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Metallurgical and Structural Integrity of Post Weld Heat Treated Weld

Overlay Cladding and Buttering

GROUP SPONSORED
PROJECT OUTLINE

PR21901

August 2013

Summary

Stainless steel and nickel alloy weld overlay cladding/buttering, widely


used in industry, are often post weld heat treated (PWHT) at
temperatures in excess of 600C for prolonged periods depending on the
substrate material grade and thickness. Exposure at such high
temperatures for long durations may compromise the metallurgical and
structural integrity of the cladding/buttering. In addition, factors such as
differences in physical properties, weld metal dilution, build-up of residual
stresses, and migration of alloying elements at the interface may make it
more prone to failure in service. To avoid such degradation of the cladding
and the interface, many large components are fabricated and heat treated
prior to cladding thereby limiting the application of some of the most
productive cladding techniques, and increasing the cost of production. The
current understanding on the extent of metallurgical and structural
degradation of stainless steel/nickel alloy cladding/interface due to PWHT
is limited.

This project will review current manufacturing and testing practices


followed in the industry. Stainless steel/nickel alloy weld overlay cladding
will be manufactured employing a set of processes selected in agreement
with the sponsors and will be subjected to PWHT at different temperatures
and durations. The effect of PWHT will be established through detailed
modelling of the interface, metallographic investigation, mechanical
testing, and corrosion testing.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
Metallurgical and Structural Integrity of Post Weld Heat Treated Weld
Overlay Cladding and Buttering

Project Concept

Stainless steel/nickel alloy weld metals are known to be susceptible to degradation due to high temperature
exposure, hence controlled welding procedures are employed in their manufacture. For example, a major nickel
alloy consumable manufacturer recommends a maximum interpass temperature of 93C for cladding whilst
such cladding/buttering is often subjected to PWHT at much higher temperatures for prolonged periods,
depending on the substrate material and thickness as a part of weld overlay cladding or if further fabrication
involves welding.

The region of most concern in cladding/buttering is the


interface between the overlay and the substrate. Any fusion
welding process will introduce a heat affected zone (HAZ)
altering the microstructure and properties at the interface.
Unfavourable composition/microstructure may also be
developed at the interface due to weld metal dilution and
alloying element segregation/migration. This combined with
any tensile residual stresses makes the interface prone to
cracking resulting in debonding of the weld overlay. In order
to avoid further degradition of clad layer and interface due
to PWHT, many components requiring prolonged post weld
heat treatment at high temperatures are fabricated and
subsequently clad necessitating the application of a less
efficient cladding technique.

The current understanding on the effect of PWHT at Transverse section of a multi-layer stainless steel
different temperatures and durations on the quality and structural weld overlay on carbon steel
structural integrity of stainless steel/nickel alloy cladding is
limited. The standard testing programme specified in Codes and Standards for weld overlay qualification may
not necessarily identify the degradation of the interface and/or overlay due to welding and PWHT. The
modelling, microstructural investigation, corrosion and mechanical testing proposed in this project will establish
the effect of PWHT on cladding. It should then be possible to optimise the production sequence and cladding
technique minimising the cost at the same time ensuring the integrity of the cladding.

Objectives

Establish the effect of PWHT at different temperatures and durations on the metallurgical and structural
integrity of stainless steel/nickel alloy weld overlay cladding through:

Literature review and detailed modelling of the interface,

Identifying the macro/microstructural changes in the overlay/interface,

Mechanical testing of weld overlay cladding/interface,

Corrosion and corrosion fatigue testing.

Benefits

A clear understanding of the impact of welding and PWHT on corrosion resistant and structural overlays.

Enhanced capability to select the right manufacturing sequence, optimum cladding process and
consumables for a given environment.

Increased confidence on integrity and reduced need for repair will reduce operating costs.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
Metallurgical and Structural Integrity of Post Weld Heat Treated Weld
Overlay Cladding and Buttering

Approach

TWI proposes to carry out this GSP in a phased manner as detailed below:

Phase 1: Initial review

A desk based review will be carried out to understand the present industrial practices with respect to the
manufacture, inspection and testing of weld overlay components requiring prolonged postweld heat treatment.
It will focus on identifying the general manufacturing sequence, welding processes, and consumables for a
range of applications specified by the sponsoring companies. The correlation between the welding process,
substrate material, consumables, and operating conditions will be explored. The results of this review will be
presented to project sponsors for their feedback on the selection of substrate material, welding process,
consumables, and heat treatment cycles, and testing environments.

Phase 2: Manufacture and inspection of weld overlay/buttering

Based on the information gathered from the literature review, a set of candidate substrate materials, cladding
processes, consumables, post weld treatment schedules, methods of inspection and testing will be selected in
agreement with the project sponsors. Weld overlay cladding/buttering will be manufactured using a number of
process-consumable-substrate material combinations with different degrees of dilution, and will be post weld
heat treated at a set of typical temperature and durations used in industry. Inspection procedures will be
optimised to detect the interfacial flaws. Inspection of the cladding/interface will be carried out using optimised
non-destructive testing techniques/procedures.

Phase 3: Interface/residual stress modelling and measurement

Computer based models of welding are now frequently used to make predictions of the thermal cycles and
associated thermal stresses that occur during welding. Modelling based methods provide a full field, full time
history prediction of the behaviour during welding and therefore have considerable advantages over a purely
experimental approach. It is proposed that modelling should be used in parallel with the experimental
programme to efficiently develop a set of conditions that will be investigated in the laboratory testing
programme. The models will be used to predict the HAZ thermal cycles and therefore the locations of greatest
interest for subsequent testing. Likewise, the predicted welding residual stresses will show locations where
cracking under the action of these stresses is likely. The modelling will also help in extrapolating the results
obtained from the smaller tests pieces to the real situation in service.

Phase 4: Mechanical testing and optimisation of inspection procedures

Mechanical testing will be carried out as recommended by DNV OS F101:2010 for a structural weld overlay.
This will include all-weld tensile testing, fracture toughness testing for weld metal, fusion line (FL), FL+2mm,
and FL+5mm into the substrate material. Additional fatigue testing will be carried out to classify the joint, and
fatigue crack growth rate tests will be carried on samples with manufactured defects to identify the effect of
interfacial flaws on the life of the component.

Phase 5: Corrosion testing

Weld overlay produced with and without PWHT will be tested for corrosion resistance for a range of mild and
severe corrosive environments. The type of corrosion testing and environment will be agreed with the sponsors

Copyright TWI Ltd 2013


Metallurgical and Structural Integrity of Post Weld Heat Treated Weld
Overlay Cladding and Buttering

Deliverables

This project will provide quantitative information on the impact of PWHT on the corrosion and structural
integrity of cladding/buttering. The results will be supported by corrosion and corrosion fatigue data, and
information on suitability of NDT techniques to ensure the weld overlay integrity quality. The sponsors will be
presented with a report at the end of each of the 5 phases above, and also a final report providing an overview
of the project.

Price and Duration

The overall estimated price for the work is 490,000 (excluding VAT), which requires 35,000 per company per
annum for 2 years (70,000 total) from each of the 7 Sponsors. It is anticipated that the project will commence
with an agreed scope of work with a minimum of 5 Sponsors.

Further Information

For further information on how a Group Sponsored Project (GSP) runs please visit:

http://www.twi.co.uk/services/research-and-consultancy/group-sponsored-projects/

GSP Co-ordinator: Lizanne Capstick

Email: gsp@twi.co.uk

Project Leader: Vinod Kumar

Email: vinod.kumar@twi.co.uk

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000

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