Experienced filler metals for

increasing power plant efficiency

V. Gross
Metallurgist, Application Technology
Hamm, Germany
TEHRAN Conference, March.2009
 Assembly of T24 Panels to a Fluidized Bed Boiler

TEHRAN Conference, March.2009

 Dickwandige Anschlußstutzen einer Frischdampfleitung aus P 91

H 010926ppt
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 One of the first steam collectors for steam power stations (P91)
fabricatet in USA in the early 1990`s
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 Features of heat resisting steels

• Resistance to creep
• Strength
• Resistance to oxidation
• Weldability !!!!!!!!!!

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 Di = 300
design pressure p = 191 bar P22, e = 103
P23, e =
design temperature T = 545°C P24, e =
61

P22, e = 155
P91, e =
55

P91, e = 67
P24, e = 83
P23, e = 91
header pipe Di = 800 mm
45
nozzle Di = 600 mm

Di = 450

H_0308
Wall thickness comparison for P22, P23, P24 and P91;

06
calculation for T-joint according to EN 13480-3
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 Waterwall tubes: T24

Tubes: T24, T92,

VM12-SHC

Steamlines
and collector: P92

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 Typical material selection

piping Eco1+2 collector

Rohre Sammler
15NiCuMoNb5-6-4
16Mo3
ZÜ1 16Mo3 (in)
13CrMo4-5
P92 (aus)
7CrMoVTiB10-10
ÜH3 P92 (in)
X20CrMoV11-1 P92 (aus)
VM 12
ZÜ2 P92 (in)
HR3C (Austenit) P92 (aus)

ÜH4 P92 (in)

P92 (aus)
ÜH2 P92 (aus)

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 pwht Av [J]
C Mn Cr Mo Ni Nb V W
GW [°C / h] * at + 20°C

16Mo3 0,16 0,60 --- 0,30 --- --- --- --- --- 180

13CrMo4-5 0,14 0,60 0,85 0,45 --- --- --- --- 690 / 2 140

15MoV5-10 0,06 1,7 1,10 1,0 --- --- 0,28 --- 720 / 2 150

14MoV6-3 0,05 1,1 0,4 0,9 --- --- 0,5 --- 700 /≥ 2 150

10CrMo9-10 0,07 0,70 2,2 0,9 --- --- --- --- 690 /≥ 2 180

X20CrMoV12-1 0,18 0,5 11,5 1,0 0,6 --- 0,3 0,5 760 / 4 40
X10CrMoVNb9-1
0,090 0,65 9,0 1,1 0,80 0,05 0,20 --- 760 / 2 50
(P91)
X11CrMoWVNb9-1-1
0,09 0,57 8,85 0,92 0,83 0,047 0,21 1,01 760 /≥ 2 50
(E911)
X10CrMoWVNb9-2
0,098 0,66 9,23 0,53 0,66 0,037 0,20 1,62 760 /≥ 2 40
(P92)
X3CrNiMoN17-13 0,15 3,6 16 --- 13 1,5 --- --- --- 50
* Holding time depending on wall thickness

Characteristic chemistry of steels and weld deposits

TEHRAN Conference, March.2009
TEHRAN Conference, March.2009
 25

Gewichtszunahme (mg/cm )
2
20 650°C

15

10
2
0,24 mg/cm
T/P92
5
VM12
0
0 1000 2000 3000 4000
Zeit (h)

Oxidation in watersteam of VM12 bei 650 °C compared to

T/P92 (ref. ALSTOM)

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 105h Creep rupture strength 300

250
T/P91
T/P24
200
T/P23
T/P22
[MPa]

150

100

50

0
500 510 520 530 540 550 560 570 580 590 600
Temperature [°C]
105 h- creep rupture values
of T/P22, T/P23 and T/P24 and T/P91 depending on temperature
TEHRAN Conference, March.2009
 Behaviour of C in - thermal expan.
ferritic micro structure - thermal conductiv.
- diffusion coeff.
Tendency to carbide formation - solubility for C
- carbide formation

effect of stable carbides

•less risk of CH4-formation > petrochemical hydrotreating reactors
•Applcation in the creep range > power plant equipment
13
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 Chemical composition of various weld metals [wt-%]

