Role of gaseous environment and secondary precipitation in microstructural degradation of Cr-Mo steel weldments at high temperatures

This study is an attempt to understand the combined role of variations in oxidizing environment and secondary precipitation, in the microstructurally different regions of a standard Cr-Mo steel weldment, on the intensity of internal oxidation during high-temperature oxidation in air and steam environments. Samples of the weld-metal, heat-affected zone (HAZ), and base-metal regions were separated from the weldment of 2.25Cr-1 Mo steel and oxidized in the environments of air and steam at 873 K. The oxide scales and underlying subscales were characterized using scanning electron microscopy (SEM), energy-dispersive X-ray (EDX) analysis, and electron probe microanalysis (EPMA). Extensive internal oxidation and oxidation-induced void formation in the subscale zone and grain-boundary cavitation in the neighboring region were found to occur during oxidation in the steam environment. However, the internal oxidation and void formation were much more extensive in the subscale regions of the HAZ than in the subscales of the weld-metal and base-metal regions. As a result, the alloy matrix in the area neighboring the subscale region of the HAZ specimen suffered extensive grain-boundary cavitation. This behavior has been attributed to a rather specific combination and complex interplay of the environment, alloy microstructure, oxidizing temperature, and nature of the resulting external scale in causing and sustaining internal oxidation. The article also discusses the role of internal oxidation-assisted microstructural degradation in deteriorating the service life of components of 2.25Cr-1Mo steel.     

Relevance of high-temperature oxidation in life assessment and microstructural degradation of Cr-Mo steel weldments

Measurement of the thickness of oxide scales that develop over high-temperature components has found an innovative application in life assessment of steam generation and handling systems. The present study is an investigation of the high-temperature corrosion and scale thickness across the weldments of a “chromium-molybdenum” steel, and reviews its possible relevance to the life assessment of the welded high-temperature components by scale thickness measurement. Results are presented of the recent investigations on the combined roles of the oxidizing environment and secondary carbide precipitation on the extent of void formation in the microstructurally different regions of weldments of the chromium-molybdenum steel. Specimens of the weld metal, heat-affected zone (HAZ), and base metal of a 2.25Cr-1Mo steel weldment were oxidized in steam. Extensive internal oxidation and oxidation-induced void formation (with a much greater intensity in the case of the HAZ) is discussed. The greater intensity of oxidation-induced void formation in the HAZ may facilitate preferential cracking in this region of the weldments and, hence, is proposed to be an important parameter in the context of the recently developed codes for life assessment of aging high-temperature components.     

An assessment of creep deformation and fracture behavior of 2.25Cr-1Mo similar and dissimilar weld joints

The evaluation of the creep deformation and fracture behavior of a 2.25Cr-1Mo steel base metal, a 2.25Cr-1Mo/2.25Cr-1Mo similar weld joint, and a 2.25Cr-1Mo/Alloy 800 dissimilar weld joint at 823 K over a stress range of 90 to 250 MPa has been carried out. The specimens for creep testing were taken from single-V weld pads fabricated by a shielded metal arc-welding process using 2.25Cr-1Mo steel (for similar-joint) and INCONEL 182 (for dissimilar-joint) electrodes. The weld pads were subsequently given a postweld heat treatment (PWHT) of 973 K for 1 hour. The microstructure and microhardness of the weld joints were evaluated in the as-welded, postweld heat-treated, and creep-tested conditions. The heat-affected zone (HAZ) of similar weld joint consisted of bainite in the coarse-prior-austenitic-grain (CPAG) region near the fusion line, followed by bainite in the fine-prior-austenitic-grain (FPAG) and intercritical regions merging with the unaffected base metal. In addition to the HAZ structures in the 2.25Cr-1Mo steel, the dissimilar weld joint displayed a definite INCONEL/2.25Cr-1Mo weld interface structure present either as a sharp line or as a diffuse region. A hardness trough was observed in the intercritical region of the HAZ in both weld joints, while a maxima in hardness was seen at the weld interface of the dissimilar weld joint. Both weld joints exhibited significantly lower rupture lives compared to the 2.25Cr-1Mo base metal. The dissimilar weld joint exhibited poor rupture life compared to the similar weld joint, at applied stresses lower than 130 MPa. In both weld joints, the strain distribution across the specimen gage length during creep testing varied significantly. During creep testing, localization of deformation occurred in the intercritical HAZ. In the similar weld joint, at all stress levels investigated, and in the dissimilar weld joint, at stresses ≥150 MPa, the creep failure occurred in the intercritical HAZ. The fracture occurred by transgranular mode with a large number of dimples. At stresses below 150 MPa, the failure in the dissimilar weld joint occurred in the CPAG HAZ near to the weld interface. The failure occurred by extensive intergranular creep cavity formation.     

