镍基焊材返修P92小径管焊口工艺

P92钢是新型铁素体耐热钢,目前国内采用其匹配焊材进行返修,焊后需进行再次热处理,而多次热处理会造成管壁的性能下降,且需要花费大量的时间和成本。在临时性返修没有匹配焊材的情况下,采用镍基焊材进行P92钢管焊口返修,返修后免做热处理,避免多次热循环对管子性能的影响,然后进行各项性能试验。结果表明,返修后的焊接接头拉伸试验合格,断裂位置位于母材;焊缝、热影响区、母材的硬度值符合规定要求;焊缝、热影响区的冲击值符合规定要求;金相组织合格。试验证明,采用镍基焊材进行临时性返修试验是可行的,但对于高温时效性能及持久强度性能,还需要进一步研究。     

Recent developments in repair welding technologies in Japan

Abstract

Developments in some difficult repair welding technologies in Japan during the past decade are reviewed. The topics covered include the repair welding of bridges in service, the temper bead method which makes it possible to omit post-weld heat treatment (PWHT) of repaired pressure vessels, the seal welding of a reactor vessel in which stress corrosion cracks were detected, low heat input repair welding of neutron irradiated stainless steel and nickel based alloys, the prevention of solidification cracking in repair welding of aged heat resistant cast steels, the development of welding materials for the mending of single crystal nickel based superalloy turbine blades, underwater repair welding of nuclear reactors, the reduction of residual stresses in repair welding, and an ultrasonic testing method for nickel based weld metals. The local PWHT of creep resistant ferritic steel tubes is also reviewed.     

Zur Entwicklung der elektrochemischen potentiokinetischen Reaktivierungsmethode – des EPR‐Tests

On the development of the electrochemical potentiokinetic reactivation method – the EPR‐test Electrochemical potentiokinetic reactivation methods, but also other polarisation methods, are suitable as quasi non destructive testing methods to describe the corrosion resistance of steels and alloys without needing a very pretentious surface preparation. They may be used also to check finished components or even on site such in service, especially welding areas or weld overlays. Compared to standard tests they are quicker, more sensitive, more objective and quasi quantitative. They may be applied not only with austenitic standard steels but also with high alloyed ferritic, martensitic or duplex steels as well as with nickel based alloys. After any case of heat treatment the sensitivity to intergranular corrosion but also to pitting or selective attack can be determined by these testing methods. They may inform on the general corrosion resistance or the microstructural changes which may occur with materials, too. Based on the experience of many years with such methods which, starting from the early developments, have now been applied to very different materials, one may attend new fields of application in research and also as a nationally and internationally testing standard.     

铝合金搅拌摩擦焊接头缺陷及焊件结构问题控制策略的研究进展

搅拌摩擦焊(Friction Stir Welding,FSW)是近些年发展起来的一种固态连接工艺,尤其适用于铝合金材料的焊接。概述了搅拌摩擦焊的局限性,主要包括接头处存在钥匙孔、焊缝减薄等缺陷及复杂结构铝合金难以焊接等问题。研究表明,通过工艺方法、流程及参量的优化能够对焊接接头缺陷和焊件结构问题进行有效控制。由此,归纳了铝合金搅拌摩擦焊接头存在的关键问题及解决策略,分析了每种工艺方法的适用对象及条件,包括摩擦塞焊(Friction Plug Welding,FPW)、填充式搅拌摩擦焊(Filled Friction Stir Welding,FFSW)、回抽式FSW、静止轴肩搅拌摩擦焊(Stationary Shoulder Friction Stir Welded,SSFSW)、沉积式FSW、双轴肩搅拌摩擦焊(Bobbin Tool Friction Stir Welding,BT-FSW)和无倾角FSW。详细探讨了每种工艺的原理和机制,阐述了每种工艺的优缺点,重点介绍了工艺的参数优化调控、辅助设备的添加及工序的改进对修复接头组织与力学性能的影响。对铝合金搅拌摩擦焊的回顾总结,将为获得高质量搅拌摩擦焊接头,实现复杂结构件焊接提供参考依据。在此基础上,对铝合金搅拌摩擦焊现存问题及挑战的解决进行了展望。     

