15. - 17. 5.

2013, Brno, Czech Republic, EU

EFFECT OF WELDING ON THE PROPERTIES OF HR3C, SUPER 304H, TP347HFG AND P92 STEELS Luk POMIKLEK, rka HERMANOV, Lenka DOBROVODSK
VTKOVICE POWER ENGINEERING a.s., Rusk 24/83, Ostrava Vtkovice, Czech Republic, lukas.pomikalek@vitkovice.cz, sarka.hermanova@vitkovice.cz, lenka.dobrovodska@vitkovice.cz

Abstract The project MPO FR - TI3/458 "Material solutions for industrial equipment working with ultra-preheated steam", the assessment and prediction of long-term durability of heterogeneous and homogeneous welded joints selected materials that can be used for heat exchange surface superheaters and reheaters newly built or refurbished power plant boilers and the acquisition of detailed and reliable information, especially about their behavior during long-term operation. In the first stage, it was necessary to make the determination and optimization of automatic welding processes (welding parameters and thermal regime during welding - preheating temperature, interpass, postheating) and subsequent heat treatment after welding. In addition, it was necessary to obtain information on the properties and behavior of the short-term tests of welds in the qualifications (WPQR) according to EN 15614-1. The results of these tests in relation to the heat treatment are the subject of the following presentation. Long-term corrosion and creep tests are currently underway. Their results, therefore, not included in this presentation. Examined heterogeneous and homogeneous Weld joints are martensitic material P92 and austenitic materials HR3C, Super 304H and Tp347HFG. Keywords: welding, heat treatment, austenitic steels, heterogeneous joints, homogeneous joints. 1 INTRODUCTION

Efforts to increase the efficiency of thermal power stations, which is the function of temperature and pressure, logically leads to the research of new materials which have to withstand the required temperatures and operating environment for long periods. This applies particularly to supercritical or ultracritical boilers, where the pressure of superheated steam at critical boiler spots (superheater and reheater) exceeds 25 MPa and its temperature can achieve values of 600-700 C. Corrosive environment on the flue gas part is given by use of coal from a concrete area of mining and is therefore specific. The subject of the project of the Ministry of Industry and Trade FR - TI3/458 "Material design for industrial equipment operating with ultra superheated steam", is to assess and predict long-term durability of heterogeneous and homogeneous weld joints of selected materials that can be used in the parts of newly built or refurbished power plant boilers and to obtain detailed and especially reliable information about their behaviour during long-term operation. To be able to accomplish this, it is first necessary to make quality weld joints including heat treatment and to ensure repeatability for the needs of production of test pieces for subsequent corrosion and creep tests. Therefore, it was necessary to obtain information on the properties and behaviour of welds in short-term tests within the qualifications (WPQR) according to SN EN 15614 -1. The results of these tests in relation to the heat treatment, or respectively without heat treatment, are the main subject-matter of this article.

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MATERIALS

As revealed by the Research of expert literature existing on the topic , which was prepared by Ing. rka Hermanov, drawing from [1], [2], [3], [4], [5], [6], [7], the above nodes are e xecuted especially with Super 304H, Tp347HFG and HR3C materials with austenitic structure. The material P92 (martensitic structure) is used as the nozzle of chambers or as an intermediate piece in conjunction with these materials. Given the planned scope of testing, the selected size of pipes was 38 x 6.3 mm. Therefore, the above materials selected for verification of welding in VPE and subsequently for further study. There are currently ongoing long-term corrosion and creep tests, so the results are not listed here. Below is the basic information about the tested steels. None of these three austenitic materials is currently included within EN. However, they are accompanies by German data sheets [14], [15], [16], which state also their inclusion in the material groups according to CR ISO 15608:2000, and the group 8.1 (Super 304H) and 8.2 (Tp347HFG, HR3C). Tab. 1 Chemical composition of materials Tp347HFG, Super 304H and HR3C in % by weight. According VdTV WB Tp 347HFG Super 304H HR3C C Si Mn P S Cr Ni 9.0 13.0 7.510.5 17.023.0 B 0.0010.010 Cu 2.50 3.50 Nb 8x C Al other -

0.06- max max max max 17.00.10 0.75 2.00 0.040 0.030 20.0 0.07- max max max max 17.00.13 0.30 1.00 0.040 0.010 19.0 max 0.10 max max max max 23.01.50 2.00 0.030 0.030 27.0

