IBP1043_09

Dissimilar steel welding and overlay covering with nickel based alloys using SMAW and
GTAW processes in the nuclear industry

Angel Rafael Arce Chilque1, Alexander Queiroz Bracarense.2, Marco Antônio Dutra Quinan 3,
Mônica Maria de Abreu Mendonça Schvartzman 3, Luciana Iglésias Lourenço Lima4, Guilherme Marconi5

Copyright 2009, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exposition 2009, held between
September, 22-24, 2009, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical
Committee of the event according to the information contained in the abstract submitted by the author(s). The contents
of the Technical Paper, as presented, were not reviewed by IBP. The organizers are not supposed to translate or correct
the submitted papers. The material, as it is presented, does not necessarily represent Brazilian Petroleum, Gas and
Biofuels Institute’ opinion or that of its Members or Representatives. Authors consent to the publication of this
Technical Paper in the Rio Pipeline Conference Proceedings.

Abstract
This work presents the welding of dissimilar ferritic steel type A508 class 3 and austenitic stainless steel type
AISI 316 L using Inconel® 600 (A182 and A82) and overlay covering with Inconel® 690 (A52) as filler metal.
Dissimilar welds with these materials without defects and weldability problems such as hot, cold, reheat cracking and
Ductility Dip Crack were obtained. Comparables mechanical properties to those of the base metal were found and
signalized the efficiency of the welding procedure and thermal treatment selected and used. This study evidences the
importance of meeting compromised properties between heat affected zone of the ferritic steel and the others regions
presents in the dissimilar joint, to elaborate the dissimilar metal welding procedure specification and weld overlay.
Metallographic studies with optical microscopy and Vickers microhardness were carried out to justified and support the
results, showing the efficiency of the technique of elaboration of dissimilar metal welding procedure and overlay. The
results are comparables and coherent with the results found by others. Some alternatives of welding procedures are
proposed to attain the efficacy. Further studies are proposed like as metallographic studies of the fine microstructure,
making use, for example, of scanning electron microscope (SEM adapted with an EDS) to explain looking to increase
the resistance to primary water stress corrosion (PWSCC) in nuclear equipments.

Introduction
Wrought Ni based alloy 600 and its correspondent weld metals, alloy A182 electrode and alloy A82 filler
metal, are very used in pressurized water reactors (PWRs). It use is due to its inherent resistance to general corrosion,
mechanical properties and impact test similar to the low alloy steel and stainless steel and its thermal expansion
coefficient that is very close to that of low alloy and carbon steel.
However in the last thirty years in PWR, primary water stress corrosion cracking (PWSCC) has been observed
in numerous Alloy 600 component items and associated welds, sometimes after relatively long incubation times. The
occurrence of PWSCC has been responsible for significant downtime and replacement power costs. Repairs and
replacements have generally utilized wrought Alloy 690 material and its compatible weld metals (Alloy 152 and Alloy
52), which have been shown to be very highly resistant to PWSCC in laboratory experiments and have been free from
cracking in operating reactors over periods already up to nearly 15 years. It is nevertheless prudent for the PWR
industry to attempt to quantify the longevity of these materials with respect to aging degradation by corrosion in order
to provide a sound technical basis for the development of future inspection requirements for repaired or replaced
component items [1]. The Brazilian nuclear power plants Angra 1 and Angra 2, make use of alloys 600 and its
correspondent weld metals A182 and A82 as dissimilar welds in nozzles of the reactor pressure vessel and others parts.
The locations in PWR where PWSCC may occur are shown in Figure.1.
PWSCC follows the three basics conditions of stress corrosion cracking (SCC) to occur: susceptible material,
corrosive environment and the presence of tensile stress [2]. The microstructure of the welded joint plays an important
role in stress corrosion cracking. The microstructures of susceptible metals can introduce hot, cold and reheat cracking,
as well as interdendritic and grain boundaries containing precipitates, impurities, segregations and the typical
solidification microstructures caused by welding that can further complicate the SCC behavior.
Preliminaires for Dissimilar Metals Welding
From the point of view of welding, in order to elaborate a Dissimilar Metals Welding Procedure it is necessary
to take into consideration different topics such as: identify the type of dissimilar metals to be welded, the filler metals,
the design of the welded joint, the operational welding technique and heat treatment used, the welding inspection.

