CHARACTERISATION OF

MICROSTRUCTURE,MECHANICAL AND
CORROSION PROPERTIES OF PULSED
MIG WELDED MODIFIED P91 STEELS.
Guided by
Prof.P.Sundararaj

Batch Members:
P.Dineshkumar (1461011)
M.Mohamed Jeelan (1461023)
M.Santhosh (1461038)
S.Saravanan (1461041)
 OBJECTIVE OF THE PROJECT
 The aim of the project is to evaluate the effect of weld metal properties in detail
by metallography, micro hardness and corrosion studies of weldments.
 To evaluate the metallurgical characteristics of P91 steel weldment. Welding is
to be carried out by pulsed MIG Welding process using shielding gas
mixtures(Ar+CO2), with optimum pulsing parameters.
 To heat-treat and alter the microstructure of the welded specimen in order to
improve its metallurgical and corrosion properties.
 To estimate of corrosion behavior of the Pulsed MIG welded P91 steel.Various
acidic and salt media have been used to evaluate the corrosion characteristics
using Tafel extrapolation. The various media are
1.HCl 2.H2SO4 3.HNO3 4.NaCl
With the estimation of corrosion behavior, We get an idea about the corrosion
properties of the weldment and basemetal and which media it suits the best.
 Modified P91 steel
•Power generating plants, boilers and steam tubes operate at higher
temperature and pressure, it calls for the development and application of
materials with improved high temperature properties.

•This steel is widely used in power plant boilers and pressure vessels,
where the steel is highly exposed to acidic and salt environments.

•Since P/T-91 is modified with vanadium, nickel, aluminum, niobium and

nitrogen, it develops very high hardness.

•Better resistance to creep, stress-corrosion cracking, higher thermal

conductivity and lower thermal expansion coefficient

•P-91 steels are supplied in a normalized and tempered condition. The

stability of M23C6 and MX is critical to the long term performance of these
alloys. .
 Modified P91 steel
 The welding process strongly influences the microstructure and
properties of the material to be welded.

 As a result of the severe thermal cycle caused by the welding process,

the original microstructure is altered and a so called heat affected zone
(HAZ) is formed.

 Heat treatment is necessary to modify the metallurgical properties of the

welded material.

 Failure of a component is initiated in a localized, microscopic region of

weldments, either during welding or in service. Each region of the HAZ
undergoes a different thermal cycle depending on its distance from the
source of heat.
Chemical composition of Modified P-91 steel
ELEMENT CONTENT EFFECT ON PROPERTIES
Chromium 9.4% 1.Increase toughness
2.Increase oxidation resistance
(Cr) 3.Wear resistance

Molybdenum 1.0% 1.Promotes hardenability of steel

2.Makes steel unusually tough at various hardness levels
(Mo) 3.Raises tensile and creep strength at high temperatures.

Carbon(C) 0.08% 1.Increase Hardness

2.Decrease toughness

Nickel(Ni) 0.13% 1.Increases toughness and resistance to impact

2.Less distortion in quenching
3.Strengthens steels.

Niobium 0.09% 1.Strong ferrite and carbide former.

2.Improve the resistance to intergranular corrosion.
(Nb) 3.Enhances mechanical properties at high temperatures.

Manganese 0.39% 1.Contributes markedly to strength and hardness

2.Counteracts brittleness from sulphur
(Mn) 3.Lower both ductility and weldability if it is present in high
percentage with high carbon content in steel.

Silicon 0.5% 1.Improve oxidation resistance

2.Act as a deoxidizer
(Si) 3.Increase hardness.

Vanadium 0.25% 1.Promotes fine grains in steel

(V) 2.Increase hardenability.

