Role of residual stress in the failure of HF-ERW welded tubes.

• HF-ERW welding resulted in the formation of tensile residual stress, resulting in failure of the tube during flattening operation. • Thermo-mechanically heat-affected zone were found to have (1 1 0)[0 0 1],(1 1 0)[1 1 ¯ 0], (0 0 1)[1 1 ¯ 0], (0 0 1)[ 11 ¯ 0] texture. • Post weld heat treatment was found to be effective in alleviating tensile residual stress and preventing tube failure. High-frequency electric resistance welding is used for manufacturing hydro formable tubes. Tube forming and welding results in the formation of residual stress. The hole drilling technique was used to evaluate the residual stress of the welded tube. Tensile residual stress of varying magnitude was observed at different locations on the tube. The weld, heat affected zone was observed to have the highest residual stress as a result of phase transformation, forming and gradually reduced towards the parent material. The generated tensile residual stress led to failure of the tube during mechanical evaluation. Additionally, electron backscattered diffraction studies (EBSD) of the fusion line and the thermo-mechanically heat-affected zone were found to have goss and cube texture. These detrimental textures can lead to easy crack propagation in the presence of defects along the fusion line. A post-weld heat treatment (PWHT) was carried out to alleviate the tensile residual stress and alter the weld microstructure. PWHT helped transform the bainite in the weld to ferrite and pearlite. The inter-critical annealing significantly reduced the tensile residual stress along the circumferential direction resulting in improved formability. [ABSTRACT FROM AUTHOR]