Welding and weldability of candidate ferritic alloys for future advanced ultrasupercritical fossil power plants

Abstract

Fossil fuels continue to be the primary source of energy in the world. The worldwide demand for clean and affordable energy will continue to grow, and a strong emphasis has been placed on increasing the efficiency and reducing the carbon footprint of new and existing fossil fired power plants. Throughout Asia, Europe and the USA, this demand is being met with programmes to develop advanced materials that have enhanced high temperature creep and corrosion properties. A new class of ferritic alloys, known as creep strength enhanced ferritic steels, has been developed to meet these requirements. This article focuses on the weldability of the advanced ferritic alloys used in boilers and boiler components of ultrasupercritical coal fired power plants. This review focuses on alloy selection; welding and weldability issues, including in service weld failure such as type IV cracking; welding of dissimilar metals; and weld repair. Future articles will address the welding and weldability issues of two other classes of materials, namely austenitic stainless steels and nickel base superalloys.     

Environmental behavior of beta titanium alloys

Stemming from their unique combination of elevated strength, low density, and good overall corrosion resistance, beta titanium alloys have become attractive candidate materials for critical, high-stress components in corrosive services. An overview of the comparative corrosion resistance of beta alloys to conventional alpha and alpha/beta titanium alloys in common industrial and aerospace service environments generally reveals attractive behavior depending on the environment and alloy composition and, in some cases, alloy condition. Expanded performance windows are especially noted for the molybdenum-rich beta alloys, particularly with regard to resisting reducing acids, stress corrosion, and high-temperature localized chloride attack, along with hydrogen and oxidation resistance. Where applicable, implications of this enhanced corrosion performance on current and perspective beta alloy applications are also noted.     

热输入对T4003/Q450NQR1异种钢焊接接头组织及性能的影响

采用奥氏体焊材ER309LSi-G焊丝对T4003铁素体不锈钢与Q450NQR1耐候钢异种钢进行两种不同焊接热输入的MAG焊接,通过显微组织和力学性能等试验,对两种焊接接头性能进行研究。结果表明:两种焊接接头均未发现缺陷,焊接接头性能较好。与0.82 kJ/mm热输入比较,0.62 kJ/mm热输入下的焊接接头冲击韧性及硬度较好,熔合线较窄,晶粒度较为细小,拉伸数值较高,更加适用于T4003铁素体不锈钢与Q450NQR1耐候钢异种钢焊接。     

Joining dispersion-strengthened,rapidly solidified,P/M Al alloys

The weldability of dispersion-strengthened, rapidly solidified Al-Fe alloys is limited by the residual hydrogen content, solidification behavior, and the high-temperature deformation behavior of these alloys. Consequently, the selection and application of welding processes and conditions to join these aluminum alloys—either to themselves or with other engineering alloys—must be based on the ability of the welding process conditions to eliminate or minimize the occurrence of fusion zone porosity; “recreate” a microstructure similar to the rapidly solidified, powder metallurgy base alloy; and/or “retain” the superior base alloy microstructure in the weld zone. Toward this end, an understanding of the physical metallurgy and high-temperature deformation characteristics of the dispersion-strengthened, rapidly solidified, powder metallurgy Al-Fe alloys and the effects of welding process conditions and parameters on weld solidification behavior and microstructural development in the weld zone will enable one to optimize welding conditions to obtain desirable combinations of weld microstructure and mechanical properties.     

Behavior of Fe-Mn-Al-C steels during cyclic tests

Alloys of the FeMnAlC system have been used for cryogenic purposes and for applications up to 673 K. At low temperatures, they have in general a better performance than austenitic Cr-Ni steels as far as fatigue is concerned, but are inferior to martensitic Cr steels. However, since the fatigue strength of FeMnAlC alloys in the temperature range of 523 to 823 K is higher than at room temperature, the present work has been conducted to describe the behavior of such alloys under the action of cyclic loading, including elasto-plastic deformation and cyclic temperatures. It has been concluded that components can be successfully subjected to cyclic loads in the elasto-plastic regime and to periodic changes in temperature under normal service conditions.     

