Search Results for weldability

Coal burning power companies are currently considering FeAlCr weld overlay claddings for corrosion protection of waterwall boiler tubes located in their furnaces. Previous studies have shown that these FeAlCr coatings exhibit excellent high-temperature corrosion resistance in several types of low NOx environments. In the present study, the susceptibility of FeAlCr weld overlay claddings to hydrogen cracking was evaluated using a gas-tungsten arc welding (GTAW) process. Microsegregation of alloying elements was determined for the FeAlCr welds and compared to a currently used Ni-based superalloy. Long-term gaseous corrosion testing of select weld overlays was conducted along with the Ni-based superalloy in a gaseous oxidizing/sulfidizing corrosion environment at 500°C. The sample weight gains were used along with analysis of the corrosion scale morphologies to determine the corrosion resistance of the coatings. It was found that although there were slight differences in the corrosion behavior of the selected FeAlCr weld coatings, all FeAlCr based alloys exhibited superior corrosion resistance to the Ni-based superalloy during exposures up to 2000 hours.

Construction of boilers that can take advantage of the higher efficiencies offered by thermodynamic cycles operating in the ultrasupercritical range will require materials having elevated temperature properties considerably superior to those of the alloys used in more conventional boilers. While many of the materials currently under consideration for ultrasupercritical boiler applications have seen use in other applications, few have been fully investigated using the product forms and section sizes required by high-temperature, high- pressure steam generators. Before any material can be considered truly applicable for use in these advanced plants, the requirements and effects of boiler industry fabrication processes must be explored in addition to determining the properties of the basic alloys. This need was recognized in a materials evaluation program sponsored by the U.S. Department of Energy and the Ohio Coal Development Office and a portion of this program has been devoted to studying the weldability of candidate ultrasupercritical boiler alloys. This paper describes the results of welding trials involving two of these alloys: Super 304H stainless steel and Controlled Chemistry Alloy 617, a variant of Inconel 617 that has been dubbed “CCA 617.” The CCA 617 was represented in both thick plate and tubular product forms, but the stainless steel was only available as tubing. Issues that might be encountered in fabricating advanced boiler headers and piping were addressed while welding the CCA 617 plate with shielded metal arc and submerged arc processes. Similarly, experience working with tubular product forms of both alloys was gained while making butt joints with an orbital gas tungsten arc process. The paper describes the problems presented, the procedures developed, and the basic characteristics of the welds produced.

Short characteristics of the out-of-date Polish power generation system are given, which shows that in the near future there will be a shortage of electrical energy and the necessity to build supercritical power units. A lignite-fired boiler will be build at the RAFAKO Boiler Plant. Supercritical operating parameters require new creep resisting steels to be applied for the boiler and pipe systems. Therefore at the Institute of Welding weldability examinations have been performed on selected Cr-W heat resisting steels. Welding thermal cycles have been simulated on steels: HCM2S (T23/P23), T92/P92, E911 and HCM12A. The influence of t 8/5 cooling times on Charpy V notch toughness, HV10 hardness and microstructure of simulated HAZ's is presented in the form of graphs and prints of microstructures. By means of simulation technique the susceptibility to reheat cracking of those steels has been evaluated. At REMAK- Opole (Enterprise for the Modernisation of Power Installations) and RAFAKO tube and pipe test joints were welded, to select proper fabrication conditions. Mechanical properties of the welded test joints, KV notch toughness of weld metals and HAZ’s and microstructures were examined and are presented.

Dissimilar metal welds (DMWs) between ferritic and austenitic materials at elevated temperatures have long posed challenges for boiler manufacturers and operators due to their potential for premature failure. As the industry moves towards higher pressures and temperatures to enhance boiler efficiencies, there is a need for superior weld metals and joint designs that optimize the economy of modern boilers and reduce reliance on austenitic materials for steam headers and piping. EPRI has developed a new filler metal, EPRI P87, to enhance the performance of DMWs. Previous work has detailed the development of EPRI P87 for shielded metal arc welding electrodes, gas-tungsten arc welding fine-wire, and its application in an ultra-supercritical steam boiler by B&W. This study examines the weldability of EPRI P87 consumables through various test methods, including Varestraint testing (both trans and spot), long-term creep testing (approximately 10,000-hour running tests), procedure qualification records for tube-to-tube weldments between traditional/advanced austenitic steels and creep-strength enhanced ferritic steels, and elevated temperature tensile testing. Macroscopic examinations from procedure qualification records using light microscopy confirmed the weldability and absence of cracking across all material combinations. The findings demonstrate that EPRI P87 is a weldable alloy with several advantages for DMW applications and highlight that specific weld joint configurations may necessitate the use of high-temperature tensile data for procedure qualifications.

