Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 1 of 14

Industrial Membership Training

Professional Members Login
Register

Sub

Advances in welded creep resistant 9-12%Cr steels

D J Abson, J S Rothwell and B J Cane
TWI
Granta Park
Cambridge, CB21 6AL, UK
Paper presented at 5th International Conference on Advances in Materials Technology for
Fossil Power Plants, 2-5 October 2007.

Abstract
Research on high chromium ferritic materials for high temperature power plant
components generally concentrates on the properties of the parent steel. Weldments,
however, are often the weak link, leading to premature failures and associated forced
outages and high maintenance spend. Clearly, consideration of the creep performance of
weld metals and associated heat-affected zones (HAZs) in these materials is important.
Despite this, relevant weldment creep rupture data are not commonly available, and
weldment creep rupture 'strength reduction factors' are not always known. This paper
provides comment on the available information on parent materials, and highlights the
need for the assessment of the creep performance of weldments. Strategies for increasing
HAZ creep rupture strength are reviewed, and some available weldment data are
considered. Less conventional welding processes (GTA/TIG variants and EB welding)
appear to provide improved creep performance of weldments. They therefore merit further
study, and should be considered for welding the new steel grades, particularly in
supercritical and ultra-supercritical applications.

Introduction
World electricity demand is increasing relentlessly, with many parts experiencing very
rapid growth. At the same time, since power plants are a major source of greenhouse
gases, there is growing pressure to reduce emissions per unit of electricity generated.
Whilst nuclear power and alternative or renewable energy generating systems are likely to
be increasingly introduced, IEA projections of new plant-builds indicate a reliance on fossil
fuels over the next 20 to 30 years. Electricity generated from coal currently accounts for
around 40% of the world's generating capacity and, because of its abundance in many of
the world's developing countries, it is likely to remain the dominant fuel in growing
economies such as China and India for the foreseeable future.
With this situation, there is a clear incentive to increase the efficiency of coal-fired plants.
Sub-critical plants typically operate at efficiencies of 35%, whereas supercritical (SC)
plants have efficiencies up to 46%, and ultra-supercritical (USC) plants achieve efficiencies
around 50%. Such efficiency improvements provide significant reduction in greenhouse gas
emissions. More than 240 high efficiency SC plants are in operation worldwide. World Coal
Institute figures for 2005 indicate that China, for example, has 22 SC units, supplying
around 14 GW of electricity. 24 USC plants also exist, with units in Denmark, Germany, the
Netherlands, Japan and the U.S.A., and many are at the planning stage elsewhere. The
concept of carbon dioxide capture is now adding further importance to the need for higher
efficiencies, since the integration of carbon capture plant gives an efficiency penalty of
around 10%. These SC and USC plants (with provision for integration of carbon-capture)
are thus clear candidates for the next generation of coal-fired plants.
SC and USC plants operate at higher temperatures and pressures than conventional sub-
critical plants, as shown in Table 1 [1] . High temperature materials technology has

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 2 of 14

consequently become the major challenge, particularly for USC plant. The reality of USC
plant has been made possible by major developments in Europe, U.S.A. and Japan in 9 to
12% Cr ferritic steels for operation up to 650°C. The evolution of steels for power plants is
shown in Table 2 [2] , and also in Figure 1. [3]
[1]
Table 1: Temperatures and pressures for different types of coal-fired plant

Temperature (°C) Pressure (bar)

Sub-critical 538 167

Supercritical 540 - 566 250

Ultra-supercritical 580 - 620 270 - 285

[2]
Table 2: Evolution of creep rupture strength for ferritic steels

600°C /10 5 h Maximum

Years Alloy Modification Creep Rupture Example Alloys Metal Use
Strength, MPa Temp., °C

1960-70 Addition of Mo or Nb, 60 EM12, HCM9M, 565

V to simple 12Cr and HT9, Tempaloy
9Cr steels F9, HT 91

1970-85 Optimization of C, Nb, 100 HCM12, T91, 593

V HCM2S

1985-95 Partial substitution of 140 1 P92, P122, P911 620

W for Mo (NF 616,
HCM12A)

Emerging Increase W and 180 1 NF12, SAVE 12 650 2

addition of Co

1
In a later paper by Masuyama [3] , 140MPa was revised to 130MPa and 180MPa was
revised to 150MPa.
2
Masuyama [3] added MARN and MARB2 steels (10 5 h creep rupture strength 150MPa).

