<".:?

ACL .

PAG 5
By accaptanca of thli artlcla, tht publiihar or rtclpltnt acknowladgat tha U.S. Govarnmant't right to rataln a nomxcluiivi, royalty-frm lleanw In and to any copyright covaring tht arttcla.

T!Tt LINE -

AUSTENITIC STAINLESS STEEL-TO-FERRITIC STEEL TRANSITION JOINT.. WELDING .FOR ELEVATED TEMPERATUp.SERVICE J. F. King, G. M. Goodwin and G. M. Slaughter Oak Ridge National Laboratory Oak Ridge, Tennessee

T!TL L..NE

ABSTRACT MARGINS -

A8STRAC1 Abstract Transition weld joints between ferritic steels and austenitic stainless steels are required for fossil-fired power plants and proposed nuclear plants. The experience with these dissimilar-metal transition joints has been generally satisfactory, but an increasing number of failures of these joints is occurring prematurely in service. These concerns with : transition joint service history prompted a program to develop more reliable joints for applications in proposed nuclear power plants. :

! TEXT

; 1.

INTRODUCTION Testing of these joints under cyclic . stress and temperature conditions resuited in failures in the ferritic material parallel and adjacent to the weld metal. ure to be: . !
:

The welding of ferritic steels to austenitic stainless steels began MARGIN'in the middle 1930's. Austenitic O ; ; . K 18% Cr-8% Ni-25% steel electrodes of Cr-12% Ni, and 25% Cr-20% Ni were .used. The lack of understanding of problems involved, together with the ;absence of alternative filler metals, .led to many failures of dissimilar metal we]as during service. Beginning around 1950, the operating temperatures of the steam power industry began to increase and the problems were aggravated. Several experimental investigations^ ^ resulted from the great interest in transition joints between low-alloy ferritic steel (primarily of the 2 1/4 Cr-1 Mo composition) and austenitic steel piping made with ansaMic steel weld metals.

The investigators attri]

buted the primary causes of the fail(1) High stresses at the interface due to differences in thermal coefficients of expansion between weld metal and base metal;
:

(2) Preferential stressoxidation at the interface; and (3) Accelerated creep in a narrow zone of the ferritic material adjacent to the interface, which has been weakened by migration of carbon into the austenitic weld metal. DISTRIBUTION OF THIS DOCUMENT IS UNLIMITED '

was taken from the outlet leg of a t'&ter investigationsKaTPJ involved superheater and was made of 2 1/4 testing of ferritic-to-austenitic Cr-1 Mo ferritic steel-to-type 321 steel joints made with various ironstainless steel, welded with Inconel and nickel-base austenitic filler 132 shielded metal-arc electrodes. metals. The general conclusion from During the service life, the joint T.TLJ: T | T L Jhis testing was that nickel-base had experienced 146 thermal cycles LiiN UNSfiiier metals were superior to ironbetween ambient temperature and base compositions. The nickel-base 5668C (1050F). weld metals greatly reduced carbon migration from the ferritic material, The failure occurred in the 2 1/4 A55 .were-highly oxidation resistant, and Cr-1 Mo ferritic steel near the 'BST3ACT M A R had thermal expansion coefficients Inconel 132 weld metal (Fig.~l). A more nearly approaching that of the higher magnification view of this ;ferritic material. Use of the nickelcrack tip in Fig. 2 shows the path base filler metals has clearly imalong which it was propagating. proved the performance of transition Several analytical techniques were joints in cyclic high-temperature utilized in the examination of this applications, but failures have still region. The findings of this investioccurred after many years of service. gation revealed that the crack ini A more thorough discussion of the itiated and propagated through a above investigations can be found in TES< narrow band in the heat-affecteda recently published^ * literature MARGIN ! zone (HAZ) of the ferritic steel, .^x review concerning welded transition very.. near_to and paralleling -the ?. n c i N " " ' O f ::AI joints.| weld fusion line. The crack propaThe concerns with service history gated most readily through a semiand the need for highly reliable continuous globular phase, found in !joints in nuclear power plant piping some areas along the fusion line. prompted a program to develop an Areas in this region with little or jimproved transition weld joint between no globular phase present failed in austenitic stainless steel and an intergranular manner in the ferritic steel. The following seccoarse-grained HAZ. The exact comtions discuss some aspects of this position of this phase and its inprogram. fluence on the failure were not 2. FAILED TRANSITION JOINT determined, but its presence appeared EXAMINATION to affect the crack propagation. (10) was made of a In addition to the fusion line phase, An examination failed transition joint taken from a other observations were made of this coal-fired utility boiler after a region. The dislocation density in service life of approximately 17 yr. the 2 1/4 Cr-1 Mo steel increased This pipe joint [63.5 nun OD x 13.2 mm markedly near the fusion line. This wall (2 1/2 in. OD x 0.0520 in. wall)] condition is probably related to

