Welding International

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Assessment of nickel alloy 625 weld overlays

deposited by the electroslag process

Soraia Simões Sandes, Camila Pereira Alvarães, Matheus Campolina

Mendes, Leonardo Sales de Araújo, Luis Felipe Guimarães de Souza & Jorge
Carlos Ferreira Jorge

To cite this article: Soraia Simões Sandes, Camila Pereira Alvarães, Matheus Campolina Mendes,
Leonardo Sales de Araújo, Luis Felipe Guimarães de Souza & Jorge Carlos Ferreira Jorge (2017):
Assessment of nickel alloy 625 weld overlays deposited by the electroslag process, Welding
International, DOI: 10.1080/09507116.2017.1347330

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Published online: 20 Oct 2017.

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 Welding International, 2017
https://doi.org/10.1080/09507116.2017.1347330

Assessment of nickel alloy 625 weld overlays deposited by the electroslag

process
Soraia Simões Sandesa, Camila Pereira Alvarãesa, Matheus Campolina Mendesa, Leonardo Sales de Araújob,
Luis Felipe Guimarães de Souzaa and Jorge Carlos Ferreira Jorgea
a
Federal Centre of Technological Education - CEFET, Office of the Director of Post-Graduate Research – DIPPG, Rio de Janeiro, Brazil.; bAlberto
Luiz Coimbra Institute of Post-Graduate Research in Engineering – COPPE, Rio de Janeiro Federal University – UFRJ, Rio de Janeiro, Brazil.

ABSTRACT KEYWORDS
Nickel-base alloy weld overlays are commonly used in the oil and gas industry to extend the Overlay; nickel alloy 625;
life of equipment under aggressive corrosion environments, since the overlays improve the electroslag
corrosion resistance without a significant increase in the cost of manufacture when compared
to massive equipment. Usually, the joints are welded by SMAW, GMAW or GTAW processes. In
Downloaded by [Australian Catholic University] at 19:52 20 October 2017

this respect, the electro slag welding process (ESW), which promotes high heat inputs and low
dilution welds, can be an interesting option for this application as it provides high productivity
as only one layer is necessary. The present work evaluates mechanical, microstructural and
corrosion properties of an Alloy 625 weld overlay deposited on ASTM A516 Grade 70 carbon steel
by the ESW process. The deposition was done with one and two layers in plates of dimension
50  mm × 400  mm × 400  mm, in the flat position and an average energy welding 11.7  kJ/mm.
After welding, a post-weld heat treatment at 620  °C for 10  h was performed, this condition
being compared with the as-welded condition. Bending tests showed no evidences of cracks.
Microstructural evaluation performed using both optical (OM), scanning (SEM) and transmission
electron microscopy techniques showed an austenitic microstructure of the weld deposit with a
low proportion of secondary phases for all conditions, and the post-welding heat treatment did
not promote significant changes in the mechanical properties. At the coarse grain heat-affected
zone (CGHAZ), the occurrence of proeutectoid ferrite, pearlite and bainite were found for one
layer deposit and refined pearlite and ferrite for two layer deposits where the microstructural
constituents were observed due to the low cooling rate. In addition, no evidence of partially
diluted zones (PDZ) were verified. Corrosion tests conducted on samples removed from the top
layer of the weld overlay cladding deposit according to ASTM G 48 Method A Standard were
considered satisfactory once no evidence of pittings was verified and the loss of mass was very
much reduced.

1. Introduction Weld overlay can be performed by various pro-

cesses, such as with covered electrodes, MIG/MAG,
An alternative for replacing high-cost materials in
hollow-wire, TIG, explosive and plasma [2,5,7,9–18].
aggressive environments is overlay welding of C-Mn
In some cases post-weld heat treatment (PWHT) is
steel with nickel superalloys [1–5]. This is an attractive
sometimes recommended for relieving residual stresses,
procedure, as it helps to improve corrosion resistance
lowering the hydrogen content or homogenizing the
without increasing the cost of manufacture of compo-
microstructure [1,9,19]. In this connection, Kahar and
nents, compared to equipment made entirely of special
Baba Pai [11] comment that the two most productive
material [3,6].
processes for overlay welding of large components that
Nickel-based alloys are widely used in various indus-
are subject to corrosion or wear are the submerged-arc
tries, such as chemical, petrochemical, nuclear reactors,
and electroslag processes, both using strip electrodes.
the arms industry, aerospace, food processing equip-
Although the submerged-arc process (SAW) is used
ment and steel-making plants [7–9], owing to the com-
most, electroslag welding (ESW) is recommended when
bination of high mechanical strength, good corrosion
higher productivity and lower degrees of dilution are
resistance and good weldability [1]. The performance
required. In this connection, Bedi et al. [10] state that the
of these alloys is connected with the face-centred cubic
ESW process is more efficient on account of its unique
structure of the matrix, which is hardenable by solid
properties, such as high deposition rate, low level of dilu-
solution or by precipitation of intermetallic compounds.
tion and high-quality deposits. The electroslag process

