Material for May 7th 2010

Welding of Heat-Resisting Steels

Lecturer Dr. Jippei Suzuki Graduate School of Engineering Mie University Department of Mechanical Engineering Faculty of Engineering, Mie University Kurima-Machiya-cho 1577, Tsu, Mie 514-8507 Tel. 059-231-9372 Fax. 059-231-9663 E-mail jsuzuki@mach.mie-u.ac.jp

Types of heat resistant steels (Fig.H1)

Service temperature for heat resistant steels

1. Carbon steels JIS SB42, SB46, SB49 2. Molybdenum alloy steels JIS SB46M, SB49M 3. Chromium-molybdenum alloy steels JIS SCMV1-6 4. Stainless steels 18Cr-8Ni 5. Heat-resistant alloy (Superalloy) Fe-Ni base, Co base, Ni base

Boiler HRA*

Petroleum Chemical Hydrogen Eng. Eng. HRA* 18Cr-8Ni

Temperature(K)

Mild steel

Mild steel Mild steel Mild steel

HRA*: heat resistant alloy

Strength of steels at elevated temperature (Fig.H2)

stress B Y C

Room temp.

T1 Elevated temp. T2

strain

Creep phenomenon (Fig.H3)

strain or elongation

High temp. High stress

Tertiary or accelerating creep

Low temp. Low stress

Instantaneous extension Primary or transient creep

Secondary or steady-rate creep

time

Creep strength at a given temperature(Fig.H4)

Strain rate , Length/Time

Fracture time , Time

Creep strength at a given strain rate

Creep strength at a given time

Applied stress

Applied stress

Creep strength of heat-resisting steels(Fig.H5)

Stress

Carbon steel

Temperature
Creep strength (1%/36000ks) of steels 3600ks=1000hr=41.7days

Creep strength of heat-resistant steels and alloy (Superalloy) (Fig.H6)

316: 316 stainless steel 304: 304 stainless steel Ni base alloy

2 1/4Cr-1Mo
1000hr creep rupture strength

1 1/4Cr-1/2Mo

304 316

Co base alloy
Fe-Ni base alloy

5Cr-1/2Mo

Carbon steel Temperature

Resistance to oxidization (Fig.H7)

Fe2O3 Fe3O4

FeO
Fe
5%Cr

FeO(Cr,Fe)2O3
8%Cr 10%Cr 15%Cr 18%Cr

Cr2O
23%Cr

Oxidization induced by O2, H2O, CO2

Cr, Al, Si form stable oxide film at elevated temperature.

Oxide film of low melting point

Vanadium attack V2O5(m.p.963K) V2O5-Na2SO4(m.p.873K) MoO3

Attack by H2S, SO2

Allowable service temperature of low alloy steels considering to oxidization (Table H1)

Type of steel Carbon steel C-1/2Mo steel 1 1/4Cr-1/2Mo steel 2 1/4Cr-1Mo steel 5Cr-1/2Mo steel 9Cr-1Mo steel

Maximum allowable temperature (K) No loading 838 838 863 908 923 972 under loading 811 811 838 838 838 838

Hydrogen embrittlement of low alloy heat resistant steels (Fig.H8)

Two types of hydrogen embrittlement 1. Reduction in thoughness at room temperature after long service of elevated temperature 2. Hydrogen attack occurring in service at elevated temperature Carbon containing in steel C High pressure high temperature hydrogen gas H2 H H

C + 4H CH4 Formation of methane gas

Nucleation of void Internal stress

Grain Boundary crack

Resistance to hydrogen attack (Fig.H9)

(high temperature-high pressure hydrogen)

Allowable service limits of Cr-Mo steels under hydrogen of high temperature-high pressure

(Nelson curve)

de-cauburization of surface de-cauburization of interior Temperature (K)

or Carbon steel

Hydrogen pressure MPa

Weldability and factors (Fig.H10)

