Balancing High Strength Tubing Selection and Cost in Hydraulic System Design IFPE 2014

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2 Balancing High Strength Tubing Selection and Cost in Hydraulic System Design IFPE 2014

3 Objectives Review the development of High Strength Steels and how that relates to hydraulic tubing development Explore various SAE specifications related to welded hydraulic tubing Discuss new developments in high strength hydraulic tubing Discuss the advantages of high strength hydraulic tubing in system design

4 High Strength Steels 70 Low Strength Steels(<270MPa) High Strength Steels(HSS) Ultra High Strength Steels(UHSS) (>700MPa) Total Elongation (%) IF IF-HS MILD IS BH CMn HSLA Next Generation AHSS DP-CP MART ,000 1,200 1,400 Tensile Strength (MPa) 1,600

5 High Strength Steels ULSAB Consortium Strength Impact Resistance Energy Absorption Fuel Efficiency Weight Reduction Cost Reduction

6 What About Hydraulic Tubing? Low Strength High Strength Few Steels(<270MPa) advances Steels(HSS) due to: Ductility requirements Total Elongation (%) ,000 1,200 1, Adding IF Carbon to increase strength reaches a Next Generation IF-HS 40 point of diminishing returns AHSS 30 Controlled BHrolling processes don t translate well CMn 20 into DOM tubing manufacture 10 MILD IS HSLA DP-CP ,000 1,200 1,400 Tensile Strength (MPa) Ultra High Strength Steels(UHSS) (>700MPa) Total Elongation (%) MART Low Strength Steels(<270MPa) IF IF-HS MILD IS BH High Strength Steels(HSS) CMn HSLA DP-CP TensileStrength (MPa) Ultra High Strength Steels(UHSS) (>700MPa) Next Generation AHSS MART 1,600 1,600

7 Chemistry Spec Comparison Comparison of SAE Hydraulic Standards SAE J-525 SAE J-2467 SAE J-2614 SAE J-2833 ERW, Cold Drawn, Low-Carbon, Annealed for Bending and Flaring ERW, Cold-Drawn, SAE 1021, SAN for Bending and Flaring ERW, Cold-Drawn HSLA, Sub-Critical Anneal for Bending and Flaring ERW, Cold-Drawn HSLA, SRA for Bending and Flaring Year Published Carbon (C) 0.06 min/0.18 max 0.17min/0.23 max 0.18 max 0.26 max Manganese (Mn) 0.30 through through max 1.60 max Phosphorus (P) 0.04 max 0.04 max max max Sulfur (S) 0.05 max 0.05 max max max Silicon (Si) n/a n/a 0.35 max 0.35 max Aluminum (Al) n/a n/a min.020 min Micro Alloying Elements n/a n/a 0.15 max 0.15 max Mpa Yield Strength (min) Mechanical Mpa Tensile Strength (min) Elongation in 50mm (min) 35% 25% 30% 15% Hardness (max) Rockwell B65 Rockwell B75 Rockwell B90 Rockwell B100 Hardness (target) None stated None stated Rockwell B85 Rockwell B92

8 High Pressure Hydraulic Low Strength Steels(<270MPa) High Strength Steels(HSS) Ultra High Strength Steels(UHSS) (>700MPa) Total Elongation (%) MILD CMn AUSTENITIC SS (3xx) 4130 HSLA HS-50 High Pressure Hydraulic HS-90 High Pressure Hydraulic ,000 1,200 1,400 Tensile Strength (MPa) 1,600

9 HS-50 Advantage Meets Chemistry and Mechanical requirements of J % increase in working pressure over J525 for like-sized tubes 28% decrease in weight when sizing wall to meet standard pressures Improved flow volume when sizing wall to meet standard pressures

10 HS-50 Advantage Questions about this table? Call us at " OD Tubing (Size 8) % Wall Size Design Working Working Pressure % Flow Spec Pressure Increase Increase J525 4, J2467 6,090 34% % J2614 7,313 61% % J , % % Theoretical Weight % Weight Decrease - 18% 28% 45% All calculations assume 25 fps flow velocity (recommended for steel pressure lines)

11 HS-50 Advantage Questions about this table? Call us at " OD Tubing (Size 12) % Wall Size Design Working Working Pressure % Flow Spec Pressure Increase Increase J525 3, J2467 4,395 34% % J2614 5,295 61% % J2833 7, % % Theoretical Weight % Weight Decrease - 18% 28% 45% All calculations assume 25 fps flow velocity (recommended for steel pressure lines)

12 HS-50 Advantage Questions about this table? Call us at " OD Tubing (Size 16) % Wall Size Design Working Working Pressure % Flow Spec Pressure Increase Increase J525 2, J2467 3,549 34% % J2614 4,272 61% % J2833 5, % % Theoretical Weight % Weight Decrease - 18% 29% 45% All calculations assume 25 fps flow velocity (recommended for steel pressure lines)

13 System Design Criteria Meet design pressure minimums Minimize pressure drop Minimize heat generation Reduce fluid turbulence Eliminate cavitation on suction lines Minimize system cost Maximize overall system efficiency

14 System Design allowable stress Material and Type Allowable Design Stress, psi Tube Specification Steel C ,500 SAE J356, J524, J525 Steel C ,000 SAE J2435, J2467 Steel, HSLA HS-50 Stainless Steel, 304 & ,000 SAE J2613, J ,800 ASTM A213, A449, A279 Alloy Steel C ,000 ASTM A519 Copper, K or Y 6,000 SAE J528, ASTM B75 (Design Factor of 72 F)

