The art of weld overlay - dhwt.co.kr conditions ... All SAW equipment are suitable for strip overlay Only welding head to be modified ... Submerged arc Electroslag

06/10/2011

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Ch LOUPPE The art of weld overlay

Ch. LOUPPECh. LOUPPE

The art of weld overlay

06/10/2011




Agenda

Industry Description

Process Description

Request of customer

Welding conditions

Corrosion & disbonding tests

Customer collaboration

Conclusions

06/10/2011




The most economical solution to

produce the whole component is to

used dual material

Outside

low alloy steel for mechanical properties

Inside

Special alloy for corrosion resistance


Mains properties requested for largecomponents for the chemical, petrochemicaland nuclear industries:

Highly alloyed material to providecorrosion protection

Material to meet requirement forstructural integrity

06/10/2011




Clad plate ( mainly roll- bonded)

Thin layer of an expensive material coming in contact with

corrosive media

Lower cost substrate material is used to give the desired

structural integrity.

Weld overlaying solutionsGive the designer and fabricator a large freedom for

choosing a wide variety of load bearing material and strip

chemistry to resist to different corrosive media.

The flexibility in shaping finished components weld overlay

process depends on many factors including access, welding

position, the applied alloy, and economics


06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




SAW

Flux is fed from both side

Heat is generated by electrical arc

FluxSlag

Flux is fed only from one side

Heat is generated by Joule’s effect

ESW

Process Description

Liquid Flux Slag

06/10/2011




ESW

Strip electrode

arc flux

Strip electrode

fused flux

SAW

Arc temperature > 3000°C

The arc is moving from one side

to the other side

Fused flux temperature < 2000°C

Process Description

06/10/2011




SAW vs. ESW

YesNoMagnetic control

23 kg/h, 0.6 m2/h14 kg/h, 0.4 m2/hDeposition rate

10 %18 %Dilution rate

42 A/mm²25 A/mm²Current density in strip

18 cm/min12 cm/minVelocity

24 V28 VVoltage

1250 A750 ACurrentTypicalweldingparameters

Joule-effectElectrical arcSource of heat

NoYesElectrical arc

ESWSAW60 x 0,5mm strip

Process Description

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Highest deposition ratesKg / H

Process

Process Description

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%

Process

Dilution rates

Process Description

06/10/2011




Process Description

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Uniform penetration

Uniform migration of impurities with Strip.

Low crack sensitivity

Migration to the center

Because of the basicity of the flux, the austenitic structure is claddedwithout any problems

Direction of impurities migration

Process Description

06/10/2011




Main characteristics No essential difference with conventional subarc wire installation

All SAW equipment are suitable for strip overlay

Only welding head to be modified

Main advantages Very uniform penetration

Low dilution

Homogeneous distribution of alloying

Flat surface

High deposition rate

Strip weld overlay process outlines

Process Description

06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




Productivity

Increase the weld overlay deposition rate of theCorrosion Resistant Alloy in order to reduce labour costs

Reduce quantity of the CRA material deposited persquare meter.

Request of the customer

How can I reduce the manufacturing cost of the vessel

Request of customer

06/10/2011




•• High deposition rate with high speed fluxesHigh deposition rate with high speed fluxes• Speed limit: up to 45 cm/min

• Deposition rate : up to 40 kg/h (60mm strip)

•• Monolayer with standard strip and compensated fluxesMonolayer with standard strip and compensated fluxes• Speed limit: 20 cm/min

• 1 layer application with standard strip

•• Monolayer with over alloyed strip and standard fluxesMonolayer with over alloyed strip and standard fluxes• Speed limit: 20 cm/min

