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06/10/2011
11AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Ch. LOUPPECh. LOUPPE
The art of weld overlay
06/10/2011
22AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
33AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
The most economical solution to
produce the whole component is to
used dual material
Outside
low alloy steel for mechanical properties
Inside
Special alloy for corrosion resistance
Industry Description
Mains properties requested for largecomponents for the chemical, petrochemicaland nuclear industries:
Highly alloyed material to providecorrosion protection
Material to meet requirement forstructural integrity
06/10/2011
44AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Clad plate ( mainly roll- bonded)
Thin layer of an expensive material coming in contact with
corrosive media
Lower cost substrate material is used to give the desired
structural integrity.
Weld overlaying solutionsGive the designer and fabricator a large freedom for
choosing a wide variety of load bearing material and strip
chemistry to resist to different corrosive media.
The flexibility in shaping finished components weld overlay
process depends on many factors including access, welding
position, the applied alloy, and economics
Industry Description
06/10/2011
55AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
66AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
SAW
Flux is fed from both side
Heat is generated by electrical arc
FluxSlag
Flux is fed only from one side
Heat is generated by Joule’s effect
ESW
Process Description
Liquid Flux Slag
06/10/2011
77AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
ESW
Strip electrode
arc flux
Strip electrode
fused flux
SAW
Arc temperature > 3000°C
The arc is moving from one side
to the other side
Fused flux temperature < 2000°C
Process Description
06/10/2011
88AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
SAW vs. ESW
YesNoMagnetic control
23 kg/h, 0.6 m2/h14 kg/h, 0.4 m2/hDeposition rate
10 %18 %Dilution rate
42 A/mm²25 A/mm²Current density in strip
18 cm/min12 cm/minVelocity
24 V28 VVoltage
1250 A750 ACurrentTypicalweldingparameters
Joule-effectElectrical arcSource of heat
NoYesElectrical arc
ESWSAW60 x 0,5mm strip
Process Description
06/10/2011
99AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Highest deposition ratesKg / H
Process
Process Description
06/10/2011
1010AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
%
Process
Dilution rates
Process Description
06/10/2011
1111AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Process Description
06/10/2011
1212AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Uniform penetration
Uniform migration of impurities with Strip.
Low crack sensitivity
Migration to the center
Because of the basicity of the flux, the austenitic structure is claddedwithout any problems
Direction of impurities migration
Process Description
06/10/2011
1313AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Main characteristics No essential difference with conventional subarc wire installation
All SAW equipment are suitable for strip overlay
Only welding head to be modified
Main advantages Very uniform penetration
Low dilution
Homogeneous distribution of alloying
Flat surface
High deposition rate
Strip weld overlay process outlines
Process Description
06/10/2011
1414AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
1515AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Productivity
Increase the weld overlay deposition rate of theCorrosion Resistant Alloy in order to reduce labour costs
Reduce quantity of the CRA material deposited persquare meter.
Request of the customer
How can I reduce the manufacturing cost of the vessel
Request of customer
06/10/2011
1616AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
•• High deposition rate with high speed fluxesHigh deposition rate with high speed fluxes• Speed limit: up to 45 cm/min
• Deposition rate : up to 40 kg/h (60mm strip)
•• Monolayer with standard strip and compensated fluxesMonolayer with standard strip and compensated fluxes• Speed limit: 20 cm/min
• 1 layer application with standard strip
•• Monolayer with over alloyed strip and standard fluxesMonolayer with over alloyed strip and standard fluxes• Speed limit: 20 cm/min
• 1 layer application with standard fluxes
ALW Innovation
06/10/2011
1717AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
ESW cladding new ALW range
ELT 308-1
Suprastrip 19.9LNb
Suprastrip 19.12.3L ELT 316-1ELT 300S
Suprastrip 19.13.4 L