1
Dr. es Sc, Metallurgist Engineer, CETEN
2
Ph.D., Mechanical Engineer, UFMG
3
Dr., Nuclear Technology Development Centre, CDTN
4
M.Sc., Federal University of Minas Gerais - UFMG
5
M.Sc., Federal Center of Technological Education, CEFET-MG
 Figure 1 - Locations in PWR where PWSCC may occur[1].

In the present case, the base metals to be welded are a low alloy steel SA508 class 3 with a high alloy steel ,austenitic
stainless steel AISI 316 L; the filler metal, normally used is a nickel based alloy type inconel 600, A82 with GTAW for
buttering and root passes and A182 electrode with SMAW for filling and finishing passes. For overlay, inconel 690
weld metal A52 will be used with GTAW. The chemical and mechanical properties of the base and filler metals will be
controlled.
The choice of the welded joint design, groove and penetration depend on the welding processes, thickness and quality
of the weld required, ainsi as the accessibility, position of the welding and inspection technique.
The operational welding technique considers, otherwise, the cleanness of the welded joint and groove, the assembly, the
pre-heat, inter-pass temperature and post-heat, the welding technique for deposition: in this work is used the “temper
bead” technique (3). For buttering the ferritic steel and for weld overlay, low heat input is used to avoid excessive grain
growth and maintain a minimal of dilution.
Definition of the welding parameters, (I, V, welding speed, heat input, etc), number of buttering layers, cleanliness and
preparation between passes, definition of welding deposition, sequence of beads and layers, the fill and finish pass, the
external surface finish to receive the overlay, the post weld stress relief heat treatment, as well the welding inspection,
(before, during and after welding), to be specified.
Preliminary welds will be made in plates of the dissimilar metals in order to specify the procedure.
Weld Overlay
Because of recent incidents related to primary water stress corrosion cracking (PWSCC) in pressurized water
reactor (PWR) with nozzles welded with inconel 600 alloy and penetration locations welded with additional A82 and
A182 metals, the use of overlays for mitigation and repair of various plants components has led to the use of corrosion
resistant high nickel welding alloys (Ni-Cr-Fe) in particular alloy 52/52M which are known to be resistant to PWSCC.
On the other side, many of the most susceptible locations have access limitations, which make examination difficult
limiting the type of mitigation process that can effectively be applied. For this reason many of the utilities have decided
to apply weld overlay to many of these alloys configurations. Full structural weld overlays subject the inner portion of
the pipe to compressive stress, which is known to prevent the initiation of stress corrosion cracking. Several detrimental
phenomena have been observed using this alloy in a wide range of applications including weld overlay for repairing of
nozzle to safe – end locations on PWR`s. These weld discontinuities include micro-fissure, ductility dip cracking
(DDC) and lack of fusion (LOF). This has not been as significant as an issue with the manual filler rod 152, but is a
concern due to the similar chemistries. In response to the welding problems the 52M was developed. The 52M alloy
presents the advantage to give a weld with low values of aluminum oxides and low Niobium content and presents a
better resistance to Ductility Dip Cracking ( DCP),but it is necessary to have more attention for other problems of
weldability [4].
This work, explain about the welding and overlay covering of dissimilar ferritic steel type A508 class 3 and
austenitic stainless steel type AISI 316 L using Inconel® 600 (A182 and A82) for the weld and Inconel® 690 (A52) for
the overlay as filler metal, using specifics welding conditions. Some dissimilar welds with these materials are
experienced as regard to the best welding procedures specifications capable to give dissimilar welded joint and overlay
with good weldability, microstructures, mechanical properties and corrosion resistance.

