Review of Corrosion Resistant Co-Extruded

Tube Development for Power Boilers

T. F L A T L E Y and T. T H U R S F I E L D

Conditions encountered in operating a high temperature plant often impose conflicting

demands for optimum strength and long term corrosion resistance. The use of con-
ventional single walled tubes could force undesirable modifications to tube parameters or
ameliations of the operating conditions. The answer to this problem could be the use of
a double walled tube which is metallurgically bonded to ensure stability in the high
temperature environment. A standard alloy can be selected for mechanical strength which
is then protected from aggressive corrosion~oxidation by cladding with a dissimilar alloy.
Hot co-extrusion is used to produce this type of tube. The design and manufacturing
aspects of various combinations of carbon steel, stainless, and alloy steels are described.
Particular attention is given to the substantial service experience of using some 250 km
of co-extruded tubes, for furnace walls and superheater/reheater replacements in large
pulverized coal fired boilers in the UK. The evidence obtained indicates that in areas of
extreme fireside attack, the use of this type of tube can double the period between planned
outages. A brief review is made of other examples in the energy and chemical process
industries where this type of tube is used.

INTRODUCTION sufficient. This, of course, requires that the designers' pre-

dicted corrosion rates are not excessive and that a materials
High temperature corrosion and premature failure of metal
data base exists for different corrosion potentials. However,
tubes in the energy and process plant industries invariably
in existing plant and particularly future advanced cycle de-
causes expensive plant shutdowns when the problem is first
signs, the continued aim for improved efficiencies, higher
encountered. Even the subsequent prevention or control of
temperatures and pressures, and good availabilities can
the tube wastage can still impose high repair and mainte-
make the task of designing durable tubes from monobloc
nance costs at regular intervals or may shorten the safe
materials almost impossible. Indeed, in most instances it is
operating period between planned overhauls.
not economic to derate or modify the plant to decrease metal
Traditionally, the designer of new plants has been able to
temperatures.
minimize the corrosion potential of known aggressive fuels
A growing tendency in the power industry is to extend
or a particular chemical process environment by improving
plant life beyond the normal 100 kh design to some 250 kh.
the stage design heat transfer characteristics and thereby the
This will intensify the economic management of corrosion,
tubes' intended thermal status. Alternatively, upgrading the
particularly if repetitive repair and maintenance is required
tube materials specification to a better conventional alloy,
to overcome the shortcomings of conventional tube mate-
e.g., a ferritic to a stainless steel, or simply increasing the
rials, cope with deteriorating fuels, and maintain high
previous tube wall thickness corrosion allowance, may be
availability.
Attempts over the past twenty years to ameliorate high
T. FLATLEY is with Central Electricity Generating Board,
Harrogate, England. T. THURSFIELD is with TI Stainless Tubes temperature fireside corrosion with protective coatings,
Limited, Walsall, England. metal shields, and metal bandages have never been success-

92 VOL.8, NO. 1, JUNE 1986 9 AMERICANSOCIETYFOR METALS J. MATERIALSFOR ENERGYSYSTEMS

 bonded double wall tube. The manufacturing and in-service
considerations associated with materials selection/
compatability will be described, together with the composite
tube design criteria for individual wall thickness in compli-
ance with established BS and ASME pressure parts codes.
Specific reference to materials combinations developed for
the Central Electricity Generating Board application, in-
volving a T310 stainless/carbon steel for furnace tube and
T310 stainless/Esshete 1250 steel* for superheat stages, will

*Esshete 1250 is a high temperature high strength stainless steel devel-

oped by the British Steel Corporation and is now incorporated in the British
Standard BS 3059 Pt 2 and the ASTM A213 UNS Designation $21500.

Fig. 1--Modest corrosion wastage causing thick edge creep failure of be a central theme throughout the paper. Highlights of the
T321 superheater tube, after 85 kh. tube fabrication characteristics, welding, and quality control
procedures will be given.

MANUFACTURE OF BI-METALLIC TUBE

Two basic methods of bi-metallic tube manufacture are now
well developed and commercially available for different
industrial applications.
Mechanically bonded, clad, or bi-metallic tube are all
terms frequently used by engineers to describe a double wall
tube produced by a cold working process. The most com-
mon method of manufacture is to take two separately made
tubes, sleeve one inside the other, and then cold draw both
together through a die to achieve a tight fitting mechanical
bond. The advantage of such tubes is that they are relatively
easy to manufacture and therefore not expensive. Their dis-
Fig. 2--Severely pitted T316 reheater tube after 40 kh service in coal advantage is that they do not have a chemically bonded
fired plant.
interface and rely on the cold work in the outer layer to
retain the tight fit. Cold clad tubes thus have a tendency to
ful over long periods but probably did encourage the concept layer separation and failure in service due to stress relaxa-
and eventual progress toward the development of a durable tion if high temperatures are encountered. This behavior
bi-metallic tube. ~.2
The use of a double wall tube which has different materi-
als on the inside and outside is a long-established concept
becoming of increasing interest from the sixties onward
as the environment in larger plants became more aggres-
sive. 3 Such bi-metallic tubes can overcome the seemingly
conflicting dual property requirements of achieving high
temperature strength and superior corrosion resistance not
available from a single alloy.
The first generation bi-metallic tubes produced by cold
forming methods relied simply on a tight mechanical fit and
were thus prone to layer separation and cladding breakdown
at higher temperatures. Accordingly, the new composites
were developed in the sixties specifically for higher tem-
perature applications by the process now known as hot co-
extrusion. This requires the direct co-reduction of two large
concentric billets by hot extrusion to form a very strong
metallurgically bonded bi-metallic tube.
This paper will review the manufacturing procedure and Fig. 3--Cold mechanically bonded bi-metallic tube showing inner stain-
experience necessary to produce a sound metallurgically less steel and copper outer for acetic acid plant.