Suprastrip 24.13L
Suprastrip 21.13.3L
Suprastrip 21.11LNb
Suprastrip 24.13LNb
Suprastrip 19.9L
Stainless steel solution
high speed flux
Monolayer fluxes
Standard flux
ELT 300
Strip Weld overlay
ELT 347-1
06/10/2011
1818AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
347 Single layer ESW alloying flux innovation
ESW flux ELT 300
• Single layer over alloyed strip SUPRASTRIP 21.11 LNb
ESW flux ELT 300S
• Single layer over alloyed strip SUPRASTRIP 24.13 LNb
ESW flux ELT 347-1 new alloying flux
• Single layer standard strip SUPRASTRIP 19.9 LNb
Solution Flux Strip 60mm X 0.5mm C Cr Ni Nb Current speed
Single layer ELT 300 Suprastrip 21.11 LNb 0,03 19,0 9,9 0,4 1200 17
ELT 300S Suprastrip 24.13 LNb 0,05 19,2 10,5 0,42 1500 35
ELT 300S Suprastrip 19.9LNb 0,02 19,3 10,4 0,38 1500 25
Single layer HS ELT 300S Suprastrip 24.13 LNb 0,04 19,4 10,6 0,45 1800 40
Single layer ELT 347-1 Suprastrip 19.9LNb 0,03 19,0 10,5 0,48 1200 17
Two layers
Strip Weld overlay
06/10/2011
1919AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
316L ESW compensated flux innovation
ESW flux ELT 300
• Single layer over alloyed strip SUPRASTRIP 21.13.3L
ESW flux ELT 316-1 compensated flux
• Single layer standard strip SUPRASTRIP 19.12.3 L
Solution Flux Strip 60mm X 0.5mm C Cr Ni Mo
Single layer ELT 300 Suprastrip 21 13 3 L 0,03 19,0 9,9 2,6
Single layer ELT 316-1 Suprastrip19 12 3L 0,03 19,0 10,5 2,75
ELT 300S Suprastrip 21 13 3 L 0,05 19,2 10,5 2,1
ELT 300S Suprastrip 19 12 3L 0,02 19,3 10,4 2,6
Two layers
Strip Weld overlay
06/10/2011
2020AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
ESW cladding new ALW range
Nickel Base solution
Monolayer fluxes
Standard flux
ELT 600S
Suprastrip 825
Suprastrip 600
Suprastrip 625
ELT 600
high speed flux
ELT 825-1
ELT 625-1
06/10/2011
2121AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Current ( A ) : 750 1250 1500 1250
Voltage ( V ) 26 24 24 24
Speed (cm/min ) 10 16 35 16
Dilution ( % ) 18 9 25 7
C content (%) 0,045 0,030 0,060 0,025on 0.18%C Steel
SAW ESW HS S L
ESW ESW
06/10/2011
2222AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
0,71,10,690,45Depo Rate
(m²/H)
24272314Depo Rate( Kg / H)
4,53,14,34,5Thickness
( mm )
ESW SLESW HSESWSAW
06/10/2011
2323AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
0,50 Kg0,68 Kg1 KgQuantity
0,33 H0,42 H1 HTime
0,65 €0,85 €1 €Product
1 layer2 layers2 layers
ElectroslagSubmerged arc
06/10/2011
2424AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
2525AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Welding conditions
are mainly governed by the customer’s specifications
Base material
Thickness to be reached
Analyse to be reached
Ferrite
Welding parameter V, I, S
Welding conditions
06/10/2011
2626AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Base material
Some base material like SA-508 class 2 ( forged and plate material) aresubject to reheat crackingCracking occurs only in grain-coarsened region of the base metal heataffected zone at the weld bead overlap and when the second bead of high-heat-input is added, which reheats the heat-affected zone (HAZ) in thecarbon steel
This phenomena doesn't occurs when using material made to fine-grain
practice and heat-treated to refine the grain structure, as perSA-533 Grade
B Class I
Metallographic examinations showed that the cracks were in the coarse-
grained region of the HAZ which had been fully austenitized by the first
bead and then reheated to just below the AC1 temperature, i e 600-700 °C,
by the subsequent adjacent bead,
Welding conditions
06/10/2011
2727AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Welding conditions
lnfluence of the temperature cycle on grain size range during welding
06/10/2011
2828AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
0 5 10 15 20 25 30 35
Bead n° X Bead n° X+1
AC3
AC1
Critical areaAC1
AC3
Thermal cycle of the
critical area
Bead n° X Bead n° X+1
AC1
AC3
Welding conditions
06/10/2011
2929AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Thickness to be reached
Sometime minimum : 2 layers
Sometime minimum 6 – 8mm
Sometime warranty of the chemistry at 3 ( or 3,2 ) mm fromthe surface
ASME IX CODE : Minimum qualified thickness
Welding conditions
06/10/2011
3030AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Analyse to be reached
Chemistry for 316L type
ASME 2 A for Base material : SA-240ASME 2 C for weld deposit : SFA 5.4
ASME 2 C for the strip : SFA 5.9
2,0-3,011,0-14,018,0-20,00,030SFA 5.9
2,0-3,011,0-14,017,0-20,00,04SFA 5.4
2,0-3,010,0-14,016,0-18,00,030SA-240
MoNiCrC
Welding conditions
06/10/2011
