4 - Welding of The New Bainitic Steels T-P23 and T-P24

Filler metals for welding of T/P23 and T/P24
Volker Gro; Dr. Herbert Heuser; Dr. Claus Jochum

Bhler Schweisstechnik Deutschland GmbH, Hamm, Germany
Power Conference, February 24. 2008, Balve-Eisborn
7CrWVMoNb9-6
(T/P 23)
7CrMoVTiB10-10
(T/P 24)
VALLOUREC & MANNESMANN TUBES

Chemical composition (wt-%)
Si
Mn
Al
Cu
Cr
Ni
Mo
Nb
0,07
0,28
0,54
0,008
0,004
0,018
0,041
2,08
0,047
0,08
0,22
1,65
0,002
0,026
0,011
Continuous cooling temperature (CCT)- diagram of T/P23

GTA all weld metal and T 23 pipe weld with Union I P23
Chemical composition [wt-%]; wire: Union I P23

C
Si
Mn
Cr
Ni
Mo
Nb
0,08
0,27
0,54
2,14
0,04
0,08
0,21
1,58
0,031
0,01
0,002
Mechanical properties, (without PWHT)

a) GTA all weld metal, wire- : 2,4 mm
TS
[MPa]
Elong. CVN, ISO-V

[%]
[J]
Hardness
[HV 10]
+ 20
+ 450
857
951
19,2
240
779
888
16,0
---
---
+ 500
732
842
14,2
---
---
max. 270
b) Pipe joint: T 23, pipe- a: 50,8 x 7,5 mm (2 x 0,3 in); wire- : 0,8 mm
Preheat
[C]
none
+ 175
Test temp.
[C]
+ 20
+ 20
4
3
2
1,5
YS
[MPa]
7,5
Test temp.
[C]
[mm]
YS
[MPa]
TS
[MPa]
Location
of fracture
CVN, ISO-V * [J]

WM
Hardness
[HV 5]
491
495
607
611
BM
BM
31
29
max. 313
--* small specimen 5 x 8 [mm]
Chemical composition of various weld metals [wt-%]

C
Si
Mn
Cr
Ni
Mo
Nb
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

Welding process
PWHT
[C/h]
Test
temperature
+ [C]
YS
[MPa]
TS
[MPa]
Elongation
[%]
CVN, ISO-V
[J]
Hardness
[HV10]
GTAW
Union I P23
: 2,4 mm
--740/2
740/2
20
20
550
639
520
426
818
620
449
21,4
20,2
17,4
228 230 268

261 286 299
---
270
250
---
SMAW
Thermanit P23
: 4,0 mm
740/2
740/15
740/15
20
20
550
509
421
302
625
553
350
19
25
26,4
SAW
Union S P23
flux: UV 430 TTR-W
wire-: 4,0 mm
740/2
20
615
702
18,1
128 136 140

156 156 160
---
187 204 208
227
192
---
237
Chemical composition and mechanical properties of matching filler

metals for T/P23; all weld metal for various welding processes
PWHT
[C/h]
Test
temperature
+ [C]
740/1
740/1
TS
CVN, ISO-V
[J]
WM
HAZ
[MPa]
Location
of
fracture
Bending
angle
[]
20
580
BM
180
124 150 153
92 156 223
< 250
600
333
BM
---
---
---
---
Pipe dimension:
219 x 30 [mm]
Welding
consumables:
root, GMAW: Union I P23

2 filler passes SMAW: Thermanit P23
10 filler passes SAW: Union S P23, 3,2 mm
flux: UV 430 TTR-W
Preheat temp.:
250C
Interpass temp.:
max. 300C
SAW:
I s = 450 Amps. (=/+), U
Hardness
[HV10]
= 28 V; v s = 52 cm/min, E = 14,5 kJ/cm
Results of a circumferential P23 weld with matching filler metals

min . 72,3
W.E.D. 585,6
711,2O.D.
min. 24,5
W.E.D. 585,6
610 O.D.
non acceptable
optimised seam location
Weld connection P23 (different wall thickness)

