Proceedings of the ASME 2018 Symposium on Elevated Temperature Application
of Materials for Fossil, Nuclear, and Petrochemical Industries
WELD OVERLAY OF HIGHLY CORROSION RESISTANT NICKEL CHROMIUM
MOLYBDENUM ALLOYS, UNS N06059, ON LOW ALLOY EQUIPMENT OPERATING
AT HIGH TEMPERATURE
A. Volpi
Technological Department
ALFA LAVAL OLMI s.p.a.
Suisio, Bergamo, Italy
ABSTRACT
Corrosion conditions in the Chemical and Oil and Gas
Industries are such that equipment must withstand pressure and
corrosion at high temperatures.
Due to the fact that in many cases only the internal surface
is exposed to corrosive attack, and so only that surface needs to
be protected, savings on material costs can be achieved by
taking advantage of the weld overlay technique.
Weld overlay, through the choice of alloy, is selected to
resist to the corrosive attack. Parent material can be selected
based on the required strength at temperature.
In recent years, highly corrosion resistant Nickel
Chromium-Molybdenum Alloys have been developed to operate
in the most severe corrosive environments.
One of the recent developments in this family of materials,
is Alloy 59 UNS N06059 that is replacing Hastelloy C-2000
UNS N06200 and Hastelloy C-22 UNS N06022. Nickel-
Chromium-Molybdenum alloys are the most versatile nickel
alloys, because they contain molybdenum, which protects
against corrosion under reducing conditions, and chromium
which protects against corrosion under oxidizing conditions.
Wrought products produced from these alloys are
processed to obtain a homogeneous austenitic grain structure.
Weld overlay or weld deposit, due to the fundamental
differences in processing compared to base material, result in a
more heterogeneous metallurgical grain structure that in general
shows however a good level of corrosion resistance.
Weld or Weld overlay features are highly dependent on
electric parameters, filler metal, technique, base material
temperature, etc., and for this reason the general settings of the
welding process need to be finalized and tested, with the intent
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ETAM2018
April 3-5, 2018, Seattle, WA, USA
ETAM2018-6715
G. Serra
Technological Department
ALFA LAVAL OLMI s.p.a.
Suisio, Bergamo, Italy
of optimizing all these parameters in order to allow the best
corrosion results.
A research activity has been carried out by ALFA LAVAL
OLMI to define a processes and parameters’ selection in order
to obtain a weld deposit with a behavior as close as possible to
wrought Alloy 59 base material.
INTRODUCTION
Today for pressure vessels operating at high
temperatures and in severe corrosion environments, stainless
steel material or Nickel alloys can be applied with the aim to
protect the internal surface of the vessel.
Weld overlay is a solution that makes it possible to
alter the exposed surface of the parent metal, which has been
selected based on the required strength at the working
temperature, by applying one or more metallurgically bonded
layers that have a chemistry and metallurgy capable of
guaranteeing surface protection against the effects of corrosion
and/or erosion or other phenomena caused by the service. Weld
Overlay is an efficient and cost-saving solution, due to the fact
that only the surface exposed to corrosion (commonly process
side) will be protected with a noble and expensive alloy.
The weld overlay fusion welding process, is optimized
when the deposited weld metal and the parent metal are alike,
from metallurgical and physical point of view; both materials
should have sufficient miscibility one in the other, in the molten
state and at the solid state, so that they do not generate
excessive segregations, or real separations during the rapid
cooling process typical of fusion welding.
In some cases, where the selected materials to be
joined are incompatible one with the other, different methods of
 cladding need to be used. (e.g., Titanium on Iron base parent Volume of filler Metal added (Vfm)
Weld Pass
metal). Other methods of applying cladding to create a