3131AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
δ-ferrite fraction is undesirable
mainly for selective corrosion stresses FN<0.6 ( urea requirement )
Low δ-ferrite fraction is beneficial
high resistance to hot cracking
For alloy type 308L; 316L, 3 < FN < 10
For alloy type 347 : 4 < FN < 8
High δ-ferrite content is necessary
resistance to stress corrosion 30 < FN < 75 (Duplex weld overlay)
Influence of δ ferrite in weld overlay
Welding conditions
The δ ferrite is non-uniformly distributed in a given weld
06/10/2011
3232AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
From “ welding Metallurgy and weldability of Stainless Steels” By John C. Lippold and Damian J. Kotecki
Weld solidification cracking
susceptibility Based on Varestraint
data
Use of WRC92 diagram to predict
solidification behaviour and Ferrite
Number
AF
FA
F
A
06/10/2011
3333AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
From “ welding Metallurgy and weldability of Stainless Steels” By John C. Lippold and Damian J. Kotecki
Effect of solidification type on grain boundary tortuosity
Austenite solidification ( A ) Ferrite Austenite solidification ( F A )
06/10/2011
3434AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
WRC 92
Welding conditions
Dil for SS347
Dil max for E347
06/10/2011
3535AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Suprastrip 21 11 L Nb Typical values Cr : 21.4% Ni 11.3%
Min FN
FN & Dil vs speed
Th vs speed
1m/min(900A)
1.5m/min(1200A)
2m/min(1500A)
Th. mm
Welding speed cm/min
Welding conditions
Max FN
06/10/2011
3636AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
7.212.760.0450.490.03210.3318.810.521.410.027- 3.0mm
5.69.760.0450.500.05010.3018.920.521.420.030- 1.5mm
4.57.27.50.0450.0510.04310.2619.470.471.400.035Surface
0.010.210.401.200.21BM
PWHTASWRCNNbMoNiCrSiMnC
Welding consumables
Electrode : Suprastrip 21-11-LNb 60 x 0,5mm
Flux : ELT 300S
Welding conditions
Base material: Type P1 according to ASME IX, thickness : 40mm
Preheat : Room temperature
Interpasse temperature : 150°C
Post weld heat treatment : 4H at 620°C.
Welding Parameters
Current : 1250A Voltage : 24V Welding speed : 17cm/min
F N
06/10/2011
3737AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
FN
02468
101214
Surface -1,5mm -3,0mm
Distance from surface
WRC92 AS PWHT
06/10/2011
3838AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
3939AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Corrosion Production Operation
Selection of Corrosion resistant alloys
This is a three steps process.
First, resistance to general corrosion must be ensured (primarily
function of the Cr).
Secondly, resistance to localized attack must be ensured (primarily
function of Mo).
Finally the resistance to environmental stress cracking is sought at the
highest feasible strength level (Ni content plays the principal role).
06/10/2011
4040AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Typical corrosion tests applied
Appearance of cracks after
bend test. Metallographic
examination of a section is
necessary
24hBoiling650 - 675°C
1H
Copper-copper
sulfate-sulfuric
acid
IntergranularAustenitic
Stainless steelsA262E
Time for cracks initiating, rate
for crack growth, time to
failure
155°CNoMagnesium
chloride
Stress-
corrosion-
cracking
Metals and alloysG36
corrosion rate (mass loss)
or mm/ Year5x48hBoiling
675°C 1h
commonlyNitric acidIntergranular
Austenitic
Stainless steelsA262C
Corrosion rate (mass loss) +
eventually metallographic
examination
120 for 825
alloyBoilingNo
Ferric sulfate -
Sulfuric acidIntergranularNi and Cr alloysG28A
according G46 : mass loss, pit
density, average pit diameter,
average pit depth
72h in the
standard,
sometimes
24h in
practice
22 or 50°CNoFerric chloridePitting and
creviceStainless steelsG48A
Type of examinationTime in
solution
Temperatu
re
Sensitization
treatment
Conditions in the standard
Type of solutionType of
corrosionType of alloy
Standa
rd
06/10/2011
4141AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Strip Weld overlay
Dimensions
75 x 20 x 3 mm
Appearance of cracks after
bend test. Metallographic
examination of a section is
necessary
24hBoiling650 - 675°C
1H
Copper-copper
sulfate-sulfuric
acid
IntergranularAustenitic
Stainless steelsA262E
Type of examinationTime in
solution
Temperatu
re
Sensitization
treatment
Conditions in the standard
Type of solutionType of
corrosionType of alloy
Standa
rd
corrosion rate (mass loss)
or mm/ Year5x48hBoiling
675°C 1h
commonlyNitric acidIntergranular
Austenitic
Stainless steelsA262C
06/10/2011
4242AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Type of examinationTime in
