Obtaining low alloy steels with different Ni contents and similar microstructures and mechanical properties

Low alloy steels are used in many applications in the oil and gas industry. The addition of Ni in these steels improves their low temperature fracture toughness and hardenability, with a low penalty on weldability. However, ISO 15156-2 standard restricts Ni content up to a 1 wt% limit, requiring additional and expensive tests if higher Ni steels are to be used. This limit is based on the hypothesis that higher contents of Ni may negatively affect Sulfide Stress Cracking (SSC) resistance in sour service applications. On the other hand, several investigators have concluded that SSC resistance depends on microstructure and hardness rather than Ni content. The 1 wt% Ni limit imposed by ISO 15156-2 is controversial, as recently pointed out by other authors. This work aims to develop alloys and heat treatments tailored to obtain the same microstructure and hardness in steels with different Ni contents (from 0 to 5 wt %), therefore leaving Ni content as the main variable. This will allow, in a future stage of the project, to study the effect of Ni on the SSC crack propagation kinetics. Transformation temperatures of the alloys were measured with differential scanning calorimetry (DSC). Characterization of the as-quenched samples confirmed a fully martensite microstructure. Tempering of the samples allowed obtaining hardness values near 22 HRC. Microstructure was evaluated with optical and scanning electron microscope and hardness measurements. Tensile tests were performed to evaluate mechanical properties as a function of Ni content.