equilibrium. When large temperature N E . . . " "fluctuations"cannotHbe avoided, as in this case, the effect of the difference in thermal expansion must be A as An exact failure mechanism could not reduced. A practical way of doing be determined from this examination, this is to separate the dissimilar -C,INS but it was reaffirmed that transimetal pair with a material or series tion joint design is very important. of materials whose coefficient of : . The basic concerns that have been thermal expansion (CTE) are between recognized for many years are still those of the two to be joined. The applicable, including: effect of this is to distribute the (1) Select filler metals that difference in CTE over several inter\ ' minimize migration of faces so that the mismatch at any carbon from the ferritic one interface is acceptably low. ' steel; TWT The coefficients of thermal expanMARGIN(2) Minimize the differences sion were examined for a number of : . r T : L__iR.jpoefficients .of..thermal materials considered for. use in the ,-, , MA r | N ! expansion between the joint between 2 1/4 Cr-1 Mo and type 1 metals in the joint; and 316 stainless steel (Fig. 3 ) . An (3) Minimize stresses at the attractive candidate for an interj weld interfaces. mediate material is alloy 800H. Other materials were ruled out be- : 3. TRANSITION JOINT DESIGN cause they were not approved for use A study^ ' was conducted to estabin this application by ASME Code Case lish the design of piping transition 1592 which limits materials to 2 1/4 joints for a liquid metal fast breeder Cr-1 Mo steel, alloy 800H, and types reactor plant. The basic materials 304 or 316 stainless steel. ' It was to be joined are 2 1/4 Cr-1 Mo feralso desirable to select welding fitic steel and type 316 austenitic filler metals which have a CTE bestainless steel. The mismatch in tween the base materials to be thermal expansion properties of joined in each joint. these two materials is the major A welding filler metal meeting ANS cause of high stresses at the ferritic specification ERNiCr-3 (commonly steel-austenitic steel weld joint known as Inconel 82) has a CTE during cyclic temperature service.

the high" stresses created by the - a -cyclic temperature service. It was also found that a sharp increase in hardness occurred in a narrow band in the weld metal adjacent to the T!T|_fusion line. The formation of carUN^bide precipitates in this region caused the hardness increase and indicates carbon diffusion from the .ferritic steel to the weld metal.

The least severe stress situation occurs when the joint is maintained at a constant temperature, since the stress level will decrease by relaxation, which in turn lowers the creep rate and the joint reaches
r

.ERNiCr-3._filler. metal. Asecond . calculation was made with alloy 800H substituted for type 316. The maximum stresses were observed to occur at the same location for both of 'JSTSACT these welds (Figs. 5 and 6 ) . Maxi- " mum tensile stresses occur at the inside diameter in the type 316 or alloy 800H adjacent to the weld. The maximum.compressive stresses occur at the same location in the 2 1/4 Cr-1 Mo steel. Comparison of these 4. DESIGN ANALYSIS ; i two joint types revealed the use of To determine if significant improvealloy 800H in the transition joint TEXT ment could be obtained from this provided a 37% decrease in peak hoop M A R G I N three-metal transition joint, a destress in the 2 1/4 Cr-1 Mo steel, r c r "tSil^a^sTrfess' analysis was~performed Hoop stresses represent the -largest. ;..;.-, IN to compare it with a conventional component of total stress. direct joint between 2 1/4 Cr-1 Mo The effect of weld joint groove angle steel and type 316 stainless steel. was investigated after the beneficial A finite element computer model was effect of alloy 800H was demonstrated. used to determine the effect of both Analyses identical to the one just < the joint materials and joint geometry described were made for the 2 1/4 on stresses at the dissimilar metal Cr-1 Mo steel/alloy 800H joint with weld. An elastic analysis was per90, 60, and 30 included groove angles. formed on a 600-mm (24-in.) OD, 13-mmIt was found that both hoop and shear wall (0.5-in.-wall) thickness pipe stresses decrease with decreasing operating at 519C (965F) with an angle, but by a smaller amount than internal pressure of 1.104 MPa. The resulted from the use of alloy 800H. thermal transient used was a drop in When the effect of both the alloy temperature from 519C (96SF) to 800H and the small groove angle are 343C (650F) in 1000 sec. The conadded, hoop stresses in the 2 1/4 tribution to the total stress was Cr-1 Mo steel are decreased by 38%. from three sources: (1) thermal