Selected from Soldagem & Inspeção 2016 21(4) 417–427.

© 2017 Informa UK Limited, trading as Taylor & Francis Group

 2   S. S. SANDES ET AL.
with strip electrodes has found wide application in the
surfacing of equipment in the chemical, petrochemical
and nuclear industries [19].
The present work assesses the behaviour of the
mechanical, microstructural and corrosion properties
of overlays of nickel alloy 625 deposited by the electro-
slag process with strip electrodes on carbon steel ASTM
A 516 Grade 70, with one and two layers for assessing
a possible effect of reheating on the characteristics of
the overlay, in the as-welded condition and after heat
treatment.
2.  Materials and methods
2.1. Materials
Plates of carbon steel ASTM A516 Gr. 70 of dimensions
50 mm × 400 mm × 400 mm were used as the substrate
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material. A strip electrode with thickness of 0.5 mm and
width of 60 mm of class AWS 5.14 EQ-NiCrMo-3 was
used for producing the overlay with nickel alloy 625.
Table 1 shows the chemical composition of the materials,
according to the manufacturers’ information.
2.2. Welding
The overlays were deposited by the electroslag process
with strip electrodes by two different methods. The first
overlay was produced in four passes in a single layer in
the flat welding position, while the second overlay was
produced in two layers, the first being produced in the
same conditions as the first overlay and the second layer
in two passes. The welding parameters shown in Table
2 were used.
After welding, heat treatments were carried out, con-
sisting of heating at 620 °C for 10 h, followed by cooling
in air, this condition being comparable to the as-welded
condition of the weld metal.
2.3.  Mechanical testing
Vickers microhardness tests were performed with appli-
cation of a load of 500 gf, consisting of scanning the
hardness perpendicularly to the fusion line, with spac-
ing of the indentations of 0.25 mm, including the base
metal, interface and deposited metal. Bend tests were
also carried out according to the ASME standard Section
IX [20].
Table 1. Chemical composition of the materials (wt.%).
Element, wt.% C Si Mn
Steel ASTM A516 Gr.70 0.15 0.20 0.95
Nickel alloy 625 0.03 0.40 0.30
2.4.  Metallographic tests
Metallographic analysis was undertaken, consisting of
macrographs, optical micrographs (OM) and scanning
electron microscopy (SEM) and analysis by energy dis-
persive spectroscopy (EDS) for characterization of the
microstructure, identification and quantification of sec-
ondary phases and of the presence of partially diluted
zones (PDZ) near the fusion line. For quantitative anal-
ysis of the secondary phases, we used the method of
counting points in a metallographic grid with 100 points
on the SEM screen and magnification of 1000 times. At
least 10 fields were counted at random for each condi-
tion, making up a total of 1000 points per specimen,
located in the relative position at 3 mm from the fusion
line. For analysis of the precipitation of hardening phases
in the overlay, specimens were taken at about 3 mm from
the fusion line for transmission electron microscopy
(TEM).
Specimen preparation consisted of the conventional
technique of grinding and polishing, followed by elec-
trolytic etching with 10% oxalic acid at 6 V for the weld
metal and conventional etching with 2% Nital for the
base metal. For analysis by TEM, discs with a diame-
ter of 3 mm were prepared, with electrolytic finishing
treatment of the region of observation (Tenupol 5) in a
solution of 9% of perchloric acid and 91% of ethanol, at
−20 °C and 30 V.
To obtain an estimate of the phases formed in the
overlay, thermodynamic calculations were carried out
using Thermocalc software and the TTNI8 database.
The chemical composition considered was that at about
3 mm from the fusion line.
2.5.  Chemical analysis
Chemical analysis was performed by optical emission
spectrometry on specimens of the overlay taken at differ-
ent distances from the fusion line, so as to allow analysis
of the variation of the main alloying elements along the
overlay, such as nickel and chromium and iron.
2.6.  Corrosion tests
The corrosion tests were carried out according to
standard ASTM G-48 [21], method A, with standard
NORSOK M 601 as the acceptance criterion [22]. The
specimens were taken from the overlay in the relative
position at 3 mm from the fusion line.
Ni Cr Mo Nb Fe
0.01 0.02 0.01 – Bal.
Bal. 19.5 8.0 2.8 3.00
 WELDING INTERNATIONAL   3