高温合金电子束焊接温度场数值模拟

根据熔池边界准则应用有限元方法对高温合金电子束焊接温度场进行了数值模拟.通过线性插值、等效代换等方式估计材料高温参数,模拟材料状态变化.针对电子束焊接特有的钉头状焊缝及其穿透深度大的特点,采用高斯面热源与柱体热源组成的组合热源模型,对焊接温度场进行分析,模拟结果与实际焊缝取得了良好的一致.获得了一定工艺条件下高温合金电子束焊接温度场的分布特征及焊接过程热循环曲线,为优化电子束焊接工艺和电子束焊接残余应力研究提供了参考.     

旋转速度对镁/铜异种金属搅拌摩擦焊接头成形及拉伸性能的影响

保持95 mm/min焊接速度不变的条件下,通过改变旋转速度研究其对镁/铜异种金属搅拌摩擦焊接头成形和力学性能的影响。结果表明:采用750 r/min搅拌头旋转速度焊接时,焊缝表面出现起皮现象;焊核区底部形成明显的隧道槽缺陷。适当增加搅拌头旋转速度至950 r/min时,焊缝表面变得更光滑;混合区尺寸增大;内部隧道槽缺陷消失;该混合区主要由被搅碎的Mg、Cu合金和少量新生成的Mg₂Cu金属间化合物组成;接头的抗拉性能最好,抗拉强度达81.7 MPa;但是,继续增大搅拌头旋转速度至1180 r/min时,不利于接头成形,混合区底部有细小的孔洞缺陷产生。     

Effect of Heat Treatment on Microstructure and Hot Impact Toughness of Various Zones of P91 Welded Pipes

The new generation super critical thermal power plants are required to operate at enhanced thermal efficiency of over 50% to reduce the fuel consumption and environmental pollution. Creep strength-enhanced ferritic steels, commonly known as Cr-Mo alloys such as P91 (X10CrMoVNb 9-1) are such material of choice for the next generation power plants. The operating requirement of these next generation power plants is that steam temperature of around 650 °C is maintained. For such high-temperature application, creep strength of material is the primary consideration together with adequate weld heat-affected zone (HAZ) toughness. Present work deals with the effect of high service temperature on impact toughness of P91 (X10CrMoVNb 9-1) base material, weld fusion zone, and HAZ. The impact toughness of HAZ for conventional weld groove design and narrow weld groove design has been evaluated experimentally in as-welded and at different post-weld heat treatment conditions. Fractography of the impact toughness specimens of base metal, weld fusion zone, and HAZ was carried out using scanning electron microscope. The effects of heat treatment schemes on the percentage of element present at the fracture surface were also studied.     

Feinstrukturuntersuchung des Zunders von Fe-Cr-Al-Heizleiterlegierungen mit Zr-Zusatz

X-ray diffraction analyses of the oxide scales of Fe-Cr-Al heat-resisting alloys with Zr-additions X-ray diffraction analyses of oxide scales spalled during cyclic oxidation of Fe-Cr-Al heat resisting alloys with Zr-additions were performed in the temperature range of up to 1300°C. The addition of 0,2% Zr causes the formation of ZrO₂ beside the predominant Al₂O₃ in the oxide scale exhibiting both monoclinic and tetragonal structures. By means of high-temperature X-ray diffractometry it was demonstrated that the zirconium oxide shows different transformation behaviour with respect to the investigated alloy. Thermal expansion characteristics of the aluminum oxide are not influenced by the Zr-additions being important for the adherence of the scale to the alloy.     