C Si Mn Cr Ni Mo V W Nb N B
GTAW 0,08 0,27 0,54 2,14 0,04 0,08 0,21 1,58 0,031 0,011 0,002
SMAW 0,06 0,22 0,46 2,28 0,12 0,02 0,28 1,72 0,043 0,017 0,002
SAW 0,05 0,27 0,94 2,04 0,09 0,11 0,19 1,61 0,043 0,007 <0,001

Mechanical properties of weld metal

Test
PWHT YS TS Elongation CVN, ISO-V Hardness
Welding process temperature
[°C/h] [MPa] [MPa] [%] [J] [HV10]
+ [°C]

GTAW --- 20 639 818 21,4 228 230 268 270

Union I P23 740/2 20 520 620 20,2 261 286 299 250
Ø: 2,4 mm 740/2 550 426 449 17,4 --- ---

128 136 140

SMAW 740/2 20 509 625 19 227
156 156 160
Thermanit P23 740/15 20 421 553 25 192
---
Ø: 4,0 mm 740/15 550 302 350 26,4 ---

SAW
Union S P23
740/2 20 615 702 18,1 187 204 208 237
flux: UV 430 TTR-W
wire-Ø: 4,0 mm

Chemical composition and mechanical properties of matching filler

metals for T/P23; all weld metal for various welding processes
TEHRAN Conference, March.2009
 Chemical composition of various weld metals [wt-%]
C Si Mn Cr Mo V Ti Nb N B
wire 0,061 0,24 0,53 2,39 1,01 0,24 0,073 0,008 0,016 0,0037
GTAW 0,061 0,23 0,49 2,29 1,00 0,24 0,034 0,007 0,014 0,0020
SMAW 0,09 0,27 0,54 2,53 1,03 0,22 0,046 0,013 0,003
SAW 0,050 0,20 0,72 2,26 0,98 0,22 0,015 0,007 0,009 0,0010

Mechanical properties of weld metal

Test
PWHT YS TS Elongation CVN, ISO-V Hardness
Welding process temperature
[°C/h] [MPa] [MPa] [%] [J] [HV10]
+ [°C]

GTAW --- 20 664 803 19,1 298 298 298 322

Union I P24 --- 600 457 561 18,6 --- ---
Ø: 2,4 mm 740/2 20 595 699 20,3 264 280 292 230

SMAW
Thermanit P24 740/2 20 577 689 18,1 154 152 148 233
Ø: 4,0 mm

SAW
Union S P24
740/2 20 495 600 23,8 260 267 282 206
flux: UV 430 TTR-W
wire-Ø: 4,0 mm

Chemical composition of matching T/P24 weld metal

as well as mechanical properties of the GTA-, SMA- and SA-weld metal
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 Union S P 24 / UV 305

Wire-Ø: 2mm
Welding parameter:
450-500 Amps
29,5 Volt
1,1-1,3 m/min
a-mass:2x1,3x6mm
penetration:min. 6mm-0,3x6

Waterwall: T 24 tube (Ø 38x6,3mm), T24 strip (6mm)

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 pass/cap pass technique: SAW
wire-Ø: 4 mm Is = 470 A / 530 A (DC+)
T24 T24 Us = 31 V; V s = 110 cm/min.
Flux: UV 305

Wire Speci- New HT of Tensile Test (transverse) Side bend test CVN
men strips before TS Location (ISO-V)
Union No. welding MPa of fracture J at RT

S CrMoVTiB 21UR - 843 BM 180° no defects 13/14/14

1000°C/10 min.
21UU + 781 BM 180° no defects 16/11/13
760°C/30 min.

