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Heat Treatment
Heat Treatment
25
INTRODUCTION
TO HEAT
1. Welding Process
The welding process applied to metals joins two components together by fusion. The surfaces to be joined are raised locally to melting point by a source of heat provided by a variety of welding methods based on electric arc, electric resistance, flame. The process energy creates a localised molten pool into which the consumable is fed, fusing with the component surfaces and/or previously deposited weld metal. As the molten pool is moved along the joint axis, the components are heated, nonuniformly and subsequently cooled, also non-uniformly. Neighbouring elements of material try to expand and contract by differing amounts in accordancee with the sequence of the localised thermal cycle. Characteristically the cooling weld metal contracts under conditions of severe restraint, leading to the introduction of thermally induced stresses. As contraction tries to take place and the stress system strives to reach its lowest level to achieve stability, distortion will occur as yielding takes place. If the joint is restrained and cannot distort, then high levels of stress will occur and may lead to failure in the form of cracking.
Br
its Effects
'as cast' type of structure develops. In the region of parent metal at the fusion face raised to melting point, metallurgical restructuring takes place to give the heat affected zone (HAZ).
A longitudinal force on the weld is required to close the gap giving a tensile stress whilst corresponding compressive stresses in the plate material provide the equilibrium.
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Residual Stress Directions
Residual stresses will act in two principle directions; longitudinal stresses parallel to the joint and transverse stresses normal to the joint.
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In steel the heat affected zones are generally harder than the parent material with corresponding loss of ductility and resistance to impact. Since the basic sources of weld failure are a consequence of thermal behaviour, a series of potential solutions arise based on the application of heat. The welding processes have to be controlled so that the residual stresses are minimised to protect the integrity ofthe overall fabrication and the metallurgical structures of the weld metal and heat affected zones are controlled to give properties which are not inferior to those of the parent material which have been used in the design of the product. A series of heat treatment operations are associated with the welding processes, arising from the need to control these changes. These form the basis of the subject of Heat Treatment Engineering.
The distribution of longitudinal residual stresses in the section will be as shown with tensile component confined to the region of the joint.
Stress Distribution
It should not be forgotten that the value of the tensile stresses can be high often exceeding yield point magnitude.
Unrestrained Contraction Causes Distortion
I1I
Unfused Weld Metal
In making a joint, gaps would occur at the plate ends if the weld metal were allowed to expand and contract without restraint.
So far the mechanical effects of welding in the form of residual stresses have been considered. The deposition of weld metal in a molten pool and the localised melting of the joint faces of the components, along with subsequent cooling, all have metallurgical implications affecti ng the microstructu re of these regions. Cooling after welding can be relatively rapid. From the molten pool of weld metal an
2. Preheat
Br
Postheat
preparartion area is dry and remains dry throughout the welding operation. The presence of preheat, and associated benefits on cooling rate, helps to facilitate the diffusion of the hydrogen molecules out of the metallic structure.
Preheating involves raising the temperature of the parent material locally, on both sides of the joint to a value above ambient. The need for preheat is usually determined by the pertinent fabrication code and verified by the weld procedure qualification test. Preheat may be required as an aid to welding for one of four basic reasons. To control the rate of cooling, especially in the
heat affected zone, to reduce hardness. High carbon and low alloy steels harden if they are quenched from high temperatures (above cherry red). Exactly the same process can happen in a welded joint at the fusion face with the parent material. 8y raising the temperature of the base metal to be welded, to reduce the temperature differential between ambient and the resultant heat input, hardening may be contr911ed as the weld cools. Reducing hardness reduces the risk of cracking.
27
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HYDROGEN
OXYGEN
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Low
Heat Loss
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High
Porosity
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Moisture is also introduced from the welding consumables being present in electrode coatings and fluxes. To obtain the maximum benefits from preheat in controlling hydrogen, it must be accompanied by careful controls over removal of moisture from the welding consumables by following manufacturers baking and storage instructions.
Guidance for the need to preheat is generally obtained from the national fabrication codes, which will list recommended minimum temperatures for steel types grouped by composition and also relate the minimum section thickness to which they apply. For the purposes of illustration, the preheat requirements of high pressure pipework codes 8S2633, ANSI 831.1, and ANSI 831.3 are compared.
