EXCELLENT JOINT EFFICIENCY IN GTAW HOT WIRE NARROW GAP APPLICATIONS

In situations where, foremost, the required weld joints must exhibit strength, integrity and corrosion resistance, such as for thick walled components for super critical power plants or nuclear power plants, the application of hot-wire Gas Tungsten Arc Welding (GTAW), specifically GTAW Narrow Gap Welding (GTAW NG), is finding increased use. GTAW-NG is generally regarded as a low deposition process and higher deposition processes find wider use within the power generation industry. However, GTAW hot wire offers superior weld properties and excellent joint efficiency in narrow gap applications. See figure 1. A variation of the GTAW process, where the low metal deposition is offset by an extremely narrow groove (see figure 2), GTAW-NG welding becomes quite competitive for thick walled components, including steam generator tubes, nozzles, casings, rotors and valves. This advantage is especially true when considering other GTAW advantages: low distortion, low residual stresses, its capability for cracking-free deposit, superior mechanical properties, and excellent weld seam quality. Both material and construction of HP turbine and valve housings for advanced steam conditions have improved in the last several years, now being suitable for steam parameters up to 300 bar and over 600C (1100F) see figures 3/4. As a result, wall thickness of high pressure components has increased significantly. High pressure casings made of temperature resistant martensitic 10% Cr steel with a wall thickness of 180 mm are joined to valve housings.
Figure 2: Typical NG macro cross section

Figure 1 : GTAW - Hot wire principle

For example, the connection of a high pressure inner turbine casing to a main control valve for ultra super critical power plants, such as those sold recently by Siemens, has a wall thickness of 180 mm. Because of complex non rotational symmetry, those welds require stationary components and a rotating, orbital weld head. The wall thickness range makes extraordinary demands on the welding process (see figure 5). For both economical and qualitative reasons this weld was performed using hot-wire GTAW-NG.
2006

Figure 3 Source : SIEMENS PG Welded connection between HP turbine housing and main control valve

Figure 4 Source : SIEMENS PG HP casing and main control valve prepared for welding

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Note that hot wire welding causes less shrinkage therefore joint preparation is slightly different to cold wire welding. The angle in the lower area must compensate for shrinkage, which is continuously reduced increasing the welded thickness of the joint. Idealistically the side walls are parallel after welding. Since the welding consumable enters the weld pool already preheated, less shrinkage results from the arcs power density, which is lower than in cold wire welding. Characteristics of this weld include excellent mechanical properties that exceed the base material requirements. See figures 6/7.
Figure 5

Figure 6

Figure 7

Welding the regular workpiece also demands close attention during preparation of the parts to be welded. Tolerance requirements for machining the weld preparation are in the range of 0,1 mm for the butt joint in the root area. Even tolerance for the angle must be precise. Conclusion With all of its inherent properties, hot-wire GTAW-NG is a method that should be considered for welding thick walled power plant components. It is a competitive process, offering strength, integrity, and corrosion resistance, as well as low distortion, low residual stresses, a capability for cracking-free deposit, superior mechanical properties, and excellent weld seam quality.

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