Materials and Experimental Methods

Table 1 shows the base metal and filler metals chemical compositions. Plates of alloys ASTM A-508 class 3
and AISI 316L were used to form the dissimilar metal welded joint. The plates were welded manually, following the
welding procedures used for the nozzle to pipe welding in the Brazilian power plant Angra 1. The J groove weld was
prepared by joining two 130 x 300 mm pieces of 36 mm (ASTM A-508 class 3) and 31 mm (AISI 316L) thick plate. It
was produced by 3 root passes with gas tungsten arc welding (GTAW) with 82 alloy wire and 37 weld passes by
shielded manual arc welding (SMAW) with 182 alloy electrode. A typical schema of the weld design is shown in Figure
2, and the conditions for each weld pass are listed in Table 2. Before the welding, 5 layers of buttering were applied on
the ASTM A-508 class 3 plate by manual gas tungsten arc welding with Alloy 82.
 The resulting thickness of the buttering was about 5 - 8 mm. Due to the carbon equivalent of the A508 steel
(Ceq(iiw) = 0.604) after the buttering the piece was machined and post weld heat treated at 600ºC during 2 hours. The
pieces were then pre-heated at 150 ºC before welding and the maximum inter-pass temperature was 200ºC in order to
eliminated the hydrogen and avoid the cold cracking. After finished the dissimilar welded joint was not heat treated.
The weldments were submitted to visual inspection, dye penetrant and radiographic tests, and no weld defects were
revealed. After welding, the welded joint was cut in pieces for microstructural observation and mechanical tests.

Table 1 – Specifique chemical composition of the base and filler metals

Metals C Mn Si P S Cr Ni Nb Ti Cu Mo Al

316L 0.023 1.458 0.475 0.021 0.003 16.732 9.834 0.0199 0.029 0.142 2.097 0.011

SA 508 0.213 1.336 0.227 0.005 0.003 0.089 0.682 0.002 0.001 0.0559 0.505 0.011

182 0.047 5.810 0.572 0.015 0.006 14.930 71.820 1.890 0.183 0.019 - -

82 0.04 2.81 0.09 0.003 0.001 19.6 73.10 2.44 0.35 0.01 - -

52* 0.04 1.0 0.50 0.02 0.015 28-31.5 +Co-Re Nb+Ta 1.0 0.30 0.50 Al+Ti
max. max. max. max. max. max. mainder 0.10 max. max. max. 1.5
* Special Metals Catalogue: (Fe-7.0-11.0; others: 0.50max); filler metal: diameter- 1.2mm.

Figure 2 – The schematic weld design

Table 2 – Welding processes and conditions for various weld passes

10 - 15
10 - 15

Vickers microhardness profiles across the weld metal and base metal interface were performed at a constant
load of 100g and loading time of 25 seconds. For mechanical testing, specimens were taken from the weld plate and
machined. The geometry of the tensile tests specimens is 4mm of diameter and they were prepared in accordance with
standards ASTM G49 and ASTM E8. The samples were tested at room temperature and at 325ºC at a strain rate of
7x10-5mm/s. The mechanical properties are show in table 3 and are of the same order of the specifications.

Table 3. Mechanical Properties of Metals

Type of Yield Strength Tensile Strength Elongation
Metals YS0,2% (MPa) TS (MPa) (%)
SA 508 345 550 – 725 18

316L 170 485 40

82 385 530 30

182 * 425 576 18

182** 359 591 48

52*** 552 30

* Room temperature; ** temperature 325°C ; *** Special Metals Catalogue

Results and Discussion
Figure 3 shows the cross section macrography of the finished welded joint. In the figure it is possible to
observe the distinct regions of dissimilar metal welds. It is also possible to observe the columnar grains of the
solidification structure in the weld zone. The blew lines indicate the places where microhardness Vickers HV100 were
done.

Fig 3. Macrography of the dissimilar welded joint. Illustration of the different zones
and indication of the microhardness lines measurements. The narrows indicated the direction of the measurements.

Figure 4 shows the microstructure of AISI 316 L base metal composed of polygonal austenitic grains with a
small amount of delta ferrite. Figure 5 shows the microstructure of ASTM A508 class 3 base metal. The etching
revealed a quenched and tempered structure.

Figure 4 microstructure of the base metal AISI 316L Fig. 5 microstructure of the base metal ASTM A508 class 3.