Table 2. Welding parameters used.
Current Voltage Welding heat input
(A) (V) (kJ/mm)
1150–1250 24–26 11.7
3.  Results and discussion
According to Pachold [23], the preference for the depo-
sition of overlays by the electroslag process is supported,
among other reasons, by the possibility of producing the
overlay in a single layer. However, there may be situations
in which the welding operation may involve additional
passes, for example, in repair situations. Accordingly, in
the present work an analysis was conducted with differ-
ent procedures, with one and two layers, to assess any
effect of reheating on the characteristics of the overlay.
Figure 1 shows metallographic sections of the over-
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performance of the overlay [5,16,25]. This behaviour
means that welding with two layers is not suitable for
overlay welding of industrial equipment.
In the case of single-layer welding, the method recom-
mended for electroslag welding, a degree of dilution of
4.0%, calculated using Auto CAD software, may be con-
sidered low compared to other processes [2,15,26,27].
In addition, no evidence of defects or delamination was
observed.
The reduced degree of dilution associated with high
welding heat input also helped to prevent the occur-
rence of partially diluted zones (PDZ) along the interface
(Figure 1), normally observed in deposition by other
electric arc processes [2,3,15,28], which is an important
indication for adequate performance of the overlay. This
evidence is also supported by hardness tests (Figure 3),
which show results well below 350–400 HV, values that
are generally associated with the occurrence of PDZ

lay produced, showing the regions of the overlay, which

[2,3,15,28].
were also observed in other technical works [3,16,24].
In relation to the weld metal, examination by light
Figure 2 shows that the Fe content decreases with
microscopy (Figure 1) showed a completely austenitic
increasing distance from the fusion line in the direction
microstructure, with the usual form of solidification
of the overlay. It can be seen that only for welding with
for overlays with nickel alloy 625 [6] and showing a
one layer, the Fe content is at a level below the limit
high level of segregation and occurrence of secondary
value of 5% at distances less than the limit of 3 mm of
phases (Figure 4). In this connection, Table 3, which
layer thickness, which is suggested for good corrosion

Figure 1. Metallographic sections of the overlay. Regiao de 1 camada = Region with one layer; Regiao de 2 camadas = Region with
two layers; Metal Base = Base metal; Metal de Solda = Weld metal; Regiao de 1 camada (MO) = Region with one layer (OM); Regiao
de 2 camadas (MO) = Region with two layers (OM).
 4   S. S. SANDES ET AL.

Figure 2. Variation of the content of the main elements with distance from the fusion line. Teor (%, Peso) = Content (wt.%); Distancia
da linha de fusao (mm) = Distance from the fusion line (mm); 1 camada = 1 layer; 2 camadas = 2 layers.
Downloaded by [Australian Catholic University] at 19:52 20 October 2017

Figure 3.  Results of the microhardness tests. Microdureza Vickers (HV0.5) = Vickers microhardness (HV0.5); Como soldado  = As-
welded; TTAT = SRHT; Metal de solda = Weld metal; Metal base = Base metal; Distancia da linha de fusao (mm) = Distance from the
fusion line (mm); 1 camada = 1 layer; 2 camadas = 2 layers.

