Professional Documents
Culture Documents
Hastelloy C-276 Weld Overlay by SMAW Process PDF
Hastelloy C-276 Weld Overlay by SMAW Process PDF
com
ISSN : 2248-9622, Vol. 7, Issue 5, ( Part -3) May 2017, pp.86-91
ABSTRACT
In the modern world of industrialization the wear is eating metal assets worth millions of dollars per year. The
wear is in the form of corrosion, erosion, abrasion etc. which occur in the process industries like oil & gas,
refineries, cement plants, steel plants, shipping and offshore working structures. The equipments like pressure
vessels, heat exchangers, hydro processing reactors which very often work at elevated temperatures face
corrosion in the internal diameter.Hastelloy C-276weld overlay on ferrous material is developed for outstanding
resistance to wide variety of chemical process environments such as ferric and cupric chlorides, hot
contaminated mineral acids, solvents, chlorine and chlorine contained media, both inorganic and organic, dry
chlorine, formic and acetic acids, acetic anhydride, sea water and brine solutions.Selection of SMAW is for
development of hastalloy C-276 material with SMAW process to use as a weld overlay process at non accessible
area & where position is constraint which is not feasible by other processes like ESSC, FCAW, and SAW etc.
Cladding is a welding process in which a flux to lay the weld.An electric current, in the form
material with desired properties is deposited on the of either alternating current or direct current from a
surface of a base material. The common C/Mn or welding power supply, is used to form an electric
low alloyed inexpensive base metal has mainly a arc between the electrode and the metals to be
load carrying function. The deposited sophisticated joined. The work piece and the electrode melt
material imparts surface properties such as forming a pool of molten metal (weld pool) that
corrosion resistance; wear resistance, erosion and cools to form a joint. As the weld is laid, the flux
pitting etc., to the substrate. To the manufacturer of coating of the electrode disintegrates, giving off
pressure vessels, surfacing techniques are getting vapors that serve as a shielding gas and providing a
more and more important. Components reach sizes layer of slag, both of which protect the weld area
such that their fabrication calls upon the use of clad from atmospheric contamination.
materials. Operation
There are different processes to obtain a clad To strike the electric arc, the electrode is
material: brought into contact with the work piece by a very
Clad plates produced by rolling which are light touch with the electrode to the base metal then
mostly only available in standardized is pulled back slightly. This initiates the arc and
dimensions and grades thus the melting of the work piece and the
Explosion clad plates consumable electrode, and causes droplets of the
Clad plates made by welding electrode to be passed from the electrode to the
Further Clad Plates made by welding can be done weld pool.
using various techniques:- Striking an arc, which varies widely based
Submerged arc welding (Wire electrode) upon electrode and workpiece composition, can be
Submerged arc welding (Twin Wire electrode) the hardest skill for beginners. The orientation of
Submerged arc welding (Strip Electrode) the electrode to workpiece is where most stumble,
if the electrode is held at a perpendicular angle to
Electro slag strip welding
the workpiece the tip will likely stick to the metal
Shielded metal arc welding
which will fuse the electrode to the workpiece
Flux cored arc welding
which will cause it to heat up very rapidly. The tip
The shielded metal arc welding process is well
of the electrode needs to be at a lower angle to the
known for its versatility because it can be used in
workpiece, which allows the weld pool to flow out
all welding positions, and in both production and
of the arc. As the electrode melts, the flux covering
repair situations. It is generally not useful on thin disintegrates, giving off shielding gases that protect
sheet material. It requires no special equipment and
the weld area from oxygen and other atmospheric
can be operated easily in remote locations. It is
gases.
strictly a manual welding process.
In addition, the flux provides molten slag
which covers the filler metal as it travels from the
II. PROCESS DESCRIPTION electrode to the weld pool. Once part of the weld
Shielded metal arc welding (SMAW), also pool, the slag floats to the surface and protects the
known as manual metal arc welding (MMA or weld from contamination as it solidifies. Once
MMAW), flux shielded arc welding or informally hardened, it must be chipped away to reveal the
as stick welding, is a manual arc welding process finished weld. As welding progresses and the
that uses a consumable electrode covered with a
electrode melts, the welder must periodically stop III. EXPERIMENTATION AND
welding to remove the remaining electrode stub TESTING :
and insert a new electrode into the electrode holder. Discuss the detail about the experimental data, base
This activity, combined with chipping away the metal, filler metal, and welding procedure, welding
slag, reduces the amount of time that the welder parameters of welded specimen and testing.