corrosion resistant layer on parent metal include explosion Fusion Depth
cladding, roll cladding and spray coating, although spray
coatings must be very carefully considered, due to intrinsic
potential presence of porosity, that can create preferential path
for the corrosive agents. Volume of parent metal (Vpm)
This paper presents the analysis on the behavior of
Base Metal
highly corrosion resistant Nickel Chromium-Molybdenum
Alloys UNS N06059 weld overlay, performed with different
welding processes, on low alloy parent metal type SA 387 Gr.22 Figure 1. Schematic sketch that shown typical weld pass
Cl.2. Qualification specimens that were welded and tested are performed on parent metal support .
part of the welding procedure development carried out by ALFA
LAVAL OLMI, for manufacturing heat exchangers and pressure
vessels, employed in chemical process industry, working at high
temperature and pressure and with the process side exposed to
(1)
both oxidizing and reducing corrosive environments.
When the Dr% is high, then the volume of base material
incorporated in the weld deposit also will be high. When the
NOMENCLATURE
welding process or welding procedure involves a high Dr%, the
number of layers needed to obtain the required chemistry will
ESW Welding, electroslag
be higher than it will be with a process, or a procedure, with
SAW Welding, submerged‐arc
having a low dilution rate.
GTAW Welding, gas tungsten‐arc
Dilution rate varies with each welding process.
GTAW HW Welding, gas tungsten‐arc hot wire
Nevertheless, even with the same welding process the dilution
SMAW Welding, shielded metal‐arc
rate can vary depending on electrical parameters, travel speed,
GMAW Welding, gas metal‐arc
preheat/interpass temperature and different technique (ex.
FCAW Welding, flux‐cored arc
overlap and oscillation).
Dr% Dilution rate
PWHT Post weld heat treatment ESW STRIP
SAW STRIP
SAW WIRE
BACKGROUNG
GMAWP
GMAW
Overlay by welding is a flexible solution, that can be easily
SMAW
applied during manufacturing. It can be carried out on parts
GTAW HOT WIRE
with different shapes, different geometries and in different GTAW MANUAL
positions. The fusion welding process often is selected to obtain 0
10 20 30 40 50 70 80 90 100
the best results in terms of quality and productivity. DILUTION (%)
On extended and regular surfaces, high deposit rate Figure 2. Comparison of Dr% of different welding process.
welding processes, such as ESW or SAW Strip can be
employed; whereas, more flexible and versatile processes, such The total volume of weld pass or weld overlay in general is
as GTAW, SMAW, GMAW, or FCAW can be used when the mainly composed of filler metal.
surfaces are small or irregular. The Filler metal chemical analysis is also important in weld
Depending on the extent of dilution with base material, overlay.
different welding processes may require different numbers of Filler materials for high Nickel Chromium-Molybdenum
layers, in order to reach the desired weld deposit chemistry. alloys typically have compositions similar to comparable
Dilution rate is an important parameter in weld overlay that wrought material. When welding these alloys to themselves the
influences final overlay composition. matching filler metals are quite suitable; however, care must be
Dilution rate explains also the difference between the taken when a high Ni-Cr-Mo weld overlay is applied to
chemical composition resultant in weld deposit and the nominal unalloyed base material.
chemical composition of the employed filler material. There currently are no “overalloyed” Nickel-base filler
Dilution rate (Dr%) can be defined as the volume of base metals that are designed to compensate for the effects of critical
material, or the volume of previously deposited weld metal in alloy drop due to the dilution available on the market. That’s
case of multilayered weld overlay, incorporated in each weld why for these for these materials, the overlay welding procedure
pass, related the total volume of fused metal. “Equation (1).”