Schriftgre 24-28
VALLOUREC &
VALLOUREC
MANNESMANN
& MANNESMANN
TUBES
TUBES
1000
heating rate
80 - 120C/h
540 - 560C
min. 1h
400
250 - 300C
welding
preheating
200
cooling rate
100 - 150C/h
uniform
wall thickness
PWHT-time
depends on
wall thickness
600
740C
intermediate
stress relieving
Tem perature [C]
800
time
Temperature cycle
during the welding process of T/P23 welds (different wall thickness)
Reheat crack
in a weld connection between P23- header and T23- nozzle
2. weld
T23
45
starting points
45
1. weld
Fillet welds on tube T23 in P23- or P91- header

(starting point of single layer welds to prevent stress relief cracking at T/P23)
7CrMoVTiB10-10
(T/P 24)

Chemical composition (wt-%)
Si
Mn
Al
Cu
Cr
Ni
Mo
Nb
Ti
0,08
0,21
0,53
0,004
0,004
0,004
0,09
2,44
0,18
0,95
0,26
0,004
0,002
0,053
0,0073
Continuous cooling temperature (CCT)- diagram of T/P24

Schriftgre 24-28
VALLOUREC &
VALLOUREC
MANNESMANN
& MANNESMANN
TUBES
TUBES
1000
10
Temperature [C]
800
740C
0,5 - 4 h
depends on:
- wall tickness
- welding process
600
heating rate:
80 - 120C/h
400
cooling rate:
100 - 150C/h
200 - 280C
200
0
< 400C:
cooling in still air
preheating
welding
Time
Temperature cycle during welding and PWHT of P24

Matching filler metal for T/P24
Weld process
PWHT
C/h
YS
MPa
TS
MPa
Elong.
%
CVN
J
Hardn.
HV10
Base metal requir.
730 760
> 450
585 840
> 17
> 27
< 250
---
664
803
19,1
> 250
< 322
740/2
595
699
20,3
> 250
< 230
SMAW
4,0 mm
740/2
577
689
18,1
150
< 233
SAW
wire- 4,0 mm
740/2
495
600
23,8
260
< 206
GTAW
2,4 mm
Mechanical properties all weld metal at RT, (examples)

T/P24 - weldments
P24 (Pipe dimension: 159 x 20 mm)

Weld process
Base metal
GTA, SMA, SA*
PWHT
C/h
TS
MPa
LoF
CVN (ISO-V)
J
Hardness
HV10
Bending
angle
730 760
585 840
---
> 27
175 260
---
740/2
597
BM
200 290
< 250
180 o. k.
*) Root: GTAW; 2 Fill passes with stickelektrodes, 7 Fill passes SAW

T24 (Tube dimension: 38 x 6,3 mm; GTA-welded)
Weld
process
Base metal
GTAW
PWHT
C/h
TS
MPa
LoF
CVN (ISO-V)
J
Hardness
HV10
Bending
angle
730 760
585 840
---
> 27
175 260
---
---
639
BM
60 76
< 336
180 o. k.
Mechanical properties of girth welds at T/P24 (transverse specimen)

GTA-welding of T 24
0RHB
BM
HAZ
WM
WM
BM
T 24 - GTA girth weld; Interpasstemp. <150C; Union I P 24;

CVN weld centre: 33 J ( small specimen: 5x10mm)
CVN at different welds
Tube girth welds
all weld metal
6,3
19
17
18
16
15
14
13
Tube-: 38,3 mm
V-joint, 60
2-3 mm gap
12
15
11
10
7
8
11,6
5
4
5
3
1
4
2
2
1
Tube: 48,3 mm
V-joint, 60
2-3 mm gap
GTAW at T24; welding technique to achieve high CVN values without PWHT
GTA- welding of T24
6,3
Wurzel
GTA-welding of T 24
Accessibility at welding tube to tube on installation site

T24 girth welding; different welding technique

Tzl < 200C; thick top layer
CVN 231 J
Tzl < 250C; thin top layer
CVN 284 J
Tzl < 200C; thin top layer
CVN 244 J
Tzl < 250C; thick top layer
CVN 258 J
BM
HAZ
WM
T24- GTA girth weld;