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 93

has limited the use of such cold clad tube to relatively low
temperature, e.g., <250 ~ heat transfer processes.
Successful applications were as heat exchanger tube for
breweries and waste heat boilers for acetic acid plant. At-
tempts to utilize cold clad stainless/ferritic steel tube for
sootblower lances in power plant boilers resulted in sepa-
ration and excessive ovality in the outer austenitic layer.
Contamination, e.g., by drawing lubricants, of the bi-
metallic interspace is difficult to avoid and can cause stress
corrosion in austenitics.
The achievement of a fully bonded bi-metallic tube is
assured by the direct hot extrusion of a large diameter com-
posite billet at temperatures -1200 ~ As the extruding
billet is grossly reduced in section, e.g., factors of 10 : 1 on
cross sectional area reduction, the high extrusion pressures
and temperatures create a 'pressure forged' welding-type
effect at the bi-metallic interface, promoting rapid inter-
diffusion and extensive bonding between the two layers.
The finished product is now well known as 'metallurgically
bonded' co-extruded tube.
Originally, the interest in such tubes was purely economic
and intended to save tube material costs by adopting a
cheaper inner or outer layer component for the less demand-
ing part of the service environment. Subsequently, the prime
objective has been to protect the surface of existing high
strength steels found to have inadequate corrosion resistance
and unable to survive commercial operating lifetimes. 4
Direct extrusion is by far the most satisfactory process for
producing seamless tubes in stainless steel and high nickel
alloys. Unlike rotary piercing where the billet at some stage
is subjected to severe tensile forces, the forces involved in
extrusion are compressive throughout. This aspect can be
particularly advantageous with the higher alloyed metals
that normally have limited hot workability and low ductility.
Conventional Hot Extrusion of Monobloc Tube
Seamless stainless steel tube is normally produced in the
United Kingdom and generally elsewhere by the long estab-
lished Sejourne hot extrusion process. Solid round forged
billet, typically 0.2 meter diameter and 0.7 meter long is
Fig. 4 - - H o t extruded metallurgically bonded tube showing inner carbon
steel and stainless steel outer.
94 VOL. 8, NO. 1, JUNE 1986
Fig. 5--Section of tube/billet showing uniform dual flow characteristics
during co-extrusion.
center bored to the required tube bore size and then heated
in two stages, i.e., rotary hearth furnace to 700 ~ and then
rapid (30 seconds) induction heated to -1250 ~ prior to
insertion in the 3000 tonne extrusion press. A mandrel is
pushed through the billet's bore to protrude on the far side.
The end of the mandrel is next positioned concentrically
with a circular extrusion die. Elongation by extrusion is then
carried out by squeezing the hot billet through the annular
space formed by the die and mandrel, producing an extruded
tube around 10 meters long. Effective lubrication is an im-
portant factor in the hot extrusion since it affects the surface
finish of the tubes produced. Furthermore, it permits the use
of greater extrusion ratios which again enhances the wrought
properties of the finished product and with co-extruded ma-
terials improves their bond strength. The lubricant in general
use is glass which melts typically at - 9 0 0 ~ ensuring
uniform coverage of the billet and low surface friction dur-
ing the extrusion process.
Co-Extrusion of Bi-Metallic Tube
Bi-metallic tubes are produced by the co-extrusion of a
duplex billet; i.e., the solid inner layer forged billet is
placed inside a tight fitting outer layer cylinder. The same
well-established hot extrusion process and cold reduction
plant as that used for monobloc stainless tubes are then
employed. For applications in the power industry the
corrrosion resistant material (e.g., AISI Type 310 steel)
has always been the outer layer component to overcome
corrosive fuels.
Three Production Routes. Production of the outer layer
billet component has resulted in a choice of three different
manufacturing routes all with the same purpose of producing
a duplex composite billet prior to extrusion. A prime objec-
tive is to produce a large cylindrical billet outer with the
minimum of metal wastage. Two of the three routes make
use of a solid metal outer billet cylinder while the other
involves a compacted metallic powder outer layer com-
posite. The solid outer cylinders are produced either by hot
J. MATERIALS FOR ENERGY SYSTEMS
Fig. 6 - - T h e use of tubes with a two layered construction facilitates selection of materials combinations having optimum corrosion and mechanical properties.
Thus the tube can be tailor-made to suit the operating conditions using commercially available alloys with proven mechanical properties.
piercing and up-extrusion of a forged billet to form an en-
larged hole, or by direct centrifugal spin casting to the outer
cylinder dimensions. The powder route involves encircling
the central inner layer forged billet by an annulus of the
corrosion resistant powder alloy e.g., 50 pct Cr, 50 pct Ni
alloy all contained in a metal canister.
The two production routes producing the solid outer cyl-
inders have different degrees of interfacial fit. One method
aims at a fine machined precision surface finish for a tight
fitting air-filled sleeve fit, while the other method adopts a
coarse machined surface, possibly to reduce inter-billet ex-
trusion slip and fills the interspace with nitrogen prior to seal
welding. In the powder metal composite billet, vacuum
degassing of the billet canister and heat soak sintering are
adopted to achieve an initial degree of compaction and bi-
metallic fit prior to hot extrusion.
Fig. 7--Schematic diagram showing typical deformation and flow of
component materials during extrusion.
J. MATERIALS FOR ENERGY SYSTEMS
Irrespective of the method chosen to produce the pre-
extrusion composite billet, all three manufacturing routes
provide a sound metallurgically bonded co-extrusion prod-
uct. Most of the CEGB experience, however, is with co-
extruded tube produced by the forged inner/solid wrought
outer billet method. 5
Detailed knowledge of metal flow in the extrusion process
was acquired by a series of tests which included examination
of sectioned billets inscribed with a grid pattern. It was
established that deformation of a duplex billet followed the
same consistent flow pattern as that for monobloc tube
which thus enables the component thickness of the individ-
ual layers to be predicted accurately and consistently.
Typical relative component layer thicknesses of 1 : 1 to
1 : 4 are commonly produced, but ratios up to 1 : 5 and higher
are feasible. The thinner component can be either the inner
or outer layer dependent on the application required.
QUALITY CONTROL OF CO-EXTRUDED TUBE
Ultrasonic Testing. During the development of co-extruded
tube, most of the research has been directed toward the
reliable measurement of bond integrity over the whole inter-
face area of the tube on a production scale. The method for
bond integrity6 involves pulse echo testing at the interface of
the two materials. An immersion or contact technique is
used with an inert liquid couplant. The ultrasonic energy is
introduced normally into the tube wall and the tube or alter-
natively the probe is rotated in a helical motion which en-
sures complete surface coverage. The electronics are so
arranged that the test performs similarly to a conventional
thickness tester, but electronic gates concentrate on the bond
region. A suitable reference defect standard which is either
VOL. 8, NO. 1, JUNE 1986 95
a 25 mm long x 3 mm wide notch or a 5 mm diameter hole
is spark eroded or drilled from the inner surface of the tube.
The equipment is adjusted to produce a clearly identifiable
trigger alarm signal from the notch.
It may appear that the sensitivity has been selected in a
very arbitrary way, but considerable correlation with metal-
lographic work has been carried out to determine the area of
lack of bond which can be detected. In most cases this will
be of the order of 10 mm 2, and experience has shown that
this level of sensitivity is readily acceptable for current
applications.
Service experience with stainless/carbon tubes has shown
that lack of bond defects greater than 5 mm in circum-
ferential length can cause thermal fatigue of the stainless
outer layer when under high heat flux and thermal cycling
loads (e.g., 350 kw/m2).
Combined systems have been developed for both bond
integrity and the normal ultrasonic examination for tube
surface defects. Both can be carried out during a single pass
through a multiple probe test head.
Mechanical Testing. Room/elevated temperature proof
stress values, and UTS and elongation values are carried out
on the strength bearing alloy.
Tube dimensions, layer thickness checks, bend testing,
flattening, and drift expanding tests are carried out in accor-
dance with BS 3059 or ASTM A450.
The considerable manufacturing experience over the last
15 years with co-extruded tube has resulted in the gradual
PROBE HEAD ROTATES AT
2000 RPM IN FIXED PLANE
UBE AXIS
BOND ~ WATERCOUPLANT
DEFECT
A GOOD REGION
A TOP SURFACE ~ TOPSURFACE
ULTRABOuNDT A BACKECHO
S'GNAL / // A /
Received l I ~ t| Receivedl
time ~>
Fig. 8--Ultrasonic testing technique for detection of bond defects in
co-extruded tube.
96 VOL. 8, NO. 1, JUNE 1986
evolution of an improved quality assessment procedure.
Whether for power utility boilers or black liquor recovery
boilers specifications accepted by these industries are now
well established, and complement conventional British and
American standards.
MANUFACTURE/MATERIAL CONSIDERATIONS
FOR CO-EXTRUDED TUBE
Although in theory most combinations of metals of similar
melting points and hot flow strength can be co-extruded, in
practice one must be aware of the opportunities for bonding
which are dependent upon very short term interdiffusion of
elements during the extrusion operation. The time period for
interdiffusion is measured in seconds rather than minutes,
and often the presence of tenacious oxide films will be a
relevant factor.
Subsequent processing of the tube after initial co-
extrusion must also be borne in mind and whether com-
plementary lubricants for drawing and heat treatment cycles
can be applied. Most experience to date has been restricted
to the following combinations of materials:
Inner Layer Outer Layer
Austenitic stainless Ferritic steel
Austenitic stainless Austenitic stainless
High nickel alloy Ferritic steel
Austenitic stainless High nickel alloy
Ferritic steel Austenitic stainless
Ferritic steel Ferritic stainless
Certainly, within the range of carbon steel through the
stainless alloys into and including the higher nickel alloys,
a very wide range of combinations is possible.
A review of the experience to date for the various applica-
HELICAL PATH tions and industries can be seen in the summary table of
co-extruded experience.
High chrome high nickel alloys like 50Cr 50Ni which do
not lend themselves to wrought methods of hot working can
be consolidated from powder, cold isostatically pressed and
co-extruded to stainless or ferritic carbon steels to give ex-
cellent results.
Early Processing Problems with Hot Workability
GH
Difficulties were encountered in producing a wrought billet
in 50Cr 50Ni suitable for extrusion. This was due to the very
B LACKOF BOND
narrow hot workability range for forging. Defects were en-
countered during the pre-lift operation which again were
/, ~,CKOF
I ~, BOND related to the poor hot ductility of this alloy. The use of a
compacted metal powder was found to be a more desirable
route than conventional cast and forged.
time l> A consequence of alloy optimization to improve cor-
rosion resistance in the T310 produced changes in hot
workability. Increasing the silicon from 0.3 pet to 1.25 pet
J. MATERIALS FOR ENERGY SYSTEMS
 Summary of Co-ExtrudedTube Experience