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 should be carefully adjusted with the aim to obtain an amount of Nickel-Chromium-Molybdenum alloys are widely used in
dilution as low as possible. the chemical, petrochemical and pharmaceutical processes, as
As an example, the situation is different in case of Stainless well as in energy production, pollution control equipment and
Steel: due to the presence of less alloy elements compared to fuel gas desulfurization industries. A feature of these alloys is
nickel alloy, different types of AWS classifications can be used their high resistance to corrosion in aggressive acids, such as
as overalloyed filler metal with respect to finally required weld sulfuric, hydrochloric, and hydrofluoric.
deposit chemistry. High Ni-Cr-Mo alloys derived from the original C-alloy
These overalloyed filler metals may be used to deposit the (N1002) which was introduced to the market in cast form in
first layer of multilayer overlay, but they also may be used for 1932. The most advanced NiCrMo alloys are N06686, N06059
single layer techniques with low dilution. (e.g., ER/EQ 309LNb (Alloy 59) and Hastelloy C-2000. However, the most common
in cases where a TP347 chemistry is required or 309LMo in NiCrMo alloy in industrial applications is alloy C-276
cases where a TP316L chemistry is required). (N10276) which was introduced in the market in the mid-1960s.
In recent years some manufacturers specializing in Nickel Nickel-Chromium-Molybdenum alloys are the most versatile
alloys weld overlay filler materials have taken on this issue, and nickel alloys, because they contain molybdenum, which protects
have developed specific products, in particular, alloying flux for against corrosion under reducing conditions, and chromium
the ESW process. which protects against corrosion under oxidizing conditions. [3]
The alloying flux for the ESW process balances the [4]
reduction in alloy content due to dilution with Iron base parent One of the major applications of Ni-Cr-Mo alloys is in the
metal. This technical solution made of Strip plus its Flux, may presence of hot chloride containing solutions. Under these
be considered as a sort of over alloyed combination that for conditions most of the stainless steels would suffer crevice
some types of nickel alloys allows to achieve the desired corrosion, pitting corrosions and stress corrosion cracking
chemical analysis with a single layer of weld overlay. (SCC). [3]
One of the last in this cluster is N06059, which was
HIGH NICKEL CHROMIUM-MOLYBDENUM ALLOYS developed by VDM GmbH, Germany, as Nicrofer 5923hMo.
PROPERTIES AND METALLURGY Nicrofer 5923hMo (Alloy 59) is a Nickel-Chromium-
Molybdenum alloys with extra low carbon and silicon content.
Nickel-base alloys are solid solutions based on the element [7] Extremely low carbon and silicon contents make Alloy 59,
nickel. Even though nickel base alloys, in general, contain a less susceptible to grain boundary precipitations, which
large proportion of other alloying elements, these alloys increases its resistance to intergranular corrosion and provides
maintain the face-centered cubic lattice structure (fcc or the metallurgical stability that allows its use to temperatures as
gamma) from the predominant nickel-base element. As a high as 450°C. “Figure .3”
consequence of the fcc structure, nickel base alloys have  
excellent ductility, malleability, and formability. [2]      