A Comparison of Creep Rupture Strength of Ferritic/Austenitic Dissimilar Weld Joints of Different Grades of Cr-Mo Ferritic Steels

Evaluations of creep rupture properties of dissimilar weld joints of 2.25Cr-1Mo, 9Cr-1Mo, and 9Cr-1MoVNb steels with Alloy 800 at 823 K were carried out. The joints were fabricated by a fusion welding process employing an INCONEL 182 weld electrode. All the joints displayed lower creep rupture strength than their respective ferritic steel base metals, and the strength reduction was greater in the 2.25Cr-1Mo steel joint and less in the 9Cr-1Mo steel joint. Failure location in the joints was found to shift from the ferritic steel base metal to the intercritical region of the heat-affected zone (HAZ) of the ferritic steel (type IV cracking) with the decrease in stress. At still lower stresses, the failure in the joints occurred at the ferritic/austenitic weld interface. The stress-life variation of the joints showed two-slope behavior and the slope change coincided with the occurrence of ferritic/austenitic weld interface cracking. Preferential creep cavitation in the soft intercritical HAZ induced type IV failure, whereas creep cavitation at the interfacial particles induced ferritic/austenitic weld interface cracking. Micromechanisms of the type IV failure and the ferritic/austenitic interface cracking in the dissimilar weld joint of the ferritic steels and relative cracking susceptibility of the joints are discussed based on microstructural investigation, mechanical testing, and finite element analysis (FEA) of the stress state across the joint.     

Influence of microstructural variations in the weldment on the high-temperature corrosion of 2.25Cr-1Mo steel

In order to study the influence of microstructural variation on the oxidation of the weldment of 2.25Cr-1Mo steel, regions with different microstructures were identified by optical microscopy. The weld metal, the base metal, and the heat-affected zone (HAZ), as well as the subzones within the HAZ, i.e., the intercritical (ICR), the fine-grain bainite (FGB), and the coarse-grain bainite (CGB) regions were separated from the weldment by precise steps of metallography. Transmission electron microscopic examinations for the identification of the secondary phases in microstructurally different regions and subzones have suggested that M₂₃C₆ and M₇C₃ pre-cipitates form predominantly in the subzones of HAZ, whereas the Mo₂C type of carbide forms exclusively in the weld-metal and base-metal regions of the weldment. However, population and distribution of the secondary phases were different in the three subzones of the HAZ. In order to understand the influence of these microstructural variations on the oxidation behavior, the various regions and subzones were oxidized at 773 and 873 K. The HAZ and its constituents were found to oxidize at much higher rates than the weld metal and the base metal. Relative compositions and morphologies of the scales were compared by scanning electron microscopy with energy-dispersive analyses of X-rays (SEM/EDX), and secondary ion mass spectrometry (SIMS). Scale formed over the weld metal shows a greater tendency for spallation, as suggested by tests monitoring acoustic emission. X-ray diffraction (XRD) patterns of the scales over these specimens were taken. Results of the SEM/EDX, SIMS, and XRD investigations suggest for-mation of inner scales with less Cr(i.e., less protective) over the HAZ than over the weld-metal and the base-metal regions. Variation in the Cr contents of the scales formed over the various regions is proposed to arise from the difference in microstructural features in different regions of the weldments. Formerly with the Metallurgy Division, Indira Gandhi Centre for Atomic Research, Kalpakkan, India     

Prediction of type IV cracking behaviour of 2.25Cr-1Mo steel weld joint based on finite element analysis

Creep tests were carried out on 2.25Cr-1Mo ferritic steel base metal and its fusion welded joint at 823 K over a stress range of 100–240 MPa. The weld joint possessed lower creep rupture strength than the base metal and the reduction was more at lower applied stresses. The failure occurred in the intercritical region of heat-affected zone (HAZ) of the joint, commonly known as Type IV cracking. Type IV cracking in the joint was manifested as pronounced localization of creep deformation in the soft intercritical region of HAZ coupled with preferential creep cavitation. The creep cavitation in intercritical HAZ was found to initiate at the central region of the creep specimen and propagate outwards to the surface. To explain the above observations, the stress and strain distributions across the weld joint during creep exposure were estimated by using finite element analysis. For this purpose creep tests were also carried out on the deposited weld metal and simulated HAZ structures (viz. coarse-grain structure, fine-grain structure, and intercritically annealed structure) of the joint. Creep rupture strength of different constituents of joint were in the increasing order of intercritical HAZ, fine-grain HAZ, base metal, weld metal and coarse-grain HAZ. Localized preferential creep straining in the intercritical HAZ of weld joint as observed experimentally was supported by the finite element analysis. Estimated higher principal stress at the interior regions of intercritical HAZ explained the pronounced creep cavitation at these regions leading to Type IV failure of the joint.     