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Mater;al Hardens
Ome
ocl~
Material Softens
Post Heat This is the term given to the extension of preheat on completion of welding at the same or increased temperature. Its purpose is to effect diffusion of hydrogen from the joint and reduce susceptibility to the associated form of cracking. It is usually applied to the higher strength carbon managenese steels and the low alloy steels where the risk of hydrogen cracking is higher.
Post heat treatments are not reflected in national standards or codes, but are often specified by the client who has incorporated their equivalent into the weld procedure qualification test. The temperatures and soak times are derived from numerous technical papers published on this topic.
when
slower
cooling
Time
----..
An estimate of weld metal root 38thick BS metal18S 1719) 20'Cpermissable 12.5 REQUIREMENTS 100'C 30mm requiredweld metal 50'C thicknesses 30 Non hydgrogen 150'C 5'C runSteel to 5'C 12.5mm steel 100'C Matching thickness diameter not and 200'C 127mm Material12.5 Minimum Above Material allowed30mm Carbon20 or200'C All toH1rods20'C30 thickness root controlled Above 12.5All 5'C 12.5 run. All mm I joint mm I FOR weld 2633: 1987 thickness Up Up (greatest thickness of joint diameter preheat (greatest hydrogen levels can be made of temp 20 PREHEAT 5'C Hydrogen controlled Not Low from a knowledge of the 20 Above30mm Above 12.5 Up to Up to 0.40%C 7Cr'I)Mo preheat temperature potential steel Carbon hydrogen level in theMinimum Carbon-moly consumables
2.5
I r~XI
Low
Medium
High
Special
Note re 8S.2633
The table is for guidance only. It illustrates the contents of the preheat section of BS. 2633 (Table 5) which should be consulted in its entirety. A number of other important standards give guidance on preheat, these include:
ASME Code
Section III : Nuclear power plant components Section VIII: ASME Boiler and pressure vessel code
BS 1113
Water tube steam generating plant Fusion welding of steel castings Part 1 - Production, rectification and repair Part 2 - Fabrication welding
BS 4570
BS 5135
Metal arc welding of carbon and carbon-manganese steels Unfired fusion welded pressure vessels Note re ANS1/B31-1
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BS 5500
Special
ANS1/B31-3
The table below is for guidance only. Reference should be made to the appropriate specification
Minimum 50 Recommended '/{ Group REQUIREMENTS below 1" above OR300 -250 '/1" causes increased residual stress PREHEATAlloysVanadium 00KSI & FOR PETROLEUM -or 175 -175 & chromium (ANSI 6% - 400 Carbon Steel AN 71 Others 250. 50 0.30% above ANS1831.1 27 Chromium 300 400 Carbon 1" 300 3 175 350 P-9A - 50 P98 Preheat Temperature 'F 8%,9% Nickel Nickel '/1% 71 '/{ ManganeseAustenitic300KSI & below '/{60 -KSI or- both REFINERY PIPING above B.31-1.19901 High Alloy Ferritic- 10% SI 8.31.3 Chromium Martensitic Chromium 2'/4%max 50 '1)%-2% 200 Above - 50 Metal Material Number 3 & 71 10E & above - -175 P21-P52 50 Above 1 KSI 175 1" groupabove -175 ~::sne~ ~;:;~~;~~~' 8ase Others - 300
120%
Weldmg
at sub-zero
temperatures
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11
100
100
200
300
400C
on
residual
stresses
engineered system is capable of providing appropriate levels of performance. Benefits of Post Weld Heat Treatment
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100%
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80%
29
60%
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40%
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20%
0%
700
200
300
400
500
600
Stress relieving temperature ("C) Effect of stress relieving at various temperatures Reduced Residual Stresses
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"-
-0
co
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Improved
Metallurgical
Structure
Postheated Weld
The soak tempertures are held within the upper and lower limits of the soak range for the appropriate period of time. The heat treatment system (including insulation), zonal division and number of thermocouples is such that the energy input and level of control is capable of enabling these objectives to be met ensuring that the integrity of the overall structure is not jeopardised. For local heat treatments, controls have to be implemented to provide assurance that the
Improved
Corrosion
Resistance
Remove
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PWHT
Improved
Machinability
.