Fig.1. Chart
showing the
progressive
development
of 9-12%Cr
steels [3]

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 3 of 14

The opportunities offered by the advanced steels in terms of USC plants, however, may not
fully materialise if plant reliability suffers. Poor confidence in the long term performance of
welds, particularly in components such as steam piping, headers and valves, is a major
safety and economic concern. The phenomenon of type IV cracking is recognised as a
primary failure mechanism that limits the life of components operating at elevated
temperatures.
Type IV cracking has plagued the power industry for around 30 years. Unfortunately, with
increasing precipitate-strengthening in the advanced ferritic steels, the effect on lifetime
may be exacerbated. In other words, the weldment-parent creep strength ratio, WPCSR
(commonly called the weld creep rupture 'strength reduction factor') can decrease, i.e.
worsen, with increasing parent metal creep strength. Type IV cracking can thus erode the
benefits achieved in parent metal creep strength. Unless the problem can be reduced or
overcome, for example by placing welds in lower stress or lower temperature locations,
there will need to be more conservative design philosophies and remnant life assessments
based on parent metal strength, which realistically account for long-term WPCSR values.
This paper considers possible solutions to the problem of type IV cracking, including
improvements in the welding process, and the need for long-term weldment data as a
prerequisite for any new high temperature design approach using advanced ferritic steels.

Parent steel developments

Whilst substantial improvements have been made over the last four decades in the
development of 9-12%Cr creep-resistant steels, [4] the steam temperatures in recent and
projected thermal power stations are now approaching the upper temperature limit for
ferritic steels. An understanding of the microstructural factors that control long term creep
rupture strength is vital for further improvements in creep rupture strength. Two basic alloy
design philosophies are possible. One is to adopt nominally 9%Cr as the base, recognising
that the alloys will have inadequate steam oxidation resistance, and will require cladding in
order to operate at temperatures of the order of 650°C. Alternatively, the poorer creep
rupture strength of 10.5%Cr steels [5] might be improved through judicious choice of
alloying. The improved oxidation resistance of higher chromium steels would eliminate the
need for cladding. In all cases, it is essential to avoid the formation of delta ferrite, since its
presence is detrimental to creep rupture strength. [6]
In designing further alloys based on a nominally 9%Cr composition in the European COST
536 programme, Hald [7] stated the basic design ideas as:

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 4 of 14

z Avoid Z-phase formation (with low Cr contents)

z Achieve Laves phase strengthening
z Add other nitride formers (Ti, Ta, Zr and Hf)
z Optimize the boron and nitrogen contents

Creep damage in power plant steels is associated with grain boundary precipitates. In most
Cr-containing ferritic steels, grain boundary precipitates, such as M 23 C 6 , provide
favourable nucleation sites for creep damage, in the form of grain boundary cavities and
micro-cracks. An increase in the proportion of intragranular MX type particles, such as VN,
is beneficial. Hald [7] reviewed the development of 9-12%Cr steels. He noted that the poor
long term creep rupture strength of some of the recently-developed alloys demonstrated
that the ideas behind the alloy design have been based on a lack of understanding of the
long-term microstructure stability of this class of alloys. Microstructural explanations for the
improved creep strength of the new 9-12% Cr steels should be found in mechanisms which
retard the migration of dislocations and sub-grain boundaries, and thus delay the
accumulation of creep strain with time.
Among recent developments, including some on experimental alloy systems, Yin and
Faulkner [8] showed that ion implantation of hafnium into thin foils of a 9 wt-%Cr ferritic
steel can markedly improve the creep properties of the material. The addition of hafnium
markedly increased the volume fraction of MX precipitates, and completely eliminated the
formation of the common grain boundary M 23 C 6 particles.

Semba and Abe [9] showed the beneficial effect on creep rupture strength of a progressive
increase in boron up to 0.0139% in their 0.08%C-9%Cr-3%W-3%Co-0.2%V-0.05%Nb-
0.008%N alloys. Steels with boron or nitrogen contents at higher levels lead to the
detrimental formation of coarse BN precipitates. The solubility limit of BN at 1150°C is
expressed by the equation:
[10]
log(%B) = - 2.45 log(%N) - 6.81
Figure 2 shows how this equation defines a boundary beyond which coarse precipitates
form. Although nitrogen is an important addition for the formation of fine MX precipitates,
which enhance creep strength, high solution temperatures are required during steel
processing, leading to extra costs for the steel maker. Taneike et al, [11] employed a
solution treatment temperature of 1,300°C to take titanium carbo-nitrides into solution, but
observed a substantial reduction in the minimum creep rate at 650°C in 8.4%Cr steels
containing 0.047%Ti, 0.13%C and 0.006%N. Optimizing the solution treatment
temperature is an important aspect of producing modern B-containing steels.