Inconel alloy 740 is a precipitation-hardenable nickel-chromium-cobalt alloy with niobium, derived from Nimonic 263, and is considered a prime candidate for the demanding conditions of advanced ultrasupercritical boilers. It offers an exceptional combination of stress rupture strength and corrosion resistance under steam conditions of 760°C (1400°F) and 34.5 MPa (5000 psi), surpassing other candidate alloys. Initially, Inconel alloy 740 was prone to liquation cracking in sections thicker than 12.7 mm (0.50 in), but this issue has been resolved through modifications in the chemical composition of both the base and weld metals. Current concerns focus on the weld strength reduction factor for direct-age weldments. This has led to further development in welding Inconel alloy 740 using Haynes 282, which has higher creep strength and may mitigate the weld strength reduction factor. This study details successful efforts to eliminate liquation cracking and compares the properties of Inconel alloy 740 and Haynes 282 filler materials using the gas tungsten arc welding process.

Inconel alloy 740, a precipitation-hardenable nickel-chromium-cobalt alloy with niobium addition, has emerged as a leading candidate material for ultra-supercritical (USC) boilers due to its superior stress rupture strength and corrosion resistance at operating temperatures near 760°C. While derived from Nimonic alloy 263, alloy 740's unique chemistry necessitates comprehensive weldability studies to address potential challenges including heat-affected zone liquation cracking, ductility-dip cracking, and post-weld heat treatment cracking. This ongoing investigation examines the alloy's weldability characteristics through material characterization studies comparing its cracking sensitivity to established aerospace alloys like Waspalloy and Inconel alloy 718. The research applies aerospace industry expertise to boiler applications requiring sections up to three inches thick, with gas tungsten arc welding and pulsed gas metal arc welding identified as the most promising processes for producing sound, crack-free welds.

Advanced power generation systems, including advanced ultrasupercritical (A-USC) steam and supercritical carbon dioxide (sCO 2 ) plants operating above 700°C, are crucial for reducing carbon dioxide emissions through improved efficiency. While nickel superalloys meet these extreme operating conditions, their high cost and poor weldability present significant challenges. This study employs integrated computational materials engineering (ICME) strategies, combining computational thermodynamics and kinetics with multi-objective Bayesian optimization (MOBO), to develop improved nickel superalloy compositions. The novel approach focuses on utilizing Ni 3 Ti (η) phase strengthening instead of conventional Ni 3 (Ti,Al) (γ’) strengthening to enhance weldability and reduce costs while maintaining high-temperature creep strength. Three optimized compositions were produced and experimentally evaluated through casting, forging, and rolling processes, with their microstructures and mechanical properties compared to industry standards Nimonic 263, Waspaloy, and 740H. Weldability assessment included solidification cracking and stress relaxation cracking tests, while hot hardness measurements provided strength screening. The study evaluates both the effectiveness of the ICME design methodology and the practical potential of these cost-effective η-phase strengthened alloys as replacements for traditional nickel superalloys in advanced energy applications.