Component
Overall Range
Installation Outer Inner Size Range Wall Thk. Quantity
Application Location Period Material Material mm Ratio m
Power utility final superheater T310M or steel 1250 33 to 65 od 1:1.1
boilers (coal fired) final reheater 1969 to 1984 T310M + Nb to 200,000
3rd stage reheater 3.2 to 9 thk 1: 2.2
1979 t2R72 44 to 54 od 1:1.3 1200
6.4 to 8.3 thk 1 : 1.96
3rd stage reheater 1974 50Cr In 800H 1:2
1982 50Ni 54 od 3000 (UK only)
5.95 to 9.2 thk 1 : 3.84
furnace walls 1974 to 1984 T304 or carbon
T310M or steel 50 to 76od 1:1 to 30,000
T310M + Nb 440 6 to 8.3 thk 1:3.75
furnace walls 1982 13Cr4AI carbon 76.2 od 1 : 1.3 30 (trial)
steel 440 7 thk
furnace walls 1981 T446 carbon 68.5 od 1: 1.3 36 (trial)
steel 440 7 thk
furnace walls 1981 50Cr carbon 76.2 od 1:1.1 20 (trial)
50Ni steel 440 8.3 thk
furnace walls 1982 12CrMoV carbon 76.2 od 1:1.1 20 (trial)
(sootblower steel 440 8.3 thk
ports)
Black liquor furnace walls 1969 to 1984 T304 carbon 50.8 to 76 od 1:2.3 250,000 +
recovery boilers steel to (estimate)
SA 210 5.6 to 7.2 thk 1:3.3
grade AI
Ammonia reforming quench coolers 1973 to 1974 15Mo3 alloy 600 38 to 42 od 1:2.3 8000
plant carbon to
alloy 4.9 to 6.5 thk 1:3.3
PWR nuclear outlet nozzles 1960 to 1981 T304L carbon steel 111 od 1:1.67 8O0
plant 21 thk
Combined cycle gasifiers 1984 N A C - C R 3 5 A ASTMA213 T11
power plant T310M + Nb ASTM A213 Tll
Super critical superheaters 1984 SUS 310S 17/14 CuMo
coal fired units
superheaters 1984 N A C - C R 3 5 A 17/14 CuMo

produced cracking during pre-lifting which was overcome
by adjustment to the extrusion temperature.
Metallurgical Bonding
During assembly of the composite billet considerable care is
exercised to ensure smooth contamination free surfaces at
the billet interface. Continuous air ingress during billet heat-
ing is prevented by seal welding each end of the billet face.
Bonding does not occur until extrusion commences. Metal
deformation breaks surface oxide films at the interface and
diffusion bonding at high temperatures and pressures take
place. The interdiffusion of elements across the interface is
characteristic of the co-extruded product and provides the
high bond strength. The interstitial element carbon is poten-
tially the most mobile and attempts should be made to
minimize the difference in carbon levels for new component
materials, to avoid any deleterious metallurgical effects and
local hardening at or adjacent to the interface.
Metallographic examination o f T310 stainless/carbon
steel combinations indicates that local hardening can oc-
cur just inside the stainless steel boundary due to short
range carbon transport. This effect appears to stabilize after
some 20 to 25 kh and has not been found to be detrimental.
Nickel and chromium are other potentially active elements.
Faulkner and Bridges 7 evaluated the interdiffusion charac-
teristics of a range of composite materials by relating the ex-
cess carbon content between two alloys to the diffusion bond
width developed in service at temperatures up to 700 ~
They recognized that normal n i o b i u m or titanium sta-
bilization of alloys would reduce the free carbon content and
thereby its transfer into the lower carbon material in the
co-extruded tube. The use of a pure nickel interlayer or
zirconium additions to the donor alloy to provide a barrier
against excessive interdiffusivity in service was also in-
vestigated. Our service experience totaling around 65 kh
has shown this to be unnecessary. These workers cautioned