Fig.2. Solubility limit for BN at 1150°C for high

Cr steel, with the corresponding information
for the Fe-B-N system from Fountain et al
superimposed [9]

Type IV failure and its consequences for creep rupture life

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 5 of 14

Creep rupture studies on modified 9-12%Cr steels have been largely focused on the rupture
strength of the parent steels. Much less attention has been given to the behaviour of
weldments. The failure of high chromium steels in power plant components is often
associated with failure in the 'type IV' region. In short term, high stress laboratory tests on
welded joints, failure generally occurs in the parent steel or weld metal. However, at lower
stresses and after longer times, the failure location switches to the outer region of the
visible HAZ. This has been classified as a type IV failure, and the location identified as the
type IV region. The classification of the different failure locations has been discussed by
Brear and Fleming [12] and Francis et al. [4] Type IV cracking is the most troublesome in-
service failure classification facing the industry today.
In 9%Cr steels, Cerjak and Letofsky [13] found that the transition to type IV cracking
occurred after test durations of ~10,000h. In their article on 91 grade steel weldments,
Brear and Fleming [12] examined equations to describe parent steel and type IV creep
rupture failures in grade 91 steels. The intersection of these two equations predicts the
transition from parent metal failure (at high stresses and short times) to HAZ failure (at
lower stresses and longer times). They found good agreement between experimental data
and the equations describing HAZ behaviour due to Nath and Masuyama. [14]
Abe [15] carried out creep rupture tests on simulated HCM12A specimens that had been
heated to temperatures in the range 800 to 1,000°C, to simulate different parts of the HAZ.
He reported that, while hardness had its minimum value after heating to temperatures near
the Ac 1 , the creep rupture time in tests carried out at 650°C had its minimum value in
specimens heated to temperatures near the Ac 3
. From their results, it appears that at high
stresses (140MPa), failure preferentially occurred in specimens heated slightly below the Ac
3
i.e. intercritically heated, whilst at lower stresses (<120MPa), the minima shifted to
specimens heated to just beyond the Ac 3
i.e. the fully transformed fine grained specimens.
This apparent shift in failure position with stress may explain why both regions of the outer
HAZ have been associated with type IV failure.
It has been reported that type IV cracking of the weldments can reduce creep life,
compared with parent design life, by as much as a factor of five. [16-18] When considering
creep rupture strength, Nath and Masuyama [14] reported that, at 600°C, 10,000h
extrapolated data for grade 91 weldments indicated a 37% disparity between the parent
steel and the HAZ, i.e. a WPCSR of 0.63. However, it should be recognised that the extent
of the disparity increases progressively with increasing log (exposure time), as shown by
Sawaragi [19] for 2.25%Cr-1%Mo weldments. In creep rupture tests at 538°C on tubular
modified 9%Cr-1%Mo specimens, a progressive reduction in WPCSR from 0.94 to 0.93 to
0.90 for rupture times of 10 1 , 10 3 and 10 5 h, respectively, was reported by Blass et al.
[20]
In a study of grades E911, 91, 92, and 122 weldments, in the UK-funded Fourcrack
programme, it was concluded that the weldment creep rupture strength 'falls towards a
floor value of about 60% of the parent strength in the longer term'. [21]
Parent steel and cross-weld creep rupture data for 92 grade steel, tested at 650°C, have
been presented by Abe, [22] Figure 3. Similar data have also been presented by Abe and
Tabuchi [23] for grade 122 steel. The important features of this figure are that, for long
exposure times, the parent steel creep rupture strength falls below a linear extrapolation of
the short term data, and that the disparity between the parent steel and the cross-weld
creep rupture strength increases progressively with increasing life, i.e. the WPCSR
decreases.

Fig.3. Creep rupture data of Abe [22] for

parent steel and cross-weld specimens of
92 grade and a boron-containing steel

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 6 of 14

tested at 650°C

The first issue, i.e. the parent steel creep rupture strength, has been addressed by
Japanese researchers, who incorporated an increased slope for a second straight line fitted
to long term creep data, obtained at stress levels less than 50% of the 0.2% offset yield
strength. [24,6] They have called this method 'region splitting'. It is clearly essential, when
extrapolating short-term parent steel test data to projected long service lives, to ensure
that appropriate allowance is made for the increasing fall-off in parent steel creep rupture
strength with time.
Concerning the second issue, i.e. the weldment behaviour, WPCSR values estimated from
the data in Figure 3, are plotted in Figure 4, along with similar data obtained for grades 91
and 122 from a variety of sources. The linear extrapolation suggests that the WPCSR
appropriate for a 30 year design life at 650°C for this steel is of the order of 0.27!
Furthermore a linear extrapolation may be optimistic. This is clearly at variance with, and
much more alarming than, the conclusion of the Fourcrack programme cited above, even
though 92 and 122 steel grades were included in both studies. The information in Figure 4
reveals that, in addition to measures needed for extrapolation of parent material data,
allowance must also be made for the progressive decrease in WPCSR, when extrapolating
short term data to longer times.