greater than the 2 1/4 Cr-1 Mo steel. This filler metal, conventionally used in austenitic/ ferritic dissimilar weld joints, was selected for the 2 1/4 Cr-1 Mo steel T!7L$O alloy 800H joint. Filler metals -'^-"with CTE falling between or near the alloy 800H and type 316 stainless steel are the iron base austenitics. It was concluded after evaluation A8S -pf A several filler metals of this . MARclass that type 16-8-2 (16% Cr-8% Ni2% Mo) was the best choice for this application. These considerations produced a transition joint spool piece design with a gradual change in expansion properties j(Fig. 4 ) .

: expansion mismatch, (2) temperature gradients through the wall thickness, and (3) internal pressure.

Stresses were calculated for a direct weld between 2 1/4 Cr-1 Mo and type 316 with a 75 included angle using "ITL
'_iNE

joints. 'Austenitic stainless steel to ferriR

Failures of these joints

are attributed to metallurgical changes in the HAZ of the welds and creep-fatigue damage resulting from the mis-match of thermal expansion properties of the materials and the :TLi cyclic temperature service. It has been found by finite element analysis techniques that a 38% decrease in stress is possible at the critical ferritic steel-weld metal 3 ,HACT interface by: (1) using a material INS with an intermediate coefficient of thermal expansion between the ferritic steel and austenitic stainless steel, and (2) the use of small angle weld joint geometries. i ! 1. 7. REFERENCES I G. E. Lien, F. Eberle, and R. D.

tic steel transition joints for elevated-temperature service continue to be an area of concern.
T|

Ti-Failures of these joints in fossil^firedjelectrical.generating plants can result in shutdowns at times when all generating capacity available is needed. Similar problems may be

ABSfaced by future breeder reactor

M R

* ^i*ants7* The continuing effort to improve transition joint service life may ultimately produce an economical and reliable solution to the problem. An understanding of the contributing factors to early failure plus careful design of future joints offers areas of improvement. The work described in this paper has guided the welding development programs'- * f r producing transition joint spool
rpieces_intended-

Wylie, "Results of Service Test Program on Transition Welds Between Austenitic and Ferritic Steels at Plants," Trans. ASME 76: (1954). 2. R. W. Emerson, R. W. Jackson, and C. A. Dauber, "Transition Joints Between Austenitic and Ferritic Steel Piping for High Temperature Steam Service," Veld. J. (NX) 419): 358-S-393-S (1962). 3. R. V. Blaser, F. Eberle, and J. T. Tucker, "Welds Between Dissimilar Alloys and Full Size Steam Piping," Am. Soo. Test. Mater. Proa. 50: 798-807 (1950). 4. 0. R. Carpenter, N. C. Jessen, J. L. Oberg, and R. D. Wylie, "Some Considerations in the Joining of Dissimilar Metals for High-Temperature High Pressure Service, Am. Soo. Test. Mater. Proa. 50: 809-57 (1950). 1075-83 'r"r the Phillip" SponTand "Twin Branch" M " ' G I N

MARGIN

for futurejiuclear..,

serviced

Base materials and weld

filler metals were selected to reduce the mismatch in coefficients of therjmal expansion. Also, a filler metal was selected to minimize the carbon migration problem from the .ferritic steel. Various testing programs are being conducted to characterize the benefit of these joints using intermediate materials and hopefully gain information for predicting service life expectancy. 6. CONCLUSIONS

Studies have been conducted to gain insight into the failure mechanisms and improve the service life of ferritic to austenitic steel transition