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 97

the designer on the possibility of iron and chromium transfer
which could form the brittle sigma phase. Again, in the
power industry application for furnace wall co-extruded
tubes, chromium diffusion temperatures are too low
(450 ~ for sigma to be of real concern.
Bonding Defects. Manufacturing experience of inter-
facial defects has invariably been attributed to inadvertent
contamination of the duplex billet interface causing local
hindrance to the interdiffusion bonding process. Carbon
steel or low alloy billets are particularly vulnerable to sur-
face rusting prior to assembly.
During the commencement of extrusion the inner layer
material extrudes through the die. Immediately afterward,
the outer material flows through the die orifice to achieve
steady state conditions and consistent layer thickness. Dur-
ing this period, pressure at the interface gradually increases
until bonding occurs. The extent of extrusion before a satis-
factory bond is achieved can vary and is dependent upon
tube size, component wall thickness, and material combi-
nations. Clearly, there will be a region at the tube end
where bonding will not occur or be incomplete; this is
normally cut off.
It is typical for this region to vary somewhat from batch
to batch and even from tube to tube which can make the
achievement of fixed cut lengths of tube difficult without
incurring a high yield loss.
The ultrasonic test procedures described previously have
proved to be very effective at locating areas of lack of bond.
Thermal Compatibility of Materials
The basic requirement of selecting two metals with optimum
strength and corrosion resistance has resulted in the combi-
nation of austenitic and ferritic steels for evaporator tube
applications in power plant furnaces and recovery boilers.
Thermal Fatigue. The large difference in thermal expan-
sion coefficients for these steels would seem to introduce
potentially unacceptable thermal stresses during tube ser-
vice and could cause thermal fatigue in some applications.
Various researchers have simulated the maximum service
stresses introduced by the differential thermal strains.
Thermal cycling tests between 200 and 500 ~ and between
200 and 700 ~ on a T304/carbon steel co-extruded tube
over some 5000/10500 cycles did not produce any damage
to the metallurgical bond. Deliberately selected pre-existing
surface cracks did, however, propagate to the bond during
testing. 8 Good correlation between theoretically calculated
fatigue cracking characteristics and those produced by
laboratory simulation of service conditions have been ob-
tained. Hence, for future combinations of bi-metallic tubes
reliable predictions can be made in advance of confirmatory
fatigue testing.
Thermal cycling fatigue studies 3 on a T310/Esshete 1250
co-extruded tube welded to a conventional monobloc T347
98 VOL.8, NO. 1, JUNE 1986
tube were carried out in the range 300 to 700 ~ for 4220
cycles without any signs of bond damage or cracking be-
tween the two austenitic layers or the weld region itself. In
this instance the differential in the thermal expansion coeffi-
cients is relatively small, but the tests are nevertheless in full
agreement with 15 years service experience for this same
tube combination in superheaters operating at 650 ~ 4
In black liquor recovery boilers, co-extruded membrane
walls particularly at smelt spout openings and air ports have
experienced excessive service temperatures and resulted
in thermal fatigue cracking of the outer stainless layer.
This problem has been overcome by design modifications to
produce lower thermal stress levels and improved opera-
tional practices. 9
Thermal Conductivity. For the application of stainless
cladded carbon steel tubes in place of monobloc carbon
tubes for furnace evaporator tubes, concern was expressed
over the relative change in thermal conductivity. In retro-
spect, this has not been found to give any problems, and
although austenitic alloys are around half the conductivity of
ferritic steel, this is overshadowed by the very much lower
conductivity of oxide films and corrosion/ash deposits
which occur during normal operation of coal fired utility
boilers. Such deposits can reduce thermal conductivity by
60 times that of carbon steel.~~
Metallurgical Condition and Heat Treatment. Virtually
all co-extruded applications combine a standard high tem-
perature alloy with a corrosion resistant cladding.
The majority of tubes are produced with the corrosion
resistant cladding on the outer surface, but this is not a
restriction of the co-extrusion technique which is able to
produce tubes with the cladding on the inside surface just as
easily. However, due consideration must be given to the
application of thermal treatments, since the objective must
be to optimize both the mechanical properties and corrosion
resistance; e.g., compromise heat treatment of the black
liquor T304/carbon tube must be chosen to reduce sensi-
tization in the stainless, or alternatively low carbon Type
304 can be used.
Each combination or prospective combination must be
assessed with this aim in mind. During initial design of the
T310/carbon steel furnace evaporator tube for CEGB it was
found necessary to slow cool the tube after extrusion to
avoid the formation of bainite/martensite in the inner
strength bearing carbon steel. Unfortunately, this tended
to produce precipitation of M23C6 in the stainless clad-
ding which marginally reduced oxidation/corrosion resis-
tance. This was avoided by stabilization of the T310
with niobium. ~l
When cold working is required, a satisfactory heat treat-
ment must be applied, which is complementary to both
materials. Often problems can occur when this heat treat-
ment is nonstandard for the strength bearing alloy, leading
J. MATERIALSFOR ENERGYSYSTEMS
to difficulties in predicting the long term rupture strength
properties. A potential problem was overcome with
T310/Esshete 1250 tube by adding niobium to the T310 to
prevent grain growth. ~2This allowed a higher solution tem-
perature to be used in order to achieve the optimum stress
rupture properties of the load bearing alloy.
TUBE DESIGN CRITERIA
British Standards
The design philosophy adopted by the CEGB for co-
extruded tubes was based on a "fitness for purpose" criterion
and/or the British Standard Code for Water Steam Gener-
ating Plant BS 1113. A deliberately pragmatic approach was
necessarily evolved to deal with the specific engineering
problems being experienced in the existing plant caused by
severe fireside corrosion.