0.30- 0.003N 0.05-0.12 0.60 0.030 0.200.60 N 0.15-0.35

Tab. 2 Chemical compoistion of P92 materials in % by weight According EN 10216C Si Mn P S Cr Ni B Mo Nb Al N V W 2 0.07- max 0.30- max max 8.50- max 0.001- 0.30- 0.04- max 0.030- 0.15- 1.50P92 0.13 0.50 0.60 0.020 0.010 9.50 0.40 0.006 0.60 0.09 0.040 0.070 0.25 2.00 Tab. 3 Mechanical values for selected materials according to WB or respectively according to EN Yield Yield strength at Breaking Elongation Impact strength elevated Name of dimension strength A energy KV Rp0.2 temperature [MPa] [%] [J] [MPa] Rp0.2 [MPa] testing temperature [C] 20 20 650 20 20 HR3C Super 304H Tp347HFG P92 295 235 205 440 655-900 590-850 550-750 620-850 180 135 126 248* 30 35 35 19 85 85 85 40

*) Valid for temperature of 600 C The available literature was used as a source of information about the behaviour of these materials and they were assessed in terms of their mechanical properties, creep, corrosion resistance on both the flue gas part and the steam part (which is not subject to further monitoring) and microstructure. [8], [9], [10], [11], [12], [13], [14], [15], [16]. It should be noted that there is relatively enough information on the properties of these steels and straight pipes (see, e.g., the above-mentioned literature, etc.). On the other hand, we can not obtain source literature for effects of welding (or the influence of other technological operations) on the properties of these new steels and weld joint itself. If there is such information, then it is only a summary and comparison of results of

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creep or corrosion in welds and base material, without more detailed information on the welding process and vice versa. 3 THEORY OF WELDING AND HEAT TREATMENT

Since these are modified austenitic materials, welding must be performed paying attention mainly to the cracking in hot, i.e. the thermal input. The main source of information for welding of these steels document of the Japanese company Sumitomo [11], [12], [13], which mentions not only the recommended filler metals and welding parameters, but also photos of welded joints and the results, such as the structure, hardness progress curves and results of creep tests of the welded joints. The results obtained at the end of this project will be compared with the above values. Information, or in some cases the requirements for heat treatment (HT) after welding, can also be obtained from the German material sheets [14], [15], [16]. In austenitic materials that information is not completely congruent, which is why the project verifies corrosion properties of welds after HT and without HT. After welding, according to literature, homogeneous welds and welds between austenitic materials do no longer have to be heat treated. Solution annealing must necessarily be included only in cases of the use of materials in corrosive environment containing chlorine. Solution annealing is done by inserting the product in a heated furnace or by the fastest possible heat-up, holding time of 1 min per one mm of thickness after the temperature of the surface is achieved and rapid cooling in water. Rapid cooling is included for the reason of the fastest possible crossing of the critical temperature values, where there would be a risk of embrittlement of steel, while slow cooling would prolong the holding time at the temperature, which could lead to grain coarsening. The temperature of heat treatment after welding must be slightly lower than the final solution annealing performed by the manufacturer, which is indicated in the certification. The literature does not listed the scheme for heterogeneous joint between HR3C and Super 304H respectively between HR3C and Tp347HFG. Therefore, HT within this work was performed according to both temperature values and optimum thermal scheme was subsequently chosen based on the results of mechanical properties. This scheme was then used for processing joints intended for connections for corrosion and creep tests. 4 WELDING AND HEAT TREATMENT

Welding method: The pipe butt joints are executed in the root layer using 141 method (GTAW respectively TIG) using non-fusing electrode in a protective atmosphere of inert gas (argon) in the field of power engineering. Other (filler) layers, in the case of materials with thicker wall, are performed with coated electrode 111 (SMAW, respectively MMA). Here, due to the "small" wall thickness, the weld joint was made applying method, that is 141. Technology and welding position: In order to ensure repeatability of weld joints and to minimize the impact of the human factor, priority was given to automated welding technology on the Polysoude company devices. This is called orbital welding, where both jointed ends of the tubes are approximated and centred in horizontal position and do not move during welding. Welding head moves along a circle (orbit) around the tube and executes the weld. The number of layers was set at three. The orbital welding technology thus involves all welding positions, whereas the welding parameters in individual sectors (sections, positions) gradually change according to pre-tested and pre-programmed setting. Input heat for individual connections and the layers was in the range from 1100 to 1900 J/mm excluding the efficacy of the method. Filler metals: The existing equipment of the Polysoude machine for orbital welding allows welding with a wire diameter of only 0.8 mm and a wound on an "infinite" coil (i.e., as for the method 135 GMAW, respectively MAG). After the analysis of the issue and in consultation with the supplier, we decided for welding wires from the company BHLER UDDEHOLM in the following grades and denominations: Thermanit 304HCu for homogeneous weld joints of steel Super 304H