• 1 layer application with standard fluxes

ALW Innovation

06/10/2011




ESW cladding new ALW range

ELT 308-1

Suprastrip 19.9LNb

Suprastrip 19.12.3L ELT 316-1ELT 300S

Suprastrip 19.13.4 L

Suprastrip 24.13L

Suprastrip 21.13.3L

Suprastrip 21.11LNb

Suprastrip 24.13LNb

Suprastrip 19.9L

Stainless steel solution

high speed flux

Monolayer fluxes

Standard flux

ELT 300

Strip Weld overlay

ELT 347-1

06/10/2011




347 Single layer ESW alloying flux innovation

ESW flux ELT 300

• Single layer over alloyed strip SUPRASTRIP 21.11 LNb

ESW flux ELT 300S

• Single layer over alloyed strip SUPRASTRIP 24.13 LNb

ESW flux ELT 347-1 new alloying flux

• Single layer standard strip SUPRASTRIP 19.9 LNb

Solution Flux Strip 60mm X 0.5mm C Cr Ni Nb Current speed

Single layer ELT 300 Suprastrip 21.11 LNb 0,03 19,0 9,9 0,4 1200 17

ELT 300S Suprastrip 24.13 LNb 0,05 19,2 10,5 0,42 1500 35

ELT 300S Suprastrip 19.9LNb 0,02 19,3 10,4 0,38 1500 25

Single layer HS ELT 300S Suprastrip 24.13 LNb 0,04 19,4 10,6 0,45 1800 40

Single layer ELT 347-1 Suprastrip 19.9LNb 0,03 19,0 10,5 0,48 1200 17

Two layers

Strip Weld overlay

06/10/2011




316L ESW compensated flux innovation

ESW flux ELT 300

• Single layer over alloyed strip SUPRASTRIP 21.13.3L

ESW flux ELT 316-1 compensated flux

• Single layer standard strip SUPRASTRIP 19.12.3 L

Solution Flux Strip 60mm X 0.5mm C Cr Ni Mo

Single layer ELT 300 Suprastrip 21 13 3 L 0,03 19,0 9,9 2,6

Single layer ELT 316-1 Suprastrip19 12 3L 0,03 19,0 10,5 2,75

ELT 300S Suprastrip 21 13 3 L 0,05 19,2 10,5 2,1

ELT 300S Suprastrip 19 12 3L 0,02 19,3 10,4 2,6

Two layers

Strip Weld overlay

06/10/2011




ESW cladding new ALW range

Nickel Base solution

Monolayer fluxes

Standard flux

ELT 600S

Suprastrip 825

Suprastrip 600

Suprastrip 625

ELT 600

high speed flux

ELT 825-1

ELT 625-1

06/10/2011




Current ( A ) : 750 1250 1500 1250

Voltage ( V ) 26 24 24 24

Speed (cm/min ) 10 16 35 16

Dilution ( % ) 18 9 25 7

C content (%) 0,045 0,030 0,060 0,025on 0.18%C Steel

SAW ESW HS S L

ESW ESW

06/10/2011




0,71,10,690,45Depo Rate

(m²/H)

24272314Depo Rate( Kg / H)

4,53,14,34,5Thickness

( mm )

ESW SLESW HSESWSAW

06/10/2011




0,50 Kg0,68 Kg1 KgQuantity

0,33 H0,42 H1 HTime

0,65 €0,85 €1 €Product

1 layer2 layers2 layers

ElectroslagSubmerged arc

06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




Welding conditions

are mainly governed by the customer’s specifications

Base material

Thickness to be reached

Analyse to be reached

Ferrite

Welding parameter V, I, S

Welding conditions

06/10/2011




Base material

Some base material like SA-508 class 2 ( forged and plate material) aresubject to reheat crackingCracking occurs only in grain-coarsened region of the base metal heataffected zone at the weld bead overlap and when the second bead of high-heat-input is added, which reheats the heat-affected zone (HAZ) in thecarbon steel

This phenomena doesn't occurs when using material made to fine-grain

practice and heat-treated to refine the grain structure, as perSA-533 Grade

B Class I

Metallographic examinations showed that the cracks were in the coarse-

grained region of the HAZ which had been fully austenitized by the first

bead and then reheated to just below the AC1 temperature, i e 600-700 °C,

by the subsequent adjacent bead,

Welding conditions

06/10/2011




Welding conditions

lnfluence of the temperature cycle on grain size range during welding

06/10/2011




0 5 10 15 20 25 30 35

Bead n° X Bead n° X+1

AC3

AC1

Critical areaAC1

AC3

Thermal cycle of the

critical area

Bead n° X Bead n° X+1

AC1

AC3

Welding conditions

06/10/2011




Thickness to be reached

Sometime minimum : 2 layers

Sometime minimum 6 – 8mm

Sometime warranty of the chemistry at 3 ( or 3,2 ) mm fromthe surface

ASME IX CODE : Minimum qualified thickness

Welding conditions

06/10/2011




Analyse to be reached

Chemistry for 316L type

ASME 2 A for Base material : SA-240ASME 2 C for weld deposit : SFA 5.4

ASME 2 C for the strip : SFA 5.9

2,0-3,011,0-14,018,0-20,00,030SFA 5.9

2,0-3,011,0-14,017,0-20,00,04SFA 5.4

2,0-3,010,0-14,016,0-18,00,030SA-240

MoNiCrC

Welding conditions

06/10/2011




δ-ferrite fraction is undesirable

mainly for selective corrosion stresses FN<0.6 ( urea requirement )

