Welding of ferritic creep-resistant steels

Job Knowledge
Creep is a long term failure mechanism that, in most metals, occurs at elevated temperatures
(see Job Knowledge No. 81 ). Creep strength in the ferritic steels is achieved by alloying with
elements that will provide enhanced strength at high temperatures. Chromium (Cr) and
molybdenum (Mo) are the two principal alloying elements but vanadium (V) and niobium (Nb)
may also be added.
Table 1 gives the nominal composition of the commoner creep resistant steels. In addition to the
use of these steels in creep service they also have resistance to hydrogen attack and corrosion by
sulphur bearing hydrocarbons. They are therefore found in power generation and the oil and gas
industries.
Table 1 Nominal composition and mechanical properties of the creep resistant steels
Composition nominal %

Steel grade

C
max
C1/2Mo
//CrMoV
1CrMo
2Cr1Mo
5CrMo
9Cr1Mo
9CrMoVNb
(9Crmod or
P91)

0.3
0.14
0.13
0.13
0.13
0.13

Cr Mo

0.5
0.5 0.6 0.25
1.2 0.5
2.25 1.0
5.0 0.5
9.0 1.0

Mechanical properties - typical

Nb

UTS
N/mm2

0.2%
Elongn
Proof
%
N/mm2

520
585
530
555
690
675

320
330
350
350
475
475

35
25
35
35
28
30

0.13 8.75 1.0 0.23 0.08 650

480

30

CharpyV
J/C
min
27@20
27@20
27@20
27@23

40@20

The creep resistant steels all contain strong carbide and/or nitride forming elements. These are
intended to provide a fine dispersion of precipitates that both increase the tensile strength and
impede the formation of the voids illustrated in Fig 1 and Fig 2 of Job Knowledge No. 81.
Chromium is also added to reduce the scaling or oxidation of the steel at high temperatures. Each
steel grade has a creep limit (a stress and temperature above which it should not be used) and a
similar limit on oxidation resistance. The allowable temperature increases with the alloy content,
enabling the more highly alloyed steels to be used up 650C.
The //CrMoVsteel is a special case. It was developed for the power generation industry in
the UK and is unlikely to be encountered elsewhere but some notes have been included as it may
be found in older plant scheduled for repair.

As the alloy content increases then so does the hardenability (the ability to form martensite) of
the steel. CMo, CMV and 1CrMo steels form ferritic/bainitic structures, the other more
highly alloyed steels forming martensite, even at relatively slow cooling rates. This should give
some hint as to one of the problems encountered when welding this family of steels; that of
hydrogen induced cold cracking (see Job Knowledge No. 45), since martensite is generally hard,
brittle and sensitive to the presence of hydrogen. Low hydrogen welding processes are therefore
essential. This includes ensuring that any shield gases are of high purity and are dry; ideally with
a dew point less than 50C.
Preheat is essential for most of the alloys (the IIW carbon equivalent method is not valid for
these grades of steel) and few welding specifications give much guidance regarding
recommended preheat temperatures. However, ASME B31.3 and EN 1011 Part 2 both contain
recommendations. Table 2 is adapted from the EN specification for processes with hydrogen
limited to between five and 10mls of hydrogen in 100gms of weld metal (Scale C). It may be
permissible to use lower preheats if the hydrogen content is reduced to less than 5mls/100gm; for
instance when depositing a TIG root pass. This could be confirmed during welding procedure
development.
Table 2 Recommended preheat and interpass temperatures
Steel Grade
C1/2Mo
//CrMoV
1CrMo
2Cr1Mo
5CrMo
9Cr1Mo
9Cr1MoVNb

Thickness
(mm)
15
>1530
>30
All
15
>15
15
>15
All
All
All

Min. Preheat
(C)
20
75
100
150
100
150
150
200
200
200
200

Max. Interpass
(C)
250
300
300
350
350
350
350

11/4Cr1/2Mo power station boiler header

An additional problem that may be encountered with the creep resistant steels is that of reheat cracking (see Job Knowledge No. 48 ). This is a cracking
mechanism that takes place, as the name suggests, during reheating of the welded joint, either when the weld is post weld heat treated (PWHT) or is put
into high temperature service without PWHT.
The most sensitive grades are those containing vanadium; the //CrMoV steel being one of the most sensitive. It is so sensitive that it may be
necessary to maintain the preheat and hot grind and blend the weld toes of a thick, highly restrained weld to reduce stress concentrations before
immediately performing the PWHT operation.
Solutions to this problem are control of residual elements to low levels, low heat input to minimise grain growth in the HAZ and devising a welding
procedure that results in the maximum amount of grain refinement in the HAZ. Rapid heating through the temperature range 350 - 600C at which the
steel is most sensitive can also help. This approach must be treated with some caution as too rapid a temperature rise can cause unacceptable stresses
and distortion and may violate code requirements.

Most of the creep resistant steels require PWHT; mandatory in all of the application codes. This is to ensure that the hard microstructures formed during
welding are softened and toughness improved. It is also necessary to heat treat the weld and HAZs to ensure that the precipitates, required to give best
creep performance, are of the correct size and distribution. PWHT temperatures and soak times must therefore be closely controlled to develop the
required mechanical properties. Typical temperatures and times are given in Table 3. These figures are typical only and it is important that the item is
heat treated precisely in accordance with the relevant application code; ASME VIII, BS PD5500, EN 13445 etc.
Table 3 Typical PWHT temperatures and times

Temperature
Range (C)

Steel Grade

Soak Time
(hours)

C1/2Mo

630 - 670

1 per 25mm

//CrMoV

650 - 680

1 per 25mm

1CrMo

650 -700

1 per 25mm

2Cr1Mo

680 - 720

2 min

5CrMo

710 - 750

2 min

9Cr1Mo

730 - 760

2 min

9Cr1MoVNb

730 - 760

2 min

The PWHT temperature of the 1CrMo and the 2Cr1Mo steels are sometimes changed from the ranges given inTable 3 in order to develop specific
properties; see for example Table 4.4.1 in BS PD5500.
The 9CrMoVNb steel is particularly sensitive to PWHT times and temperatures and great care must be exercised when PWHT'ing this particular grade of
steel.
Any alloy containing more than 2% chromium will need to be bore purged with an inert gas such as argon when depositing a TIG root pass. Exposure of
the molten weld pool to the atmosphere results in some of the chromium boiling off giving rise to a porous or 'coked' bead on the reverse side of the
weld. This adversely affects both mechanical properties and corrosion resistance.
Welding consumables matching the parent metal composition are readily available for all of these steels for most of the welding processes. An exception
to this is the //CrMoV steel which is conventionally welded with a 2Cr1Mo filler. Dissimilar metal joints made between components from within this
group of ferritic steels or with the carbon manganese steels are usually welded using a filler metal that matches the less highly alloyed steel. PWHT
temperature for the dissimilar metal joints can be a problem and tends to be a compromise between overtempering the lower alloyed steel and
undertempering the more highly alloyed metal.