Figure 6 (A) shows the interface between the A508 ferritic steel (black) and the Buttering (alloy 82). Figure 6
(B) shows the buttering region, (C) the microstructure of the root area and (D) the weld pool region. The
microstructures of alloys 182 and 82 weld metals are fully austenitic. The dendritic microstructure is clear in the
buttering area and in the weld pool region. The grain structure is columnar and forms in the heat flow direction. The
dendrites shapes depend on the position on the fusion zone. They are more closely spaced at the bottom part compared
with the upper part of the weld.
Figure 6 – Microstructure of dissimilar weld regions: (A) Interface A508(black)/A82(buttering); (B) buttering (middle);
(C) root area – alloy 82;(D); pool weld (alloy 182).

Figure 7 shows the fusion line between alloy 182 and AISI 316L. The interface shows the presence of unmixed
zone, the portion of the base metal that melted and solidified during the welding process. Welds between dissimilar
combinations are known to exhibit unmixed or partially mixed zones where the microstructure and chemical
composition are quite different from that of the surrounding weld metal [3].

Figure 7 – Microstructure of fusion line between alloy 182 and AISI 316L

Explain difference between weld metal grain boundary and in the dendrites grain boundaries. A detailed
characterization of the chemical composition of the segregation and secondary phase precipitation is in elaboration that
will be matter of another publication. The microhardness Hv measurements were taken along a line in the top, middle
and bottom of the weld included both base metals, the heat affected zone (HAZ) and the weld area as showed before in
Figure 3. The distributions of microhardness are graphically presented in Figure 8.
In Figure 8, the profile lines 1 and 3 show the distribution of the microhardness along the entire dissimilar
welded joint. In particular the results showed that the hardness Hv in the HAZ of the ferritic steel is of the same order of
the others parts of the welded joint. This meaning that the pos-weld heat treatment applied after buttering was
appropriated to eliminate the quenched structure present in the HAZ of the ferritic steel. These profiles together with the
2 and 4 profiles of weld metal and buttering region respectively, showed microhardness values from 180 to 270 HV100.
The continuous and relative smooth variation of the hardness in the welded joint is similar to the tensile strength
showed in Table 3. The results obtained for the dissimilar welded joint with the welding procedure designed show that
it is possible to meet a good compromise between microstructures, mechanical properties and appropriate weldability of
different regions with capacity to guarantee the integrity of the welded joint.
It is still necessary to do a specific microstructural and microchemical study of the sub-structures of the different
regions to explain some differences in the fusion line, root and weld pool zone caused by the multipass technique used.
This will help to explain the unlike behavior that may be met between these regions from the point of view of the
corrosion and weldability [6].
 Profile 1

Hardness (Hv)
Hardness Hv

Distance (mm)
Distance ( mm)
Distance (mm)
(a) (b)
Hardness (Hv)

Distance (mm) Hardness (Hv) (Hv)

Hardness
Distance (mm)

(c) (d)
Fig. 8. Microhardness Hv distribution in the line 1 (a), line 2 (b), line 3 (c) and line 4 (d) showed in Figure 3.
Figure 9 shows the macrography for the dissimilar welded joint after deposit of four preliminaries layers
(overlay) of inconel A52 with GTAW. No defects were detected in the visual inspection of the weld for any of the two
welding conditions used and showed in Table 4. Figure 10 shows, by one side the underbead Hardness Hv in the HAZ
in the as welded conditions, with 90 and 130 Amperes(samples 1 and 3 respectively), giving values between 400 and
500 Hv, this results denotes the small influence in the hardness of the welding current choices in this work; by other
side, the profile of Vickers micro hardness take under the beads in the HAZ, where the beads were deposited side by
side such as to produce a layer, welded with preheat from 150 to 200°C(samples 5 and 7), high values of the hardness
Vickers between 300 to 500 Hv are found, showing some small influence of the pre-heat used in the hardness.However
an apparently cyclical variation of the hardness showed would be related to some small thermal effect of one bead on
other one in the form as deposited, side by side. Figure 11 shows the profile of the micro hardness Hv taked under the
overlay (with four layers) in the HAZ of the ferritic steel welded using the temper weld technique without grinding with
pre-heat and interpass temperature between 150-200°C (condition 1). The beads in all the layers were deposited such as
one bead was deposited above 50% of the other one trying to obtain a heat treatment of one bead up the other.Values of
HV100 between 260 to 380 are presents in the growing grain size region of the HAZ of the ferritic steel using the
condition 1 as welding. Fig.12 show the profile of the Vickers hardness taked under the layers in the HAZ of the ferritic
steel welded with pre-heat and interpass temperature ranging from 200 to 250° C (condition 2); values of HV100 of the
same order of the condition 1 are obtained in the growing grain size region of the HAZ.