Existing plant scantlings required that replacement fur-
nace wall tubes could be accommodated into either tangent
tube or membrane wall construction. The co-extruded tube
bore diameters were to remain unchanged so as not to
change the designer's original pressure flow/heat transfer
specification.
Additional or excessive weight increases on tube pendant
stages resulting from increased tube thickness would not be
acceptable nor would significant increases in tube outside
diameter so as to avoid corresponding changes in heat pick-
up in convective heat transfer passes.
The applicable design stresses 5 for selecting the inner
layer thickness are obtained with reference to BS lll3/BS
3059. The outer layer thickness is selected solely on plant
corrosion data and the required service life and is taken as
non load bearing. Thus, during the design calculations only
the inner layer is permitted to be the strength bearing com-
ponent. The original tube internal diameter is retained when-
ever possible, and the overall tube thickness would remain
the same or reduced if a weight/cost advantage is permis-
sible without affecting design life. The use of Esshete 1250
steel for superheaters often permits the design of a thinner
inner layer because of its superior creep strength over the
300 series austenitic steel. 13
Where the actual service temperature of tube to be re-
placed is known, this maximum steady value is used for the
tube design stress calculations. Tube design life is usually
optional, but ideally a minimum target value of 100 kh is
normal. The pragmatic approach adopts a balance between
the strength and corrosion requirements. While adhering to
mandatory rules concerning the determination of minimum
thickness for strength considerations, every attempt is made
to increase the thickness of the corrosion resistant cladding.
In the severe fireside environments encountered in the
United Kingdom, corrosion is normally the life-determining
feature of the boiler tubes.
J. MATERIALS FOR ENERGY SYSTEMS
American Standards
The use of co-extruded in accordance with the ASME Boiler
and Pressure Vessel code is also permissible following ap-
proval of case code 1874. The design criteria are very simi-
lar to those used in the United Kingdom, with the inner
strength bearing core material only being considered during
design calculations. This code is used extensively for the
design of furnace wall membrane panels for black liquor
recovery boilers.
UPDATED EXPERIENCE IN UNITED KINGDOM
POWER UTILITY BOILERS
Two major industries have solved their boiler tube external
fireside corrosion problems in existing plants by developing
co-extruded bi-metallic tubes. These are the electricity
utility and the paper pulp industry. The United Kingdom
Central Electricity Generating Board began large scale in-
stallation of co-extruded steel tubes in 1976 after a series
of successful trials started in 1967, and their performance to
date has been very encouraging. Twelve CEGB coal fired
boilers now have a total of some 230 km installed. New
replacement schemes are now in progress to achieve the
250 kh extended plant life without further maintenance.
Parallel experience has also been obtained in the paper pulp
industry with co-extruded tubes to overcome severe corro-
sion in the furnace zone caused by the molten sulfate/sulfite
liquors. Here, too, performance has been outstanding, and
use of composite tubes in some 62 recovery boilers is a
rapidly expanding application. 9
Co-extruded tubes have now been used by the CEGB to
overcome fireside corrosion in the evaporator and super-
heater sections of coal fired boilers for the past decade. The
severe fireside attack on conventional tube materials is re-
lated to the use of aggressive medium to high chlorine bitu-
minous coals, i.e., 0.2 to 0.5 pct C1. Several major reviews
have been published by the CEGB on the two distinct mech-
anisms of furnace and superheater type c o r r o s i o n , 11'12'14-j6
and all concluded that a materials solution is the most eco-
nomical approach.
These investigations considered the alternative remedial
actions to avoid tube failures and heavy repetitive main-
tenance schedules, including material bandaging, metal
shields, and protective coatings in addition to the various
combinations of co-extruded tube. 17
For corrosion rates greater than 0.4 mm/yr and 0.2 mm/
yr for furnace and superheater, respectively, composite tubes
were found to be the best technical/economical solution.
The two major combinations of co-extruded tube which
evolved both had a T310 stainless steel outer cladding which
has given corrosion improvement factors between 2 to
5 • that of the original installed tube for both furnace wall
and superheaters.
VOL. 8, NO. 1, JUNE 1986 99
Furnace Membrane Wall
To date the majority of furnace wall co-extruded tubes in-
stalled in CEGB boilers are of tangent wall construction.
The first performance trials with a T310/carbon steel in a
membrane wall construction are currently in progress in a
660 MW boiler operating at 450 ~ metal temperature and
2700 psi. The tubes were 63.5 mm od x 3.4 mm T310 on
3.0 mm carbon steel to correspond with the existing tube
dimensions. Samples removed after 30 kh to date indicate
satisfactory performance with no sign of cracking or dis-
tortion of the membrane fillet welds or butt welds joined to
the existing carbon steel tubes. The corrosion benefit over
the adjacent carbon steel monobloc tubes was a factor of
x2.5 for the outer layer which would give a projected total
service life of some 167 kh compared to the present 81 kh
Fig. 10--Photomicrographs showing little change in structural condition
for the original tube. after 30 kh at 450 ~ metal temperature and 2700 psi service pressure.
Highlights of the metallurgical investigation are presented
in Figure 9, showing results of corrosion performance and
mechanical tests.
Corrosion. The photograph shows a section through
three adjacent tubes from the trial panel, two co-extruded,
one carbon steel monobloc.
Corrosion rates measured at fireside surface:
Co-extruded: 0.17 mm/yr
Carbon steel monobloc: 0.50 mm/yr
Flattening and flaring tests after 30 kh exhibited compa-
rable ductility levels to tubes in the supplied condition.
A micro-hardness traverse across the stainless/carbon
steel bond after the 30 kh service was carried out. This
indicated the characteristic hardening effect with peaks of
- 5 0 0 HV 0.025, decreasing over a 40/xm band into the
Fig. 11--Bend test on longitudinal strip section--co-extruded tube after
stainless layer. 30 kh--bore in compression.

