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Weldability of 17-4 PH stainless steel in centrifugal compressor impeller

applications

Article  in  Journal of Materials Processing Technology · December 2004

DOI: 10.1016/j.jmatprotec.2004.07.117

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 Journal of Materials Processing Technology xxx (2004) xxx–xxx

3 Weldability of 17-4 PH stainless steel in centrifugal compressor

4 impeller applications
5 J. Nowacki∗
6 Institute of Materials Engineering, Technical University of Szczecin, Al. Piastow 19, 70 310 Szczecin, Poland

Accepted 26 July 2004

8 Abstract

9 Weldability of 17-4 PH stainless steel for centrifugal compressor impeller was considered. Welding tests were carried out on the precipitation-
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10 hardened steel of the 17-4 PH type. Possibilities of joining centrifugal compressor impeller parts as important elements of turbo machines
11 were considered. Two means of welding (1 1 1) and (1 1 4), as well as following heat treatment have been considered. The best results: high
tensile strength and high corrosion resistance were obtained for saturating for the wheels welded in temperature 1313 K/2 h followed by ageing
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12

13 in 893 K/2 h or only annealed for stress reliving in temperature 893 K/2 h after welding.
14 © 2004 Published by Elsevier B.V.

15 Keywords: Centrifugal compressor impeller; Vacuum brazing; Structure and properties of the brazed joints
16
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17 1. Introduction 2. Manufacture of impellers 35

18 Modernization and maintenance of movement of centrifu- There are a few types of constructions of the shrouded 36

19 gal compressors in the petrochemical and chemical industry impellers. The right selection of it benefits with the better 37
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20 is one of the most complicated constructional—technological efficiency of the particular stage and whole compressor and 38

21 and organizational problems and needs considerable over- also operational properties. In practice there are following 39

22 heads. Modernization of centrifugal compressor concen- constructions: 40

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23 trates on a substitution of used up compressor impellers.

24 Centrifugal compressor impeller wheel in terms of con- (a) strictly radial, with two-dimensional blades – the most 41
25 struction, dimensional tolerances, technology and service principal construction, 42
26 conditions (Fig. 1) is one of the most advanced ma- (b) two types of impellers with complex construction of 43
chine elements. High-quality impellers are the solution of:
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27
blades: 44
28 three-dimensional aerodynamics and thermodynamics cal- • with diagonal inlet and higher efficiency than two- 45
29 culation, three-dimensional computer aided design, three- dimensional, 46
30 dimensional stress calculation, 3- or 5-axis computer aided • with axial–radial three-dimensional impellers (the 47
31 machining, advanced technology of joining method ap- highest efficiency). 48
plied and number of inspections and tests of the se-
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32

33 lected material and fabricated impellers done (Fig. 2)

The field of application is big enough to use both types 49
34 [1–2].
of impellers, depending on various criteria. If the shrouded 50

impeller is made from forging, the cover is usually manu- 51

factured as a separate part (except cases, when channels are 52

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∗ Tel.: +48 91 449 47 51; fax: +48 91 449 43 56. being manufactured using electro-erosion process or 5-axis 53

E-mail address: jnowacki@ps.pl. milling). 54

1 0924-0136/$ – see front matter © 2004 Published by Elsevier B.V.

2 doi:10.1016/j.jmatprotec.2004.07.117
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 2 J. Nowacki / Journal of Materials Processing Technology xxx (2004) xxx–xxx

Fig. 1. Centrifugal compressor impeller wheel scheme.