     
Nickel alloys are highly resistant to corrosion, and, in most
      
environments, nickel alloys outperform the most advanced
      
stainless steels. One of the reasons is because nickel can be       
alloyed more heavily than iron. [3]       
Based on chemical composition, corrosion-resistant nickel-       
base alloys can be grouped as commercially Pure Nickel, Ni-Cu       
alloys, Ni-Mo alloys, Ni-Cr-Mo, and Ni-Cr-Fe alloys. [3]       
In evidence in this paper is the group of Ni-Cr-Mo alloys;       
the following table gives their compositions.  
    

 
     
 
  
           
        
              
              
              
        
     
        
Table 1. Composition of the Ni-Cr-Mo alloys. Value in mpy, convert to mm/y by multiplying by 0,0254
(-) No data available
Table 2. General corrosion resistance in acid solutions [5].

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   
  
  
  
  
  
  
Table 3. Critical crevice (CCT) and Critical pitting (CPT)
temperature following testing in the ASTM G48 C and D
environments of 6% FeCl3 + 1HCl for 72 hours [5].
While the high alloy content explains the good corrosion
resistance of these alloys in several environments, this same
high alloy content may adversely impact their metallurgical
stability. If these alloys are exposed to high temperature for
extended periods of time, they may develop precipitates,
(carbides and intermetallic phases rich in Cr and Mo), that
deplete the adjacent grain area, which in turn affects their
mechanical and corrosion characteristics.
The precipitation may result in intergranular corrosion
Intergranular corrosion takes place when the corrosion rate
of the grain boundary areas exceeds that of the grain interiors.
This difference in corrosion rate is generally the result of
differences in compositions between the grain boundary and the
interior. Whether or not these precipitations may damage the
corrosion properties depends on the type of alloys, the
temperature of exposure and the time at the temperature of
exposure. Long times at relatively high temperatures produces
continuous grain boundary precipitates and creates in the
adjacent grain a depleted zone that can be highly susceptible to
corrosion. Exposure to high temperatures for a short time may
produce isolated precipitates or carbides that will not affect
corrosion behavior. For these reason, the problems produced by
the isothermal heat treatments experiments are not usually
manifested in welding [7].
Figure N°3 and figure N°4 show the effect of these
precipitates and how the corrosion and mechanical properties
can change during the exposition at the temperature. [6]
Figure 3. Time-Temperature-sensitizations (TTS) diagram
of Nickel Chromium-Molybdenum alloy tested according to
ASTM G28 A. Areas to the right of the curves indicate
intergranular corrosion > 50µm 8 (0,002in) [6]
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Figure 4. Rp0,2 Yeld Strenght of Nicrofer 5923 in
comparison with other Nickel alloys [6]
These metallurgical phenomena do not normally affect the
corrosion resistance or mechanical integrity of the weld deposit,
but they must be considered during the development of welding
procedures.
The appropriate corrosion testing to evaluate susceptibility
to intergranular corrosion should be carried out during
procedure qualification; ASTM G28 Method A can be used for
this analysis.
ALLOY 59 WELDMENTS
A series of weldments have been produced and tests have
been performed by ALFA LAVAL OLMI in order to qualify
different welding processes / procedures that can approximate
the composition of alloy 59 wrought material in weld overlay
deposit.
One of the first issue to be addressed is the effect of Post
weld heat treatment (PWHT) requirements on both base metal
and weld overlay. The required level of base metal strength
dictated the use of low alloy 2.25 Cr 1Mo as the pressure vessel
parent metal. PWHT is mandatory for this type of base material.
As a result, any weld or weld overlay applied to this parent
metal, necessarily entail post weld heat treatment.
The positive effects that the PWHT has on the 2.25 Cr 1Mo
heat affected zone adversely affect Alloy 59 corrosion behavior.
With the aim of preserving Alloy 59’s outstanding
corrosion behavior, an appropriate sequence of weld deposits
have been selected.
A barrier layer of the Nickel alloy UNS 66025, was
deposited as the 1° first layer of weld overlay, on 2.25 Cr 1Mo
base metal. This barrier layer of Inconel UNS66025 is the only
one that undergoes PWHT with the pressure vessel.
Consequently, the weld layer of Alloy 59 has been
deposited after PWHT, which eliminates the risk of
sensitizatiion during isothermal heat treatments.
 Due to the different geometry and extension which need to 3°, 4° and 5° Layer SMAW Ø 4mm
be weld overlayed, different welding process with different E-NiCrMo-13 Tp.ALLOY 59
AFTER PWHT 8mm
level of productivity have been qualified.
On large surfaces such as the internal diameter of the 5mm

pressure vessel and the tube sheet, mechanized ESW 60x0,5

Strip have been selected. ESW was preferred to SAW due to it’s
lower dilution rate. For all other areas, more flexible processes 1° and 2nd Layer SMAW
E-NiCrMo-3 Ø 4mm Inconel tp. 625
such as Manual SMAW and Semiautomatic GTAW Hot Wire BEFORE PWHT
have been carried out.
Sequences and filler metal relevant to the tested weld
overlay, are shown in the sketch below.   
2° and 3° Layer ESW 60x0,5 mm
EQ NiCrMo-13 Tp.ALLOY 59
  
9mm
MIN
AFTER PWHT

4.5mm   


  

1° Layer ESW 60x0,5 mm
EQ NiCrMo-3 Inconel tp. 625
BEFORE PWHT   

  

   Table 6. Schematic description SMAW weldment.
  
Initially, also the GMAW Pulsed welding process has been
 considered, but later, due to the good productivity, and the more
  
 regular and smoother weld surface of GTAW HW, the latter was
  selected.

 
   WELDING PROCESS QUALIFICATION TESTS
   After welding, the coupons have been subjected to the
Table 4. Schematic description ESW weldment. following tests:
The first step of welding process verification is non-
3°, 4° and 5° Layer GTAW HW Ø 0,8mm destructive examinations.
ER NiCrMo-13 Tp.ALLOY 59
AFTER PWHT 9mm Usually, qualification tests coupons have been verified by
non-destructive examination through visual inspection, dye
5mm penetrant testing and ultrasonic examination. These NDE tests
verified that the surface was free from unacceptable indications
and that the weld overlay was properly fused between layers
1° and 2nd Layer GTAW HW
ER NiCrMo-3 Ø0,9mm Inconel tp. 625
and to the parent metal.
BEFORE PWHT Non-destructive tests also have been carried out at
different stages in the deposition of the overlay.
Visual inspection, dye penetrant testing and ultrasonic
   examinations have been carried out after deposition of the

  Inconel 625 first layer and before PWHT, on the same layer
  after PWHT, and at the completion of the Alloy 59 layers.
 Methods and acceptance criteria can be in accordance with
  
 ASME BPV code section V or with the applicable ISO
   standards.

