Nickel and HT Alloys For Petrochemical Applications

Nickel & Special HT steels
Petrochemical applications
UTP Schweissmaterial
Application Technology
Contents
Requirements of petrochemical processes
Base material selection
Welding consumables for petrochemical appliances
Examination of long-term behaviour of welding consumables
Other aspects to be considered
Summary
2 | UTP Schweissmaterial
Nickel for HT applications
June 2012
Oil processing in refinery
Distillation takes place at different temperature and

pressure levels.
E.g.: Ammonia synthesis at 100 bar and 600C
Therefore, petrochemical plants are composed of
different base metals.
An oil refinery is a combination of all these units.
Source: howstuffworks.com
June 2012
Temperature:
Pressure:
from RT up to 1200C
up to 600 bar
June 2012
In order to guarantee reliable and

safe processing conditions, base
materials and welding consumables
are selected to fulfil the following
requirements:
Oxidation resistance
Carburisation resistance
Low embrittlement tendency
Creep rupture strength
June 2012
Contents
Summary
June 2012
Operating temperatures for different materials
Temperature F
2192
1050-1100C
1832
centrifugal
casting
CrNi
alloys
1472
900-1200C
NiCr
alloys
700C
600C
1112
high-temperature
resistant
CrMo
752
steels
G-X40CrNiSi2520 X10NiCrAlTi3220
ASTM A531 Grade
NiCr15Fe
HK40
stainless
steels
G-X40NiCrNb3525 NiCr22Mo9Nb
ASTM A297 HP40
NiCr23Fe
X6CrNi1811
ASTM A240 304H
392
X20CrMoV121
X10CrMoVNb91
NiCr25FeAlY
X6CrNiMo1713
ASTM A240 316H
NiCr23Co12Mo
June 2012
X5NiCrCeNb3227
Chemical composition of iron-base alloys
Chemical composition
Main alloying elements in wt %
Iron Base Alloys

Material
No.
EN Designation
ASTM
Designation
Ni
Cr
Fe
Nb
Si
Others
1.4859
GX10NiCrNbSi32-20
CT 15C
32
20
0,10
1,0
1,0
Mn<2,0
1.4848
GX40CrNiSi25-20
HK 40
20
25
0,40
1,8
Mn<2,0
1.4857
GX45NiCrSi35-25
HP 40
34
25
0,4
1,8
Mn<2,0
1.4868
GX50CrNiSi30-30
30
30
0,5
1,8
0,5<Mn<1,5
1.4889
GX45NiCrNbSiTi45-35
45
35
0,45
1,8
Mn < 1,5
35/45
June 2012
1,7
Chemical composition of nickel-base alloys
Nickel base alloys

Common
name
EN
Designation
Ni
Cr
Fe
Al
Ti
NiCr23Fe
23
16
0,08
1,4
0,4
Alloy 602CA N06602 2.4633
NiCr25FeAlY
25
9,5
0,2
2,1
0,14
Alloy 600 L
LC-NiCr15Fe
15
<0,025
2.4815
G-NiCr15
15
22
0,5
2.4879
G-NiCr28W
29
11
0,45
4,5%W
9%Mo
3,5%Nb
Alloy 601
UNS
No.
Mat.
No.
N06601 2.4851
N06600 2.4817
NA22H
Alloy 625
N06625 2.4856
NiCr22Mo9Nb
22
<3
<0,025
Alloy 617
N06617 2.4663 NiCr23Co12Mo
22
<2
0,05-0,1
50
<1,0
<0,1
Alloy 657
2.4680
G-NiCr50Nb
June 2012
Others
0,08%Y
0,07%Zr
<0,3
0,4
9%Mo
12%Co
1,5%Nb
0,15%N
Requirements for high-temperature alloys
Carburising resistance
Low embrittlement tendency
Creep rupture strength
June 2012
Oxidation
In order to reduce oxidation rate, you need elements which hinder the diffusion of
O2 inside the material and which have a high affinity to O2
(e.g. Al, Si, Nb)
Influence of alloying elements:
Cr > 25 %; higher Cr content stabilizes oxide films but causes sigma phase
Ni has a beneficial effect on cyclic oxidation
Higher Si-content promotes oxidation resistance, esp. bonding of oxide layer
Rare earth elements enhance oxide stability
June 2012
Chipped-off
material
Main alloying elements in wt%
Common
name
Ni
Cr
Fe
Al
Ti
Alloy 601
23
16 0,08 1,4
0,4
Alloy
602CA
25
9,5
0,2
Others
2,1 0,14
0,08%Y
0,07%Zr
June 2012
Chipped-off
material
Initial dimension
Comparison of corrosion attack on