Iron(Fe) Balance
 Heat treatment cycle of P91 steels

Normalizing
1040oC
1 hour Tempering
Temperature

Air 760oC
Cooling 1 hour
Air
Cooling

Time
Physical properties of modified P91 steel

 Optimum strength and toughness

 High temperature creep strength

 High thermal conductivity

 Low thermal expansion co efficient

 Resistance to stress corrosion cracking

 High temperature oxidation resistance

Mechanical properties of modified P91 steel

Yield Tensile Hardness Impact

Elongation
strength strength (10 kg load) energy
(%)
(MPa) (MPa) (VHN) (J)

557 672 18 202 227

Preparation of Weldment
 Pulsed MIG Welding was performed on the base metal using single
“V” groove butt joint type with an inclined angle of 60° having land
height of 12mm and mixture of CO2and Argon was used as
shielding gases. The two base metals were kept close together in the
flat position (1G) with a root gap of 1.5mm and welded at the
junction of two end points. The base metal of 12mm thickness was
obtained in N&T condition. Base metals were cleaned with a
grinding machine to remove the oxide layer from the surfaces
FILLER WIRE DETAILS
The pulsed MIG welding filler wire is low hydrogen 9Cr-1Mo steel
wire.
The filler wire diameter is 1.2mm conforming to ER 90S-B9 .
ER – indicates an electrode or a welding rod
90 – indicates tensile strength of 90,000psi
S – indicate solid electrode or rod
B9 – indicate basic coated
Chemical composition of filler wire in Wt%

C Si Mn Cr Mo Ni Nb V

0.1 0.3 0.5 9.0 1.0 0.7 0.06 0.2

 Mechanical properties of filler wire
Tensile Strength - 772.212MPa
Yield Strength - 689.475MPa
Elongation - 17%

 All Weld metal properties

Tensile Strength -689.475MPa
Yield Strength - 586.05MPa
Elongation - 22%
Welding and welding parameters
 Welding has been carried out with the help of Fronius Pulsed MIG
welding
machine. Welding is carried out with DCEP. The specimen has been
subjected to multi passes.
Shielding gas
 Welding parameters are
Parameter
5% CO2+95% Ar
 subjectedVoltage(v)
to multi-passes 17.3
Current(amp) 72

Wire feeding
1.8
rate(m/min)

Welding
5.06
speed(mm/sec)

Pulsed
125
current(amp)

Background
18
current(amp)

Heat input(J/mm) 245.77

No.of pass 5
Pre heating
 Purpose of maintaining minimum preheats and inter-pass temperature is to

ensure slow cooling of the weld joint after welding.

 Heat lost by conduction is reduced and hence lower heat transfer rate.

 For high expansion materials pre heated weld bead cools slowly and cracking

tendency is eliminated. Preheat application should be continuous all throughout

welding and it’s always prudent to use electrical resistance or electrical

induction heating.

 It provides better temperature control & uniform heat distribution

 Non homogeneous microstructures can be eliminated

 Typical values of preheat or inter-pass temperature is in the range of 200-

250oC.
Preheat, Welding & PWHT cycle
Pulsed MIG welding
•Pulsed MIG process is modified from of steady current MIG process, in
which metal transfer takes place in pulses rather than continuous as in
conventional steady current pulsed MIG.
•In pulsed MIG process, the cycle with periods of alternative high and low
arc current controls the droplets detachment and results in the spray type of
droplet detachment with a more uniform size and frequency at lower
values of average current.
•This provides a smaller and controlled weld pool, which allows the
welding of even thin material in all positions with less distortion.
•Pulsed arc welding enables droplets to be projected across the arc gap at
the regular frequency, using pulses of current in the spray transfer range
from a special supplied power source.
Wave diagram of Pulsed MIG welding
Advantages of Pulsed MIG welding

 Heat input given to the weld metal is low

 Results in narrow heat affected zone.

 Metals are transferred by spray mode in pulsed condition, instantaneous

solidification takes place.

 Fine grains in weld region.

 High toughness for the weld metal.

