Schmidt + Clemens: Weld Repair Practices in High Temperature Materials

Metallurgical & Technical Developments
Schmidt + Clemens
Weld Repair Practices

in
High Temperature Materials
Metallurgical Services
Pedro Imízcoz
Table of Contents
•Metallurgical Background for Lack of Weldability
•Recovery Ductility Treatment
•Welding Procedures
•No recomendable repairs
•Failure/Causes for Weld Joints
•Case Studies
12th S+C Petrochemical Symposium

Table of Contents
•Case Studies

Metallurgical Background for Lack of Weldability

•Changes in the chemical composition:
•Due to the Process Gas (carburization)
•Due to the Combustion Gas (nitrification)
•Changes in the microstructure
•Ageing Phenomenon
•Secundary Carbides Precipitation
•Coarse grains, rounding and isolation of carbides
•Creep – Void formation

Nitridation

Carburization

•Changes in the microstructure:

Ageing Phenomenon
Secondary Carbides Precipitation

Ageing Phenomenon
Coarser grains
rounded and isolated carbides

Creep – Void Formation MACRO

CRACKS
MICRO
CRACKS
ORIENTED
ISOLATED VOIDS
VOIDS
Creep Strain
I II III
Exposure Time

Weld Material
Base Material
Decarburized
Micro old base & weld material Micro new base & weld material

Table of Contents
•Case Studies

Recovery Ductility Treatment
•Heat Treatment - Solution Annealed
•Secondary carbides redisolution
•Mechanical Treatment - Shot peening
•Grain recrystalization

•Changes in the microstrucutre
•Heat Treatment - Solution Annealed
Before After

•Mechanical Treatment - Shot peening
Before After
Especially for Static Casting fittings

Table of Contents
•Case Studies

Welding Procedure for Aged material
No
Solution Shot
Machining Dye Check
Defects Annealing Peening
Indications
RT
End NDT
OK Welding
Not Acceptable
RT HT HT
Buttering Buttering Welding

Welding Aged Material
1. Machining
Use Portable Cutting Tool
Preferable small Bevel angles (30º): Less Filler Material
OD: Remove ~0.5-mm (Roughness, Oxidation,
De-Carburization)
ID: Remove ~0.5-mm.
Ethylene Tubes:
Remove Carburized Layer max. 20%Wall
1.5%C Max. Content for Welding
3. Solution Annealing
Re-dissolve carbides improving ductility
a) Heating
Heat up at a rate of 150ºC/hour
Maintain during 1 hour / inch of wall thickness + 1h
b) Cooling with Forced Air (compressor)
4. Shot Peening
Stress Relief
Re-crystallization (mainly for static castings)
Apply over Bevels and adjacent Areas
Room Temperature Welding
a) Root Pass
Reformer (Manifolds & collectors):
GTAW (string beads)
Apply two GTAW passes when thickness > 3/4”
Ethylene: Use always SMAW with Ni-base Filler
b) Filler & Cover Pass:
SMAW: Small diameter coated electrode (2.4-mm)
Low Welding Amperage
High Welding Speed
Narrow Linear Beads
Narrow Multi-Linear Beads for Final Pass
Shot peening between passes
Room Temperature Buttering & Welding
1. R.T. Buttering:
100%SMAW Small diameter coated electrode (2.4-mm)
Low Welding Amperage
High Welding Speed
Narrow Linear Beads
Shot peening between passes
6-8 mm buttering for tubes
~19 mm buttering for thick static castings
2. Bevel Machining
3. Dye Penetrant Test
4. Room Temperature Welding
5. NDT: Dye Penetrant & Radiography
1. Machining 30° 2. Buttering 6-8 mm
0.5 mm
Old Material Old Material
0.5 mm 1 mm
50 mm
3. Machining 30° 4. Weld

Max. 5 mm
4-5 mm Old New

Old
1 mm
3 mm
High Temperature Buttering & RT Welding
1. H.T. Buttering
Heat up the piece to the following Temperature:
700ºC for CA 4859
900-1000ºC for CA 4852 / CA ET 45M
2. 100% SMAW. Coated electrode 4-mm diameter
Inter-pass temperature same as point 1
6-8 mm buttering for tubes
19 mm buttering for thick static castings
3. Bevel Machining
4. Dye Penetrant Test
5. Room Temperature Welding
High Temperature Welding
Apply when:
RT welding fails
Thick Static castings, Severe ageing
G/CA 4859 alloy with Nb/C > 8
1. Root Pass
SMAW coated electrode, 3.25 diameter
2. Heat the piece up to Process Temperature:
700ºC for CA 4859
900-1000ºC for CA 4852 / CA ET 45M
3. Welding Process:
SMAW coated electrode, 3.25 or 4 mm diameter
Inter-pass temperature same as point 2
4. Controlled low cooling rate to 200ºC. Then free cooling.
High Temperature Welding
Ductility increase with Temperature
50 G4859
Elongation (%)
G4852
15
0 500 1000
Temperature (°C)
G/CA 4852 = 25Cr/35Ni Nb (HP40)