Fig.4. WPCSR values derived from creep rupture data of cross-

weld or simulated fine-grain HAZ specimens tested at 650°C for
grade 122 [23] , grade 92 [22] and grade 91. [25] A linear
extrapolation is tentatively assumed, up to a 30 year life. A
single data point for grade 9, from ASME code case N-253-14
[26]
, is represented here as a 100,000h value. Equivalent times
at 600°C are shown, using a Larson-Miller constant of

a)
36;
and

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 7 of 14

b) 20

In all cases, it should also be recognised that, particularly for small diameter test
specimens, at least part of the apparent fall-off in creep rupture strength at long exposure
times will be attributable to the loss of cross-section through oxidation, unless a suitable
protective atmosphere is provided. [27]
Masuyama [28] and Kimura et al [29] noted that changing the constant in the Larsen-Miller
parameter has a strong influence on the value of the parameter, and thus on the estimated
creep rupture life at a different temperature. Kimura et al [29] have shown how more
accurate fitting of data can be achieved in the type IV region by using a different constant.
Therefore, also included in Figure 4, on a second abscissa is the equivalent time at 600°C,
estimated using the Larsen-Miller parameter with an assumed constant of 36 ( Figure 3a)
and 20 ( Figure 3b). This demonstrates the strong effect of changing the Larsen-Miller
constant on the lifetimes of weldments at temperatures different from that of the test data
available. Clearly, the test temperature and the creep rupture life must be reported
whenever WPCSR values are quoted. If predictions are made for temperatures other than
the test temperature, there must be confidence in the applicability of the parametric
constant chosen.
In agreement with this, data obtained by Kubon and Sobotka [30] for grade 91 steel show
that the ratio was 0.77 after 10,000h at 600°C, but decreased with increasing time and
temperature. Even with this modest diminution of extrapolated creep rupture strength, for
a 91 grade parent steel creep rupture life of 10,000h, there is a dramatic reduction in the
HAZ (type IV) rupture life to only 1,700h.

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 8 of 14

The sizing of component thicknesses in the ASME boiler and pressure vessel construction
codes [31-33] , is normally based on closed form equations which include an allowable stress
for the material of construction and an efficiency factor (E). The allowable stresses are
supplied by ASME (2004), and are based on the parent material properties at the design
temperature. Most commonly for creep service the allowable stress is taken to be 67% of
the average creep rupture stress of the parent material at 100,000 h. The allowable stress
does not consider the loss of strength due to the presence of weldments. The efficiency
factor varies between the different ASME construction codes. However, Section I (2004)
states that E is 1 for seamless and welded cylinders or the ligament efficiency. Hence, for
components designed to ASME section I with no ligaments, there will be no allowance for
weld creep rupture strength reduction.
It appears from the information presented above that premature weldment failure is likely
wherever weldments in fabrications from 91 grade and similar steels operating at
temperatures around 600°C are subjected to stresses that are of similar magnitude to the
parent steel design stresses. It is likely that utilities that have used these steels in high
pressure steam service at such temperatures with inadequate allowance for the presence
of weldments are 'sitting on a time-bomb', and that monitoring and perhaps in-service
stress measurements are required urgently to avoid catastrophic premature failures.

Improving the WPCSR and avoiding type IV failure

Through parent steel developments
In view of the importance of failure in the type IV region during long-term service, it is
inevitable that increasing attention will be given to the creep rupture properties of the
HAZ. One approach to improving the creep rupture strength of the type IV region is to
modify the parent steel composition.
For 91 grade steel tested t 650°C, Iseda et al [34] reported an improvement in both the
parent steel creep rupture strength and the WPCSR, as nitrogen was increased, for times
up to 40,000h. However, lower nitrogen levels would clearly be required if the beneficial
effects of increased boron levels are to be exploited.
The single most effective step towards the elimination of type IV failure and its negative
effect on the WPCSR has been the addition of boron. As well as improving the parent steel
creep properties, boron has been shown to improve the WPCSR substantially. [35,22,34]
Tabuchi et al [35] added from 90 to 180ppm B to low nitrogen (<0.0017%), 9%Cr steels.
They tested cross-weld specimens, and reported that 90-130ppm was the optimum level to
improve both parent steel and HAZ creep rupture strength. A similar conclusion was
reached by Kondo et al [36] , who studied welded joints and simulated HAZs. The beneficial
effect of boron was attributed to it combining within M23C6, and suppressing its
coarsening, thereby reducing the minimum creep rate. [37-38] It also prevented the
formation of a fine-grain HAZ, which adds to the evidence pertaining to this region being
the most susceptible to type IV cracking.
The substitution of tungsten for Mo has also been reported to be very effective in
enhancing the creep rupture strength of the HAZ. [39] However, this route of enquiry does
not appear to have been addressed by other investigators.

