Micro Analysis on Lamination

Lamination is one of the very common defect in the manufacturing process

of seamless metallic pipes. It is a sub-surface type defect that mostly occurs
in parallel to the pipe surface.
Microstructure abnormality, inclusion rate & crack of raw material, soaking
time, temperature & maintenance issues are liable for lamination.
Case 1: Microstructure abnormality of raw material

100 X 100 X

500 X 200 X
Ferrite
Pearlite
Fig: Microstructure of billet of Fig: Microstructure of billet of
Kamaldeep with banded Bhushan with banded pearlite
pearlite where ASTM grain size where ASTM grain size no. 7
no. 5
Remark:
During produce of casting bloom from ingot, micro segregation is induced
by phase transformation during cooling. Micro segregation across the
pearlite structure the concentrations of Mn, Si, S, P, and Al were higher in
the pearlite colonies compared with ferrite grains and pearlite become
banded.
In the cooling process, a carbon atom migrates from the low-manganese
regions toward the high-manganese regions and therefore, the carbon-rich
and carbon-depleted regions form ferrite and pearlite layers, respectively.
Soft ferrite zone become rolled at first then rolling pressure applied on
banded pearlite that’s why uneven rolling force impressed on surface and
forming lamination layer.
Coarse PBS (Pearlite band structure) causes the cracking and uneven
deformation of steel & crack extends during hot rolling. Ferrite micro
region have crack arrester geometry.

Case 2: Inclusion rate of raw material

Fig: Inclusion test of billet of Prakash

steel
A B C D
T H T H T H T H
0.5 0.5 1 0 - - 2 4
Remark:
More globular oxide inclusions are present, and the inclusion rating is not
in acceptable limit. High inclusion rate increase the chance of lamination
formation.
Case 3: Soaking temperature & time
3.1 Decarb observation on tube
Decarb of laminated tube Decarb of non-laminated OK
tube

250 X

250X

100 X
Ferrite
Pearlite
Carbide network

Remark: At laminated tube there is more decarb throughout lamination

zone. Total decarb value 221.667 µ. At non-laminated tube there is no such
more decarb.

3.2 Decarb observation on direct drop out billet

Billet dia: 71 mm.
Condition: Direct dropout billet from furnace.
R/M: Kamaldeep
 Fig: Decarb (50 X)

Complete Decarb Partial Decarb Total Decarb

486.666 µ 1130.000 µ 1616.666 µ

Remark: The total decarb is 1616.666 µ, due to over shocked. The value is
never acceptable. If soaking temperature & time is more than standard, then
due to oversoaked carbon atom will evaporate from surface decarb value
will more and lamination form.
3.3 Decarb observation on particular lamination zone

100 X 50 X
Contain partial Decarb with 226.667 µ Spreading depth of lamination from
from lamination. OD is 1120.00 µ.
Remark:
Here we can have observed that the lamination contains a thin oxide scale
layer outside it. Also it follows four manners of crack initiation,
propagation, energy releasing branch and inclusion stop point.
From this microstructure we can see that here is uniform ferrite, pearlite &
minor carbide network with decarb. During hot rolling due to high
temperature & over soaking, carbon become evaporate and decarb
formation occur on surface. One side of lamination is decarb area and
another side is without decarb, so two different characteristic of zone form
lamination. The decarb added grain become melt slight before than normal
grain. The decarb zone is soft than without Decarb area. During high hot-
rolling pressure, the soft decarb area become overlap on another zone as a
lamination form.

Case 4: Maintenance issue

Sometime due to maintenance problem OD or ID lamination can form as a
crack.
4.1 OD Lamination (as a crack form)
 If Piercing & TRG roller is pitted
 Due to worn guide shoe.
4.2 ID Lamination (as a crack form)
 High thrust load & water pr.
 Worn plug & mandrel vibration
4.3 Microstructure observation of Lamination (as a crack form)

Fig: Microstructure at lamination zone

Remark: Here no such decarb throughout lamination, so no over shocking
condition shown here. But ferrite & perlite phase grain flow towards the
crack formation direction. So we can conclude that its form due to
excessive material flow toward crack. The cracks or lamination placed in
front of pipe’s front face. The front face impressed high thrust load during
shearing by piercer. Also mandrel run with vibration during piercing. So the
cause of lamination is maintenance issue of high load.
Case 4: Surface condition of billet
OD with hairy OD without hairy crack after Deep Long
crack grind
Zone1 70.71 mm 70.25 mm 0.46 mm 9.75 mm
Zone2 69.83 mm 69.69 mm 0.14 mm 13 mm
Zone3 70.36 mm 69.66 mm 0.7mm 6.24 mm

Fig: DP test of billet

Remark: Thoroughly we check the whole surface of billet by naked eye no
hairy crack visible. But after dye penetration more than one hairy cracks are
visible, which will open up during hot rolling and surely form lamination.