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(According to EN ISO 14343-A: WZ 18 16 1 CuH; according to AWS A5.9-96: ER304HCu (mod.) Thermanit 617 (or resp. UTP A 6170 Co) for other homogeneous and heterogeneous joints (according to EN ISO 18274: S Ni 6617 (NiCr22Co12Mo9); according to AWS A5.14-05: ERNiCrCoMo-1; Wr.-Nr. 2.4627) Tab. 4 Chemical composition of filler materials in wt. % based on catalogues FM C Si Mn 3.2 0.1 Cu 3.0 Mo 0.8 9.0 8.5 Cr Ni Ti 0.5 0.4 Fe 1.0 1.0 Nb 0.4 Al 1.0 1.0 N 0.2 Co 11.0 11.5

Thermanit 304 HCu 0.10 0.4 Thermanit 617 UTP A6170 Co 0.05 0.1 0.06 0.3

18.0 16.0 21.5 rest 22.0 rest

Tab. 5 Average mechanical values of filler materials according to catalogues Name of dimension Thermanit 304 HCu Thermanit 617 UTP A 6170 Co Yield strength Rp0.2 [MPa] >350 >450 (Rp1.0) >450 Tensile Elongation A strength Rm [%] [MPa] >590 >700 >720 >30 >30 >30 Impact energy KV [J] >60 >60 >120

Welded combinations: A total of 14 combinations of welded joints was executed - see table 6. Tab. 6 Executed welded joints Ord. No. 1 2 3 4 5 6 7 1 material S 304H S 304H S 304H S 304H S 304H HR3C HR3C
st

2 material HR3C HR3C HR3C S 304H S 304H HR3C HR3C

nd

Filler metals

HT temper ature 1130C 1230C

Ord. No. 8 9 10 11 12

1 material

st

2 material

nd

Filler metals Thm 617 Thm 617 A 6170Co A 6170Co A 6170Co A 6170Co A 6170Co

HT temper ature 750C 750C 1170C

Thm 617 Thm 617 Thm 617

HR3C S 304H Tp347HFG Tp347HFG Tp347HFG Tp347HFG Tp347HFG

P92 P92 Tp347HFG Tp347HFG HR3C HR3C P92

Thm 304HCu 1130C Thm 304HCu Thm 617 Thm 617 1230C

1170C

13 14

750C

Heat processing: Homogeneous and heterogeneous welded joints of austenitic steels after welding were subjected to solution annealing with a holding time of 15 minutes at the temperature specified in the table, followed by cooling in water. Subsequently, the same weld joints were executed without heat treatment. Heterogeneous welded joints with P92 material must be subjected to post-weld heat treatment (PWHT) to the temperature indicated in the table with a longer holding time and subsequent controlled cooling. The aim of the performed tests of the same joints of austenitic materials with solution annealing and without HT was to examine the differences in the properties without HT and with HT. These differences will be monitored also in creep and corrosion tests.

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RESULTS

Due to the extensive range of the data obtained and the limited space for this publication, the below results are only verbally summarized. Hardness measurement: Measurement of hardness throughout the welded joints shows uniformity, but in some areas there are isolated peaks. Heat treatment resulted in an even more uniform hardness. All measured values were satisfactory both in design without HT and with HT. Heat treatment had no significant effect on the hardness of the welded joint. Impact test: The values of impact energy are generally increased after heat treatment. A small degrease was observed only in the homogeneous joint of Super 304H depending on specimen location in the weld (in the PA and PE welding position). The highest values occurred in the welded metal in the sampling area group marked as PE. In HAZ areas the values were significantly increased compared to the weld metal. Tensile test: The test specimens were ruptured in the weld joint or in base materials. Always, however, the measured values were higher than the required minimum value for a given combination of materials. Effect of HT is minimal (there was a slight decrease in tensile strength). The results of the tensile tests are indicative only for all these weldments (though a necessary condition for issuance of WPQR). Tested steels belong to a group of heat-resistant steels, i.e. steels operating at high temperatures. For these steels the important value is the creep rupture strength (RmT), which is determined by creep tests. Macrostructure: The macrostructure of all welded joints is satisfactory in terms of integrity and quality of the weld. Microstructure: the individual metallographic reports described the microstructures (from base materials: austenite respectively martensite, across the welded joint: Nb and Ti carbides excluded inside as well as around grain boundaries, -ferrite in the wed metal and HAZ). Microstructure was etched with etchant ell. H2CrO4. Determination of grain size and -ferrite content in the weld metal and the heat-affected zone was not required within the qualifications. Therefore, the determination of -ferrite content in accordance with ASTM E 562 using LECO IA 32 analyzer including grain size is gradually ensured. The heat treatment increases the grain size in the overheating zone, especially in the material Super 304H. It is obvious from the macrostructure (figure 1). Determination of the causes of the grain growth is subject to current investigation. Theoretical assumptions, however, suggest that this grain growth should not have a negative effect on creep. The effect on corrosion, however, is another issue. The effect of HT on the above phenomena will be subject to further testing.