Through welding process development

A novel approach to improving the creep rupture strength of the type IV region, as noted
by Bell [40] , is to carry out a partial tempering of the parent steel prior to welding, and
completing the tempering treatment as the post-weld heat treatment, as described by
Sikka. [41] This approach almost doubled the creep life, compared with conventionally heat
treated 9%Cr steel weldments in the short term (<10,000 hours); [42] it would be
interesting to see the effect over a longer test period. Other process variables suspected to
have a strong influence on the type IV creep life of weldments have been highlighted by
Francis et al. [43] Among the variables shown to influence type IV cracking, as determined
by Baysian neural network analysis, were pre-heat temperature and PWHT time.
A further strategy, which could presumably be combined with the half tempering approach,

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 9 of 14

is to join modified 9% Cr steels by welding processes that create a very narrow HAZ (and
therefore a shorter thermal cycle, and less time for over ageing of precipitates). Abe [15]
reported that electron beam welding, which produces a very narrow HAZ, had a beneficial
effect on the creep rupture performance of the type IV region, with more recent data
confirming the behaviour; [23] see Figure 5. The approximate HAZ widths of electron beam
and GTA/TIG welds were 0.5mm and 2.5mm, respectively, and the cross-weld creep
rupture life of EB welds was approximately twice that of GTA/TIG welds. [15,23] However,
consideration should be given to any adverse effects on toughness of EB welds in such
steels. [44] A number of alternative processes, including EB, narrow gap GTA/TIG, and
friction welding are currently being investigated in one of the creep research programmes at
TWI within the European COST programme.

Fig.5. Creep rupture data for grade 122

weldments produced with different
welding processes [23]

Albert et al [45] have shown that simulated fine grain HAZ and real weldments behave
significantly differently in terms their creep strain. This observation was attributed to the
triaxiality introduced by the different creep properties in the various regions of the HAZ.
They pointed out that changing the weld preparation angle can alter the stress state of the
joint, and influence creep results significantly. They concluded that 'By reducing HAZ width
or the groove angle of the joint, this stress state can be altered to achieve significant
improvement in rupture life of the weld joints'.

Weld metal development

Welding consumables have been developed with matching or near-matching properties, for
welding 92 grade 9%Cr steels by manual metal arc and submerged arc welding [46-48] and
flux-cored wire welding [47-48] However, where creep rupture properties are presented, they
are generally marginally inferior to those of the 92 grade parent steel. In view of the lower
creep rupture strength of the HAZ at long durations, the creep rupture strength of the weld
metal is probably of little consequence.
For their series of experimental weld metal compositions, Vanderschaeghe et al [47] showed
the detrimental effect of increasing oxygen and also boron content on impact toughness.
However, few long-term creep rupture test data are available, and so it will be of interest to
see how the various consumables perform in long-term tests.
Limited creep rupture data, from tests at 600°C have been presented for experimental rutile
flux-cored wires, for which the optimum Ti addition was ~0.06%. [49] For welds containing
9%Cr-1% Co~0.06%Ti~0.003%B, the maximum test duration was ~9,000h, with a creep
rupture strength ~40% greater than that of 92 grade parent steel. Despite the short test
duration, it is a dramatic improvement in creep rupture strength that warrants further
qualification. An unusual feature of the failure was the extensive ductility (~80% reduction
of area) displayed. The reason for the substantial enhancement of creep rupture strength
from the Ti addition has not yet been elucidated, but is assumed to result from a change in
the character of some of the precipitating phases.
Whilst it would be undesirable to employ a weld metal that over-matched the parent steel

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 10 of 14

creep rupture strength by such a large margin, it is nevertheless vital to press ahead with
the development of weld metals, in order to be able to weld the higher creep strength
parent steels that are currently emerging. The development of improved weld metals will
become particularly important as the problem of type IV cracking diminishes.

