METALLURGY DEPARTMENT

HIP Process Overview

Manufacture
Powder production HIP Cycle Secondary
Can

Expected advantages:
1. Design flexibility

2. Reduction of welding & related processes for assemblies. Net

shaped parts

3. Uniform metallurgical properties.

Results in schedule compression in complex

assemblies & cost reduction
.
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Powder Production

Molten metal

Gas jets

Atomized metal powder

Collecting Can

Powder approximately 100-150 microns

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Can manufacture
“The can holds the powders in place and defines part shape”

Outer capsule parts Inner capsule parts Welded

Welding
Can

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Can deformation – Types of

Cans Type 1
(100% Powder)
Type 2
(hollow cylinder)
Powder occupies the
Powder occupies 100% of
sides of a can with
can to form a solid
the centre becoming a
geometry
bore

powder

powder
Original Size

After HIP
powder

powder

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 METALLURGY DEPARTMENT

Powder Filling
Powder Container

Hoses filling
ports

Capsule

Vibrating Table Can filled with

powder and
vacuum evacuated
to draw off the air.

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 METALLURGY DEPARTMENT

HIP Furnace
1. Vacuum
Large pressure vessel –
danger of leakage of argon 2. Gas
that displaces air & can
endanger personnel
injection

3. Heat Up

Heat expands gas

& this creates
enormous pressure
which collapses
the can onto the
powder; hence
consolidating into
100% density

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 METALLURGY DEPARTMENT

HIP Cycle
start with powders that are progressively consolidated into a 100% dense part

Several parts after

increases thethe
to crunch HIPcan &cycle
Pressure increases as temperature
densify
with the can still around them.
the powders

Note the multiple location of the

ports.

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 METALLURGY DEPARTMENT

Some HIP examples & review of

advantages gained
Uniform
Reduction metallurgical
of secondaries
Reduction
properties of welding
example & The advantage of not

example #5: 3D/5D #6: bends

de-rating a critical

secondaries
Design
2” example #3:
advantage
joint connection #4: area is apparent with
this design.

Pump
Manifold
shapedCasing
example
Net #1:
sections
#2:
bends T-joint
Swivel
avoids the need for
induction
Because of bending & subsequent
the uniformly heat treat
fine grain
requirements.
structure, the design stresses do not&need
The
Multiple
Integrating
A substantial
whole bores
component
features
amount
can besuch
of
incorporated
can
machining
as
beweldolets,
produced
into to
to be de-rated
nearnear
the
flanges,
welding
net is
tees
net
shape as normally
reduced
shape
& vents
design.
with
that required
thiswould
Note in
nearnormally
the
net Note the integration
forgings.
have
shape
insidetoof
part.
be welded.
the capsule. Note the equipment of features and the
significant reduction
necessary to perform
of welding obtained
induction bending
Chevron JSM manifold up to
80% reduction in welding

Feature
would
typically be
welded

Inside of capsule

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 METALLURGY DEPARTMENT

Contrast of Duplex Microstructure as

HIP Metallurgical design advantage is due to the fact that the
grains are automatically considered as fine. Forging design
a Function of Processing
values are de-rated unless proven to have fine grains via
metallographic verification.

DNV RP-F112 1
(fine)

80%

65
ksi

1 65 52
80%
(fine) ksi ksi

Cast dendritic Forged structure HIP microstructure

structure

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 METALLURGY DEPARTMENT

Some Don’ts in HIP Design

MATERIAL TAKE-OFF - APACHE CONISTON MANIFOLD EXAMPLE

MANIFOLD MODULE

STANDARDS & RESPONSIBI

LITY UNIT TOTAL
(REF)/ACTUAL Straight pipe can UNIT
be obtained
ITEM DESCRIPTION QTY1 (CFI OR WEIGHT WEIGHT
PART No'S MEASURE
commercially CONTRACTO (lbs) (lbs)
API / ASME ETC
HIP more practical with R)
Material/Tri
duplex/super duplex alloys Pressure
  HEADER ITEMS Size m/          