Ti > 500C; CVN weld center: 9 J; small specimen: 5 x 10 (mm)
Magnification: 500 x
Ti < 150C
Ti > 500C
no precipitation
grain boundary precipitation
T24- GTA girth weld with high and low interpass temperature
Hardness at T24 welded joint; no PWHT

400
H ar d ne ss H V1 0
350
300
250
Cap
Root
200
150
100
50
BM
HAZ
WM
HAZ
BM
H_ 020612us
T24 - Waterwall
T24 waterwall, P91 - header
P91 collector; T24 tubes, welded with T24 filler
Welding of T24 - tubes in P91 - header
Welding of T24-tubes in P91-header
T24 tubes and strips
T24 waterwall
PWHT; T24 tubes in P91 - header
T24; Formieren
Conclusions
The efficiency of power plants can be improved by the new ferritic

banitic steels T/P23 and T/P24.
Matching filler metals have been developed.
No PWHT is required for GTAW of T23/24 girth welding and

SAW of waterwalls
Creep rupture tests of weldments are running. Test results more

than 10.000h indicate that the developed filler metals will fulfill the
requirements. Tests are running up to > 30.000h.
Many thanks for your attention


4 - Welding of The New Bainitic Steels T-P23 and T-P24

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4 - Welding of The New Bainitic Steels T-P23 and T-P24

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Filler metals for welding of T/P23 and T/P24

Volker Gro; Dr. Herbert Heuser; Dr. Claus Jochum

Power Conference, February 24. 2008, Balve-Eisborn

Power Conference, February 24. 2008, Balve-Eisborn

VALLOUREC & MANNESMANN TUBES

Continuous cooling temperature (CCT)- diagram of T/P23

Chemical composition [wt-%]; wire: Union I P23

Mechanical properties, (without PWHT)

Elong. CVN, ISO-V

CVN, ISO-V * [J]

Power Conference, February 24. 2008, Balve-Eisborn

VALLOUREC & MANNESMANN TUBES

Chemical composition of various weld metals [wt-%]

Mechanical properties of weld metal

228 230 268

128 136 140

187 204 208

Chemical composition and mechanical properties of matching filler

VALLOUREC & MANNESMANN TUBES

124 150 153

root, GMAW: Union I P23

I s = 450 Amps. (=/+), U

= 28 V; v s = 52 cm/min, E = 14,5 kJ/cm

Results of a circumferential P23 weld with matching filler metals

VALLOUREC & MANNESMANN TUBES

optimised seam location

Weld connection P23 (different wall thickness)

Tem perature [C]

VALLOUREC & MANNESMANN TUBES

VALLOUREC & MANNESMANN TUBES

Fillet welds on tube T23 in P23- or P91- header

Power Conference, February 24. 2008, Balve-Eisborn

VALLOUREC & MANNESMANN TUBES

Continuous cooling temperature (CCT)- diagram of T/P24

Temperature cycle during welding and PWHT of P24

Matching filler metal for T/P24

Base metal requir.

Mechanical properties all weld metal at RT, (examples)

P24 (Pipe dimension: 159 x 20 mm)

*) Root: GTAW; 2 Fill passes with stickelektrodes, 7 Fill passes SAW

Mechanical properties of girth welds at T/P24 (transverse specimen)

T 24 - GTA girth weld; Interpasstemp. <150C; Union I P 24;

CVN at different welds

Tube girth welds

all weld metal

GTA- welding of T24

Power Conference, February 24. 2008, Balve-Eisborn

Accessibility at welding tube to tube on installation site

T24 girth welding; different welding technique

Tzl < 250C; thin top layer

Power Conference, February 24. 2008, Balve-Eisborn

Tzl < 200C; thin top layer

VALLOUREC & MANNESMANN TUBES

T24- GTA girth weld;

VALLOUREC & MANNESMANN TUBES

grain boundary precipitation

Hardness at T24 welded joint; no PWHT

Power Conference, February 24. 2008, Balve-Eisborn

Power Conference, February 24. 2008, Balve-Eisborn

T24 waterwall, P91 - header

Power Conference, February 24. 2008, Balve-Eisborn

P91 collector; T24 tubes, welded with T24 filler

Power Conference, February 24. 2008, Balve-Eisborn