shows the value of the coefficient of distribution (k),
contributes to understanding, already reported in the
literature [4,14,29–32] on the segregation of elements
such as Mo and Nb to the interdendritic region, enrich-
ing this region and consequently depleting the centre
of the dendrites of these elements and enriching them
with elements such as Ni. In fact, a tendency is noted for
slight segregation of the elements Ni and Cr to the solid
(k > 1) and for a marked effect of segregation of Mo and
especially of Nb to the interdendritic regions, this being
deemed to be responsible for the formation of secondary
phases in overlays with nickel alloy 625 [4,32].
According to Cieslak et al. [33], alloys without Nb
solidify with simple transformation L → γ, without any
eutectic reaction, and have a relatively narrow range of
solidification temperature. On the other hand, when
alloys containing Nb solidify they display a reaction of
the eutectic type and various secondary phases, such
as NbC and Laves phases. Du Pont et al. [19] state that
the following sequence occurs in alloys containing Nb:
(1) L → L + γ →
(2) L + γ + NbC → L + γ + NbC + M6C →
(3) L  +  γ NbC  +  M6C  +  Laves →
γ + NbC + M6C + Laves.
As support for predicting the phases present in the
overlay, Figure 5 shows a diagram obtained by thermo-
dynamic calculations using the Thermocalc software and
the TTNI8 database. Since the deposition and solidi-
fication of the overlay by the electroslag process was
carried out in a single step, a solidification diagram was
constructed, showing the phases formed in the course
of cooling. This diagram is based on Scheil’s equations
[34]. For the alloy, the sequence of formation of phases
predicted in the diagram is: L → L + γ → L + γ + NbC + →
L + γ + NbC + Laves → L + γ + NbC + Laves + σ + →

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Figure 4. Occurrence of segregation and secondary phases in the weld metal (SEM). Etching: oxalic acid. Laves = Laves; Fase Laves
(Cr-16,9, Ni-42,9, Mo-17,77, Nb-18,0) = Laves phase (Cr-16.9, Ni-42.9, Mo-17.77, Nb-18.0); Carboneto de Nb = Nb carbide.
Table 3. Coefficient of distribution k: segregation of elements.
Centre of the dendrite Interdendritic region
Item (Cs) (Ci)
Cr 22.58 19.99
Ni 61.63 55.49
Mo 8.85 12.61
Nb 1.90 7.71
L + γ + NbC + Laves + δ → L + γ + Laves + δ + M6C + σ.
It should be emphasized that during solidification there
is segregation of Mo and Nb to the interdendritic liquid,
locally enriching-said regions and causing the formation
of phases rich in these elements such as σ and Laves.
Figure 6 shows pseudo-binary diagrams with Nb and
Mo, showing that segregation of these elements causes
formation of phases such as Laves and σ.
Since heat treatment at 620 °C for 10 h was carried out
after deposition of the overlay, calculations of the equi-
librium of phases formed at this temperature were also
undertaken. Precipitations of σ and γ″ phases were pre-
dicted for this temperature. The γ″ phase is metastable,
of body-centred tetragonal structure, and its presence
in nickel alloy 625 may lead to an increase in strength.
The results obtained in the present work are in
agreement with this prediction, since we observed the
presence of secondary phases, Laves rich in Nb and
Nb carbides (Figure 4), with a volume fraction below
WELDING INTERNATIONAL   5
1.5% in the weld metal investigated. These results are
consistent with those reported by various other authors
k [1,3,7,15,19,24,33,35–38].
1.13 Owing to the high-welding heat input applied, the
1.11
0.70 microstructure of the coarse-grained region of the HAZ
0.25 (CGRHAZ) consisted of pro-eutectoid ferrite, pearlite
and bainite for the deposit with one layer. For the deposit
with two layers, the region of the base metal near the
interface, identified here as the normalized coarse-
grained region of the HAZ (NCGRHAZ), displayed
refined ferrite and pearlite, as a result of the reheating
effect caused by the thermal cycle of this second layer
(Figure 7). These microstructures with low hardness
(Figure 3) are also relevant, as they differ from the mar-
tensitic microstructure with higher hardness normally
found in this region when deposition is performed by
other welding processes [15,17,28]. In the specific case
in the present work, the higher hardness values in the
base metal were always below 250 HV, the value recom-
mended by standard NACE M0175 [39] for qualification
of welding processes.
Stress-relief heat treatment (SRHT) is sometimes car-
ried out to alleviate residual stresses, lower the hydrogen
content, homogenize the microstructure or maintain
the levels of the hardness values within a certain range
[19,24,26,40]. However, phases may be precipitated
during execution of heat treatment. In this connection,
 6   S. S. SANDES ET AL.
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Figure 5.  Scheil Diagram for the weld metals. Temperatura
°C  =  Temperature °C Fraçao molar das fases sólidas  =  Mole
fraction of the solid phases. 1: LIQUID; 2: MATRIX – LIQUID; 3:
MATRIX – MC – LIQUID; 4: MATRIX – MC – LAVES – LIQUID; 5:
MATRIX – MC – LAVES – LIQUID – SIGMA; 6: MATRIX – MC –
LAVES – LIQUID – DELTA; 7: MATRIX – LAVES – LIQUID – M6C
– DELTA – SIGMA.
Cortial et al. [1], studying the effect of SRHT on the
microstructure and mechanical properties of deposits
made with nickel alloy 625, observed an increase in
mechanical strength and a reduction in ductility due to
the precipitation of the γ″ phase (Ni3Nb) in the inter-
dendritic space only for temperatures above 750  °C.
Figure 6.  Pseudo-binary diagram for the weld metal with variations of: (a) Nb; (b) Mo. The hatched regions show the region of
formation of the σ phase. LIQUIDO = LIQUID; MATRIZ = MATRIX; GAMA = GAMMA; ALFA = ALPHA; Temperatura °C = Temperature
(°C); % em massa de Nb = Nb, wt.%; % em massa de Mo = Mo, wt.%.
However, in recent works, Suave et al. [41,42] observed
the appearance of this phase for ageing temperatures
in the range 550–750  °C. As can be seen in Figure 8,
observation by TEM confirms precipitation of γ″ along
the matrix, in the form of fine precipitation, which indi-
cates that the increase in hardness in the weld metal after
SRHT (Figure 3) is associated with precipitation of this
phase, as is verified in other studies that are available
[1,19,37,41,42].
In the HAZ, SRHT promoted tempering of the
microstructure, with consequent reduction in hardness
(Figure 3).
In general, SRHT carried out at 620  °C did not
cause significant changes in mechanical properties, for
although it contributed to small changes in the results
of the hardness tests (Figure 3), no incidence of defects
was observed in the bend tests (Figure 9).
Based on the results obtained, it is assessed that the
single-layer electroslag process may be an attractive
alternative for depositing overlays of nickel alloy 625
on carbon steels, as it allows defect-free overlays to be
obtained, with suitable mechanical and microstructural
properties, and with a lower risk of problems arising at
the interface due to the high welding heat inputs applied.
It could also be verified that there were only small
changes resulting from SRHT, which is a more important
factor owing to the stability of the deposits, when repairs
are necessary. Thus, the option for deposition in a single
pass offers advantages in that there is an improvement
in productivity in the deposition operations.
In order to confirm that this process can be used in
the deposition of high-quality overlays at high produc-
tivity, with just a single layer, corrosion tests were car-
ried out according to the standard required for process
qualification [21]. Table 4 shows the results of the tests,
 WELDING INTERNATIONAL   7