55 The blades can be also manufactured separately, but more

56 often they are milled from the hub disc. Progress of cen-
57 trifugal compressors, and especially of the application of a
58 shrouded impellers with narrow flow passages, revealed the Fig. 3. Cross-section of the impeller wheel welded by classical method: (1)
59 necessity of developing new methods of joining the impeller weld; (2) blade and hub disc; (3) cover disc.
60 parts: the hub disk, blades and matching cover. These meth-
61 ods can be classified into three main groups: welding, braz-
ing, and riveting. Application of the joining method is strictly
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62

63 dependent on blade geometry (two-dimensional or three-

64 dimensional), impeller dimensions (outer diameter and chan-
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65 nel width) and operating conditions (mechanical stresses,

66 kind of the flowing medium and temperature). At present
67 the most often used method of joining wheel elements is
68 welding [1]. In dependences to geometry of the wheel, and
69 mechanical stresses various methods of welding can be used
(Figs. 2–5). Area of welding application covers all types of
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70

71 impellers, which tangential velocities not exceed 340 m/s –

72 practical limit of the closed wheel application. Welding does Fig. 4. Cross-section of the impeller wheel welded by slot arc welding before
73 not find the application in construction of impeller with nar- machining: (a) general scheme; (b and c) shape of the slot.
74 row flow passages, as to technological restrictions. In those
75 cases for joining of wheel elements vacuum brazing is used Welding is the most often technique applied for joining 79

[2–3]. the impeller parts. Depending on the geometry of the flow 80

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76

77 At present the most often used method of joining wheel channel and mechanical stresses there are following types of 81

78 elements is welding. that technology (Figs. 3–5): 82

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Fig. 2. Diagram of manufacturing process for centrifugal compressor impeller.

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 J. Nowacki / Journal of Materials Processing Technology xxx (2004) xxx–xxx 3

Table 2
Chemical composition of 17-4 PH steel used in the investigation (%)
C 0.05
Mn 0.98
P 0.03
S 0.03
Si 1.00
Cr 15.2
Ni 4.50
Cu 3.45
Nb + Ti 0.22

4. Experimental tests and results 107

Fig. 5. Cross-section of the impeller wheel welded laser beam-fusion before
machining: (1) weld length; (2) laser beam; (3) weld face; (4) cover disc; (6)
As a result of construction and exploitation conditions 108
hub disc.
analyses of the impeller, two method of welding: shielded 109

metal arc welding (SMAW) and flux core arc welding 110

83 • welding in the channel, (FCAW). 111

84 • slot welding, Chemical composition of 17-4 PH steel used in the in- 112

85 • electron-beam welding, vestigation is presented in Table 2. Core arc welding-114 113

•
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86 laser welding. has been selected. As filler metal have been chosen: covered 114

electrode Avesta 309 Mo and core wire Cvomacore DW 309 115

The range of application of welding method includes all
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87
MoL (Tables 3 and 4). Welding tests have been executed in 116
88 the impeller types and the entire flowing medium. There is a horizontal position. After welding joints were subjected to 117
89 also no limitation from the point of view of circumferen- heat treatment in different conditions. Metallographical ex- 118
90 tial speed which can reach 320–340 m/s (such speed is lim- aminations, tensile strength, yield strength, notched impact 119
91 ited rather by material mechanical properties). Welding is not strength, Vickers hardness and corrosion tests in 50% HNO3 120
92 used for production of shrouded impellers with narrow flow solution in temperature 388 K and duration of 24, 72 and 121
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93 passages [4–5]. 144 h of the obtained joints have been made. 122

The results of mechanical properties of the joints are pre- 123

sented in Tables 5 and 6, and Figs. 6 and 7. Joints made by 124

94 3. Materials for the impellers covered electrode have higher Rm , R0,2 and HV, but lower A5 125

than that made by core wire [7]. Impact strength of both joints 126

95 Precipitation-hardened stainless steels: X5CrNiCu- is similar. Mechanical properties are strongly influenced by 127
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96 Nb17.4, X4CrNi13.4, X2OCrMo13, X5CrNiMo16.5, conditions of heat treatment after welding in both cases. The 128

97 23CrNiMo7.4.7, 14CrMoV6.9, 14-5 PH are applied for the optimal set of properties, as far as centrifugal compressor 129

98 impellers as to the yield point, and corrosion resistance [4–5].