  

  

Table 5. Schematic description GTAW HW weldment.

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 The second step of verification is a more comprehensive For wire and strip the ASME section II-part C SFA 5.14 is
analysis that must be done through laboratory tests. For a applicable.
thorough evaluation of the weld overlay deposit behavior the The situation in this case can be different respect to
following tests have been done: SMAW electrode.
• Macro-graphic examinations
• Chemical analysis on weld deposit      
• Susceptibility to Intergranular corrosions test ASTM ≤    ≤ 
G28 A 
• Micrographic examinations      
≤ ≤ ≤ ≤ ≤ ≤
Chemical analysis on weld deposit Table 9. Required chemical analysis for ER NiCrMo-13 (taken
from ASME BPV Section II part C)
Usually the same requirements applicable to wrought
material are requested for the weld overlay deposit. Filler core metal raw material comes from wrought material and
In the Table 7 are listed the chemical restrictions relevant to keeps the same limitations in its chemistry. It is important to
wrought material Alloy 59. clarify that chemical requirements listed in SFA 5.14 are related
to chemical composition of the electrodes or the rods
      themselves, and not to undiluted weld metal as per SFA 5.11.
≤    ≤  If filler metal classified according to ER NiCrMo-13 SFA 5.14
 is employed in the shielded gas fusion welding process, as an
      example GMAW or GTAW, chemical analysis of the weld
≤ ≤ ≤ ≤ ≤ ≤ deposit generally satisfies the wrought material’s chemical
Table 7. Required chemical analysis for wrought material limitations, since the loss of oxidizable elements in the electric
(taken from table1 SB 462 UNS N06059) arc transfer is negligible.
If Wire or strip have been employed with fusion welding
These limitations, especially for Si and Al, may be processes shielded by slag, as for example SAW or ESW, the
problematic for some welding processes in view of the fact that pick-up of elements such as Silicon is inevitable.
the conditions encountered during welding are quite different Based on the above clarification, during the qualification of the
than those encountered during the production of wrought welding process, we deemed it acceptable to apply the
material. Therefore, the compositional limits applied to weld following limitations for all weld overlay deposit.
deposit Alloy 59 may be slightly different relative to the
limitations applied to wrought material.      
See for example the requirements listed in ASME section ≤    ≤ ≤0,40
II-part C SFA 5.11 for undiluted weld deposit. (Table 8) 
     
      ≤ ≤ ≤ ≤ ≤ ≤
≤    ≤ - Table 10. ALLOY 59 weld deposit Limitations

      Depth of chemical analysis
≤ ≤ ≤ ≤ - -
Table 8. Required chemical analysis for ENiCrMo-13 Weld overlay in general protects the process side of the
(taken from ASME BPV Section II part C) item. This protection is obtained if a certain thickness of the
weld deposit on the surface to be protected will satisfy chemical
As indicated, the Mn. range differs substantially from that analysis requirements. Conversely, if chemical analysis is
of the wrought material, though it is unlikely that an ALLOY 59 verified only on the surface of the weld, and if there is a
electrode weld deposit would contain as much as 1% Mn. The significant reduction in alloy content immediately beneath the
presence of this element is set up around 0,5% but due to its surface, then the serviceability of the overlay can be
deoxidation action, remains around 0,2% in the weld deposit. compromised by corrosion or erosion once damage penetrates
In the SMAW weld deposit elements such as Aluminum beyond the original overlay surface.
and Silicon compared to Manganese, may remain slightly Therefore, it typically is necessary to guarantee the
different with respect to the wrought material limitation. specified alloy overlay chemistry to a depth of at least 3mm.
If chemical analysis at this depth has been verified as
satisfactory, all the volume of weld metal above can be
considered in compliance with the required chemistry.