Nicrofer 6023 H (alloy 601) and
Nicrofer 6025 HAT (alloy 602 CA)
after 1000 h at 1200C (2192F)
in air
June 2012
Test medium:
Air
Air temperature:
1200C
Time:
1000 hrs
Mechanism of carburization
Decomposition of hydrocarbons creates free carbon,

which diffuses through the grain boundaries into the material.
Carburization increases with rising temperature;

The rate roughly doubles for every 38C tube metal temperature increase.
Consequences of carburization:
Decrease of melting point
Carbide formation with chromium depletion
Loss of ductility due to carbide formation
June 2012
Carburization
3,5
Carburized at temperature for
260 hours in carbon granulate
Increase in carbon [%]
3,0
2,5
2,0
HK-40
25/20
Increase of alloy carburization

under rising temperature
HP-45
25/35 mod.
35/45
1,5
1,0
0,5
0,0
950
1150 [C]
1050
1800
1900
2100 [F]
2000
Temperature
June 2012
Carburization
There are
Cr, Ni and Si are

effective barriers
numerous & complex

factors:
Synergistic additions of
W, Nb, Ti and Zr
considerably improve
resistance to carburization
June 2012
Creep behaviour
Creep is the tendency of a solid material to slowly deform

permanently under the influence of stresses (and temperature).
Strengthening mechanisms against creep:

Solid solution hardening (Cr, Mo, Co, W)
Precipitation hardening (Al, Ti, Nb)
Formation of carbides (Ti, Nb, V, B)
Manipulation of grain size (coarse / fine)
Purity to trace elements
June 2012
Metallographic explanation for creep behaviour
Microstructure of alloy 800H

after 33470 h, 650C (1202F), 11 N/mm.
On the grain boundaries,
slight formation of chromium carbides
visible, grain size about 170 m,
Initially: 140 m
Mag. 500:1
Microstructure of alloy 800H

after 25760h, 850C (1562F), 1.8 N/mm.
On the grain boundaries,
agglomeration of carbides,
the grains have grown,
grain size about 220 m
Mag. 500:1
June 2012
Requirements for high-temperature alloys
They should be still weldable!
June 2012
How to weld these

materials - similar
or dissimilar?
June 2012
Contents
Summary
June 2012
UTP welding consumables for Fe-base alloys
Iron Base Metals

Material No.
1.4859
EN Designation
GX10NiCrNbSi32-20
ASTM Des.
Si
Cr
Ni
Nb
CT 15C
0,1
20
32
Mn < 2.0
0,14
0,3
21
33
1,3
4,5 % Mn
0,4
1,8
25
20
Mn < 2.0
0,4
25
35
1,2
1,5 % Mn
0,4
1,8
25
34
Mn < 2.0
0,4
25
35
1,2
1,5 % Mn
0,5
35
45
Mn < 1.5
0,45
35
45
0,9
0,8 % Mn
UTP 2133 Mn
1.4848
GX40CrNiSi25-20
HK 40
UTP 2535 Nb
1.4857
GX45NiCrSi35-25
HP
UTP 2535 Nb
1.4889
GX45NiCrNbSiTi45-35
35/45
UTP 2535 Nb
Filler metal
June 2012
Others
UTP welding consumables for Ni-base alloys
Nickel base alloys
Ni
R
Cr
Fe
C
Al
Ti
23
16
0,08
1,4 0,4
25
10
0,8
1,8
25
9,5
0,2
2,1
1,8
Filler metals
Common name Material No. EN Designation

Alloy 601
2.4851
NiCr23Fe
UTP 6225 Al
Alloy 602CA
2.4633
NiCr25FeAlY
Alloy 600 L
2.4817
LC-NiCr15Fe
R
R
25
15
10
8
0,8
<0,025
2.4815
G-NiCr15
15
22
0,5
R
R
R
16
29
29
6
11
15
0,04
0,45
0,45
22
<3
<0,025
22
1,5
0,03
22
<2
0,05-0,1
UTP 6170 Co
21
0,6
0,7
UTP 5848 Nb
R
R
50
50
<1
-
<0,1
<0,1
UTP 6225 Al
UTP 7015 Mo
NA22H
2.4879
G-NiCr28W
UTP 2949W
Alloy 625
2.4856
NiCr22Mo9Nb
UTP 6222 Mo
Alloy 617
Alloy 657
2.4663
2.4680
|
NiCr23Co12Mo
G-NiCr20Nb
June 2012
Others
0,08%Y;
0,1 0,07%Zr
0,08%Y;
0,14 0,07%Zr
0,08%Y;
0,07%Zr
<0,3
6,2%Mn
2,2%Nb
4,5%W
4,5%W
9%Mo;
3,5%Nb
3,3%Nb
9%Mo
9%Mo;
0,4 12%Co
9%Mo
0,3 12%Co
1,5%Nb
0,15%N
1,5%Nb
Creep strength
Creep rupture strength and high-temperature plastic deformation are