Concluding remarks
In view of the decrease in WPCSR values with increasing creep rupture life, the design of
existing plant that operate at temperatures close to 600°C should be reviewed, and
appropriate action taken if the assumed WPCSR values were non-conservative. Where the
deployment of new steel grades is concerned, long term (>10,000h) test results should be
taken into account not only for the parent steel, but also for the weldments to be used.
Extrapolation of short term data obtained outside the type IV regime is greatly misleading,
and possibly dangerous. The change in WPCSR over time needs to be predicted accurately
for the type IV region, so that appropriate life-time projections can be made. It is clear
that the test temperature and the creep rupture life must be reported whenever WPCSR
values are quoted, and that care must be exercised in manipulating data determined at
different temperatures.
Research should be aimed at increasing the WPCSR and increasing further our
understanding of the mechanisms by which type IV degradation occurs. To this effect,
revised parent steel compositions will need to be combined with alternative welding
processes to achieve optimal performance. Results for EB welds appear to give promising
improvements in the HAZ creep rupture strength ratio, and should be explored further,
together with other alternative welding processes. R&D programmes to address these
issues are being initiated at TWI and work is ongoing within the European COST program,
with emphasis on commercial fabrication, as well as performance improvement.
As continued improvements are made to the creep strength of parent steels and of the
HAZ region, it is clear that further development of welding consumables is required, to
ensure that the weld metal is not the creep weak region in long-term service.

Conclusions

1. WPCSR values (commonly called weld creep rupture 'strength reduction factors') are not
constant, but decrease with increasing creep rupture life.
2. There is evidence that type IV behaviour can be improved by incorporating boron.
3. Type IV behaviour can be improved by welding with processes producing a short
thermal cycle, thereby producing a narrow HAZ, together with attention to weld
preparation, preheat and PWHT.

Acknowledgements
The Authors would like to acknowledge Paul Woollin and Ian Partridge of TWI for their
contributions to the paper.

References

1. World Coal Institute web site, June 2007, www.msm.cam.ac.uk/phase-

trans/2005/link/188.pdf

2. Viswanathan R, Purget R, Rao U: 'Materials technology for advanced coal power plants',
www.msm.com.ac.uk/phase-trans/2005/link/188.pdf

3. Masuyama F: 'Advance power plant developments and materials experience in Japan',

Proc 8th Liege Conference September 2006, Liege, Belgium, Research Centre Julich,
2006, Eds. J Lecompte-Beckers et al, Vol. 53 Part I 175-187.

4. Francis J A, Mazur W and Bhadeshia H K D H: 'Type IV cracking in ferritic power plant

steels', Mat. Sci. & Tech. 2006, 22(12), 1387-1395.

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 11 of 14

5. Hald J: Microstructure and long-term creep properties of 9-12%Cr steels', Proc. ECCC
Creep Conf. on Creep and fracture in high temperature components - design & life
assessment issues, 12-14 September 2005, London, U.K., Eds. I A Shibli et al,
European Creep Collaborative Committee, 2005, 20-30.

6. Igarashi M, Yoshizawa M, Iseda A, 'Long-tem creep strength degradation in T122/P122

steels for USC power plants', Proc 8th Liege Conf. September 2006, Liege, Belgium,
Research Centre Jülich, 2006, Eds. J Lecompte-Beckers et al, Vol. 53, Pt II, 1095-1104.

7. Hald J: 'Metallography and alloy design in the COST 536 action', Proc 8th Liege Conf.
September 2006, Liege, Belgium, Research Centre Jülich, 2006, Eds. J Lecompte-
Beckers et al, Vol. 53 Part II, 917-930.

8. Yin Y F and Faulkner R G: 'Creep damage and grain boundary precipitation in power
plant metals', Mater. Sci. Technol. 2005, 21(11), 1239-1246.

9. Semba H and Abe F: 'Alloy design and creep strength of advanced 9%Cr USC boiler
steels containing high boron', Proc 8th Liege Conf. September 2006, Liege, Belgium,
Research Centre Jülich, 2006, Eds. J Lecompte-Beckers et al, Vol. 53, Pt II, 1041-1052.

10. Sakuraya K, Okada H, and Abe F: 'BN type inclusions formed in high Cr ferritic heat
resistant steel', Energy Materials, 2006, 1(3), 158-166.

11. Taneike M, Fujitsuna N and Abe F: 'Improvements of creep strength by fine distribution
of TiC in 9Cr ferritic heat resistant steel', Materials Science and Technology 2004, 20
(11), 1455-1461.

12. Brear, J M and Fleming A: 'Prediction of P91 life under plant operating conditions', ETD
Int. Conf. on High Temperature Plant Integrity and Life Extension, 14-16 Apr 2004,
Robinson College, Cambridge, UK.

13. Cerjak H: and Letofsky E: 'The behaviour of weldings in large 9% Cr alloy castings',
Proc. Fifth In. Charles Parsons Turbine Conf. on advanced materials for 21st century
turbines and power plant, 3-7 July 2000, Churchill College, Cambridge, UK, Eds. A
Strang et al The University Press, Cambridge 2000, 386-398.

14. Nath B and Masuyama F: 'Materials comparisons between NF616 HCM12A and TB12M -
1: Dissimilar metal welds', Proc. EPRI/National Power Conference on New steels for
advanced plant up to 620°C, 11 May 1995, London, Society of Chemical Industry,
London, UK, Ed. E Metcalfe, 1995, 114-134.