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 If the overlay composition at 3mm in the depth does not satisfy Acceptance criteria applied to these corrosion test is:
the specified chemistry requirements, then additional layers 1,5mm/years.
need to be carried out or a different welding procedure must to The requirements on ASTM G28 method A usually applied to
be applied. Alloy 59 wrought material, may be slightly different: 1,2 ÷ 1,5
mm/years.
Although the metallurgical structure of weld overlay is
Position of Chemical analysis
more heterogenous than that of wrought base material, and
Alloy 59 although the potential for the presence of precipitates is greater,
Weld deposit
3mm weld overlay and in general weld deposits, reach the required
corrosion rate.
Corrosion tests samples have been taken in the weld
deposit, according to prescription listed in ASTM G28, in the
position shown in the Figure.6

Corrosion test sample

Figure.5 Schematic sketch that shows a Chemical analysis taken

at 3mm below the surface.

Susceptibility to intergranular corrosions test

For Nickel Chromium-Molybdenum wrought material,

supply heat treatments conditions are selected with the aim to
finalize the most homogenous metallurgical grain structure. For
Figure.6 Schematic sketch that shown where the corrosion test
weld deposits, however, due to nature of the thermal cycles
sample have been taken; transversal to weld direction
experienced by the deposits, it is impossible to achieve the same
results.
Corrosion tests samples need to represent as nearly as
Wrought material is supplied in the solution annealed
possible the tested material, as used in service. For this reason,
condition. This heat treatment consists in annealing at
need to contain as welded deposit surface as much as possible.
temperatures sufficiently high to reach the highest solubility of
the major alloying elements in the nickel-base material,
followed by water quenching or rapidly cooling by other means. RESULTS OF THE TESTS
Rapid cooling after annealing promotes a homogeneous
structure and suppresses harmful precipitations. Detail on Samples preparation and etching
For weldments, the temperature and cooling rate during
solidification cannot be controlled as per wrought materials, Macro-graphic examinations have been:
consequently a more heterogeneous grain structure will result. - prepared according to: ASTM E3-11(2017)
Precipitation at the grain boundary or in interdendritic - etched according to ASTM E340-15 - HCl + H2O +
regions of intermetallic phases may occur, but these will affect H2O2
corrosion behavior only if they grow excessively, leading to Micro-graphic examinations have been:
sensitization. Electrical parameters, travel speed, and in general - prepared according to: ASTM E3-11(2017)
the Heat input, are a few of the thermal factors that have a direct - etched according to ASTM E407-07(2015) Etchant
effect on cooling rate of the deposited weld metal, and so on N°13 (Electrolytic Oxalic Acid)
metallurgical structure.
High heat input affects the weld thermal cycle, causing the
weld deposit to remain at high temperatures for a longer time to
the slow cooling rate; this can promote grain boundary
precipitation.
Precipitation can be limited using a low heat input welding
procedure, which reduces the time the weld deposit spends at
high temperature because of a more rapid cooling rate.
Susceptibility to intergranular corrosion on weld overlay
deposit Alloy 59 described in this paper has been evaluated in
accordance with ASTM G28 method A.

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 ESW Process 60x0,5 strip These tests have been shown that corrosion rate and max depth
of attack, can vary depending on welding parameters, weld
Macro-graphic Examinations technique, and area in weld deposit, where corrosion test
sample has been taken.

Depth of attack

Figure.7 Macro Examination on Machine ESW 60x0,5 welded

samples

Figure.9 Depth of attack evaluated on unetched Micro-

Examination on as welded side of corrosion samples.

Figure.8 Macro Examination 5X on Machine ESW 60x0,5

welded samples that well shown the main dendrite morphology

Chemical Analysis

     

     0,01
Figure.10 Depth of attack evaluated on unetched Micro-

Examination on machined side of corrosion samples.
     
     

Corrosion Test Results

    

    
  As welded Machined
surface surface
(µm) (µm)

     

Several welding tests have been done with ESW process with
the aim to obtain a weld deposit with the best corrosion
properties.

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 Micrographic Examination

Figure.11 The micrographic examinations carried out with Figure.14 Macro Examination 5X on SMAW welded
200X magnification shows very large dendrites, compared samples that shown the main dendrite morphology
to other welding process.
Chemical Analysis

     

     0,01

     
     

Corrosion Test Results

    

    
  As welded Machined
surface surface
(µm) (µm)

     

Figure.12 As weld surface on corrosion tested samples,

etched and examined with magnification 100X. Depth of attack

SMAW PROCESS

Macro-graphic Examinations

Figure.13 Macro Examination on SMAW welded samples

Figure.15 Depth of attack evaluated on unetched Micro-
Examination on as welded side of corrosion sample.