Welding parameters

1. Hardening of HAZ and Lowering ductility

2. Toughness of welds

Influence of alloying elements

3. Cold crack induced hydrogen in weld metal and HAZ

Hydrogen Influence of impurities

4. Crack caused by PWHT (reheat crack)

Conditions of PWHT

5. Embrittlement caused by long period heating

Service conditions

Hardenability of heat resistant steels (Fig.H11)

specimen

water

water

water

Jominy end quenching test Examples of Jominy curves

Distance from quenched end (mm)

Hardness (HRC)

Hardening of heat affected zone (Fig.H12)

0.11C-0.77Si-0.46Mn-1.27Cr-0.50Mo 0.13C-0.31Si-0.46Mn-2.39Cr-0.97Mo

Temperature

Time 0.10C-0.27Si-0.45Mn-4.31Cr-0.59Mo

Temperature

Time

400
VHN

4.3Cr-0.6Mo 2 1/4Cr-1Mo

300 200 100

Temperature

Hardness

1 1/4Cr-1/2Mo

0 10
Time

102

103

104
s

Cooling time from A3 to 773K

Influence of pre-heating temperature on hardness (Fig.H13)

Average hardness of weld metal(HV)

Pre-heating temperature(K)

Peak hardness in HAZ(HV)

Pre-heating temperature(K)

Cold crack (Fig.H14)

Hydrogen is released at elevated temperature.

Amount of hydrogen

Three factors of cold crack 1. Hard microstructure 2. Hydrogen 3. Stress

Holding time

Percentage of crack (%)

Local heating

Pre-heating temperature

Effect of post-weld heat treatment to prevent cold crack (Fig.H15)

Post heating of welds is effective to prevent cold cracking. Temperature

(s)

No cracking

about 1 hr Cracking

Holding time

PWHT crack (Reheat crack) (Fig.H16)

Crack along prior-austenite grain boundary During post-weld heat treatment

Main foctors 1. Alloying elements G=(%Cr)+3.3(%Mo)+8.1(%V)-2 (for high strength steels) When G>0, the crack occurs. PSR=(%Cr)+(%Cu)+2(%Mo)+10(%V) +7(%Nb)+5(%Ti)-2 %Cr1.5, 0.10%C 0.25, %Cu 1.0, %Mo 2.0, %V, %Nb, %Ti 0.15 When PSR0, the crack occurs. 2. Impurity P, S increase the sensitivity to crack.

3. Parameters of welding and PWHT

Postweld heat treatment on heat resistant steels (Fig.H17)

The welds are heated below Ac1 to reduce the harmful factor, such as residual stress. Then, the welds are cooled uniformly to prevent the occurrence of thermal stress. Purposes of PWHT To reduce residual welding stress (Stress Relief annealing) To improve mechanical properties and performance to erosion (Normalizing, Quench/Temper, Solution treatment) To prevent cold cracking (Post-weld heating)
Standards of PWHT
steel
1 3 4 5 2 1/4Cr-1Mo 5Cr-1/2Mo 9Cr-1Mo 9 3 1/2Ni 823 823853 868908 868908 853893 863983 868908 Carbon steel C-Mo 1 1/4Cr-1/2Mo

(unit: K)
JIS Z 3700
873 873 873

HPIS
823 863 863* 893 923* 948

ISO/DIS 2694
823873 853893 893933

ASME SecVIII
868 868 868

ASME SecIII
868948 868948 868948

BS 5500
87320 923953 903943 923973 903943 953993 9831023 9831033

BS2633 (tube)
853893 903943* 923953 903943 953993 9731023

ANSI B31.3 (tube)

868923 868993 9781018

8981023* 953 948 9431013* 9481033

9781033 9831033

948* 973

Influence of PWHT on mechanical properties (Tensile strength) (Fig.H18)

Tensile strength

single

Larson-Miller parameter

Temp.

time

Tensile strength is decreased with increasing heating temperature and prolonging heating time.