Fig. 1 Homogeneous weld joint Super 304H after HT 6 CONCLUSION

The above results prove that the welds were produced in the quality required by SN EN ISO 15614-1 standard and supplementary regulations (AD2000 Merkblatt HP2/1 and PED directive (97/23/EC)). The tests have shown that the processes of welding and heat treatment cause structural changes (hardening phase precipitation and coarsening of grains in the overheating zone), but changes in the mechanical properties are not significant.

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However, these results can not in any case provide enough information to predict creep-resistance, or corrosion resistance (on the flue gas part) of specific examined welds in various corrosive environments, either the heat treatment with or without it (austenitic materials). This is subject to further a long-term research within the above project, and the results will be interpretable only for reproduction of these specific combinations of basic and filler materials, welding or heat treatment method. ACKNOWLEDGMENT This project was supported by the Ministry of Industry and Trade of the Czech Republic within the framework of a research and development (program TIP3). BIBLIOGRAPHY
[1] HUSEMANN, R. U. Advanced (700C) PF power plant: A clean european technology. Babcock-Hitachi EUROPE, October 2005, p. 20. ISEDA, A., OKADA, H., SEMBA, H., IGARASHI, M. Long term creep properties and microstructure of Super304H, TP347HFG a HR3C for A-USC boilers. Energy Materials: Materials Science and Engineering for Energy Systems. December 2007, 9. 199-206, ISSN 1748-9237. OKADA, H., IGARASHI, M. Long-Term Service Experience With Advanced Austenitic Alloys in Eddystone Power Station. Volume 9: Eighth International Conference on Creep and Fatigue at Elevated Temperatures. Creep 2007-26561, p. 181-188, ISBN 0-7918-4287-8. VISWANATHAN, R., BAKKER, W. Materials for Ultrasupercritical Coal Power Plants Boiler Materials: Part 1. July 2000, p. 81-95. VISWANATHAN, R., SARVER, J.,TANZOSH, J. M. Boiler Materials for Ultra-Supercritical Coal Power Plants Steamside oxidation. Journal of Materials Engineering and Performance. December 2005, p. 255-274, ISSN 10599495. STREK, K., EVELOV, K. Dodvka tlakovch st z austenitickch materil a niklovch slitin (Supply of pressure parts of austenitic materials and nickel alloys), Ostrava, August 2008. Modern energetick stroje (Modern Power Generation Machinery). Presentation: Technical University of Ostrava - Energy Research Centre. BYSTRIANSK, J., KUERA. Dje ovlivujc vznik oxidickch vrstev s dobrmi ochrannmi vlastnostmi na ocelch v parovodnm prosted energetickch okruh (Actions Affecting Formation of Oxidic Layers with Good Protective Properties on Steels in Steam-Ducting Environment of Energy Circuits) In Metal 2004. Collection of lectures 13th year of conference, Hradec nad Moravic, May 2004, ISBN 80-85988-95-X. RICHARDOT, D., VAILANT, J. C. Vallourec & Mannesmann Tubes. The T92/P92 Book. 2000, 68 p. SVOBODOV, M. Aplikan omezen ropevn oceli P92 (Application Limits of Creep -Resistant Steel P92). Information portal and magazine All For Power. July 2009. ISSN 1802-8535. Sumitomo Metal Ind. Properties after long time service exposure of Super 304H steel subes in power plant. September 1996. Sumitomo Metal Ind. Fabrication of HR3C Steel Tubes. February 2000. Sumitomo Metal Ind. Fabrication of Super304H Steel Tubes. May 2004. VdTV-Werkstoffblatt 550 - Warmfester Walz- und Schmiedestahl X10CrNiCuNb18-9-3 (1.4907), 12/2010. VdTV-Werkstoffblatt 546 - Warmfester Walz- und Schmiedestahl X6crNiNbN25-20 (1.4952), 03/2008. VdTV-Werkstoffblatt 547 - Warmfester Walz- und Schmiedestahl X8CrNi19-11 (1.4952), 06/2007.

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