. Full-scale experiments were also performed in laboratory. Initially, the tool-joint assembly procedure was actually performed to monitor the resulting strain/stress level in selected points of the aluminum pipe. Three full-scale aluminum drill pipe specimens were then fatigue tested under combined cyclic bending and constant axial tension. In parallel, a finite element model of the tool-joint region, where two drill pipe specimens failed in the fatigue tests, was developed. The model was first used to reproduce the tool-joint assembly. Then, the physical experiments were simulated numerically in order to obtain the actual stress distribution in this region. Good correlation between full-scale and small-scale fatigue tests was obtained by adjusting the strain/stress levels monitored in the full-scale tests in light of the numerical simulations.

MULTIAXIAL FATIGUE OF ALUMINUM DRILL PIPES - EXPERIMENTS AND NUMERICAL ANALYSES

2021 ◽  
pp. 1-27
Author(s):  
Marcelo Igor Lourenço ◽  
Theodoro Antoun Netto ◽  
Neilon Silva ◽  
João Carlos Plácido
Keyword(s):  
Element Model ◽  
Complex Stress ◽  
Complex Stress State ◽  
Multiaxial Fatigue ◽  
Full Scale ◽  
Numerical Analyses ◽  
Small Scale ◽  
Drill Pipes ◽  
Full Scale Tests ◽  
Tool Joint

Abstract This paper presents an experimental test program and numerical analyses conducted on aluminum alloy drill-pipes with two different geometries. Small-scale characterization tests were conducted to determine both the material mechanical properties and the fatigue SN curves. Full-scale fatigue tests of the components are also presented. A finite element model of the drill pipes, including the tool-joint region, was developed. The model simulates, through different load steps, the tool-joint hot assembly and the experimental loads in order to obtain the actual stress distribution during the full-scale tests. Maximum stress amplitude in the aluminum pipes was found to be coincident with the edge of the connector, at the same location where failure was observed in full-scale tests. The study revealed that such pipes present a complex stress state near their connection to the steel tool joints due to their geometry and the residual stresses induced during the assembly of the steel connectors onto the aluminum pipes. Finally, multi-axial fatigue models were calibrated with the results of the small-scale tests and applied to the stress-strain state obtained numerically. Theoretical predictions were correlated to full-scale fatigue test results.

scholarly journals THREAD RESTORATION TECHNOLOGY OF TOOL-JOINT IN DRILL PIPES BY METHOD OF ELECTRIC CONTACT WELD DEPOSITION INTO UPSET GROOVE

2018 ◽  
Vol 2018 (7) ◽  
pp. 19-25
Author(s):  
Андрей Паренко ◽  
Andrey Parenko ◽  
Константин Макаренко ◽  
Konstantin Makarenko
Keyword(s):  
Drill Pipe ◽  
Thermal Impact ◽  
Electric Contact ◽  
Major Repair ◽  
Impact Area ◽  
Drill Pipes ◽  
Tool Joint

In connection with a relatively high cost of drill pipes large companies loss caused by rejection achieves tens millions of rubles. And at the same time it is necessary to take into account that the tool-joint thread rejection does not mean at all unworthiness to operation a drill pipe itself as having restored an inter-lock it is possible to continue the operation of a res-tored product. In such a way, one of the priority direc-tions at major repair of drill pipes is a restoration of interlock geometrical joints. In this paper there is considered a technology for repair of a worn thread in an interlock of drill pipes and its updating at the expense of electric contact weld deposition used into an upset groove. The method of-fered allows keeping a pipe without its shortening at repair at the expense of additional metal application directly upon a thread area and decreasing a thermal impact area and also increasing operation properties of a restored pipe.

scholarly journals The Effect of Laser Peening without Coating on the Fatigue of a 6082-T6 Aluminum Alloy with a Curved Notch

Metals ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 728 ◽  
Author(s):  
Enrico Troiani ◽  
Nicola Zavatta
Keyword(s):  
Aluminum Alloy ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Fatigue Behavior ◽  
Surface Hardness ◽  
Element Model ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Laser Peening ◽  
Laser Peening Without Coating

Laser shock peening has established itself as an effective surface treatment to enhance the fatigue properties of metallic materials. Although a number of works have dealt with the formation of residual stresses, and their consequent effects on the fatigue behavior, the influence of material geometry on the peening process has not been widely addressed. In this paper, Laser Peening without Coating (LPwC) is applied at the surface of a notch in specimens made of a 6082-T6 aluminum alloy. The treated specimens are tested by three-point bending fatigue tests, and their fatigue life is compared to that of untreated samples with an identical geometry. The fatigue life of the treated specimens is found to be 1.7 to 3.3 times longer. Brinell hardness measurements evidence an increase in the surface hardness of about 50%, following the treatment. The material response to peening is modelled by a finite element model, and the compressive residual stresses are computed accordingly. Stresses as high as −210 MPa are present at the notch. The ratio between the notch curvature and the laser spot radius is proposed as a parameter to evaluate the influence of the notch.