G. M. Goodwin received the Ph.D degree from Rensselaer Polytechnic * G* M# S l a u 8 h t e r and T- R Housley, Institute in 1968. He is currently'^ Welding of Ferritic Steels to -Group Leader of the-Welding and: Brazing Group in the Metals and J. (NY) 43(10): 454-S-460-S (1964). Ceramics Division, Oak Ridge 7. V. N. Zemzin, "The Long Time National Laboratory. His areas of ..Strengths of Welded Joints Between interest include filler metal a n d ' ^ MARAustenitic. Steels and Pearlitic or procedure development for joining Chromium Steels," Weld. Prod. 7: stainless steels, nickel-base alloys, ,1-9 (1961). 8. Yu. N. Gotal'skii and V. V. Snisar, and development of equipment and techniques for automated welding of "Certain Special Features of the pipe in a variety of alloys. Failure of Welded Joints Between G. M. Slaughter. Manager, Engineering Materials Section of the Metals and Ceramics Division, Oak Ridge National Laboratory has studied the TEXT welding behavior of a wide range of -.,- yT MARCIN iron^and jiickel-base materials_as_j. ,S(WG ties of Welded Transition Joints Bewell as refractory metals, and has tueen Austenitie Stainless St-els and developed procedures for joining of Ferritio Steels A Literature Review, these materials into reactor components. ORNL-TM-5163 (November 1975). 10. R. J. Gray, J. F. King, J. M. 'Leitnaker, and G. M. Slaughter, Exam- Research sponsored by the Reactor Research and Technology, US Departination of a Failed Transition Joint ment of Energy under contract and the Associated Base Metals, W-7405-eng-26 with the Union ORNL-5223 (January 1977). Carbide Corporation. ; 8. BIOGRAPHIES J. F. King is a development engineer in the Welding and Brazing Group of the Metals and Ceramics Division, Oak Ridge National Laboratory, Oak Ridge, Tennessee. He received the BWE degree from Ohio State University in 1968. At that time, he joined the Oak Ridge Y-12 Plant in the Dissimilar Steels IVhen Subjected to |Leads for Long Periods at High !Temperatures," Aut. Weld. 7: 5-8 ; (1969). 9. J. F. King, Behavior and Proper-

5r;?j;J-T/Ttacfier and F.: Ebeirle, "Development o a Ferritic-Austenitic Weld Joint for Steam Plant Applications," Weld. J. (til) (35)11: S92-S-S40-S (1956).

Development Division Welding Group. From 1974 to present, he has worked at the Oak Ridge National Laboratory.

TITLE UN? -

ABSTRACT MARGINS -

AS57.?ACT MARGiNS

FIG. 1. TYPICAL FAILURE FOUND IN FERRITIC STEEL-TOAUSTENITIC STAINLESS STEEL TRANSITION WELD JOINTS.

TEXT MARGIN' 301

FIG. 2. A FAILURE IN TRANSITION WELD JOINT SHOWING THE CRACK TIP IN THE 2 1/4 Cr-1 Mo STEEL NEAR THE FUSION LINE.

TYPF PAOE

FOR Al.i.

.ir

: .-..(

-',!. i ,

II
TITLE

ORNL-DWG 75-7747R

TiTLE LINE

'9 9
A8STRACT MARGINS - <
X
111

82 g
-1 Mo_

A8STSACT

MEAN THERMAL EXPANSION FROM ROOM TEMPERATURE

1
200 400 600

1
BOO

1
1000

1200

1400

TEMPERATURE (F) i FIG. 3. MEAN COEFFICIENTS OF THERMAL EXPANSION AS A FUNCTION OF TEMPERATURE FOR TRANSITION JOINT MATERIALS.
TEXT MARGIN

""XT BODY OF TEXT .30DY TEXT

ORNL-DWG 75-7748R2 ERNiCr-3 8.31 Mo STEEL 7.8 ALLOY 800 9.4 16-8-2 9.6

TYPE 316 STAINLESS STEEL 10.3

FIG. 4. TRANSITION JOINT CONFIGURATION DEVELOPED IN THIS STUDY. MEAN COEFFICIENTS OF THERMAL EXPANSION FROM 21 to 538C (70 to 1000F) ARE NOTED BELOW EACH MATERIAL.

-.

//

0RNL-0WG75-7746R

-\Z
TJTUE LiNE

MARGIN;

ABSTRACT I -ASGiflS

STRESS FREE STATE 1350"F SODIUM TEMPERATURE 65OF STRESS IN ksi

' FIG. 5 . ISO-STRESS PLOT OF 2 1 / 4 C r - 1 Mo ERNiCr-3/316 STAINLESS STEEL WELD JOINT, 7 5 INCLUDED ANGLE.

TEXT

;
TCXT

MARGIN;
ORNL-OWG 75-7749R

ERNiCr-3

-6 -10

HOOP STRESS STRESS FREE STATE 1350F SODIUM TEMPERATURE 650F STRESS IN ksi

FIG. 6 . ISO-STRESS PLOT OF 2 1 / 4 Cr-1 Mo/ERNiCr-3/ALLOY 800H WELD JOINT, 7 5 INCLUDED^ANGLE.