15. Abe F: 'R & D of advanced ferritic steels for 650°C USC boilers', in Ultra-steel 2000,
Proc. Int. Workshop on the innovative structural materials for infrastructure in 21st
century, 12-13 January 2000, Tsukuba, Japan, National Research Institute for Metals,
2000, 119-129.

16. Ellis F V and Viswanathan R: 'Review of type IV cracking in piping welds' Proc. Int. Conf.
on Integrity of high-temperature welds, Institution of Mechanical Engineers, 1998, 125-
134.

17. Tabuchi M, Watanabe T, Kubo K, Matsui M, Kinugawa J and Abe F: 'Creep crack growth
behaviour in the HAZ of weldments of W containing high Cr steel', Int. J. Pressure
vessels and piping, 2001, 78, 779-784.

18. Albert K, Matsui M, Watanabe T, Hongo H, Kubo K and Tabuchi M: 'Microstructural

investigations on type IV cracking in high Cr steel', ISIJ International 2002 42(12)
1497-1504.

19. Sawaragi Y: 'Creep rupture properties of welds (1): Low alloy steels, high-Cr ferritic

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 12 of 14

steels, Cu-Ni base steels', Welding Int. 1995, 9(7), 515-519.

20. Blass J, Battiste R L and O'Connor D G: 'Reduction factors for creep strength and fatigue
life of modified 9Cr -1 Mo steel weldments: conformation by axial or torsional tests of
tubular specimens with longitudinal or circumferential welds', PVP Vol. 213, Pressure
Vessel integrity ASME 1991, 253-259.

21. Allen D J, Harvey B and Brett S J: 'Fourcrack' - An investigation of the creep

performance of advanced high alloy steel welds', Proc. ECCC Creep Conf. on Creep and
fracture in high temperature components - design & life assessment issues, 12-14
September 2005, London, Eds. I A Shibli et al, European Creep Collaborative
Committee, London, 2005, 772- 782, and 'Fourcrack - Advanced coal-fired power plant
steels - Avoidance of premature weld failure by type IV cracking', Project summary 304,
2005, available from the U.K. Department of Trade and Industry web site
www.dti.gov.uk/files/file20068.pdf

22. Abe F: 'High performance creep resistant steels for 21st century power plants', Proc
Eurocorr Exhibition, 2-4 Nov. 2005, Italy (Keynote paper in the high temperature
materials - boilers session).

23. Abe F and Tabuchi M: 'Microstructure and creep strength of welds in advanced ferritic
power plant steels', Science and Technology of Welding, 2004, 9(1), 22-30.

24. Kimura K, Sawada K, Kushima H and Toda Y: Degradation behaviour and long-term
creep strength of 12Cr ferritic creep resistant steels', Proc 8th Liege Conf. September
2006, Liege, Belgium, Research Centre Jülich, 2006, Eds. J Lecompte-Beckers et al, Vol.
53, Pt II, 1105-1116.

25. American Society of Mechanical Engineers, 2004: ASME Boiler and Pressure vessel code
Section III: 'Rules for construction of nuclear facility components'.

26. American Society of Mechanical Engineers, Code Case N-253-14, Construction of class 3
components for elevated temperature service, Section III, Division 1, 2006, Appendix C,
Table C-1.3 (e).

27. Cane B J: 'Creep life assessment techniques - Decade of progress'. ASME, Pressure
Vessels and Piping Division, Special Publication, New York, 1993.

28. Masuyama F: 'Creep strength reduction and risk in high strength ferritic steel welds',
Proc. IOM Conf. on Integrity of high temperature welds, 24-26 April 2007, London, IOM
Communications, 2007, 497-506.

29. Kimura K, Sawada K, Kushima H and Toda Y: 'Influence of composition partitioning on

creep strength of high chromium ferritic creep resistant steels', Proc. IOM Conference
on Integrity of high temperature welds 24-26 April 2007, London, IOM Communications,
2007, 497-506.

30. Kubon Z and Sobotka J: 'Assessment of long-term creep properties, creep failure and
strength reduction factor of boiler tube and pipe weldments', Proc. Baltica VI , VTT
Symposium 234 on Life management and maintenance for power plants, 8-10 June
2004, Helsinki, Eds. J Veivo and P Auerkari, VTT, 2004, 477-490.

31. American Society of Mechanical Engineers, 2004: ASME Boiler and pressure vessel code
Section I: 'Rules for construction of power boilers'.

32. American Society of Mechanical Engineers, 2004: ASME Boiler and pressure vessel code
Section VIII Division 1:' Rules for construction of pressure vessels'.