Influence of PWHT on mechanical properties (Creep rupture stress and Toughness) (Fig.H19)
aswelded

Creep rupture strength at 823K(MPa)

SMAW bearing Ti SMAW Submerged arc welding GMAW

Absorbed energy

Larson-Miller parameter
Temp. time

Temperature of PWHT (K) (holing time 18ks)

Influence of PWHT on bond toughness of A533B steel weld (150mm)

Influence of chemical compositions on temper embrittlement in 2 1/4Cr-1Mo steels welds (Fig.H20)

step cooling

Forged material

Steel plate

at 283K

Temper embrittlement

Temper embrittlement is observed in low alloy steels Containing Ni, Cr, Mo. It does not occur in plain carbon steels. Temper embrittlement is remarkable in the steels with High impulity contents, such as P, Sb, Sn and As. Fracture occures along prior-austenite grain boundary.

Temper embrittlement is reversible. Ii is possible to Recover toughness, heating over the temperature range of embrittlement.

(Fig.21)

A: as-received T: PWHT S: Step cooling SS: Double step cooling R: Re-tempering treatment

vTrs

W.M.: weld metal

W.M.

W.M.

W.M. W.M. W.M.

Temper embrittlement of heat resisting steels

vTrs :

Surface transition temperature (2mm V-notch Charpy test)

vTrs

W.M. W.M.

W.M.

Welding of stainless steels - Schaeffler diagram (Fig.S1)

30

Nieq=%Ni+30%C+0.5%Mn

A
20

A+M

10

M A+M+F F
20 30 40

F+M
0 10

M+F

Creq=%Cr+%Mo+1.5%Si+0.5%Nb

Welding of stainless steels

30

4 problems (Fig.S2)

Nieq=%Ni+30%C+0.5%Mn

A
20

Hot cracking above 1250 A+M

10

Embrittlement due to phase precipitation during heat-treatment or slow cooling

M Cold cracking due to martensite (pre-heating) M+F

10

A+M+F F Embrittlement due to grain coarsening

20 30 40

F+M
0

Creq=%Cr+%Mo+1.5%Si+0.5%Nb

Problems

1. Explain the dilution.

2. Estimate the Ni and Cr contents of weld metal, when the stainless steel of 18%Cr-8%Ni is welded using the electrode of 2%Ni-28%Cr, assuming that the dilution is 20%. 3. We should weld the stainless steel of 0.36%C-2.0%Si-0.4%Mn-14.0%Ni -15.0%Cr, and we want that the Ni and Cr equivalents of weld metal are 8% and 22%Cr, respectively. Determine the chemical compositions of electrode, assuming that the dilution is 20%.

4. Estimate the Ni and Cr equivalents of weld metal, when the steels of 8%Ni-18%Cr and 0.15%C-2%Cr-1%Mo are but-welded by using the electrode of 26%Cr, assuming that the dilution is 20%.

Answer 1
1. Explain the dilution.

(Fig.S3)

A; mass of melted electrode

Mass of weld metal C = A+B

B; mass of melted base metal plates

Answer 1

Dilution of base metal =

B C

B A+B

Answer 2 (Fig.S4)
2. Estimate the Ni and Cr contents of weld metal, when the stainless steel of 18%Cr-8%Ni is welded using the electrode of 2%Ni-28%Cr, assuming that the dilution is 20%.

30

Nieq=%Ni+30%C+0.5%Mn

20

10

4 1
0 10 20 30 40

Answer 2 3%Ni-26%Cr

Creq=%Cr+%Mo+1.5%Si+0.5%Nb

Answer 3
3. We should weld the stainless steel of 0.36%C-2.0%Si-0.4%Mn-14.0%Ni-15.0%Cr, and we want that the Ni and Cr equivalents of weld metal are 8% and 22%Cr, respectively. Determine the chemical compositions of electrode, assuming that the dilution is 20%. Nieq(B.M.)=%Ni+30%C+0.5%Mn=14.0+300.36+0.50.4=25.0 Creq(B.M.)=%Cr+%Mo+1.5%Si+0.5%Nb=15.0+1.52.0=18.0

Answer 3
Nieq(B.M.)dilution+Nieq(El.)(1-dilution)= Nieq(W.M) 25.00.2+Nieq(El.)(1-0.2)=8 Nieq(El.)=3.75=4% Creq(B.M.)dilution+Creq(El.)(1-dilution)= Creq(W.M) 18.00.2+Creq(El.)(1-0.2)=22 Creq(El.)=23%