can spend laying the weld, making SMAW one of
the least efficient welding processes. In general, the 3.1 Experimentation was conducted as per
operator factor, or the percentage of operator's time following flow chart
spent laying weld, is approximately 25%
The actual welding technique utilized
depends on the electrode, the composition of the
workpiece, and the position of the joint being
welded. The choice of electrode and welding
position also determine the welding speed. Flat
welds require the least operator skill, and can be
done with electrodes that melt quickly but solidify
slowly. This permits higher welding speeds.
Sloped, vertical or upside-down welding
requires more operator skill, and often necessitates
the use of an electrode that solidifies quickly to
prevent the molten metal from flowing out of the
weld pool. However, this generally means that the
electrode melts less quickly, thus increasing the
time required to lay the weld.
Fig.2
Parameters Range
Welding current (I) 80-130 Amp
Voltage (V) 22-28V
Travel Speed 220-250 mm/min
Pre heat 75 degree Celsius
Interpass Max 200
Polarity DCEP
Table 3
Fig.3
3.4 Post Weld Heat Treatment (PWHT)
PWHT was performed at 610 -620⁰ C for 135 minutes after completion of testing with heating rate 50⁰ C/ hr
and cooling rate 40⁰ C /hr.
IV. RESULTS
o Slag Inclusion : No
o Undercut : No
o Crater porosity & Crack : No
Dye Penetrant Testing : Acceptable as per ASME Sec IX .
Ultrasonic Examination : Satisfactory
Fig.4
Macro Examination : Noporosity, No Lack of Fusion &complete fusion of weld metal & base metal
BendTest:satisfactory
CORROSION TESTING AS PER ASTM [4]. A.Eghlimi “dilution and ferrite number
G28 METHOD B prediction in pulsed current cladding of
Result observed: super duplex stainless steel using RSM”
Initial weight of specimen:10.9212g ASM international (2013).
Weight after 24 hours : 10.8545g [5]. T. Kannan: “effect of flux cored arc welding
Weight loss : 0.0667g (0.70 mg) process parameters on duplex stainless steel
CORROSION TESTING AS PER ASTMG48 clad quality”. Journal of materials
METHOD B processing technology 176(2006).
Result observed: [6]. R.A Daemen: submerged arc stainless steel
Testing results at temperature 50°C strip cladding: the development of welding
Initial weight of specimen : 33.5063g products for surfacing with a type of 316 L
Weight after 24 hours : 33.5048g low ferrite stainless steel alloy. Welding
Weight loss (g) : 0.0015 Research supplement January-1970.
Weight loss (mg) : 1.50 [7]. S.Pak “Electro slag and Submerged Arc
No Crevice crack observed on the surface at 20X stainless steel strip cladding.”published by
Magnification. ESAB in Svetsaren No.3,1996
[8]. J. Garg, “reuse of slag in stainless steel
V. CONCLUSION cladding and its effect on chemistry of
Typical to weld HastelloyC-276 welded cladding in SAW process “Journal of
successfully meeting the requirement of ASME Sec Environmental research &
IX & Sec IIC. Development(March 2012).
[9]. Cary, Howard B.; Helzer, Scott C.
Scope of Future Work (2005), Modern Welding Technology, Upper
As a future work, we will establish corrosion test as Saddle River, New Jersey: Pearson
per customer requirement such as ASTM G-48 Education.
method A-pitting corrosion ASTM G-36 etc.
REFERENCES
[1]. E. M. Sherif , “ Corrosion of Duplex
Stainless Steel Alloy 2209 in Acidic and
Neutral Chloride solutions and its
passivation by Ruthenium as an alloying
element.”International journal of
electrochemical Science 7 (2012)
[2]. S. D. Kahar ," Corrosion Behavior of
Electro Slag Strip Cladding Weld Overlays
in Different Acid Solutions ”, Int. Journal of
Engineering Research and applications Vol.
3, Issue 4,july-aug 2013 pp.590-595, 2012
[3]. M. Patel," Application of Electro Slag Strip
Cladding for reactors in Hydrogen Based
Refinery”2009-IIW india