Olefin furnaces contain gravity cast U-bend fittings from Fe-Ni-Cr alloys that can experience premature failures due to a combination of harsh service conditions. The fittings undergo steep temperature variations during startup and shutdown, outer diameter (OD) oxidation from furnace flue gases, and inner diameter (ID) carburization from process fluids. As a result, cracking often occurs along large solidification grain boundaries from interconnected networks of carbides and secondary phases. To address these degradation concerns, Wire Arc Additive Manufacturing (WAAM) is being used to produce a functionally graded fitting that provides increased oxidation, carburization, creep, and thermal fatigue resistance. Three welding wire compositions have been designed based on thermodynamic and kinetic modeling techniques to address the appropriate corrosion resistance and mechanical properties needed in the OD, Core, and ID regions of the U- bend fitting cross-section. A Fe-35Cr-45Ni-0.7Nb solid welding wire is being used for the Core section, and metal-cored welding wires based around this composition with additions of Si or Al are being used for the OD and ID sections, respectively. This study involved weldability evaluation focused on understanding the microstructures and potential additive manufacturing printability challenges associated with graded WAAM structures using these welding wires. To achieve this, Cast Pin Tear Testing (CPTT) was performed to evaluate solidification cracking susceptibility of the welding wires. Additionally, Scheil calculations were performed in Thermo-Calc software to predict solidification microstructures. To validate the results, SEM characterization was conducted on cast buttons of each welding wire to identify phases in the respective microstructures. These unique data will help inform WAAM design parameters needed to produce a Functionally Graded Material (FGM) that improves the lifetime of Fe-Ni-Cr U-bend fittings in olefin furnaces.?

High gamma prime Ni-based superalloys comprising ≥3.5 % Al are difficult to weld due to high propensity of these materials to weld solidification, heat affected zone liquation, and stress-strain cracking. In this study the root cause analysis of cracking and overview on the developed weldable Ni-based superalloys for repair of turbine engine components manufactured from equiaxed (EA), directionally solidified (DS), and single crystal (SX) materials as well as for 3D AM is provided. It is shown that the problem with the solidification and HAZ liquation cracking of turbine engine components manufactured from EA and DS superalloys was successfully resolved by modification of welding materials with boron and silicon to provide a sufficient amount of eutectic at terminal solidification to promote self-healing of liquation cracks along the weld - base material interface. For crack repair of turbine engine components and 3D AM ductile LW4280, LW7901 and LCT materials were developed. It is shown that LW7901 and LCT welding materials comprising 30 - 32 wt.% Co produced sound welds by GTAW-MA on various SX and DS materials. Welds demonstrated high ductility, desirable combination of strength and oxidation properties for tip repair of turbine blades. Examples of tip repair of turbine blades are provided.

Solidification cracking (SC) is a defect that occurs in the weld metal at the end of the solidification. It is associated with the presence of mechanical and thermal stresses, besides a susceptible chemical composition. Materials with a high solidification temperature range (STR) are more prone to the occurrence of these defects due to the formation of eutectic liquids wetting along the grain boundaries. The liquid film collapses once the structure shrinks and stresses act during the solidification. Thus, predicting the occurrence of SC before the welding process is important to address the problem and avoid the failure of welded components. The nuclear power industry has several applications with dissimilar welding and SC-susceptible materials, such as austenitic stainless steels, and Ni-based alloys. Compositional optimization stands out as a viable approach to effectively mitigate SC in austenitic alloys. The integration of computational modeling into welding has significantly revolutionized the field of materials science, enabling the rapid and cost-effective development of innovative alloys. In this work, a SC resistance evaluation is used to sort welding materials based on a computational fluid dynamic (CFC) model and the alloy's chemical composition. An index named Flow Resistance Index (FRI) is used to compare different base materials and filler metals as a function of dilution. This calculation provides insights into the susceptibility to SC in dissimilar welding, particularly within a defined dilution range for various alloys. To assess the effectiveness of this approach, the relative susceptibility of the materials was compared to well-established experimental data carried out using weldability tests (Transvarestraint and cast pin tear test). The FRI calculation was programmed in Python language and was able to rank different materials and indicate the most susceptible alloy combination based on the dilution and chemical composition.

This paper focuses on the key properties of newly developed high-strength, heat-resistant steels for application in ultra-supercritical (USC) boilers. For some ferritic steels, improvements made to enhance their resistance to steam oxidation are highlighted. The latest welding techniques employed for these steels are introduced. Additionally, the high-temperature strength and weldability of Alloy 617 (52Ni-22Cr-13Co-9Mo-Ti-Al), a potential candidate material for the next generation of 700°C USC boilers, are described. The paper provides insights into the materials and welding technologies crucial for the development of advanced USC boilers operating at higher temperatures.