33. American Society of Mechanical Engineers, 2004: ASME Boiler and pressure vessel code

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 13 of 14

Section VIII Division 2:' Alternative rules for construction of pressure vessels'.

34. Iseda A, Sawaragi Y and Natori A: 'Properties of welded joint of 9%Cr-1%Mo-V-Nb

steel', Proc. Symp. on Joining of Materials for 2000 AD, 12-14 Dec.1991, Tiruchirapalli,
India, Publ.: Tiruchirapalli, India; Indian Institute of Welding; 1991, 465-470.

35. Tabuchi M, Masayuki K, Kubo K and Albert S K: 'Improvement of type IV creep cracking
resistance of 9Cr heat resisting steels by boron addition', OMNI 2004, 3(3), 1-11.

36. Kondo M, Tabuchi M, Tsukamoto S, Yin F and Abe F: 'Suppressing type IV failure via
modification of heat affected zone microstructures using high boron content in 9Cr heat
resistant steel welded joints', Science and Technology of Welding and Joining, 2006, 11
(2), 216-223.

37. Abe F, Okada H, Wanikawa S, Tabuchi M, Itagaki T, Kimura K, Yamaguchi K and

Igarashi M: 'Guiding principles for development of advanced ferritic steels for 650°C
USC boilers', Proc. 7th Liege Conf. On Materials for advanced power engineering, 2002,
Eds. J Lecompte-Beckers et al, European Commission, 2002, 1397-1406.

38. Abe F: 'Metallurgy for long-term stabilization of ferritic steels for thick section boiler
components in USC power plants', Proc 8th Liege Conf. September 2006, Liege,
Belgium, Research Centre Jülich, 2006, Eds. J Lecompte-Beckers et al, Vol. 53, Part II,
965-980.

39. Otoguro Y, Matsubara M, Itoh I and Nakazawa T: 'Creep rupture strength of heat
affected zone for 9Cr ferritic heat resistant steels', Nuclear Engineering and Design,
2000, 196, 51-61.

40. Bell K: 'An Analysis of published creep rupture data for modified 9% Cr steel weldments'
TWI Research Report for Industrial Members, 598/1997, March 1997.

41. Sikka V K: 'Method for welding chromium molybdenum steels' US Patent No. 4, 612,
070, September 1986.

42. Coussement C, de Witte M, Dhooge A, Dobbelaere R and van der Donckt E: 'High-
temperature properties of improved 9% Cr steel weldments', Revue de la Soudure
1990, 1, 58-63.

43. Francis J A, Mazur W and Bhadeshia HKDH: 'Trends in welding research'. Pine Mountain,
CA, USA, May 2005, ASM International. From review article 'Type IV Cracking in Ferritic
Steels'.

44. Panton-Kent R: 'Weld metal toughness of MMA and electron beam welded modified 9Cr-
1Mo steel', TWI Research Report for Industrial Members, 429/1990, November 1990.

45. Albert S K, Tabuchi M, Hongo H, Watanabe T, Kubo K and Matsui M: 'Effect of welding
process and grave angle on type IV cracking behaviour of weld joints of a ferritic steel'.
Science and Technology of Welding and Joining 2005, vol 10, No.2, 149-156.

46. Heuser H and Jochum C: 'Properties of matching filler metals for P91, E911 and P92',
Proc. 3rd EPRI Conf. on Advances in materials technology for fossil power plants, 5-6
April 2001, Swansea, U.K. Ed. R. Viswanathan, W. T. Bakker, J. D. Parker, Institute of
Materials, 2001, 249-265.

47. Vanderschaeghe A, Gabrel J and Bonnet C: 'Mise au point des consommables et

procedures de soudage pour l'acier grade 92', (in French), ('Development of welding
consumables and procedures for steel grade 92'), Proc. ESOPE Conf. 23-25 October
2001, Paris.

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010
Advances in welded creep resistant 9-12%Cr steels (October 2007) Page 14 of 14

48. Metrode Products Limited, 'P92 welding consumables for the power generation industry',
Metrode Products Limited web site 2007.

49. Abson D J, Rothwell J S and Woollin P: 'The Influence of Ti, Al and Nb on the Toughness
and Creep Rupture Strength of Grade 92 Steel Weld Metal' Proc IOM Conf. on Integrity
of high temperature welds, 24-26 April 2007, London, IOM Communications, 2007, 129-
138. (See also Abson D J: 'The influence of Ti and Al on the toughness and creep
rupture strength of grade 92 steel weld metal', TWI Research Report for Industrial
Members, 833/2005, September 2005.).

Last Reviewed 2007 / Copyright © 2007 TWI Ltd

http://www.twi.co.uk/content/spdjaoct07.html 21-09-2010