not required) 9Cr lMo 12CrMoV(WI
POSTWELD TREATMENT FOR 590-620 None 630-670 (optimum HEAT601 thickness but REQUIREMENTS 601 680-720 Temperature 120)of wall thickness thin 2.5welds) to 127mm 720-760 2.5 (minimum 1201 60) 710-760 5 (minimumcreepl301 120) (minimum 60) 580-620 1801 SS 2633: 180) Not {minimum 30)(welds only) 630-670 180 required in furnace (pipework thinLocalrequired 127mm wall heattreatment up Soaking Not irrespective 60) andwall up to
Time at temperature: Minutes/mm thickness
where
Special Note re BS.2633 The table is for guidance only. It illustrates the contents of the post weld heat section of SS. 2633 (Table 6) which should be consulted in its entirety. Also see SS. 1113 for post weld heat treatment requirements for water tube steam generating plant. For certain service conditions and for pipes of O.15%OC maximum, post weld heat treatment of welds in pipes up to and including 12.5mm thick and fillet welded attachments where the throat thickness does not exceed 12mm is not required subject to satisfactory welding procedure tests. Special Note re ANSI/B311 & ANSI/B313
The table below is for guidance only. Reference should be made to the appropriate specification
CarbonalloymartensiticAbove 31{1025/10851 hourB3.1chromium Steel 9% nickel steel -2% None 3/t TREATMENTRequirement {Inch1 hour0.25% 1100/1200 2" hour min1250/1300 Boiler of 1350/14251 1300/1400 1400/14751 1 Brinell 4 Manganeseaustenitic Postweld coolingKSll100/1300minhour/inchSoakPiping 3% chromium vanadium Nickel POST - 10% steels 1350/14502ANSI B.31.3 1KSIREOUIREMENTS FOR130011375 Chromium ferriticmax 1225/13001-1100/1200 hour{lnch11100/1200above to 600) alloy 2'/4% '12% '/2% 3/4'or0.15%rate toabove '/{,hourOD, down {Inch. 3/"-1100 -11751KSI-1300/1375 External carbon '/2" hours min. SI 3% &hour{lnch 71 carbon, 3/t 4" 300/Hr above Nonebemin (note: 71 hourabove 00,0.15% Above 'h", hourlinch 9A '12".4" max 1100/1325 High ChromiumWELD HEAT Heat Treatment241-5/s" minCarbon 0.15% carbon PETROLEUM AN hour Material Group min. 225 Brinell max 1 hour min. 9B - above 112",1100 - 1175 1 hour
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Heat Treatment of Pipewelds with 48kV A Heat Treatment Unit and Pad Elements
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CIRCUIT 1
CIRCUIT 2
32002 34 19 43007 32001 42011 StockOty. 10334 48kVThermocouple Heat Treatment Unit 35024 11 See Req.19 Insulating 6 Unit 41756172Fibre As 16 TYPICAL Thermocouple Attachment 3 See 1522No. Sets with Plug CHANNEL TripleRange Elements48kVA Mats HeatingChannel Cable 2HighA6212-18 Cables Description CeramicPage 2m Range way Temperature Cement Splitter
HEAT TREATMENT
UNIT PACKAGE
Circumferential Stress Relief of Pressure Vessel Welded Seams using Twin Bulkhead Method and Channel Elements .