Fatigue Behavior and Deformation of Aluminum and Steel HVOF Sprayed with WC-Co Coatings

1997 ◽  
Author(s):  
A. Ibrahim ◽  
C.C. Berndt
Keyword(s):  
Fatigue Life ◽  
Room Temperature ◽  
Fatigue Behavior ◽  
Three Dimensional ◽  
Element Model ◽  
Fatigue Tests ◽  
Dimensional Finite Element ◽  
Life Distributions ◽  
Three Dimensional Finite Element ◽  
Good Agreement

Abstract The effect of WC-Co coating on the high cycle fatigue (HCF) behavior of SAE 12L14 steel and 2024-T4 aluminum was investigated. The fatigue tests were performed at room temperature and 370°C. The fatigue life distributions of specimens in the polished, grit blasted, peened, and coated conditions are presented as a function of the probability of failure. HVOF sprayed WC-Co coating has influenced the fatigue life of aluminum and steel. Factors contributing to this influence, which include grit blasting, elastic modulus, and residual stress, are discussed. A three-dimensional finite-element model (FEM) of the coated specimen was used to calculate the stress distribution across the coating and the substrate. The results of the analytical model are in good agreement with fatigue lives observed experimentally.

Investigation into Tangential Force and Axial Stress Effects on Fretting Fatigue Behavior

2005 ◽  
Vol 128 (2) ◽  
pp. 202-209 ◽  
Author(s):  
Hyukjae Lee ◽  
Shankar Mall
Keyword(s):  
Phase Difference ◽  
Cyclic Load ◽  
Fatigue Behavior ◽  
Axial Stress ◽  
Tangential Force ◽  
Fretting Fatigue ◽  
Fatigue Tests ◽  
Partial Slip ◽  
Relative Slip ◽  
Force Range

Fretting fatigue behavior of a titanium alloy was investigated using a dual actuator test setup which was capable to apply the pad displacement independent of the applied cyclic load on specimen. Fretting fatigue tests were conducted using this setup with a phase difference between cyclic load on the specimen and tangential force on the fretting pad with cylinder-on-flat contact configuration under partial slip condition. Two axial stress ratios were used. The relative slip range and tangential force range were related to each other and this relationship was not influenced by phase difference, axial stress ratio, and contact load under the partial slip condition. Change in the phase difference caused the change in relative slip as well as tangential force for a given applied pad displacement and axial load. However, there was no effect of phase difference on fretting fatigue life at a given relative slip level. Fretting fatigue tests with a fully reversed axial stress showed longer fatigue life than tension-tension counterparts at a given relative slip, tangential force range, and axial stress range. Finite element analysis was conducted by including the complete load history effects, which showed that stress distribution on the contact surface stabilized after the first fatigue cycle. Unlike relative slip and∕or tangential force range, a critical plane-based parameter appears to take into account the stress ratio effects to characterize fretting fatigue behavior.

Aluminum Drill Pipe Fatigue Analysis

2004 ◽  
Author(s):  
Guilherme Farias Miscow ◽  
Joa˜o Carlos Ribeiro Pla´cido ◽  
Paulo Emi´lio Valada˜o de Miranda ◽  
Theodoro Antoun Netto
Keyword(s):  
Fatigue Life ◽  
Structural Integrity ◽  
Crack Nucleation ◽  
Drill Pipe ◽  
Drill String ◽  
Small Scale ◽  
Second Phase ◽  
Horizontal Section ◽  
Steel Drill ◽  
Drill Pipes

While drilling extended reach wells, the weight per foot of the drill string is a critical design parameter that can limit the depth to be reached. One practical solution is the use of drill pipes made of alternative materials to the conventional steel drill pipes. The most direct options are titanium and aluminum. Titanium is in general impaired due to its high cost, although the titanium alloy Ti-6Al4V has already been used in the airplane industry. More recently, Russia has been manufacturing drill pipes using aluminum alloys of the system Al-Cu-Mg, similar to alloys 2024, also used in airplanes. These pipes present a reasonable commercial cost. Drill pipe fatigue damage occurs under cyclic loading conditions due to, for instance, rotation in curved sections of the well. Failures caused by crack nucleation and propagation are one of the highest risks to the structural integrity of these pipes. Usually, failure mechanisms develop in the transition region of the tool joint. Several mechanical and metallurgical factors affect the fatigue life of drill pipes. The former are mainly geometric discontinuities such as transition zones, pits and slip marks. The latter are related to the size and distribution of crystalline grains, phases and second phase particles (inclusions). In this study, the roles played by both factors in the fatigue life of drill pipes are studied through an experimental test program. The fundamental fatigue mechanisms are investigated via laboratory tests in small-scale coupons performed in an opto-mechanical fatigue apparatus. Additionally, full-scale fatigue testes on three aluminum drill pipes were performed. The pipes tested are being used in the horizontal section of some extended reach wells in the Northeast of Brazil.