Hydrogen attack behavior of the heat affected zone of a 2.25Cr-1Mo steel weldment

The kinetics of hydrogen attack (HA) has been studied in the heat affected zone (HAZ) in a 2.25Cr-1Mo steel weld to determine the relative rates of attack and bubble nucleation in the HAZ, base metal, and weld metal. The HAZ was found to suffer hydrogen attack at nearly twice the rate of the base metal, but not as rapidly as the weld metal. Nucleation of bubbles does not occur during HA of the HAZ of a 2.25Cr-1Mo steel, on exposure to hydrogen pressure of 20.5 MPa or less, but does occur at higher pressures up to 31.5 MPa (4500 psi) at 550 °C, or up to 27.5 MPa (4000 psi) at 580 °C. Such nucleation results in enhancement of the HA rate by a factor of six. The weak dependence of nucleation effects on hydrogen pressure and the saturation of the nucleation effects in a short time suggest some thermally activated nucleation of fresh bubbles. Formerly with The Ohio State University.     

Transition of Crack from Type IV to Type II Resulting from Improved Utilization of Boron in the Modified 9Cr-1Mo Steel Weldment

The roles of boron and heat-treatment temperature in improving the type IV cracking resistance of modified 9Cr-1Mo steel weldment were studied. Two different heats of P91 steel, one without boron, designated as P91 and the other with controlled addition of boron with very low nitrogen, designated as P91B, were melted for the current study. The addition of Boron to modified 9Cr-1Mo steel has increased the resistance against softening in fine-grained heat-affected zones (FGHAZ) and intercritical heat-affected zones (ICHAZ) of the weldment. Creep rupture life of boron containing modified 9Cr-1Mo steel weldment, prepared from 1423?K (1150?°C) normalized base metal, was found to be much higher than that prepared from 1323?K (1050?°C) normalized base metal because of the stabilization of lath martensite by fine M₂₃C₆ precipitates. This finding is in contrast to the reduction in creep rupture life of P91 weldment prepared from 1423?K (1150?°C) normalized base metal compared with that of the weldment prepared from 1323?K (1050?°C) normalized base metal. The trace of failure path from the weld metal to ICHAZ in P91B weldment was indicative of type II failure in contrast to type IV failure outside the HAZ and base metal junction in P91 weldment, which suggested that boron strengthened the microstructure of the HAZ, whereby the utilization of boron at a higher normalizing temperature seemed to be significantly greater than that at the lower normalizing temperature.     

Effect of Application of Short and Long Holds on Fatigue Life of Modified 9Cr-1Mo Steel Weld Joint

Modified 9Cr-1Mo steel is a heat-treatable steel and hence the microstructure is temperature sensitive. During welding, the weld joint (WJ) is exposed to various temperatures resulting in a complex heterogeneous microstructure across the weld joint, such as the weld metal, heat-affected zone (HAZ) (consisting of coarse-grained HAZ, fine-grained HAZ, and intercritical HAZ), and the unaffected base metal of varying mechanical properties. The overall creep–fatigue interaction (CFI) response of the WJ is hence due to a complex interplay between various factors such as surface oxides and stress relaxation (SR) occurring in each microstructural zone. It has been demonstrated that SR occurring during application of hold in a CFI cycle is an important parameter that controls fatigue life. Creep–fatigue damage in a cavitation-resistant material such as modified 9Cr-1Mo steel base metal is accommodated in the form of microstructural degradation. However, due to the complex heterogeneous microstructure across the weld joint, SR will be different in different microstructural zones. Hence, the damage is accommodated in the form of preferential coarsening of the substructure, cavity formation around the coarsened carbides, and new surface formation such as cracks in the soft heat-affected zone.     