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ROLLER SUPPORTS FOR EXPANSION 6 CHANNEL 415V DISTRIBUTION UNIT AND TEMPERATURE RECORDER FIXED SUPPORTS
STEEL BULKHEADS 4-12mm RODS IRON MESH WIRED TO BULKHEADS THERMOCOUPLES ATTACHED TO WELDED SEAM AND AT GRADIENT POSITIONS
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4-BANK CHANNEL ELEMENTS
n n
MINERAL WOOL MATS 60mm THICK WITH SINGLE LAYER OVER GRADIENT ZONES AND DOUBLE LAYER OVER THE HEATED ZONE
PACKAGE 340002 6 40006Qty. Stock18 27750TemperatureCement 9 119 6' 9Wool 3200211 14002Page 10 1 22 506-014 420111 Mineral2Channel Elements Unit 62m 30001No.(4/3Insulation Phase) Channel Thermocouple Distribution (2 Phase) 4-Bank43007 Cable Cable (31Unit Heater) Description 641756(79 415V AttachmentElements) Point 19 Recorder 3As Bales TYPICALwith Plug Ptsl FOR PWHT OF 3M DIAMETER way3 Splitter 30mThermocoupleHeating Compensating (11 High12110 Temperature FeedReq. Cable
SEAM
therefore
98.9
244 241 224 1120 214 210 2642 760 2660 588 1670 888 2678 866 2714 893 2696 821 1724 816 1652 988 1688 904 662482 680488 698493 716499 3650 1470 3668 3686 1490 1480 1460 900 910 920 930 940 2030 350 360 370 380 390 2606 510 2624 382 2570 604 1616 993 1580766 1634 899 626471 608466 590460 644477 3578 3560 3596 1420 1410 1430 1440 880 870 860 890 1960 1990 330 320 310 340 2534 271 1544 649 572454 554449 1400 1390 850 840 1950 300 290 2516 666 1526 788 2498 654 1508 793 1380 1370 830 820 1930 1920 280 270 2480 266 1472 1043 1490 1099 482427 3452 1350 1360 800 810 1910 250 260 478.4416 2426 554 2444 560 1454 1088 3416 3398 1330 1340 1320 780 790 770 1890 248 249 247 1310 760 246 471.2712 496.4732 2372 527 2354 521 1382 599 3344 3326 1300 1290 1280 750 740 730 1850 1840 245 243 467.7716 465.8704 2318 393 1328 799 3290 1270 1260 1820 720 710 242 460.41021 2282 321 2264 777 2246 1066 1292 810 1274 838 1256 877 3254 3236 3218 1250 1240 1230 1220 1800 700 1790 690 1780 680 670 240 239 238 237 451.4332 455.0343 2174 771 2210 1082 1220 871 3146 3164 3182 1180 1190 1200 1210 630 1740 640 650 1760 660 235 236 233 234 1994 660 1090 1640 540 444.2310 449.6327 447.81027 2120 360 2138 1010 2084 749 1130 804 1148 849 1112 832 3074 3092 1160 1170 1140 1150 610 620 1690 600 1710 590 1700 231 229 232 230 422.6243 424.4249 433.4277 420.8238 417.2227 437.1288 428.0260 440.6299 431.6727 442.41077 1814 577 1076 304 2048 1016 1958 1060 1850 1049 1868 738 1922 643 1022 1104 896217 986218 914219 824213 878 910 842 938 950 943 2822 966 2804 960 2930 2876 2966 2894 3020 3038 1070 1030 1010 1020 1000 1060 1080 1050 1040 1100 1110 1130 990 1550 1540 1580 1600 1590 1680 570 1620 1560 1570 520 1610 460 470 450 480 530 1630 510 490 440 500 550 1660 560 580 1670 223 216 215 222 221 220 226 227 228 415.4221 413.6216 411.8210 1778 549 1742 571 788 977 770 921 2732 980 970 960 950 1510 1500 1530 1520 430 420 410 400 211 1706 982 734504 3632 3704 1450 2000 2010 2020 2040 2588 627 1598 999 1614 1970 1980 2552 621 1562 616 3542 3524 1940 536443 518438 3506 3488 2462 582 500432 3470 1900 480.2421 476.6410 2408 566 1436 782 1418 688 3434 1880 1870 474.8404 