SUPERHEATER/REHEATER PENDANT TUBES

Fig. 9--Section through three adjacent furnace tubes from the trial panel
showing minimal attack on stainless cladding of co-extruded tube.
Since 1976 co-extruded tube has been the preferred remedial
action for the resistance of severe fireside corrosion in
superheaters/reheaters of coal fired boilers in the United
Kingdom. The majority of superheater tube installed,
amounting to 230 kM, has been of the T310/Esshete 1250
combination, but in areas of very severe corrosion 50Cr
50Ni in place of the T310 has been specified. ~4.18Since 1969
modifications to the chemical analysis of the T310 have
taken place to optimize corrosion performance. These modi-
fications have involved increasing the silicon content to 0.75
to 1.5 pct, chromium to a minimum of 25 pct, and niobium
to 8 • C minimum. These adjustments have also been found
to be beneficial to the furnace wall application.
Sample reheater tubes have recently been examined after
33 kh service in the furnace exit of a 550 MW boiler opera-
ting at 680 ~ metal, 1200 ~ gas, and 600 psi steam pres-
sure. Coal chlorine content was particularly high at around

100 VOL. 8, NO. 1, JUNE 1986 L MATERIALS FOR ENERGY SYSTEMS

Mechanical Properties of Inner Strength Bearing Carbon Steel

Yield Strength UTS Pet Elongation

Tests at 20 ~ Nmm2 (ksi) Nmm~( k s i ) 5.65~o
As supplied 326/410(47/60) 484/547 (70/79) 35/37
After 30 kh 363/387 (53/56) 512/522 (74/76) 27/29
service

Stainless T310 Outer

Fig. 13--As installed co-extruded tube with a 2.9 mm outer T310 and a
2.0 mm inner layer Esshete 1250.