the key properties to determine the tube wall thickness.
The design is usually made for 100,000 hours of service life.
Cr and C control the rupture strength through carbide formation.
Nb is a solid solution strengthener as are W and Mo.
Nb and additions of Ti and Zr produce extremely fine carbides and participate in

the formation and strengthening of the alloy (temperature-stable carbides).
June 2012
Contents
Summary
June 2012
Creep strength
To increase the working temperature of a weld material,

TV requests creep strength values after
minimum 30,000 hrs at different temperatures.
June 2012
Testing of creep strength
Plate after welding
1 sawn plate
2 prepared specimen
3 ready specimen
4 tested specimen
1000C (1832F), 1071 hrs, 10 N/mm2
June 2012
Testing of creep strength
Specimen in test
June 2012
Embrittlement behaviour
Embrittlement tendency is checked after ageing

at different temperatures by Charpy impact test.
June 2012
Testing of embrittlement behaviour
Plate after welding
June 2012
Plate in oven
Testing of embrittlement behaviour
UTP 068 HH
10,000 hrs, 950C
after testing
1 plate machined
2 after 10,000 hrs, 950C
3 - machined
June 2012
Embrittlement behaviour
200
Av ( ISO-V ) [ J ]
950C
750C
850C
150
Ageing of
E NiCrFe-2
(UTP 7015 Mo)
550C
100
650C
50
0
1
10
time [ h ]
100
1.000
10.000
test temperature: RT
June 2012
100.000
Contents
Summary
June 2012
Thermal expansion coefficient
20
19
thermal expansion coefficient
m
-6
m x grd x 10
18
17
16
15
UTP 2133Mn
alloy 800H
1.4859
C-steel
Alloy 625
14
13
12
11
10
200
300
400
500
600
temperature C
June 2012
700
800
900
June 2012
Base material:
Manaurite 36X
(25Cr 35Ni Nb)
June 2012
Contents
Summary
June 2012
Summary
For high-temperature application use welding consumables with similar

chemical composition to match the properties of the base metal.
Creep strength plays a key-role in the development of welding
consumables.
Corresponding expansion coefficients are also important for the structure
lifetime.
These filler metals are available for SMAW and GTAW.
Qualification of BWG welding consumables is crucial to meet high quality
requirements.
June 2012
for your attention
June 2012

Nickel and HT Alloys For Petrochemical Applications

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Nickel & Special HT steels

Requirements of petrochemical processes

Base material selection

Welding consumables for petrochemical appliances

Examination of long-term behaviour of welding consumables

Other aspects to be considered

Nickel for HT applications

Oil processing in refinery

Distillation takes place at different temperature and

Nickel for HT applications

Oil processing in refinery

Oil processing in refinery

In order to guarantee reliable and

Nickel for HT applications

Requirements of petrochemical processes

Base material selection

Welding consumables for petrochemical appliances

Examination of long-term behaviour of welding consumables

Other aspects to be considered

Nickel for HT applications

Operating temperatures for different materials

Nickel for HT applications

Chemical composition of iron-base alloys

Iron Base Alloys

Nickel for HT applications

Chemical composition of nickel-base alloys

Nickel base alloys

Alloy 602CA N06602 2.4633

N06617 2.4663 NiCr23Co12Mo

Nickel for HT applications

Requirements for high-temperature alloys

Low embrittlement tendency

Creep rupture strength

Nickel for HT applications

Nickel for HT applications

Nickel for HT applications

Comparison of corrosion attack on

Nickel for HT applications

Decomposition of hydrocarbons creates free carbon,

Carburization increases with rising temperature;

Nickel for HT applications

Increase in carbon [%]

Increase of alloy carburization

Nickel for HT applications

Cr, Ni and Si are

numerous & complex

Nickel for HT applications

Creep is the tendency of a solid material to slowly deform

Strengthening mechanisms against creep:

Nickel for HT applications

Metallographic explanation for creep behaviour

Microstructure of alloy 800H

Microstructure of alloy 800H

Nickel for HT applications

Requirements for high-temperature alloys

They should be still weldable!

Nickel for HT applications

How to weld these

Nickel for HT applications

Requirements of petrochemical processes

Base material selection

Welding consumables for petrochemical appliances

Examination of long-term behaviour of welding consumables