The Institute of Materials Science, Welding and Forming (IWS) conducts research activities on ferritic/martensitic 9-12% Cr steels through an interconnected network of projects. These projects focus on mechanical properties of base and weld metals, microstructural characterization of creep and damage kinetics, weldability, microstructure analysis during creep, modeling of precipitation and coarsening kinetics, and deformation behavior under creep loading. The individual projects are briefly described, outlining the conceptual approach towards quantitatively describing the creep behavior of 9-12% Cr steels. The research efforts aim to comprehensively understand and model the creep performance of these advanced steel grades by investigating their microstructural evolution, damage mechanisms, precipitation kinetics, and deformation characteristics under creep conditions. The integrated projects examine both base metals and welded joints, providing insights into material properties, weldability, and microstructure-property relationships critical for their application in high-temperature components.

This paper presents RAFAKO S.A. experience within the field of research and implementation of new group of creep-resistant steel grades with addition of tungsten, including the selection of filler metal, welding procedures and selected results of mechanical properties testing carried out during the implementation of welding process for elements of steam superheaters of the boilers with supercritical parameters. It summarizes the experience and results of research works carried out in RAFAKO, Silesian Technical University in Katowice and Welding Institute in Gliwice within the framework of COST 522 program concerning the influence of simulation of element temperature operating conditions on Chaгpy V notch toughness, HV10 hardness, microstructure of simulated HAZ's, assessment of steel weldability, strength properties. The welded joints structure stability and HAZ after stress relief annealing and after ageing - simulation of element operating conditions are presented in the form of graphs and prints of microstructures.

The manufacture of large, complex components for ultra-supercritical and oxy-combustion applications will be extremely costly for industry over the next few decades as many of these components will be manufactured from expensive, high strength, nickel-based alloys casting and forgings. The current feasibility study investigates the use of an alternative manufacturing method, powder metallurgy and hot isostatic processing (PM/HIP), to produce high quality, and potentially less expensive components for power generation applications. Benefits of the process include manufacture of components to near-net shapes, precise chemistry control, a homogeneous microstructure, increased material utilization, good weldability, and improved inspectability.

This study explores the expanded applications of Alloy J513, a high-performance material traditionally used in cast engine valvetrain components, for powder metallurgy and surface cladding applications. While already recognized for its superior heat and wear resistance at a lower cost compared to cobalt-based hardfacing materials, J513 demonstrates additional advantages in powder metallurgy applications due to its ability to achieve desired powder characteristics through atomization without requiring post-atomization annealing. Through experimental investigation based on fundamental metallurgical principles and cladding engineering processes, the presented research demonstrates J513’s exceptional weldability and favorable weldment structure compared to conventional cobalt-based alloys. The study establishes crucial relationships between weldment behavior and unit energy input, providing valuable insights for advanced cladding techniques while highlighting J513’s potential as a sustainable alternative to traditional nickel- and cobalt-based alloys in various manufacturing processes, including surface overlay and additive manufacturing.

Utilities worldwide are facing increased demand for additional electricity, reduced plant emissions and greater efficiency. Part of the solution is achieved by increasing boiler temperature, pressure and coal ash corrosion resistance of the materials of boiler construction. In this paper, a new nickel-base tube alloy, INCONEL alloy 740, meeting this challenge is characterized with emphasis on mechanical properties, coal ash and steam corrosion resistance as well as weldability. Microstructural stability as a function of temperature and time is addressed as well as some of the early methodology employed to arrive at the current chemical composition. Brief mention is made of certain current and future alloy characterization efforts and potential environmental benefits to be expected should the boiler technology utilizing INCONEL alloy 740 be adopted.