S 1 CrMo 2 21UV - 716 BM 180° no defects 20/23/20

Hardness max. 351 HV10

Creep rupture test at 550 °C: stress 175 MPa ⇒ actual testing time > 1704 h
stress 160 MPa ⇒ actual testing time > 1512 h

Ongoing creep rupture test of T24-SAW weldments with T24-strips

TEHRAN Conference, March.2009
 Ac1b – transition temperature, weld metal

AC1b
C Si Mn Cr Ni Mo V W Nb N
[°C]
Thermanit
0,09 0,20 0,57 8,85 0,83 0,92 0,21 1,01 0,047 0,054 780
MTS 911
Thermanit
0,10 0,22 0,63 9,05 0,69 0,53 0,19 1,52 0,040 0,057 800
MTS 616

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 Thermanit MTS 616

Wire- ø: 3,2 mm, 380-420 Amps., 28 Volts, v: 50 cm/min, TP : 250°C, Ti : 300°C

Chemical composition (wt-%); all weld metal
C Si Mn Cr Ni Mo V W Nb N
0,09 0,36 0,60 8,45 0,73 0,41 0,17 1,59 0,034 0,059

Mechanical properties, a) all weld metal

Test Elongation CVN
PWHT YS TS
temperature A5 ISO-V
[°C/h] [MPa] [MPa]
+ [°C] [%] [J]
760/2 20 678 789 19,8 35
760/4 20 621 742 20,8 53

b) girth weld; pipe P 92, pipe- ø: 300 mm, wall thickness: 40 mm

Test Elongation Location CVN
PWHT TS Hardness
temperature A5 of ISO-V
[°C/h] [MPa] [HV10]
+ [°C] [%] fracture [J]
760/2 20 674 16,5 BM 92 238 - 250
760/4 20 678 15 BM 89 234 - 249
760/4 600 355 18 BM --- ---

Mechanical properties of SA-weld metal

Thermanit MTS 616 / Marathon 543 and a girth weld at P92-pipe

TEHRAN Conference, March.2009

 265

fusion line
fusion line
255 SMAW-vertical
245 70 MPa, 650°C, 4295 h
Hardness [HV 10]

fracture face
235
225
215
205
195
185
175 Base metal HAZ Weld metal HAZ
165
0 10 20 30 40 50 60 70 80 90
Length of specimen [mm]
Hardness profiles of creep samples;
welded joint (P92 / Thermanit MTS 616)

TEHRAN Conference, March.2009

 Thermanit MTS 616 (P92 filler metal)

1000

600°C
Stress (MPa)

100

LBH
UP
T/P92_Eval. 2004
+/- 20%

10
10 100 1000 10000 100000
Time (h)

Creep Tests on T/P92 Welds at 600°C

TEHRAN Conference, March.2009
 1000

+ 0

800 760°C - 10
Temperature [°C]

2-4h
Heating rate Cooling rate
600 80 - 120°C/h 100 - 150°C/h

400 slow
250 - 300°C cooling rate
< 400°C
200 cooling in still air
·
20 - 100°C
· ·
0 necessary cooling down after welding or soaking
0 0,5 1 welding
preheating 1,5 2 2,5 3 3,5
and 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 9,51010,51111,51212,51313,5
soaking
Time

Heat control during welding and PWHT- condition for P92

TEHRAN Conference, March.2009

 All weld metal chemistry (matching VM 12)

C Mn Cr Ni Mo V W Nb N Co B
GTAW
Thermanit 0,17 0,43 11,67 0,40 0,03 0,22 1,44 0,060 0,044 1,64 0,003
MTS 5 CoT
Covered elect.
Thermanit
0,134 0,66 11,28 0,79 0,33 0,24 1,48 0,068 0,052 1,59 0,003
MTS 5 CoT
Ø 4,0 mm