Carbon Steel Inner

Fig. 12-- Photomicrographof the bond area of above30 kh strip specimen
after bending.

0.5 pet annual average. The tubes were 54 mm x 2.9 mm

outer T310 and 2.0 m m Esshete 1250 inner and were in-
stalled in 1977 as leading tube inserts in locations previously
experiencing severe corrosion at rates exceeding 1.7 mm/yr.
The corrosion benefit for the T310 co-extruded tube over the
adjacent austenitic monobloc tubes was a factor of 3.2,
which would give a projected total service life of some
53 kh compared to the present 17 kh.
In another 500 MW coal fired boiler T310/Esshete 1250
co-extruded superheater tubes with a 3.4 mm outer/3 mm
inner c o m b i n a t i o n are indicating corrosion rates of
0.43 m m / y r compared to the original T316 monobloc tube
of 0.90 mm/yr. The operating conditions were 640 ~
metal, 1050 ~ gas, and 0.25 pet annual average for coal
chlorine. The improved corrosion performance of the T310
over the previous example was due entirely to lower tem-
perature and chlorine levels.
Highlights of the metallurgical investigation are presented
showing results of corrosion performance and mechanical
tests. The reference standard used for the mechanical test
evaluations was the ESI Specification 680710 "Tubes and
Fig. 14--Same co-extrudedtube after 33 kh service showing severefire-
side attack in aggressiveenvironment. Benefit factor x 3.2.
Tube Elements for Boilers (Metallurgically Bonded Co-
Extruded Tubes)".
Corrosion. The photographs show the pitted tube taken
from the superheater section after 33 kh.
Flattening and flaring test after 33 kh also exhibited com-
parable ductility levels as tubes in the supplied condition.
Fabrication and Welding
Most applications of co-extruded tube require some form of
tube bending and welding attachment. Tube bending charac-
teristics have been found to be identical to those for mono-
bloc tubes, and even bends as tight as ld are regularly made
without difficulty and with no bond separation.

J. MATERIALSFOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 101

 Mechanical Properties of Inner Strength Bearing Steel 1250

1 Pct Proof Stress UTS Pet Elongation

Tests at 20 ~ Nmm2 (ksi) Nmm2 (ksi) 5.65V'-~
As supplied 345/439(50/64) 597/680(87/99) 43/49
After 33kh 378/386(55/56) 643/645 (93/94) 40/42

Fig. 17-- Photomicrographof the bondareaof above33 kh strip specimen

after bending.

Butt welding co-extruded tubes to each other or to adja-

Fig. 15--Bend test on longitudinal strip specimen after 33 kh service.
Bore in compression.
Fig. 16--Photomicrographshowing service precipitationcharacteristics
after 33 kh at 680 ~ metal temperatureand 400 psi steam pressure.
cent monobloc tubes and panel welding for the construction
of boiler walls are the most frequent fabrication require-
ment. A general rule is that a matching or similar filler
material is selected for each layer to maintain properties in
the weld zone equivalent to the parent tube. Conventional
welding techniques with normal methods of quality control
have been found readily acceptable for co-extruded tubes.
For example, suitable welding techniques are Shielded
Metal Arc (SMA/MMA) and Gas Tungsten Arc (GTA/TIG).
Gas Metal Arc (GMA/MIG) is used by some boiler makers,
notably in Scandinavia, but more careful control of welding
parameters is necessary.
In the United Kingdom, co-extruded butt joint prepara-
tion is generally in accordance with the British Standard BS
2633. It is common procedure on the normal tube sizes for
the initial root run to be autogeneous GTA/TIG, which can
be followed if required by further GTA/TIG or SMA/MMA
runs using an appropriate inner layer filler. When the correct
thickness of the inner strength bearing material is achieved,
the outer layer filler material compatible with corrosion
resistant alloy, e.g., T309, is applied by SMA/MMA.
When co-extruded inserts are being joined to existing
boiler tubes, a general policy is to place the weld terminals
ouside the corrosion zone, when possible, and hence use a
single conventional weld filler metal comparable with the
existing monobloc tube. For major replacements involving
co-extruded to co-extruded welds, the double fill method
is used.
Panel welding of co-extruded tubes to form gas tight
tangential or membrane walls is now a standard operation.
To date, the co-extruded tube has comprised an inner carbon
alloy material with an outer stainless cladding. The most
common requirement is the membrane welding of panels for
black liquor recovery boilers.
The most critical feature of the process used is to achieve
good control of weld penetration to avoid the risk of over
penetration into the carbon material and hence deterioration
of mechanical properties.

102 VOL.8, NO. 1, JUNE 1986 J. MATERIALSFOR ENERGYSYSTEMS

Fig. 18--Typical butt weld between two lengths of co-extruded reheater tube. 40.9 mm o.d • 4.0 mm overall thickness.

Fig. 19--Fabrication characteristics of co-extruded tube.