Steel castings of creep-resistant steels are critical components in the high and intermediate pressure turbine sections of fossil fuel-fired power plants. As plant efficiencies improve and emission standards tighten, steam parameters become more stringent, necessitating constant enhancement of material creep resistance. Steel foundries alone cannot conduct necessary material development at an appropriate scale, so all power plant component suppliers cooperate to define optimal chemical compositions, perform test melts, creep tests, microstructure investigations, and test pilot components, such as through the COST program developing new 9-12%Cr cast steel grades. This paper illustrates a steel foundry's role in COST, describing the transfer of these new cast steel grades from research into commercial production of heavy cast components, outlining incurred problems, process development cycles, comparisons with low-alloy steels, welding tests, base material/weld investigations, heat treatment optimization, and casting of pilot components/weldability test plates to verify castability of larger parts and make necessary adjustments. Parallel to ongoing COST creep tests, the steel grades were introduced into commercial large component production, involving solutions to process-related issues, with over 180 components successfully manufactured to date, while further COST program developments present ongoing challenges.

This study investigated the creep rupture strength and microstructure evolution in welded joints of high-boron, low-nitrogen 9Cr steels developed by NIMS. The welds were fabricated using the GTAW process and Inconel-type filler metal on steel plates with varying boron content (47-180 ppm). Creep rupture tests were conducted at 923K for up to 10,000 hours. Despite their higher boron content, these steels exhibited good weldability. Welded joints of the boron steel displayed superior creep properties compared to conventional high-chromium ferritic steel welds like P92 and P122. Notably, no Type IV failures were observed during creep testing. Welding introduced a large-grained microstructure in the heat-affected zone (HAZ) heated to the austenite transformation temperature (Ac3 HAZ). This contrasts with the grain refinement observed in the same region of conventional heat-resistant steel welds. Interestingly, the grain size in this large microstructure was nearly identical to that of the base metal. Analysis of the simulated Ac3 HAZ revealed crystal orientation distributions almost identical to those of the original specimen. This suggests a regeneration of the original austenite structure during the alpha-to-gamma phase transformation. Simulated Ac3 HAZ structures of the boron steel achieved creep life nearly equivalent to the base metal. The suppression of Type IV failure and improved creep resistance in welded joints of the boron steels are likely attributed to the large-grained HAZ microstructures and stabilization of M 23 C 6 precipitates. The optimal boron content for achieving the best creep resistance in welded joints appears to lie between 90 and 130 ppm, combined with minimized nitrogen content.

Welding processes and fabrication techniques have been studied in the development of Advanced USC boilers. Advanced 9Cr steels, Fe-Ni alloy (HR6W) and Nickel base alloys (HR35, Alloy 617, Alloy 263, Alloy 740 and Alloy 740H) have been selected as candidate materials for the boiler. The weld joints of these alloys were prepared from plates, small diameter tubes and large pipes, and welding procedure tests were performed. In this study, TIG and SMAW were applied. Both welding process produced good weld joints, and they showed good results in bending tests, tensile tests and the Charpy impact test. To select the annealing conditions for stress relief, stress relaxation tests and hardness tests were conducted on the weld joints after various heat treatments. The microstructure was also evaluated by SEM and TEM. Creep rupture tests are being performed for the weld joints with and without heat treatment. The maximum creep rupture tests are expected to take over 100,000 hours. In the study of fabrication techniques, hot bending tests by high frequency induction heating for large pipes and cold/hot bending tests for small diameter tubes were established. After the bending tests, mechanical property tests such as tensile tests, impact tests and creep rupture tests were conducted. The effect of pre-strain on creep strength was studied to take the creep test results after bending into consideration. The creep rupture test will be continued for specimens from weld joints and bending pipes to show their long term reliability.

ASTM Grade 23 is a 2.25Cr-0.3Mo-1.5W-V-Nb-B steel widely used for the fabrication of boiler components of the most recent ultra super critical power plants; it combines high creep resistance, enhanced oxidation and corrosion resistance and good weldability. Microstructural, mechanical, and creep properties of seamless tubes and pipes after normalizing and tempering heat treatment are compared with those obtained after cold bending and hot induction bending. The creep resistance is obtained through the precipitation of fine carbides after tempering. A broad program of TEM investigations on crept samples has been carried out in order to assess the evolution of the microstructure and its phases after long term high-temperature exposure, in terms of chemical composition, size and distribution of precipitates.