TEHRAN Conference, March.2009

 Mechanical testing: all weld metal and VM12 joint

a) All weld metal at RT

Process pwht Rp0,2 Rm A5 Av (ISO-V) Hardn.
(°C / h) (MPa) (MPa) (%) (J) HV10
GTAW
770 / 2 684 822 18,5 38 / 43 / 47 297
Thermanit MTS 5 CoT
electrode
Thermanit MTS 5 CoT 770 / 2 689 832 17,2 41 / 42 / 48 281
Ø 4,0 mm

b) Joint, pipe Ø 140 mm; wall thickness 10 mm

pwht Rm fracture Av (ISO-V) hardness
Process
(°C / h) (MPa) location (J) HV10
GTAW
770 / 0,5 745 GW 37 / 38 / 40 max. 351
Thermanit MTS 5 CoT
electrode
Thermanit MTS 5 CoT 770 / 2 728 GW 47 / 51 / 51 max. 297
Ø 4,0 mm
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 Matching Filler Metal for
Super 304 H
SMAW: Thermanit 304 H Cu

Chemical composition all weld metal; El-Ø 3,2 mm

C Si Mn P S Cr Mo Ni Cu Nb N B
0,087 0,32 3,34 0,010 0,005 17,69 0,90 16,34 2,91 0,38 0,209 ---

Mechanical properties all weld metal

Test temp. YS TS Elongation R. o. A. CVN (ISO-V)
[°C] [MPa] [MPa] [%] [%] [J]
RT min. 235 590 - 850 min. 35 min. 85
+650 min. 135
RT 541 711 30,1 55,1 88 88 90
+650 350 464 25,0 39,3
Ongoing test: Altering; MVT-test
Optimizing Analysis (Nb ↑), Coating stability

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 CVN [J] CVN [ft-lb]
80 60

70
50
60
40
50

40 30

30
20
20
10
10

0 0
. . . . .

Toughness at + 20°C in relation to the weld build –up

(SMAW – all weld metal for P91)
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 Different bead formation in SMA welds;
Phoenix SH Chromo 2 KS, Ø 4,0 mm, 3G up
toughness
low high

thick beads thin, weaved beads

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 PWHT: 760°C

70
Impact energy at rt [J]

60

50 28 kJ/cm
Ø 4,0 mm; Pos. 3G up
40

30

20

10

0
12 kJ/cm
1 2 3 4 5 6 7
Ø 4,0 mm; Pos. 3G up
Holding time [h]

SMAW for P91 Thermanit Chromo 9 V,iInfluence of weld build-up on toughness

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 SMAW: Thermanit MTS 616; ø: 4,0 mm
70

60
PWHT: 760°C

50
PWHT: 750°C
CVN [J]

40

30 PWHT: 740°C

20

10

0
1 2 3 4 5 6 7

Holding time [h]

Influence of the PWHT-condition

to the toughness of the all weld metal for P92
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 Temp. range of pwht equipment

•record by thermocouple in the furnace: 705°C

•actual: 740 -760°C

!!!! thermocouple to be attached to the coupon !!!!

770

765 Kanal 1
Kanal 2
Kanal 3
Kanal 4
Kanal 5
760
-low cost for equipment
Kanal 6
Kanal 7
Kanal 8
Temperatur in °C

Kanal 9
755 Kanal 10

-far cheaper than repeat test

Kanal 11
Kanal 12
Kanal 13
750 Kanal 14
Kanal 15
Kanal 16
Kanal 17 -online control on PC possible
745 Kanal 18
Kanal 19
Kanal 20

740
Kanal 21
Kanal 22
Kanal 23
LESS RISKS
Kanal 24
Kanal 25
Kanal 27
735

730
14,0 14,2 14,4 14,6 14,8 15,0 15,2 15,4 15,6 15,8 16,0
Zeit in Stunden

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 Overheating issue
• Reason:
– Interpass temp. (recom. max 230°C) was measured on top side.
– loss in temp. from actual weld location to top side not considered

Temp. ~230°C

Close to top/bottom
Temp. gradient!
2 dimensional heat
~400°C flow has to be
considered

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 Schematic range of welding parameters
(e.g. amperage, preheating, interpass temp., pwht)

X20
QA-system + martensitic
martensitic
Controls P91 / P92
to be developped
ccordingly bainitic
bainitic
CrMo steel / Ni-steel

Perlite
Perlite
Low alloy steel

C-steel

- optimum
parameters +
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