Characterization of Microstructures across the Heat-Affected Zone of the Modified 9Cr-1Mo Weld Joint to Understand Its Role in Promoting Type IV Cracking

In the postweld heat-treated (PWHT) fusion welded modified 9Cr-1Mo steel joint, a soft zone was identified at the outer edge of the heat-affected zone (HAZ) of the base metal adjacent to the deposited weld metal. Hardness and tensile tests were performed on the base metal subjected to soaking for 5 minutes at temperatures below Ac₁ to above Ac₃ and tempering at the PWHT condition. These tests indicated that the soft zone in the weld joint corresponds to the intercritical region of HAZ. Creep tests were conducted on the base metal and cross weld joint. At relatively lower stresses and higher test temperatures, the weld joint possessed lower creep rupture life than the base metal, and the difference in creep rupture life increased with the decrease in stress and increase in temperature. Preferential accumulation of creep deformation coupled with extensive creep cavitation in the intercritical region of HAZ led to the premature failure of the weld joint in the intercritical region of the HAZ, commonly known as type IV cracking. The microstructures across the HAZ of the weld joint have been characterized to understand the role of microstructure in promoting type IV cracking. Strength reduction in the intercritical HAZ of the joint resulted from the combined effects of coarsening of dislocation substructures and precipitates. Constrained deformation of the soft intercritical HAZ sandwich between relatively stronger constitutes of the joint induced creep cavitation in the soft zone resulting in premature failure.     

Fracture toughness behavior of ex-service 2-1/4Cr-1Mo steels from a 22-year-old fossil power plant

Elevated-temperature fracture toughness properties were developed on ex-service 2-l/4Cr-1Mo steel weldments. Fracture toughness was measured on both base and heat-affected zone (HAZ) metals. A composite specimen consisting of base, HAZ, and weld metals was used to develop fracture toughness properties in the HAZ area. It was observed that the J-R curve of the HAZ was significantly lower than that of the base metal. Increasing crack extension increased the difference between theJ-R curves of the base metal and the HAZ. Dimpled fracture was the prime fracture mode in the base metal specimen, and a mixed-mode (ductile and “granular”) fracture was found in the HAZ specimens. Scanning transmission electron microscopy (STEM) examination revealed significant intergranular carbide precipitation and agglomeration within the HAZ. The lower fracture toughness of the HAZ, as compared to the base metal, was attributed to the large accumulation of carbides in the grain boundaries of the HAZ, which weakened the grain boundaries and caused “granular” fracture.     

Three-dimensional monte carlo simulation of grain growth in the heat-affected zone of a 2.25Cr-1Mo steel weld

We report here the first three-dimensional (3-D) Monte Carlo (MC) modeling of grain growth in the heat-affected zone (HAZ) of a weldment. Computed grain-size distributions in the HAZ of a 2.25Cr-1Mo steel, for different heat inputs in the range from 1.1 to 4.8 MJ/m, were compared to independent experimental results. The simulated mean grain size for different heat inputs agreed well with the corresponding independent experimental data. The mean grain size at various locations equidistant from the fusion line were different. The predicted grain size from the 3-D model matched the experimental results more closely than that from a two-dimensional (2-D) model. When the whole calculation domain was subjected to a single thermal cycle experienced by a monitoring location within the HAZ, the computed grain size was larger than that calculated at the monitoring location by taking into account the prevailing temperature gradient due to thermal pinning. The good agreement between the simulated grain structure and the corresponding experimental results indicates significant promise for understanding grain-growth phenomena in the entire HAZ by using the MC technique.     

Microstructural Characterization of the Heat-Affected Zones in Grade 92 Steel Welds: Double-Pass and Multipass Welds

The microstructure in the heat-affected zone (HAZ) of multipass welds typical of those used in power plants and made from 9 wt pct chromium martensitic Grade 92 steel is complex. Therefore, there is a need for systematic microstructural investigations to define the different regions of the microstructure across the HAZ of Grade 92 steel welds manufactured using the traditional arc welding processes in order to understand possible failure mechanisms after long-term service. In this study, the microstructure in the HAZ of an as-fabricated two-pass bead-on-plate weld on a parent metal of Grade 92 steel has been systematically investigated and compared to a complex, multipass thick section weldment using an extensive range of electron and ion-microscopy-based techniques. A dilatometer has been used to apply controlled thermal cycles to simulate the microstructures in distinctly different regions in a multipass HAZ using sequential thermal cycles. A wide range of microstructural properties in the simulated materials were characterized and compared with the experimental observations from the weld HAZ. It has been found that the microstructure in the HAZ can be categorized by a combination of sequential thermal cycles experienced by the different zones within the complex weld metal, using the terminology developed for these regions based on a simpler, single-pass bead-on-plate weld, categorized as complete transformation, partial transformation, and overtempered.     