Low δ-ferrite fraction is beneficial

high resistance to hot cracking

For alloy type 308L; 316L, 3 < FN < 10

For alloy type 347 : 4 < FN < 8

High δ-ferrite content is necessary

resistance to stress corrosion 30 < FN < 75 (Duplex weld overlay)

Influence of δ ferrite in weld overlay

Welding conditions

The δ ferrite is non-uniformly distributed in a given weld

06/10/2011




From “ welding Metallurgy and weldability of Stainless Steels” By John C. Lippold and Damian J. Kotecki

Weld solidification cracking

susceptibility Based on Varestraint

data

Use of WRC92 diagram to predict

solidification behaviour and Ferrite

Number

AF

FA

F

A

06/10/2011




From “ welding Metallurgy and weldability of Stainless Steels” By John C. Lippold and Damian J. Kotecki

Effect of solidification type on grain boundary tortuosity

Austenite solidification ( A ) Ferrite Austenite solidification ( F A )

06/10/2011




WRC 92

Welding conditions

Dil for SS347

Dil max for E347

06/10/2011




Suprastrip 21 11 L Nb Typical values Cr : 21.4% Ni 11.3%

Min FN

FN & Dil vs speed

Th vs speed

1m/min(900A)

1.5m/min(1200A)

2m/min(1500A)

Th. mm

Welding speed cm/min

Welding conditions

Max FN

06/10/2011




7.212.760.0450.490.03210.3318.810.521.410.027- 3.0mm

5.69.760.0450.500.05010.3018.920.521.420.030- 1.5mm

4.57.27.50.0450.0510.04310.2619.470.471.400.035Surface

0.010.210.401.200.21BM

PWHTASWRCNNbMoNiCrSiMnC

Welding consumables

Electrode : Suprastrip 21-11-LNb 60 x 0,5mm

Flux : ELT 300S

Welding conditions

Base material: Type P1 according to ASME IX, thickness : 40mm

Preheat : Room temperature

Interpasse temperature : 150°C

Post weld heat treatment : 4H at 620°C.

Welding Parameters

Current : 1250A Voltage : 24V Welding speed : 17cm/min

F N

06/10/2011




FN

02468

101214

Surface -1,5mm -3,0mm

Distance from surface

WRC92 AS PWHT

06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




Corrosion Production Operation

Selection of Corrosion resistant alloys

This is a three steps process.

First, resistance to general corrosion must be ensured (primarily

function of the Cr).

Secondly, resistance to localized attack must be ensured (primarily

function of Mo).

Finally the resistance to environmental stress cracking is sought at the

highest feasible strength level (Ni content plays the principal role).

06/10/2011




Typical corrosion tests applied

Appearance of cracks after

bend test. Metallographic

examination of a section is

necessary

24hBoiling650 - 675°C

1H

Copper-copper

sulfate-sulfuric

acid

IntergranularAustenitic

Stainless steelsA262E

Time for cracks initiating, rate

for crack growth, time to

failure

155°CNoMagnesium

chloride

Stress-

corrosion-

cracking

Metals and alloysG36

corrosion rate (mass loss)

or mm/ Year5x48hBoiling

675°C 1h

commonlyNitric acidIntergranular

Austenitic

Stainless steelsA262C

Corrosion rate (mass loss) +

eventually metallographic

examination

120 for 825

alloyBoilingNo

Ferric sulfate -

Sulfuric acidIntergranularNi and Cr alloysG28A

according G46 : mass loss, pit

density, average pit diameter,

average pit depth

72h in the

standard,

sometimes

24h in

practice

22 or 50°CNoFerric chloridePitting and

creviceStainless steelsG48A

Type of examinationTime in

solution

Temperatu

re

Sensitization

treatment

Conditions in the standard

Type of solutionType of

corrosionType of alloy

Standa

rd

06/10/2011




Strip Weld overlay

Dimensions

75 x 20 x 3 mm

Appearance of cracks after

bend test. Metallographic

examination of a section is

necessary

24hBoiling650 - 675°C

1H

Copper-copper

sulfate-sulfuric

acid

IntergranularAustenitic

Stainless steelsA262E


solution

Temperatu

re

Sensitization

treatment




Standa

rd

corrosion rate (mass loss)