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 103

 For good controlability, automatic methods are preferred.
In Scandinavia, boiler makers use Metal Inert Gas
(GMA/MIG), and submerged arc SMA/MMA is not recom-
mended for anything other than small retrofit panel sections.
CEGB experience from 1976 has now totaled around
70,000 welds. No technical problems have been encoun-
tered with welding and no weld failures have occurred. No
preheat or post weld heat treatment has been required for
any of these tubes.
SUMMARY
(1) The manufacturing methods for production of co-
extruded tube are now well established and use the same
reliable extrusion technology for conventional seamless
tube. Quality assurance procedures and the ultrasonic test-
ing techniques are well defined and meet the requirements
of BS and ASME codes.
(2) United Kingdom experience gained from tube instal-
lations in the early 1970's has indicated corrosion benefit
factors between 3 and 5 using co-extruded tube. Attempts
over the past twenty years to ameliorate high tempera-
ture fireside corrosion with protective coatings, metal
shields, and metal bandages have never been successful
over long periods.
The latest co-extruded tube evaluations involving a
stainless/carbon steel tube for furnace membrane construc-
tion, and stainless/stainless superheater and reheater tubes
have been found to be giving satisfactory performance after
some 30 kh to date. It is important to note, however, that the
corrosion benefit factors were lower, i.e., of the order of
2.5, due to operation at higher temperatures and higher coal
chlorine contents.
(3) The operating experience to date has indicated very
few problems with fabrication, welding, or tube integrity
in service after periods of up to 85 kh. Initial concern re-
garding the possible rupture of the diffusion bond during
fabrication or service has not materialized. Providing tubes
are manufactured with a sound bond, there is no evidence to
date that separation will subsequently occur in service. The
problems so far encountered have been minor ones and
related to thermal fatigue in areas of high heat flux and
excessive temperatures.
(4) In recent years, overseas boiler manufacturers have
been interested in co-extruded tubes for superheater materi-
als for advanced plant operating at high pressures of 4500 to
5000 psi as well as at high temperatures of 593 to 650 ~
Combined cycle power plants and fluidized bed boilers are
also possible applications for future combinations, and re-
search is currently underway in the United States, Japan,
and the United Kingdom into such developments.
(5) Co-extruded bi-metallic tubes have now been suc-
cessfully used for some 15 years in high temperature plants
to withstand aggressive environments. Large scale installa-
104 VOL. 8, NO. 1, JUNE 1986
tions have been carried out both in the United Kingdom
Power Generation Industry and in black liquor recovery
boilers used in the paper pulp industry. The experience to
date can be assessed by the fact that around half a million
meters have now been installed. The main areas of activity
in the paper pulp industry have been the United States,
Canada, and Scandinavia. The usage of co-extruded tube in
the chemical and process plant industries has so far been
relatively small.
(6) In order that the United Kingdom power industry
maintains capacity toward the end of this century, a number
of the large 500/660 MW coal fired stations are extending
their design life from 100 kh to 250 kh. In the face of the
moderate/high chlorine bituminous coals which will pro-
duce aggressive fireside conditions, co-extruded tube is the
alternative to the otherwise high corrosion rates and un-
planned outage problems associated with conventional tube
materials. It offers the designers the opportunity to over-
come the service limitations toward the continuous aim of
higher plant efficiency and higher availability.
ACKNOWLEDGMENTS
The authors wish to thank the Director of CEGB North
Eastern Region and the Directors of TI Stainless Tubes
Limited for their permission to publish this paper. The au-
thors also wish to thank Mr. C. W. Morris of the CEGB NER
SSD for his assistance during the preparation of this work.
REFERENCES
1. A.J.B. Cutler, T. Flatley, and K.A. Hay: "Fireside Corrosion in
Power Station Boilers", Journal Combustion, December 1980 and The
Metallurgist and Materials Technologist, February 1981, p. 91.
2. T. Flatley, C.W. King, E.P. Latham, and D. Mortimer: "Potential
Materials to Combat Fireside Corrosion in Coal Fired Boilers", Spring
Residential Conference, Edinburgh, 1975, Series 3, Institution of
Metallurgists.
3. C.W. King and M. T. Robinson: "Development and use of composite
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4. K.G. Fellows: "The Design Properties of Co-extruded Tube", Pro-
ceedings of Seminar by Institution of Corrosion Science and Tech-
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5. T. Flatley, C.W. Morris, and E. P. Latham: "Co-extruded tubes im-
prove resistance to fuel ash corrosion in UK Utility Boilers", Materials
Performance, 1981, vol. 20(5).
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680710, Published by Engineering Document Unit, CEGB, Sudbury
House, London, Issue 2, January 1984.
7. R.G. Faulkner and P. J. Bridges: "Compatability Studies of Alloys for
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corrosion", as in Ref. 14.
J. MATERIALS FOR ENERGY SYSTEMS
12. T. Flatley, E. P. Latham, and C.W. Morris: "Protection against fuel
ash corrosion using high chromium alloy composite tubes", Isle of
Man Conference on Environmental Degradation of High Temperature
Materials, Institution of Metallurgists, 1980.
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Gothenburg, Sweden.
14. E. E Latham, T. Flatley, and C.W. Morris: "Comparative Per-
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Conversion Systems, D.B. Meadowcroft and M.I. Manning, eds.
J. MATERIALS FOR ENERGY SYSTEMS
15. D.J. Lees and M. E. Whitehead: "Microanalysis of Scales and Depos-
its Formed on Corroding Furnace Tubes in Coal Fired Boilers", as in
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16. C.W. Morris and R. D. Russell: "Co-extruded Tube for High Tem-
perature Plant", Proceedings of Seminar by Institution of Corrosion
Science and Technology and CEGB at Harrogate, November 1976,
SSD/NE/NI59, May 1977.
17. T. Flatley and C. W. Morris: "Control of Fuel Ash Corrosion in Coal
Fired Boilers", Proceedings of the UK National Association Corrosion
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18. D. Rahoi: "Combating Fuel Ash Corrosion with Nickel Alloys",
Metals Engineering Quarterly, February 1974.
VOL. 8, NO. 1, JUNE 1986 105