LONG-TERM CREEP AND RUPTURE PROPERTIES OF HEAT RESISTING STEELS AND ALLOYS

1.IntroductionHigh-temperaturecomponentsusedundercreepconditionsaredesignedonthebaseof100000h-creeprupturestrengthinJapan.Ontheotherhand,theestablishmentofreliablemethodsfordeterminingtheremaininglifehasearnestlybeenwishedforthehightemperaturecomponentsbeingoperatedforalongduration.Therefore,anunderstandingoflong-termcreepandrupturebehaviorisimportantforsafedesigningandreliablelifeassessmentofstructuralcomponentsofhigh-temperatureplants.NationalResearchinstituteforMetals(NRIM)hasbeenconduct…     

Corrosion performance of titanium and titanium stabilised stainless steels

Abstract

Titanium and its alloys provide industry with a number of materials which are strong, light, and very corrosion resistant. In addition, titanium is added as an alloying constituent to some stainless steels to act as a stabiliser during welding. Over the past 30 years titanium alloys have been increasingly used in process industries, and wherever ‘nil corrosion’ is considered to be an essential design feature. The main drawback to titanium usage has been relatively high cost, but freedom from plant corrosion failures, reduced downtime for maintenance, and the increasing availability of titanium have made this metal and its alloys an attractive choice in recent years. Applications include process vessels, heat exchangers, marine fittings, offshore components, pump castings, and other applications where materials encounter a hostile service environment. Nevertheless, titanium and its alloys are still subject to some forms of corrosiveattack, such as galvanic corrosion, hydrogen absorption, erosion corrosion, and crevicecorrosion. Special welding procedures are also required, which, if ignored, can lead toserious problems. This paper outlines a number of recent investigations into some problems encountered in industrial and marine environments, where both titanium metal and titanium stabilised stainless steels have suffered unexpected corrosion attack. The case histories described illustrate that titanium may show unexpected corrosion problems if certain aspects of its corrosion behaviour are overlooked.     

Evaluation of repair welding procedures for 2.25Cr–1Mo and 9Cr–1Mo steel welds

Abstract

Chromium–molybdenum steels are extensively used in the steam generator circuits of power plants. These components may require welding of the cracks that can develop during fabrication, storage, and transportation stages, or during the service life of the plant. This investigation compares repair welding methods for Cr–Mo steels, using 2.25Cr–1Mo and 9Cr–1Mo materials. To simulate aging during service, welds were heat treated at 873 K for 5000 h. Simulated repair welding of the aged welds was carried out at the weld/base metal interface, i.e. at the location at which cracks are usually reported to occur during service. Two repair welding methods (half bead and butter bead temper bead methods) conforming to the ASME Boiler and Pressure Vessel Code were used. Tensile properties, hardness profiles, and X-ray diffraction based residual stress distributions were determined for both the Cr–Mo steel welds to evaluate the simulated repair welds. Analysis of the test results showed that both the repair welding methods can be used for 2.25Cr–1Mo steel welds, although the butter bead temper bead method is much more suitable for both the 2.25Cr–1Mo and 9Cr–1Mo steel welds.     

Laser beam welding of wrought aluminium alloys

Abstract

Laser beam welding is now a common manufacturing method for a wide range of steel products from automobiles to razor blades. However, the process has only recently been approved for critical applications involving aluminium alloys, notably in the aerospace and automotive industries. The properties of aluminium alloys influence the interaction between the beam and the material to a far greater extent than for steels. The challenge of developing industrial welding procedures has therefore been considerable. The present review describes the effects of CO₂ and Nd–YAG laser beam processing parameters and the properties of the most common wrought aluminium alloys on the characteristics of welded joints. Porosity, solidification cracking, and poor weld bead geometry are shown to be the most frequently encountered imperfections. These can be eliminated through the use of appropriate filler materials, process gases, material preparation, and in some instances, adaptive control systems. Very little work has been reported on the corrosion properties of laser welded aluminium alloys. Experimental processing parameters are presented and compared using an analytical model, which can also be employed for predictive purposes. A number of industrial applications are described. These demonstrate that, for specific alloys, the process is now sufficiently well understood to be approved for high volume production, particularly in the transport industries.     