Another answer 3 (Fig.S5)

Nieq(B.M.)=%Ni+30%C+0.5%Mn=14.0+300.36+0.50.4=25.0 Creq(B.M.)=%Cr+%Mo+1.5%Si+0.5%Nb=15.0+1.52.0=18.0

30

Nieq=%Ni+30%C+0.5%Mn

20

10

10

20

30

40

Creq=%Cr+%Mo+1.5%Si+0.5%Nb

Answer 4 (Fig.S6)
4. Estimate the Ni and Cr equivalents of weld metal, when the steels of 8%Ni-18%Cr and 0.15%C2%Cr-1%Mo are but-welded by using the electrode of 26%Cr, assuming that the dilution is 20%. Nieq(0.15%C-2%Cr-1%Mo)=300.15=4.5 Creq(0.15%C-2%Cr-1%Mo)=2+1=3
30

Electrode 80% Nieq=%Ni+30%C+0.5%Mn

20

8%Ni -18%Cr

0.15%C -2%Cr -1%Mo

10

1 1

Base Metal 1 10%

Base Metal 2 10%

Answer 4
0 10

20

30

40

Nieq=about 1.5% Creq=about 23%

Creq=%Cr+%Mo+1.5%Si+0.5%Nb

Welding process applied to heat resistant steels

Shielded metal arc welding low hydrogen type electrode with similar chemical and mechanical properties to base metal plate formation of porosity lime-titania electrode low tendency of porosity good appearance relatively low ductility

Backstep welding
Submerged arc welding lower carbon, higher chromium than that of base metal plate Gas shielded metal arc welding Electroslag welding

Assessment of Reheat Cracking Sensitivity of Steels from their Chemical Compositions (Fig.J1)
14-17 October 1985 Koreaki Tamaki and Jippei Suzuki Department of Mechanical and Material Engineering Mie University, Kamihama-cho 1515 Tsu, Mie 514 JAPAN

Implant test machine modified for reheat cracking test

Fig.2 A set of the implant test specimen

Influence of chromium on the sensitivity to reheat cracking (Fig.J2)

Fig.3 Definition of critical restrain stress to produce reheat crack

Initial restraint stress , MPa Fig.4 Critical restraint stress, AW-crit of Cr-Mo-0.02%P steels

Contour lines of critical restraint stress (Fig.J3)

Comparing the critical stress to reheat cracking index G=(%Cr)+3.3(%Mo)+8.1(%V)-2 PSR=(%Cr)+(%Cu)+2(%Mo)+10(%V)+7(%Nb)+5(%Ti)-2 For simple Cr-Mo steels, G=(%Cr)+3.3(%Mo)-2=0 PSR=(%Cr)+2(%Mo)-2=0

Fig5 Contour lines of critical restraint stress of Cr-Mo-0.02%P shown in the Cr-Mo contents diagram Note: A;1/2Mo, B;3/4Cr-1/2Mo, C;1Cr-1/2Mo, D;1 1/4Cr-1/2Mo, E;2 1/4Cr-1Mo, F;3Cr-1Mo, G;5Cr-1Mo

(Fig.J4)

Influence of phosphorus on the sensitivity to reheat crack (Fig.J5)

Initial restraint stress, MPa

Fig.8 Influence of phosphorus on the critical restraint stress, AW-crit of five types of Cr-Mo steels

Initial restraint stress, MPa

Influence of manganese and sulfur on reheat cracking sensitivity of 1Cr-1/2Mo steels (Fig.J6)
Manganese reduces the sensitivity, and sulfur increases the sensitivity.

Combined influence of manganese and sulfur (Fig.J7)

Sulfur in steel=Combined sulfur as MnS + dissolved sulfur (free sulfur) Free sulfur would segregate to grain boundary, and increases the sensitivity to cracking.

Influence of vanadium (Fig.J8)

Influence of titanium (Fig.J9)

Effect of stress relaxation (Fig.J10)

Carbides precipitate during stress relief annealing. Ti+C TiC 4V+3C V4C3

Secondary hardening

High stress at elevated temperature