2390 532 1400 682 3380 1860 473.0710 2336 399 1364 632 1346 1093 3362 1830 2300 377 1310 1116 3308 1810 464.01071 462.21038 458.61032 2228 693 1238 827 3272 1770 453.2338 456.8349 2156 699 2192 1004 1166 854 1184 843 1202 860 3200 1730 1750 435.2282 446.0316 1004 516 1094 354 2102 754 2984 3110 3128 1720 426.2254 419.0232 438.8293 429.8743 2012 388 2030 371 2066 366 1832 593 1940 677 1886 610 1976 638 1904 671 1040 1110 1058 882 968 916 860 932 932 949 2948 927 2840 971 2858 954 2912 3002 3056 1650 410.0204 1795 543 1760 538 806225 752212 2786 1054 2768 2750
33
Conversion Factors
rate Specific 1.73Wm-1 0C- 1 heat capacity
0.948 (ImpkJ =0.155in2kgkggal 35.27 Imp 25.4 6.29 1.12 =0.0624Ib in gal fr = =22051bounce gal)-l 1.356J US Ib 1.609 159 3.281 =1.163Wm2 J Wm-2OC-1 =2.205Ib mile W 30.48 kcal =0.738 W ft Wm-1OC-1 =3.60 kcalh-1ft-2h-1F =2.590 kWh1 deg 2.471 kJ therm 1.055 cmha 28.32 1.102 =0.293 Btu IbfIb-1 105.5 g ft2 =0.86 ft litre gal)56.87 kJmcBtu 0.0095 Imp km2 0.86 MJ kWh =29.31 kcalm-3fr2h-1OF-1 =0.093 Wh m-2h-1OC-l =0.176 km lW =0.0149 USArea(US 0.239 mm gal =0.239 UShpWm-2OC-1 =6.93 acreh-1 =0.578 calgal ton =3412 ft2 F=hour =0.386 deg fr3kcal 67.07 Btu IbkW 10.76 kmacre 0.9144 ft-1 35.31 0.621 Power,h-1 =4.187JMJBtucm2 fr3OF-l =6.452cm2 1 ft-3OF-1 0.0283 MJ Heat Ib-10F-l =intervals(USKm-311gal)-l = Density m-3 1 Btufr' Btu ft-20F-1 =42 halitremcalIbfF-1 coefficient =5.678 ton 907 0.264 0.4536 mile2 0.984 6.23 7.48 264 =0.556 mile2 30C= =220degftlibkgtonh-1OF-1 =0.835IbImpm3gal C F-l 0.3725 barrelBtu 16.02kg USm2 0.22 1016 119.8 1.8 107 28.35 0.1 Temperature0.405 IbBtu1inmin-13h-1 1 Btu transfer =0.394kgft3kJkg-1C-lgal)-l =99.8 kg heatflow Length h-1OF-l=ergs 1 +CBtum-2OC-1 1 J =4.187 Thermal conductivitytherm (Impm-2h-10C-1 = kg m-3 F-1 = 0.144Wm-1C-l20C-1 1.163 Wm-in 2 1 kJkg-1C-1 I 1
I I
80 120 Wt. 30 10S 1.050 0.109 Extra Std. Outside 0.134 0.687 0.406 0.180 0.307 0.312 1.375 1.343 2.375 2.875 4.500 0.600 0.300 3.500 0.065 0.840 0.294 0.083 0.147 140 160 100 20 40 60 Sch. Double 0.065 0.133 0.308 0.358 0.113 0.179 1.315 0.109 0.156 0.750 2.062 0.140 0.552 0.400 0.200 0.145 0.436 0.218 0.154 0.203 0.382 0.318 0.226 1.125 0.843 0.330 0.718 0.593 0.500 0.365 0.250 0.165 0.875 0.812 0.322 0.277 0.148 0.864 0.280 0.258 0.674 0.337 0.237 1.259 0.937 0.438 0.375 1.438 1.562 0.562 1.500 1.281 1.812 1.531 0.191 0.276 1.312 1.000 0.906 0.432 1.406 0.750 1.593 1.218 1.031 0.656 1.781 1.156 0.968 1.093 1.968 1.660 1.900 4.000 12.750 10.750 8.625 6.625 5.563 14.000 16.000 20.000 18.000 24.000 0.083 0.216 0.120 Strong
5S 0.154 0.531 0.147 0.179 0.250 0.191 0.200 0.218 0.276 0.318 0.718 0.563 0.432 0.625 0.500 0.375 0.337 0.438 0.250 0.300
0.133 0.113 0.140 0.145 0.216 0.109 0.226 0.237 0.154 0.203 0.280 0.258
0.636
......
..
Engineering Data
Physical Properties Of Typical Pressure Part Steels
K-1.10-6 16.7520Heat 19.2562 to 18.0541 18.7555 Wm-1.K-1 23 20 20 7970 14.6602 12.7503 13.8561 14.6611 13.8545 12.7511 38 49 7850 42 Coefficient 25 Specific 17 33 .m-3 43 36 Thermal Density Kg Temperature 20C J.Kg-1.K-1 ConductivityTemp 14 54 45
35
Steel Steel