Fig. 9. Macrography of dissimilar welded joint overlay with four layers of inconel A52

Table 4. Welding overlay parameters

Overlay with preheat and Process Filler Electrode Current Voltage Travel speed
Interpass Temperature (°C) Metal size (mm) (A) (V) (mm/s)

Condition 1: 150 to 200 GTAW 52 1.2 90 – 130 10 – 15 1.8 – 3.0

Condition 2: 200 to 250 GTAW 52 1.2 90 – 130 10 – 15 1 – 1.5

 Profile Hv, sample 93
Amostra 93 A - Perfil LF
Profiles Hv, samples with only one layer
400

350

300
Micro Hardness (HV) Hv

Hardness Hv
250

Microdureza (HV)
200

150

As welded with 90 A Sample 1 100

As welded with 130 A Sample 3
One layer with 4 beads -90A
Sample 5 50
One layer with 4 beads – 130A
Sample 7
0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5
Distance (mm) Distância (mm)
Distance (mm)

Fig. 10 - Underbead Hv100 in the HAZ of the SA 508 – Fig. 11- Profile of Hv100 in the HAZof the SA 508 steel –
Welded without pre-heat (1,3); with pre-heat (5,7). welded with pre-heat at 150 to 200°C and temper bead
(condition 1)
Sample 23
Sample 23

Micro Hardness (HV) Hv

Micro Hardness (HV) Hv

Sample 4
Sample 2

Distance (mm)
Distance (mm)

Fig 12. Underlayer Hv100 in the HAZ of the 508 – with Fig.13. Underlayer Hv100, in the HAZ of the AISI 316L
pre-heat and interpass at 200 to 250°C and temper bead steel.(condition 1)
(Condition 2)

Figure 14 shows a distribution of Vickers hardness from the overlay to the HAZ of the ferritic steel welded
with pre-heat and interpass temperature ranging from 200 to 250°C (condition 2) and temper bead technique. There is a
variation of hardness between 230 to 320 from the fusion line of the overlay to the HAZ of the ferritic steel. The results
of the figures 11,12 and 14 for the HAZ of the ferritic steel, show that the temper bead technique as applied in this work
with the welding procedure specified for overlay is the main factor responsible for lower the hardness in the grain size
region of the HAZ; others factors such as current intensity and pre-heat and interpass temperature have a
complementary influence, in the limits of the conditions retained in this work. In fact, the temper bead technique is
performance such as annealed or tempered heat treatment on the HAZ of the ferritic steel in this case, changing and
giving appropriates microstructures to the great part of the HAZ; in particular the HAZ of the ferritic steel shows in
general a quenched and tempered microstructure.The Overlay welding procedures using pre - heat and interpass
temperature between 150 to 200°C and 200 to 250°C together to the temper bead technique allows in general the
attenuation of the hardness in the HAZ of the ferritic steel with values HV100<350. Values of HV100>350 are indicatives
of others weldability problems such as cold cracking, embrittlement and under cladding cracking in the structure [5].
The variation of microhardness inside each zone, is related too with the fine microstructure, second phase and
precipitates presents and it is matter of other study in course using, in particular, scanning electron microscope (SEM),
(EDS) and microprobe analysis [9].