Temp (PSI)
Class
10.750 OD x 0.843 WT API 6A
2166986-15 Seamless Pipe, Cr22 Duplex   141 FT CFI 89.2 12577
(9.064 ID) Cr22 Duplex
6.625 OD x 0.562 WT API 5L
2222172-16 Seamless Pipe, X-65
(5.501 ID)
HIP
X-65
wall thicknesses
  85 should
FT be CFI 36.4 3094
at least 1” to be practical
LONG RADIUS 45 DEG ELBOW PIPE 10.750 OD x 0.843 WT ASME B16.9
2254139-02 5000 4 EA CFI 84.056 336
FITTING, Cr22 DUPLEX (9.064 ID) Cr22 Duplex
LONG RADIUS ELBOW PIPE FITTING, 10.750 OD x 0.843 WT ASME B16.9
2253667-14 5000 9 EA CFI 171.6 1544
Cr22 DUPLEX (9.064 ID) Cr22 Duplex
LONG RADIUS ELBOW PIPE FITTING, 6.625 OD x 0.562 WT ASME B16.9
2253667-11 5000 6 EA CFI 41.98 252
F65 (5.501 ID) F-65

CUSHION TARGET TEE BUTT-WELD

2x 6.625 OD x 0.562 WT ASME B16.9
2254460-03 FITTING 5000 4 EA CFI 53.891 216
(5.501 ID) Cr22 Duplex
Cr22 DUPLEX

3x 10.750 OD x 0.843
STRAIGHT TEE BUTT-WELD FITTING, ASME B16.9
2253733-07 WT 5000 6 EA CFI 137.85 827
Cr22 DUPLEX Cr22 Duplex
(9.064 ID)

STRAIGHT TEE BUTT-WELD FITTING, 3x 6.625 OD x 0.562 WT ASME B16.9

2253733-08 5000 24 EA CFI 38.403 922
Cr22 DUPLEX (5.501 ID) Cr22 Duplex

REDUCING OUTLET TEE BUTT-WELD 2x 10.750 OD x 0.843

ASME B16.9
2254459-07 FITTING, WT x 6.625 OD x 0.562 5000 2 EA CFI 125 250
Cr22 Duplex
Cr22 DUPLEX WT

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HIP duplex data sheet

HIP Duplex Stainless UNSS31803
Composition (WT %)
C Cr Mo Ni N PREN
<.03 22 3 5 .17 >33.5
Heat treatment
Solution annealed & water quenched Hardness Maximum HB = 255 (HRC 25)
Solution annealing temperature = 1940oF
Mechanical Properties Minimum Typical
YS (ksi) 65 75
UT(ksi) 90 All design calculations
90 done on
Elongation (%) 25 the basis of the
35 Specified
Reduction in area (%) 45 Minimum Yield65 Strength
Impact strength@-46oC (J) 70/50 80
De-rated yield properties DNV-OS-F101 section 5
Temperature Temperature
ASTM G48 corrosion test is De-rated yield (ksi)
25oC applied to determine if 65 Defining the ratio of
50oC correct heat treatment has 60 austenite-ferrite is a
75oC been done. It is a means to 55 means to reduce
100oC check for presence of 52 susceptibility of alloy
125 Co deleterious sigma phases. 49 to cracking. The
austenite can arrest
150oC 48
cracks originating in
200 Co
45
the ferrite.
These numbers are taken from Figure 2 of the DNV-OS-F101 section 5 specification applying the de-rating against the SMYS

Some Additional Requirements

ASTM G48 method A @ 25 C for 24 hours
o
No pitting, weight loss maximum = 1g/m2
Ferrite-austenite ratio 35-55%
Metallography – no deleterious phases

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All Duplex/Super Duplex alloys are subject to a

Temperature De-rating
Temperature de-rating chart OS-F101

Example Duplex
Depending on the
SMYS - ∆ σ= temperature de-rated yield attemperature
100C the yieldthe
de-rating
alloy
is approximately 90MPa or
is de-rated as a
about 13ksi.
function of
temperature before
applying the HISC
• de-rated temperature yield =
factors described
65ksi-13ksi= 52KSI in
DNV RP-F112
• σ= .8 * 1 * 52 = 42 ksi which
is design stress for membrane
stresses only per DNV RP
F112 equation 4.1

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