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99 Steel 17-4 PH seems to be a very promising one for impellers Table 3

100 working in aggressive environments. Precipitation-hardened Chemical composition of covered electrode Avesta 309 Mo used in the in-
vestigation (%)
101 steel 17-4 PH (C%: max. 0.07, Mn%: max. 1.00, Si%: max.
102 1.00, Cr%: 15.00–17.50, Ni%: 3.00–5.00, Cu%: 3.00–5.00, C 0.03
Mn 0.8
Nb + Ti%: 0.15–0.45), owing to its high strength, high
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103
Si 0.8
104 hardness, high corrosion resistance and easy heat treatment Cr 22.8
105 (Table 1), has the extensive applications in aircraft, chemical, Ni 12.4
106 petrochemical, food, metal and papermaking industries. Mo 2.7
Ferrite content 17–25
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Table 1
Table 4
Mechanical properties of 17-4 PH steel in the different heat treatment con-
Chemical composition of core wire Cvomacore DW 309 MoL used in the
dition [6]
investigation (%)
Heat treatment Rm (MPa) R0,2 (MPa) A5 (%)
C 0.02
Delivery condition—after 1034 931 17 Mn 1.3
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saturating in 1313 K Si 0.7

Saturating in 1313 K and 1172 1034 16.0 Cr 23
ageing in 823 K Ni 12.9
Saturating in 1313 K and 1000 862 19.0 Mo 1.5
ageing in 893 K Ferrite content 16–24
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Table 5
Conditions of the heat treatment after welding, and mechanical properties of joints, filler metal-covered electrode
Condition Heat treatment R0,2 (MPa) Rm (MPa) A5 (%) K (150/5 J/cm2 )
A Stress reliving 893 K/2 h 631 750 6.2 64
B Saturating 1313 K/2 h, ageing 823 K/2 h 587 726 7.1 75
C Saturating 1313 K/2 h, ageing 893 K/2 h 670 782 6.9 70

Table 6
Conditions of the heat treatment after welding, and mechanical properties of joints, filler metal-core wire
Condition Heat treatment R0,2 (MPa) Rm (MPa) A5 (%) K (150/5 J/cm2 )
A Stress reliving 893 K/2 h 435 611 8.0 64
B Saturating 1313 K/2 h, ageing 823 K/2 h 407 580 8.8 75
C Saturating 1313 K/2 h, ageing 893 K/2 h 494 661 8.2 70

130 impeller applications are considered, have been achieved in • the poor corrosion changes are observed at the surface of 147

131 condition C of heat treatment after welding. the weld. 148

132 The results of metallographical and the joints phase con-

133 stitution investigations are presented in Figs. 8–11. Indepen- Comparing the joints that were welded in different way, 149

134 dent of conditions of heat treatment after welding all the it was noticed that samples welded by covered electrode had 150

135 samples, in heat-affected zone and in the parent material slightly better corrosion resistance than those welded by core 151
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136 had martensitic structure with precipitates and the welds had
137 austenitic–ferritic structure.
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138 The results of the joints corrosion tests and metallograph-

139 ical investigations and the joints after corrosion are presented
140 in Figs. 12–17, and Tables l–7.
141 The detailed observation of corrosion changes during cor-
142 rosion test enabled to notice the following statements:
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143 • general and pitting corrosion were observed at whole area

144 investigated,
145 • corrosion begins in the heat-affected zone and the pitting
146 corrosion is the most intense there,
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Fig. 8. Microstructure (SEM) of the heat-affected zone for sample welded

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using core wire and heat treatment condition B, martensitic structure with
carbide precipitates.
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Fig. 6. Hardness in parent metal, HAZ and weld metal in different conditions
of heat treatment after welding (covered electrode).
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Fig. 9. Microstructure (SEM) of the heat-affected zone for sample welded

Fig. 7. Hardness in parent metal, HAZ and weld metal in different conditions using core wire and heat treatment condition A, martensitic structure with
of heat treatment after welding (core wire). carbide precipitates.
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Fig. 10. Diffraction pattern of the joint in post weld heat treatment condition
A from the top: parent metal, weld, HAZ. (a) Fe ␥; (b) Fe ␣.

Fig. 13. Surface of the heat-affected zone of the sample welded by core wire
and heat-treated in condition B.
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Fig. 11. Diffraction pattern of welding joint in post weld heat treatment
condition C from the top: parent metal, weld, HAZ. (a) Fe ␥; (b) Fe ␣.