 Minimizes distortions owing to controlled heat input

 Shows marked improvement in weld quality

Post weld heat treatment
 PWHT increases ductility and toughness and decreases residual
stresses and hardness. Controlled cooling rate is required.
 These alloy components are heated to approximately 7500C, above their
upper critical transformation temperature (Ac3) until it is fully austenitic
for about 2 hours.
 Next, the steel is cooled in air to below 1000C/h, at which temperature
the steel is fully transformed into martensite. This steel forms martensite
even at air cooling because it has lower critical cooling rate.
 The material is then heated at temperatures around 4000C to temper the
martensite formed and improve ductility and toughness of the
component, and induces the formation of critical carbides and carbo-
nitride precipitates.
 Final microstructure is tempered martensite of different lath sizes in
different zones.
Pulsed MIG welded Modified P91 steel after
final treatment
Microstructural analysis

BASEMETAL HAZ

Etchant: Viella’s reagent

Magnification: 100X

WELDMENT
 As the material has lower critical cooling rate it forms martensite
even by air cooling.

 The microstructure of modified 9Cr-1Mo steel is tempered martensite

structure formed after the final normalizing and tempering heat
treatment. Precipitates are formed on PAGB’s.

 Tempered martensite is the microstructure observed. But the lath

sizes differ from weld region to base metal region. Weld region has
coarse tempered martensite lath, HAZ has finer tempered martensite
lath compared to weld region and base region has finer tempered
martensite lath compared to that of HAZ.

 Precipitates of various sizes are found to be present in every zone of

welded material
Microhardness profile
 From the hardness survey obtained it is evident that there is variation in the
micro-hardness values. There is a sudden decline in micro-hardness value
in the weld region. This is associated with the decrease in dislocation
density after PWHT process which is used to improve the mechanical
properties of the weld in accordance with the basemetal.

 Moreover the hardness in the HAZ and Weld regions keep varying, this can
be attributed to the microstructure present in the welded material. After
PWHT the material develops tempered martensite of various lath sizes.
This imposes difference in the micro-hardness values from the weld region,
HAZ and base metal. But in base metal the variation is feeble in difference.

 During PWHT certain precipitates get coarsened , this reduces the micro-
hardness values .When tempering is done at higher temperatures there is
decrease in dislocation density. Hence the hardness values keep varying in
accordance to the microstructure present in the respective regions
Corrosion test

Corrosion can be defined as deterioration of materials due to a reaction with

environment. Corrosion failures of welds occur despite the fact that the proper base
metal and filler metal have been selected, industry codes and standards have been
followed, and welds have been deposited. That passes full weld penetration and has
a proper shape and contour. Its not unusual to find the, although the wrought form
of a metal and alloys is resistant to corrosion a particular environment, the welded
counterpart is not. Further welds can be made with the addition of filler metal or
can be made autogenously (without filler metal). However, there are also many
instances in which the weld exhibits corrosion resistance superior to that of the un
welded base metal. When the weld behaves in an erratic manner, displaying both
resistance and susceptibility to corrosion attack.
Factors influencing of corrosion :
 Moisture contamination
 Weldment design
 Weld slag and Spatter
 Incomplete weld penetration or fusion
 Porosity and Cracks (crevices)
 High residual stresses
 Improper choice filler metal
 Micro segregation
 Precipitation of secondary phases
 Formation of unmixed zones
 Recrystallization and grain growth
Tafel plot extrapolation:
By using Tafel plotting system, the various region of weld metal and parent
metal are analysing various percentage of ACIDS
Woking Electrode : Modified P91 Steel specimen
Reference electrode: Silver/Silver chloride electrode
Counter electrode : Platinum electrode
Electrolyte : various acids and salt
Butler-Volmer equation,
I = Icorrexp(2.303(E-Ecorr)/βa) - exp(-2.303(E-Ecorr)/βc)
where, I is the measured cell current in amps
Icorr is the corrosion current in amps
E is the electrode potential in volts
Ecorr is the corrosion potential in volts
βa is the anodic Beta Tafel Constant in volts/decade
βc is the cathodic Beta Tafel Constant in volts/decade
Tafel plot- schematic
Corrosion rate calculation
CR = Icorr.K .EW/ A.ρ

where, CR is the Corrosion rate in mils/year

Icorr is the corrosion current in amps
K is the corrosion constant
EW is the equivalent weight
A is the area of sample exposed in cm2
Ρ is the density of the material in
grams/cm3
HCl: comparison between basemetal and
weldment
S.NO CONCEN- CORROSION CORROSION
TRATION RATE(mils/yr) RATE(mm/yr)
(N) Base Weld Base Weld