Intelligent Modeling Combining Adaptive Neuro Fuzzy Inference System and Genetic Algorithm for Optimizing Welding Process Parameters

Modified 9Cr-1Mo ferritic steel is used as a structural material for steam generator components of power plants. Generally, tungsten inert gas (TIG) welding is preferred for welding of these steels in which the depth of penetration achievable during autogenous welding is limited. Therefore, activated flux TIG (A-TIG) welding, a novel welding technique, has been developed in-house to increase the depth of penetration. In modified 9Cr-1Mo steel joints produced by the A-TIG welding process, weld bead width, depth of penetration, and heat-affected zone (HAZ) width play an important role in determining the mechanical properties as well as the performance of the weld joints during service. To obtain the desired weld bead geometry and HAZ width, it becomes important to set the welding process parameters. In this work, adaptative neuro fuzzy inference system is used to develop independent models correlating the welding process parameters like current, voltage, and torch speed with weld bead shape parameters like depth of penetration, bead width, and HAZ width. Then a genetic algorithm is employed to determine the optimum A-TIG welding process parameters to obtain the desired weld bead shape parameters and HAZ width.     

核能用2.25Cr-1Mo钢水蒸气氧化行为

 为了研究核电用2.25Cr-1Mo钢的抗蒸汽氧化性能,在500 ℃、0.1 MPa水蒸气条件下,对2.25Cr-1Mo耐热钢进行了600 h的氧化试验,利用分析天平测定样品氧化增重,获得氧化动力学曲线,通过扫描电镜观察分析了氧化膜的形貌和结构,结合X射线衍射和能谱分析对氧化产物进行物相分析。试验结果表明,2.25Cr-1Mo耐热钢的氧化增重曲线符合立方规律;氧化膜为双层结构,氧化膜内层较为致密的主要物相为(Fe,Cr)₃O₄尖晶石,氧化膜外层疏松多孔主要物相为Fe₃O₄和少量Fe₂O₃;腐蚀速率测定结果表明,该材料具有较好的抗蒸汽氧化性能。     

2.25Cr-1Mo合金钢回火脆化过时效现象的研究

研究了2.25Cr-1Mo合金钢在回火温度下时效处理时,发生回火脆化和回火脆化的过时效反偏聚现象。应用非平衡偏聚的动力学理论,确定了成分(%)为0.15C、2.32Cr、0.95Mo、0.009P的2.25Cr-1Mo合金钢在650℃140 h回火时钢中磷的非平衡晶界偏聚规律。试验得出,2.25Cr-1Mo合金钢650℃磷非平衡偏聚的临界时间t_c为20 h,晶界磷的原子浓度,由初始状态的0.016%提高至最大值2.79%。根据试验数据进行的动力学计算,得出的计算曲线与试验结果吻合,验证了非平衡晶界偏聚空位-复合体模型的扩散机制。     

Fracture toughness of modified P91 weldments

There are efforts to develop modified P91 steel (9Cr-1Mo-V) consumables to optimize strength and fracture toughness in weldments for similar and dissimilar welding of 9Cr-1Mo (modified P91) for both new construction and replacement of serviced components. Fracture toughness is an important consideration which plays a vital role in determining the performance and life of the materials under the given service conditions. Toughness characterization was done by the Crack Tip Opening Displacement (CTOD) method. Welding results in a variety of non-equilibrium microstructures in the HAZ of 9Cr-lMo-V, modified P91 steel. These variations of microstructures from wrought base material through transformed HAZ to cast weld metal, may give rise to considerable inhomogeneity with respect to tensile & creep strength and ductility across the weld joints. However the mechanical properties of the individual regions of HAZ are difficult to obtain because of the small extent over which each region exists. Welded joints are used as structural parts of boilers and pressure vessels working at high temperatures, hence the main requirement is creep resistance. In the present investigation, the fracture toughness characteristics of base metal and weld metal have been evaluated by CTOD method as per the standard BS 7448. The fracture surfaces of the CTOD tested specimens were examined under Scanning Electron Microscope (SEM). Fractographic studies revealed the mode of failure and the characteristics of the fracture surface.     

Circumventing Practical Difficulties in Determination of Threshold Stress Intensity for Stress Corrosion Cracking of Narrow Regions of Welded Structures

Determination of the threshold stress intensity for stress corrosion cracking (K _Iscc) of narrow areas such as weld and heat-affected zone (HAZ) of a weldment is a nontrivial task because of the requirements of large specimens in testing by the traditional techniques and the difficulty of restricting crack propagation to narrow regions in such specimens. This article describes a successful application of the circumferential notch tensile (CNT) technique to determine the K _Iscc of narrow regions of the weld and HAZ. Also, the microstructure of the HAZ of the manual metal arc-welded steel was simulated over a relatively small length of specimens and its K _Iscc in a hot caustic solution was determined successfully. Intergranular stress corrosion cracking was confirmed with a scanning electron microscope.