Fig. 14. The surface of the weld and the heat affected zone for sample welded
using core wire and heat treatment condition C after corrosion test (144 h),
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the best corrosion resistance, homogeneously aged at 620 ◦ C after solution

treatment (SEM).
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Fig. 12. Cross-section (SEM) of the sample welded using core wire and heat
treatment condition A – very deep pitting.
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Table 7
Comparison of mass decrement of welded joints in 50% HNO3 , temperature
388 K and test duration of 144 h, mg/cm2
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Filler metal Conditions of the heat treatment

A B C Fig. 15. The surface of the weld and heat affected zone for sample welded
using core wire and heat treatment condition B after corrosion test (144 h),
Covered electrode 39 78 45
the lowest corrosion resistance homogeneously aged at 550 ◦ C after solution
Core wire 61 83 46
treatment (SEM).
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perature of ageing has influence on corrosion resistance of 160

this area. 161

5. Conclusions 162

As far as centrifugal compressor impeller applications are 163

considered, welding of 17-4 PH steel by chosen filer materials 164

is very effective. Welded joints from 17-4 PH steel have very 165

good corrosion resistance. Corrosion that develops in heat- 166

affected zone mainly has a pitting character. While the welds 167

have an excellent resistance. 168

Lower ageing temperature improves the mechanical prop- 169

erties and hardness, but lead to decreasing the corrosion re- 170

sistance of the welded joint. Ageing temperature higher than 171

Fig. 16. The surface of the weld and heat affected zone for sample welded
using core wire and heat treatment condition A after corrosion test (144 h),
893 K ensures better corrosion resistance. The best mechan- 172

intense pitting close to the weld is observed (SEM). ical properties of joints provide heat treatment condition C 173

(saturating 1313 K/2 h, ageing 893 K/2 h). Joints in heat treat- 174

ment condition C have the best corrosion resistance for core 175

wires. Annealing A (893 K/2 h) joints after welding secures 176

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similar mechanical properties like heat treatment. 177

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References 178

[1] K. Boddenberg, Proceedings of the 15th Turbomachinery Symposium, 179

Texas University, Texas, 1996, p. 5. 180

[2] Sulzer Escher Wyss, Technical Information 1/3 (1992). 181

[3] Z. Mirski, H. Drzeniek, Proceedings of the Fifth Intern. Kollog. Hart-

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182

Fig. 17. Corrosion of welded joints (for covered electrode) for different heat und Diffusionischweisen, Bd. 192, Aachen, DSV Verlag, Düsseldorf, 183

treatments and corrosion test durations. 1998, p. 289. 184

[4] J. Nowacki, P. Świder, vol. 133, Elsevier, 2003, p. 174. 185

[5] R. Peereboom, Proceedings of the Turbomachinery Maintenance 186

152 wire [8]. Samples saturated and aged at 823 K (heat treat-
Congress on Vacuum Brazing of Turbocompressor Impellers, Hamp- 187
153 ment condition B) have the highest rate of corrosion. But shire, UK, 1993, p. 10. 188
154 comparing the surfaces of the joint very dangerous concen- [6] Product Data Bulletin No. S-22, Armco Co., The Netherlands. 189
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155 tration of pitting close to penetration zone was observed for [7] J. Nowacki, A. Łukojć, Proceedings of the International Scientific 190

156 samples welded by core wire and stress relived 893 K (heat Conference on Achievements in Mechanical and Materials Engineer- 191

ing, Polish Academy of Science, Silesian Technical University, Sopot, 192

treatment condition A). This sample was not solution treated
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157
2000, p. 395. 193
158 after welding. This zone it is the most overheated area in [8] J.N. Baranowska, Proceedings of the International Scientific Confer- 194
159 a welded joint. Structure unification after solution treatment, ence Euromat, Elsevier Conf. Mat., vol. 2, Tours France, 2000, p. 195

which takes place in heat-affected zone, causes that only tem- 1263. 196
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