or mm/ Year5x48hBoiling

675°C 1h

commonlyNitric acidIntergranular

Austenitic

Stainless steelsA262C

06/10/2011





solution

Temperatu

re

Sensitization

treatment




Standa

rd

Corrosion rate (mass loss) +

eventually metallographic

examination

120 for 825

alloyBoilingNo

Ferric sulfate -

Sulfuric acidIntergranularNi and Cr alloysG28A

Alloy 625

As welded 6H@690°C

δ masse ( g) 0.0558g 0.319 g

mm/Y 0.38 2.20

Deep. ( µm ) 15 240

06/10/2011




Stationnary state

After cooling down

Disbonding phenomena Hydrogen oversaturation

High solubility

Low diffusibility

Low solubility

High diffusibility

06/10/2011




Disbonding test installation

Temp max : 550°C

Pressure of H² : 200 Bars

Cooling rate : Max 750°C/H

ITMA SpainDimensions: Diameter : 73 mmThickness : 40 + 5 mm

Austenitic side

Welded overlay

Applicable standard : ASTM G146-01

06/10/2011




2.25Cr-1Mo Steel

Martensitic carburized layer

Austenitic weld overlay

Disbonding phenomenaTwo key words : Hydrogen oversaturation

Sensitive microstructure

06/10/2011




From API 934 2007

06/10/2011




From API 934 2007

06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




Requirement of the customer SS 304L

Process parameters Pre-heating : 150°C / Interpass : 150-200°C – Post-heating : 2h @ 200°C

Base material : 15MND5 (80mm thick)

Non destructive tests Liquid penetrant tests

Ultrasonic tests

Destructive tests Bending tests, longitudinal and transversal : bending at 4 thickness

Corrosion tests : (ASTM A 262-E) : bending

Chemical analysis : following SS 304L

Metallographic analysis, grain size in HAZ of base metal : min 5

Hardness tests in HAZ of base metal : 320 HB max


06/10/2011




Actual solution use by the customer Multi couches SAW :

Consumables 1° layer : Strip type 309L (60 x 0,5mm) 2° layer : Strip type 308L (60 x 0,5mm )

Welding parameters: Current : 750A Voltage : 27V Welding speed : 12cm/min

Heat input : 100kJ/cm Deposition rate : 13,5kg/h Thickness of deposit : 9,0 mm

Conformed to specifications


06/10/2011




5,043299HV103

Proposition #3

ES 90mm 1 layerstandard speed

8.050254HV107 – 10

Proposition #2

ES 90mm 2 layers

High speed

9.042238HV107 – 8

Proposition #1

ES 90mm 2 layersstandard speed

9.013,5ConformConform

Actual

SA 60mm 2 layersstandard speed

thickness

[mm]

Depositionrate [kg/h]

Hardness

in HAZ

Grain size

in HAZ


06/10/2011




SS 316L stainless steel

Suprastrip 21 13 3L and ELT 300S

825 nickel alloy clad plates

2 solution routes

Suprastrip 625 and ELT 600S

Suprastrip 825 and ELT 825-1


Production of Oil & Gas containing CO2,H2S, Cl- atHT/HP is growing.

For safety and long term economic reasons,Corrosion Resistant Alloys (CRA) become essential

06/10/2011




Agenda


Process Description

Request of customer

Welding conditions



Conclusions

06/10/2011




By courtesy of Nuovo Pignone

Reactor to be overlay

Alloy requested : SS 347

Single layer ESW : 50T of consumables, for 500K€ and need 1600H

Double layers ESW : 70T of consumables, for 690K€ and need 2000H

Every variation of 0.1mm cost 11000 €

Conclusion

06/10/2011




Sewon Cellontech – South Korea

Doosan Mecatec – South Korea

Larsen & Toubro – India

Nuovo Pignone – Italy

Mangiarotti – Italy

ISGEC – India

VRV – Italy

Godrej – India

ATB – Italy

Sempec – China

MISARABIA – Saudi Arabia

Confab – Brazil

Shanghai Electric – China

Some of our Customers

06/10/2011




The art of weld overlay

Documents

The art of weld overlay - dhwt.co.kr conditions ... All SAW equipment are suitable for strip overlay Only welding head to be modified ... Submerged arc Electroslag