1 0.1 1.953exp(2) 1.903e 0.3665 0.3571

xp(2)

0.5 2.120exp(2) 1.985exp(2) 0.3978 0.3725

2

3 1 2.473exp(2) 1.737exp(2) 0.4641 0.3260

4 1.5 1.484exp(2) 1.437exp(2) 0.2785 0.2696

5 2 1.869exp(2) 1.615exp(2) 0.3507 0.3031

HCl: comparison between basemetal and
weldment
 H2SO4: comparison between basemetal and
weldment
CONCEN- CORROSION CORROSION
S.NO TRATION RATE(mils/yr) RATE(mm/yr)
(N) Base Weld Base Weld

1 0.1 1.668exp(2) 2.567exp(2) 0.0254 0.4817

0.5 5.444exp(2) 5.738exp(2) 1.0217 1.0769

2
3 1 8.681exp(2) 5.336exp(2) 1.629 1.0014

4 1.5 1.009exp(3) 1.124exp(3) 0.5142 0.5734

5 2 9.35exp(2) 9.498exp(2) 1.7548 1.7826

H2SO4: comparison between basemetal and
weldment
 HNO3: comparison between basemetal and
weldment
S. CONCEN CORROSION CORROSION
NO. TRATION RATE(mils/yr) RATE(mm/yr)
(N)

Base Weld Base Weld

1 0.1 2.340exp(2) 1.940ex 0.4391 0.3641

p(2)

2 0.5 4.773exp(2) 6.993exp(2) 0.8958 1.3124

3 1.0 4.002exp(2) 8.959exp(2) 0.7511 1.6814

4 1.5 1.484exp(2) 1.437exp(2) 0.2785 0.2696

5 2 8.526exp(2) 7.438exp(2) 1.6001 1.3959

HNO3: comparison between basemetal and
weldment
NaCl: comparison between basemetal and
weldment
S.NO CONCE CORROSION CORROSION
N RATE(mils/yr) RATE(mm/yr)
TRATIO Base Weld Base Weld

N
(N)
1 0.1 7.57exp(0) 0.1784 0.1992
1.416exp(1)
0.5 1.905exp(1) 9.253exp(0) 0.1228 .1528
2
3 1 9.317exp(0) 9.131exp(0) .0794 0.0780

4 1.5 4.178exp(0) 1.563exp(1) 0.0760 0.0843

5 2 5.581exp(0) 1.899exp(1) 0.0856 0.1957

NaCl: comparison between basemetal and
weldment
Conclusion:
 Weld metal develops a tempered martensitic structure after PWHT.

 Weld zone has tempered martensite of coarser lath sizes and δ-ferrite, HAZ
has distribution of precipitates with fine lath sizes of tempered martensite
and basemetal has tempered martensitic structure with some precipitates.

 A decrease in weld metal hardness is due to PWHT which reduces the

dislocation density, HAZ has higher hardness compared to weldment and
basemetal, this can be attributed to fine precipitates formed and fine lath
sizes of tempered martensite.

 Corrosion rate of weldmetal is similar to that of basemetal and in some

cases it’s low in various concentrations of different environments.

 Corrosion rate is highest in HNO3 followed by H2SO4 and then HCl.

 Corrosion rate is least in NaCl.

 As corrosion rate is vigorous in HNO3 , it indicates that the material can be

subjected to lesser acidic environments and salt environments
Advantages of modified P91 steel

 The high creep strength of this steel to be considered for

applications in advanced power plants operating at steam
temperatures above 600°C.

 High strength

 High temperature strength

 High oxidation resistance

 Good hardenability.
Applications of modified P91 steel

 Water boilers and superheaters.

 Boiler drums.

 Collectors.

 Pumps and pressure vessels.

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Temparatures, vol 27 (2010) , pp 233-242.

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Gas Tungsten Arc Weldments in Power Plant Carbon Steel”, ASM

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(2010)
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Thank You