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 GTAW Hot Wire PROCESS

Macro-graphic Examinations

Figure.19 Macro Examination on GTAW HW welded

Figure.16 Depth of attack evaluated on unetched Micro- samples
Examination on machined side of corrosion samples.

Micrographic Examination

Figure.20 Macro Examination 5X on GTAW HW welded

samples that shown the main dendrite morphology
Figure.17 The micrographic examinations carried out with
Chemical Analysis
200X magnification shows dendrites
     
     0,26

     
     

Corrosion Test Results

    

    
  As welded Machined
surface surface
(µm) (µm)

     

Figure.18 As weld surface on corrosion tested samples,

etched and examined with magnification 100X.

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 Depth of attack
Figure.21 Depth of attack evaluated on unetched Micro-
Examination on as welded side of corrosion sample.
Figure.22 Depth of attack evaluated on unetched Micro-
Examination on machined side of corrosion samples.
Micrographic Examination
Figure.23 The micrographic examinations carried out with
200X magnification shows dendrites
11
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Figure.24 As weld surface on corrosion tested samples,
etched and examined with magnification 100X.
CONCLUSIONS
This work confirms that although weld deposit structures
are more heterogenous than those for wrought base material,
and although there is greater potential for the presence of
precipitates due to the nature of the weld thermal cycle, weld
overlay can achieve the required corrosion performance.
Severe sensitization produced by the isothermal heat
treatments are not manifested in weld deposit.
The corrosion tests results have demonstrated that weld
deposits with larger dendrites tend to exhibit higher
intergranular and interdendritic corrosion rates.
The evaluated corrosion type on the welded samples are
mainly interdendritic
High heat input affects the weld thermal cycle by slowing
the cooling rate, which causes the weld deposit to remain at a
high temperature for a longer period of time; this slow cooling
can promote precipitation and sensitization, which can
adversely affect corrosion resistance.
Conversely, precipitations (and sensitization) at grain
boundary and in the interdendritic regions can be limited by
using a low heat input welding procedure, which accelerates the
cooling rate, thereby reducing the time the weld deposit spends
at high temperature.
Metallographic examination on the corrosion tested
samples has been used for evaluation of the depth of attack.
This alternative method of intergranular corrosion evaluation
confirms that larger dendrites show also the deepest attack.
Can be understandable that, in addition to grain or
dendrite dimension, the depth of attack was influenced by
dendrite growth direction. (Compare Figure 11 to figure 17 and
23)
In ESW process, due to dimension and shape of weld
passes, dendrite mainly grows up in linear way and orthogonal
to surface (Figure 29).
Then also any precipitation of intermetallic phases will be
segregated orthogonally to the surface.
Copyright © 2018 ASME
 REFERENCES

Dendritic Growth [1] Based on Metallurgical aspects in welding single layer

claddings with CrNi(Mo)-alloyed filler materials without post
WELD OVERLAY
weld heat treatment. Authors H.Schabereiter, G.posch, J Tosch,
E.Perteneder,K.H.Gugimeier

[2] ASM Metals HandBook Volume 13A - Corrosion

BASE METAL
Figure.25 Sketch that show typical dendrite growth
direction in ESW weld passes
This explains why electroslag weld overlay deposit,
although acceptable weight loss value in intergranular corrosion
tests, shown major depth of attack than other welding processes.
Fundamentals, Testing, and Protection. Effects of metallurgical
variables on the corrosion of high-Nickel Alloys
[3] ASM Metals HandBook Volume 13A - Corrosion
Fundamentals, Testing, and Protection. Effects of chemical
compositions on the corrosion behavior of nickel corrosion
resistant alloys.
[4] D.C. Agarwal and J.kloewer, Paper 01325,
Corrosion/01, NACE International 2000

[5] Corrosion Performance and fabricability of the new

generation of Highly Corrosion Resistant Nickel-Chromium-
Molybdenum Alloys. Stephen A. McCoy, Lewis E. Shoemaker
& James R. Crum SPECIAL METALS

[6] VDM Material Data Steet N° 4030 Nicrofer ®

5923hMo – alloy 59

[7] ASM Metals HandBook Volume 13A - Corrosion

Fundamentals, Testing, and Protection. Metallurgical influenced
Corrosion

12 Copyright © 2018 ASME

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