15 System Design design pressure Design pressure, psi (4:1 design factor) Tube OD, in. Wall thickness, in. Tube ID, in. Steel 1010 (SAE J524 and J525) Steel 1021 (SAE J2467) Stainless Steel (304, 316) 4130, HSLA, HS ,700 3,250 4,050 1, ,250 3,900 4,850 1, ,650 4,400 5,500 1, ,100 4,900 6,150 1, ,800 5,750 7,200 2, ,550 6,650 8,350 2, ,450 7,750 9,750 3, ,200 8,650 10,800 3,450 Copper

16 System Design flow diameter Maximum flow rate, gpm Recommended flow diameter, in. Pressure Lines Return Lines Suction Lines Maximum flow rate, gpm Recommended flow diameter, in Pressure Lines Return Lines Suction Lines

17 Design Example 1 Existing design: OD x Wall J525 tube 4,800 psi design pressure 7 gpm flow Objective: Increase design pressure to 7,200 psi Maintain flow volume

18 Design Example 1 Option 1 increase wall thickness Meets Pressure Requirement Reduces ID to Restricts flow to 4.0 gpm Tube OD, in. Wall thickness, in. Tube ID, in. Steel 1010 (SAE J524 and J525) Design pressure, psi (4:1 design factor) Steel 1021 (SAE J2467) Stainless Steel (304, 316) 4130, HSLA, HS ,700 3,250 4,050 1, ,250 3,900 4,850 1, ,650 4,400 5,500 1, ,100 4,900 6,150 1, ,800 5,750 7,200 2, ,550 6,650 8,350 2, ,450 7,750 9,750 3, ,200 8,650 10,800 3,450 Copper

19 Design Example 1 Option 2 use HS-50, SS, or 4130 Meets pressure requirement Maintains 7.0 gpm flow Tube OD, in. Wall thickness, in. Tube ID, in. Steel 1010 (SAE J524 and J525) Design pressure, psi (4:1 design factor) Steel 1021 (SAE J2467) Stainless Steel (304, 316) 4130, HSLA, HS ,700 3,250 4,050 1, ,250 3,900 4,850 1, ,650 4,400 5,500 1, ,100 4,900 6,150 1, ,800 5,750 7,200 2, ,550 6,650 8,350 2, ,450 7,750 9,750 3, ,200 8,650 10,800 3,450 Copper

20 Design Example 2 Existing design: OD x Wall J525 tube 4,800 psi design pressure 7 gpm flow Objective: Maintain design pressure of 4,800 psi Increase flow by 25%

21 Design Example 2 Option 1 increase tube OD Meets pressure and flow targets Significant design change Cost Tube OD, in. Wall thickness, in. Tube ID, in. Steel 1010 (SAE J524 and J525) Design pressure, psi (4:1 design factor) Steel 1021 (SAE J2467) Stainless Steel (304, 316) 4130, HSLA, HS ,200 3,850 4,800 1, ,750 4,500 5,650 1, ,350 5,200 6,550 2, ,050 6,050 7,600 2, ,600 6,700 8,450 2, ,350 7,600 9,550 3,050 Copper

22 Design Example 2 Option 2 use HS-50, SS, or 4130 Increase flow to 9.0 gpm Meets pressure requirement Reduced weight Tube OD, in. Wall thickness, in. Tube ID, in. Steel 1010 (SAE J524 and J525) Design pressure, psi (4:1 design factor) Steel 1021 (SAE J2467) Stainless Steel (304, 316) 4130, HSLA, HS ,700 3,250 4,050 1, ,250 3,900 4,850 1, ,650 4,400 5,500 1, ,100 4,900 6,150 1, ,800 5,750 7,200 2, ,550 6,650 8,350 2, ,450 7,750 9,750 3, ,200 8,650 10,800 3,450 Copper

23 Cost Comparison 70 Low Strength Steels(<270MPa) High Strength Steels(HSS) Ultra High Strength Steels(UHSS) (>700MPa) 60 Total Elongation (%) MILD CMn AUSTENITIC SS (3xx) 4130 HSLA ,000 1,200 1,400 Tensile Strength (MPa) 1,600

24 Cost Comparison Relative Cost Allowable Design Stress SS, 316 seamless ,800 SS, 304 seamless ,800 SS, 316 welded ,800 SS, 304 welded ,800 Alloy C-4130, seamless ,000 Alloy C-4130, welded ,000 HSLA - HS ,000 Steel C ,000 Steel C ,500 ALLOWABLE DESIGN STRESS Relative Cost (C1010 = 1)

25 Chemistry and Mechanicals CHEMICAL COMPOSITION HS-50 & HS-90 High Pressure Hydraulic MECHANICAL REQUIREMENTS HS-50 High Pressure Hydraulic HS-90 High Pressure Hydraulic C% max Mn% max Yield Strength S% max P% max Si% max Tensile Strength MPa min psi min MPa min psi min Al% max Elong % min Micro Alloying elements (Nb, Cb, Ti, V) max Applicable Specification , , SAE J , , SAE J2833

26 Standard Sizes Plymouth HS-50 and HS-90 High Pressure Hydraulic - Standard Size Offerings Tube Wall (in.) Tube OD (in.)

27 Questions about this presentation? Contact at