Figure 7. Microstructure of the CGRHAZ for one layer and NCGRHAZ for two layers (OM). Etched: 2% Nital.
Downloaded by [Australian Catholic University] at 19:52 20 October 2017

Figure 8. Occurrence of fine precipitation of γ″ phase after SRHT in the weld metal observed by TEM. Shown at top left is the electron
diffraction pattern, where the larger bright points relate to the matrix and the smaller ones relate to the γ″ precipitates. The yellow
arrows indicate the γ″ precipitates, of fine appearance and with diffuse contours, as a function of their coherence distortion.

providing evidence of satisfactory results, with weight

loss less than is observed in other processes [15].

4. Conclusions
The following can be concluded from the results found
in the present work:
Figure 9. Appearance of the bend test specimens after testing. (1) coatings produced by the single-layer elec-
troslag process have good mechanical and
Table 4. Results of the corrosion tests. corrosion properties, despite the presence of
Condition Pitting Weight loss (g/m2)
secondary phases in the weld metal;
As-welded No 0.0 (2) SRHT does not promote significant changes in
SRHT No 0.17 the properties of the overlays;
Norsok requirement [22] No <4.00
 8   S. S. SANDES ET AL.
(3) deposition by the single-layer electroslag pro-
cess may be an interesting alternative for over-
lays of alloy 625 on carbon steel, owing to the
good mechanical and corrosion properties, low
degree of dilution and high productivity.
Acknowledgements
The authors thank the following Institutions for their sup-
port in the execution of the present work: CEFET/RJ,
PETROBRAS, UFRJ, CNPq and FINEP. Thanks are also due
to the Multiuser Microscopy Centre of the COPPE/UFRJ for
the transmission microscopy images.
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