Fatigue Tests and Design of Offshore Tubular Joints

1983 ◽  
Vol 105 (2) ◽  
pp. 189-194
Author(s):  
D. Dutta ◽  
F. Mang
Keyword(s):  
Stress Ratio ◽  
Design Method ◽  
Fatigue Behavior ◽  
Load Cycle ◽  
Fatigue Tests ◽  
Post Weld Heat Treatment ◽  
Small Scale ◽  
Plate Test ◽  
Tubular Joints ◽  
Stress Load

The AWS-X “hotspot stress-load cycle” curve used at present for designing tubular joints is based mainly on the fillet-welded plate test data and some more data from small-scale tests on tubular joints, which were available in the early 1970s. A review of further tests carried out in the recent years, including those by the authors, leads to the conclusion that the influence of the diameter and thickness of the tubes plays a significant role in the joint fatigue behavior. Hence, they must be taken into consideration while designing tubular joints accurately and more economically. A modified design method is proposed here with design curves for four diameter values. Further, the results of fatigue tests on K-type joints investigating the effect of stress ratio R and of post-weld heat treatment on the joint fatigue strength are described in this paper.

Application, Calculation and Experimental Evaluation of SCF for Aluminum Drill Pipe With Steel Connector

2010 ◽  
Author(s):  
Vadim Tikhonov ◽  
Alexander Kultsep ◽  
Rudolf Alikin ◽  
Mikhail Gelfgat ◽  
Vladimir Basovich ◽  
...  
Keyword(s):  
Fatigue Testing ◽  
Drill Pipe ◽  
Bending Moment ◽  
Full Scale ◽  
Fatigue Properties ◽  
Small Scale ◽  
Steel Tool ◽  
Friction Factors ◽  
Bending Load ◽  
Drill Pipes

Aluminum alloys are among the most promising materials for manufacture of drill pipes for deepwater and ultra-deepwater drilling in corrosive environment. Aluminum drill pipes are made with steel tool-joints to increase the number of connection makings-and-breakings. One of the major concerns of aluminum drill pipe operation in deepwater complex profile wells is the fatigue of their connection. This paper presents the results of study of fatigue properties of aluminum alloy 1953T1 Light Alloy Drill Pipes of Improved Dependability (LAIDP) 147×13 mm that are most extensively used in Russia. During assembly, the pin and box of steel tool-joint are heated and screwed on the tubular ends. After cooling, this assembly provides a reliable permanent connection. The study includes experimental determination of the S-N curve of small-scale specimens of aluminum tubular, FEA of the connection with the SCF determined and fatigue testing of the full-scale LAIDP connection. FEA is based on 3D model. The material properties of tubular are modeled as elastic-plastic. The distribution of hot-assembly stresses is considered in detail. Alternating bending load is applied by several semi-cycles. The results of analysis of Stress Concentration Factor (SCF) at various axial loads, bending moment ranges, friction factors of contact surfaces and interference of connection are given. Full-scale fatigue testing of connection specimen is carried out to verify the results of analysis.

scholarly journals From the fatigue properties of Ti6Al4V produced by ALM selective laser melting process to the mechanical design of an aeronautical part

2020 ◽  
Vol 321 ◽  
pp. 03032
Author(s):  
François Edy ◽  
Viet-Duc LE ◽  
Claudia BIERE ◽  
Monica Perez ◽  
Etienne Pessard ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
Mechanical Design ◽  
Fatigue Behavior ◽  
Melting Process ◽  
Fatigue Behaviour ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Laser Melting ◽  
Fatigue Design ◽  
Process Strategy

Selective laser melting SLM is investigated through a study of redesign and characterization of an aeronautic part made of titanium Ti6Al4V. The part must ensure an excellent static and fatigue behaviour. The methodology developed hereby follows 3 main steps: First, the influence of laser power, laser speed and hatch distance on the amount/rate of porosity is performed to define optimized process parameters. Then, the influence of building process strategy, i.e. building direction or as-built surface roughness on the static and fatigue behaviour are studied and understood by following a vast experimental campaign. Obtained properties are finally used in a topology optimization study to find the best compromise between part weight and fatigue behavior . 3 prototypes of simulated part are produced and then characterized. Fatigue tests are conducted on the component and confirm the fatigue design proposed. Obtained results are encouraging and illustrate the fatigue design optimization of a complex Additive Manufacturing component.

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