G/CA 4859 = 20Cr/32Ni (800 H cast)
Filler Material Selection
Service Temperatures:
Max.535ºC Max. 785ºC Max1100ºC
SMAW Inco 182 Inco-weld A Inco 112/117
GTAW Inco 82 Inco 82 Inco 625/617
Advantages:
Increases hot crack resistance
High Ductility
Low tendency to embrittlement
Special care with Inco 112 & 625 between 600 - 800ºC
Disadvantages:
Should not be used above 785ºC in Sulphur atmospheres
Lower Creep Resistance than matching fillers
General Advise
Most of the cases:
Solution annealing + shot peening + welding at R.T
In case solution annealing is not possible:
Shot peening + buttering + welding at R.T
Always solution annealing after cutting (never before)
Avoid using abrasive grinding & flap wheels,
use carbide tools (vidia)
Static cast materials are much more difficult to repair
than centricast
For thick static cast materials apply
aggressive peening & ¾” buttering
Ni-Base Fillers Materials
Table of Contents
•Case Studies

No recommendable repairs
•Bulging from creep damage.
•Excessive diametral expansion
•Heavy carburization
•Thermal fatigue cracks

•Bulging from creep damage :

> 3% for HK
> 6% for HP
> 10% for 20.32Nb

•Excessive Diametral expansion :

> 3% for HK
> 6% for HP
> 10% for 20.32Nb

•Heavy Carburization :
Inside carburization >1/2 wall thickness
C >1.5 %in I.D. to be welded Max 3.5% C
Carbon Profile
4
Carbon content (mass %)
3,5
2,5
1,5
0,5
0
0 1 2 3 4 5 6
ID
Depth from ID (mm)
Max 1.5% C

No recomendable repairs
Thermal fatigue cracks :
Affecting wide areas

Table of Contents
•Typical Failures on Weld Joints
•Case Studies

Typical Failures on Weld Joints
•Inadecuate diffusion
•Thermal/Mechanical Fatigue
•Creep
•Unproper filler material selection

Typical Failures on Weld Joints :
Inadecuate diffusion
•Specially on some welding methods
•Difficult to detect by NDT

Thermal/Mechanical Fatigue
•Focusly on the HAZ
•Pieces with high Thickness

Unproper filler material selection

•High Corrosion Rate
•Brittle Failure

Table of Contents
•Typical Failures on Weld Joints
•Case Studies

Case History I: Welding Carburized Material
Repair Welding Failure Succesful Welding

2. 100% GTAW Repair
2. Shot Peening
3. 100% SMAW Ni base

Case History II: Old Cone to New Tee (12 manifolds)

Case History III: Replacement of Manifold in

Reformer Harp: Weld New Manifold to 17 Years Old
Tubes
Weld repair of H.A.Z. in manifold, Kellogg harp


Tubes
Weld repair of H.A.Z. in manifold, Kellogg harp

Tubes
Weld repair of H.A.Z. in manifold, Kellogg Harp


Tubes


Tubes

THANK YOU VERY MUCH

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What are some of the metallurgical factors that can affect weldability?

What are some of the metallurgical factors that can affect weldability?

What are some typical failures that can occur in weld joints?

What are some typical failures that can occur in weld joints?

Metallurgical & Technical Developments

Weld Repair Practices

•Metallurgical Background for Lack of Weldability

•Recovery Ductility Treatment

•No recomendable repairs

•Failure/Causes for Weld Joints

12th S+C Petrochemical Symposium

•Metallurgical Background for Lack of Weldability

•Recovery Ductility Treatment

•No recomendable repairs

•Failure/Causes for Weld Joints

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Due to the Process Gas (carburization)

•Due to the Combustion Gas (nitrification)

•Changes in the microstructure

•Secundary Carbides Precipitation

•Coarse grains, rounding and isolation of carbides

•Creep – Void formation

Metallurgical Background for Lack of Weldability

•Changes in the chemical composition:

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Changes in the chemical composition:

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Changes in the microstructure:

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Changes in the microstructure:

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Changes in the microstructure:

Creep – Void Formation MACRO

12th S+C Petrochemical Symposium

Metallurgical Background for Lack of Weldability

•Changes in the microstructure:

12th S+C Petrochemical Symposium

•Metallurgical Background for Lack of Weldability

•Recovery Ductility Treatment

•No recomendable repairs

•Failure/Causes for Weld Joints

12th S+C Petrochemical Symposium

Recovery Ductility Treatment

•Changes in the microstructure

•Heat Treatment - Solution Annealed

•Secondary carbides redisolution

•Mechanical Treatment - Shot peening

12th S+C Petrochemical Symposium

Recovery Ductility Treatment

•Changes in the microstrucutre

•Heat Treatment - Solution Annealed

12th S+C Petrochemical Symposium

Recovery Ductility Treatment

•Changes in the microstructure