Figure 13 showed the microhardness of the HAZ of the AISI 316L of the same magnitude, HV100= 200. Figure
15 shows the microstructure of the weld overlay (A52) deposited on the AISI 316 L. As can be observed, a fine
dendritic structure is related to the hardness Hv variation 220 to 250 HV100. In the experiences made, no defects, such as
the Ductility Dip Cracking (DDC) detected by others authors (7 – 8) were found.
 Perfil vertical da Amostra 25

350

300

Vickers Hv
250

Dureza (HV)
200
Fusion line
Final da solda

150

100
Overlay inconel A52 508

50

0
0 1 2 3 4 5 6 7 8 9
Distância (mm)
Distance

Fig. 14. Microhardness Vickers Hv distribution from the overlay to the HAZ of the 508 steel with 200°C to 250°C of
pre-heat and interpass temperature and temper bead technique (condition 2).

Fig. 15. Microstructure of the layers with Inconel A52 on the HAZ of the AISI 316L

As showed before, the different regions of the dissimilar welded joint and overlay, had similar properties with
the welding procedures used in this work. Others authors recommend to use the filler metal A52 with T< 350°F
(<178°C) as pre-heat and interpass temperature because of the oxidation at high temperature of some elements, like Al
presented in the weld metal of A52 (4 ). This study is coherente with this recommendation.
By the way, it is necessary to meet a compromise in order to obtain a satisfactory solution to the potential weldability
problems to the dissimilar welded joint and overlay, avoiding the martensite microstructure, obtaining satisfactory
microhardness in the HAZ of the ferritic steel and a satisfactory solution to the eventual weldability problems in the
fusion zone such as the oxidation of the layers in the overlay by other part. The layers used in this study don’t make use
of the grinding between each layer such as used in the temper technique by others authors (1); perhaps in order to
compare would be interesting to considere the grinding of the beads just to remove 50% before to deposit the next layer,
of course this solution will be more expensive. The welding procedure is in advanced in order to finish the qualification
of the weld overlay procedure in plates, with some experiences being realized with the temper bead technique at
ambient temperature. After, to simulate the welding in real conditions of components in the reactor making use of a
Mock up prepared for it. Follow the measure of the residual stresses in the inner part of the mock up will be done
looking for mitigation of the primary water stress corrosion cracking (PWSCC) problem, through the introduction of
compressive residual stresses in the inner part of the dissimilar welded joint.

Conclusion

The study update performed on the elaboration of the Dissimilar Metal Welding Procedure and Weld Overlay
for the junction of ferritic ASTM 508 class 3 with AISI 316 L stainless steel with Inconel A82 and A182 for welding
and Inconel A52 for overlay covering, allow to reach the following conclusions:

1. The methodology utilized to elaborate the dissimilar metal welding procedure specification and weld overlay of
dissimilar metal welded joint, showed appropriated for qualification and practical application. The results are coherent
with the best practice utilized by others authors.

2. The Dissimilar Welding Procedure elaborated for joining the dissimilar metals, allows obtaining a good compromise
between the microstructures and mechanical properties of the different zones and regions of the welded joint showing
good weldability.

3. For the overlay, it was possible to elaborate a dissimilar metal welding procedure specification trough the
consideration of a compromise taken in account the structural integrity of the welded joint, using pre-heat and interpass
temperature at 150°C to 250°C together to the temper bead technique without grinding, avoiding in particular the
quenched structures in the ferritic HAZ. The temper bead technique showed to be the main factor for to allow an
apropriate microstructure and mechanical properties in the growing grain size region of the HAZ. This way was
possible to obtain a good weldability of the different regions in the overlay joint.

4. The classical techniques optical metallography, microhardness and tensile test has been appropriates to check the
weldability and to elaborate a dissimilar metal welding procedure and overlay for the dissimilar joint used in the
nuclear industry

5. Further study will be necessary to be performed to explain some of the results. Among these studies the analysis of
the fine microstructure using, for example, the Scanning Electron Microscope (SEM) with EDS and microprobe
analysis. Another study will be the weldability of the dissimilar weld overlay with the temper bead technique at ambient
temperature. Other study would be concern the resistance to impact and fracture mechanics, tests in the weld and in the
dissimilar welded joint. Other study should be the study of the dissimilar metal welding and weld overlay with
differents welding processes and filler metals.

Acknowledgements
The authors would acknowledge FINEP and Eletronuclear for the funding to develop the research and Cnpq for
sponsoring the support to the students, Gabriela Marcia Ribeiro and Mariana Pessoa.

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