Evaluation of the effect of heat input in superduplex stainless steel deposition by the plasma powder process*

Plasma powder surfacing is one of the latest processes for application of coatings, with control of dilution as its main feature. Surfacing with superduplex stainless steels is an interesting option for the construction and repair of equipment for applications in a highly corrosive environment, allowing the desired characteristics to be achieved: corrosion resistance and good mechanical properties. The aim of this work is to assess the ferrite content in the weld metal and the mechanical characteristics via microhardness profiles in surfacing of C-Mn steel pipes with deposition of UNS S32760 by plasma powder surfacing. Welding operations were carried out on pipes with deposition of SDSS, employing three welding heat input levels, varying the welding speed or the welding current. Then the geometry was analysed, the ferrite content in the weld metal was quantified and the microhardness profile was recorded. Variation in welding heat input caused changes in weld bead geometry, with variation in the welding current producing the most significant changes. Increase in heat input caused decrease in ferrite content of the weld metal. Regarding microhardness, only the condition with a higher level of welding current gave sufficiently high levels of microhardness in the weld metal.     

Hybrid Laser-GMAW Welding of High Strength Quenched-Tempered Steels

High-strength quenched and tempered (HSQT) steels have been widely used in structural applications where light weight is of primary design interest.Gas metal arc welding is a common way to join QT steels.When GMAW is used to join the HSQT steel,multi-pass is usually required to achieve full penetration.In addition,weld crack is often observed because of HSQT steel’s high susceptibility to hydrogen embrittlement.In addition,due to the large amount of heat input from the arc,the heat affected zone is often softened.This reduces the ductility and strength of welds and makes the weld weaker than the base metal.In this study,a hybrid laser/GMAW process is proposed to produce butt joint for 6.5mm thick HSQT A514 steel plate.Hydrogen diffusion mechanism is first discusses for GMAW and hybrid laser-GMAW welding processes.Metal transfer mode during the hybrid laser/GMAW welding process is also analyzed.A high speed CCD camera with 4000 frame/second is used to monitor the welding process in real time.Welds obtained by GMAW and hybrid laser/GMAW techniques are compared and tested by static lap shear and dynamic impact.Effects of gap between two metal plates and laser beam/GMAW torch spacing on weld property are studied.By appropriately choosing these two parameters,crack-free butt joints with full penetration can be successfully obtained by the hybrid laser/GMAW welding process for HSQT A514 steel plate.     

Investigation into properties of laser welded similar and dissimilar steel joints

Abstract

Laser beam welding is currently used in the welding of steels, aluminium alloys, thin sheets, and dissimilar materials. This high power density welding process has unique advantages of cost effectiveness, deep penetration, narrow bead and heat affected zone (HAZ) widths, and low distortion compared to other conventional welding processes. However, the metallurgical and mechanical properties of laser welds and the response of conventional materials to this new process are not yet fully established. The welding process may lead to drastic changes in the microstructure with accompanying effects on the mechanical properties and, hence, on the performance of the joint. The thermal cycles associated with laser beam welding are generally much faster than those involved in the conventional arc welding processes. This leads to the formation of a rather small weld zone that exhibits locally a high hardness in the case of C–Mn structural steels owing to the formation of martensite. It is currently difficult to determine the tensile properties (full stress–strain curves) of the laser welded joint area owing to the small size(～V 2·3 mm) of the fusion zone. Complete information on the tensile and fracture toughness properties of the fusion zone is essential for prequalification and complete understanding of the joint performance in service, as well as for conducting a defect assessment procedure on such welded joints. Therefore, an experimental investigation into the mechanical properties of laser welded joints was carried out to establish a testing procedure using fiat micro tensile specimens (0·5 mm in thickness, 2 mm in width) for determination of the tensile properties of the weld metal and H AZ of the laser beam welds. Three similar joints, namely St 37–St 37, St 52–St 52, and austenitic–austenitic, and two dissimilar ferritic–austenitic joints were produced by CO₂ laser, using 6 mm thickness plates. The mechanical properties have been examined by microhardness survey and testing of conventional transverse tensile, round tensile, and fiat microtensile specimens. The results for the micro tensile specimens were compared with those for standard round tensile specimens and this clearly showed the suitability of the microtensile specimen technique for such joints.