solution
Temperatu
re
Sensitization
treatment
Conditions in the standard
Type of solutionType of
corrosionType of alloy
Standa
rd
Corrosion rate (mass loss) +
eventually metallographic
examination
120 for 825
alloyBoilingNo
Ferric sulfate -
Sulfuric acidIntergranularNi and Cr alloysG28A
Alloy 625
As welded 6H@690°C
δ masse ( g) 0.0558g 0.319 g
mm/Y 0.38 2.20
Deep. ( µm ) 15 240
06/10/2011
4343AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Stationnary state
After cooling down
Disbonding phenomena Hydrogen oversaturation
High solubility
Low diffusibility
Low solubility
High diffusibility
06/10/2011
4444AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Disbonding test installation
Temp max : 550°C
Pressure of H² : 200 Bars
Cooling rate : Max 750°C/H
ITMA SpainDimensions: Diameter : 73 mmThickness : 40 + 5 mm
Austenitic side
Welded overlay
Applicable standard : ASTM G146-01
06/10/2011
4545AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
2.25Cr-1Mo Steel
Martensitic carburized layer
Austenitic weld overlay
Disbonding phenomenaTwo key words : Hydrogen oversaturation
Sensitive microstructure
06/10/2011
4646AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
From API 934 2007
06/10/2011
4747AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
From API 934 2007
06/10/2011
4848AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
DISSEMINATION IS PROHIBITED WITHOUT PRIOR EXPRESS AUTHORIZATION OF AIR LIQUIDE
Ch LOUPPE The art of weld overlay
Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
4949AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Requirement of the customer SS 304L
Process parameters Pre-heating : 150°C / Interpass : 150-200°C – Post-heating : 2h @ 200°C
Base material : 15MND5 (80mm thick)
Non destructive tests Liquid penetrant tests
Ultrasonic tests
Destructive tests Bending tests, longitudinal and transversal : bending at 4 thickness
Corrosion tests : (ASTM A 262-E) : bending
Chemical analysis : following SS 304L
Metallographic analysis, grain size in HAZ of base metal : min 5
Hardness tests in HAZ of base metal : 320 HB max
Customer collaboration
06/10/2011
5050AIR LIQUIDE CONFIDENTIAL AND PROPRIETARY INFORMATION. ANY UNAUTHORIZED USE OR
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Ch LOUPPE The art of weld overlay
Actual solution use by the customer Multi couches SAW :
Consumables 1° layer : Strip type 309L (60 x 0,5mm) 2° layer : Strip type 308L (60 x 0,5mm )
Welding parameters: Current : 750A Voltage : 27V Welding speed : 12cm/min
Heat input : 100kJ/cm Deposition rate : 13,5kg/h Thickness of deposit : 9,0 mm
Conformed to specifications
Customer collaboration
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Ch LOUPPE The art of weld overlay
5,043299HV103
Proposition #3
ES 90mm 1 layerstandard speed
8.050254HV107 – 10
Proposition #2
ES 90mm 2 layers
High speed
9.042238HV107 – 8
Proposition #1
ES 90mm 2 layersstandard speed
9.013,5ConformConform
Actual
SA 60mm 2 layersstandard speed
thickness
[mm]
Depositionrate [kg/h]
Hardness
in HAZ
Grain size
in HAZ
Customer collaboration
06/10/2011
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Ch LOUPPE The art of weld overlay
SS 316L stainless steel
Suprastrip 21 13 3L and ELT 300S
825 nickel alloy clad plates
2 solution routes
Suprastrip 625 and ELT 600S
Suprastrip 825 and ELT 825-1
Customer collaboration
Production of Oil & Gas containing CO2,H2S, Cl- atHT/HP is growing.
For safety and long term economic reasons,Corrosion Resistant Alloys (CRA) become essential
06/10/2011
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Agenda
Industry Description
Process Description
Request of customer
Welding conditions
Corrosion & disbonding tests
Customer collaboration
Conclusions
06/10/2011
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Ch LOUPPE The art of weld overlay
By courtesy of Nuovo Pignone
Reactor to be overlay
Alloy requested : SS 347
Single layer ESW : 50T of consumables, for 500K€ and need 1600H
Double layers ESW : 70T of consumables, for 690K€ and need 2000H
Every variation of 0.1mm cost 11000 €
Conclusion
06/10/2011
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Sewon Cellontech – South Korea
Doosan Mecatec – South Korea
Larsen & Toubro – India
Nuovo Pignone – Italy
Mangiarotti – Italy
ISGEC – India
VRV – Italy
Godrej – India
ATB – Italy
Sempec – China
MISARABIA – Saudi Arabia
Confab – Brazil
Shanghai Electric – China
Some of our Customers
06/10/2011
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Ch LOUPPE The art of weld overlay
The art of weld overlay