News & Views, Volume 44 | Dissimilar Metal Welds in Grade 91 Steel

By:  Terry Totemeier

Introduction
News & View, Volume 44 | Dissimilar Metal Welds in Grade 91 SteelA dissimilar metal weld (DMW) is created whenever alloys with substantially different chemical compositions are welded together – for example, when a low-alloy steel such as Grade 22 (2¼ Cr-1Mo) is welded to an austenitic stainless steel such as TP304H (18Cr-8Ni).  Many DMWs are commonly present in fossil-fired power plants, examples being material transitions in boiler furnace tubes, stainless steel attachments welded onto ferritic steel tubes or pipes, and stainless steel thermowells or steam sampling lines in ferritic steel pipes.  The chemical composition gradients associated with DMWs present unique issues relative to their design, in-service behavior, and life management, particularly for those DMWs operating at elevated temperatures where solid-state diffusion and cyclic thermal stresses are factors, which was previously presented in News and Views (Volume 43, page 19).

With the now widespread use of Grade 91 steel (9Cr-1Mo-V-Nb) for elevated-temperature applications in modern power plants, DMWs involving this material have become common, and increasing service experience has revealed some unique characteristics and failure mechanisms, especially in thicker-section DMWs with austenitic materials.  This article presents a short overview of Grade 91 DMWs:  their design, fabrication, and failure, with emphasis on current industry issues.

There are two basic classes of DMWs in Grade 91 steel:  ferritic-to-ferritic and ferritic-to-austenitic.  The first type corresponds to Grade 91 welded to another ferritic steel with a lower chromium content, such as Grade 22; the second type corresponds to Grade 91 welded to an austenitic stainless steel such as TP304H.  Each of these types has unique concerns and considerations.

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News & Views, Volume 43 | Metallurgical Lab: Dissimilar Metal Welds (DMW) in Boiler Tubing

By:  Tony Studer

The need for confirmation: A Case Study

News & View, Volume 43 | Metallurgical Lab- Dissimilar Metal Welds (DMW) in Boiler Tubing The need for confirmation- A Case StudyAs plants age, the need for inspection for service related damage to ensure unit reliability increases. There are several approaches that plants can take to reduce the risk of premature failures and proactively manage their DMWs. First is metallurgical sampling. Based on temperature profiles across the boiler, operating conditions, and operating history, DMWs can be selected for laboratory analysis. This will provide some insight into possible damage accumulation; however, the better approach, if damage is suspected, is to perform an ultrasonic inspection of the DMWs. This allows inspection of all the DMWs, and only requires access and surface preparation. If indications are detected, then tube sampling should be performed. It is critical to perform a metallurgical analysis of several of the DMWs suspected of containing service damage to confirm that the indications are service related and to help establish the extent of the damage compared to ultrasonic testing results. Typical DMW damage is described in the Featured Damage Mechanism article. The importance of the metallurgical analysis is demonstrated in the three following case studies.

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News & Views, Volume 43 | Metallurgical Lab Featured Damage Mechanism: Failure of Dissimilar Metal Welds (DMW) in Steam-Cooled Boiler Tubes

By:  Wendy Weiss

News & View, Volume 43 | Metallurgical Lab Featured Damage Mechanism- Failure of Dissimilar Metal Welds (DMW) in Steam-Cooled Boiler TubesLarge utility-type steam generators inevitably contain a large number of pressure part welds that join components fabricated from different alloys.

Background
The welds made between austenitic stainless steel tubing and the lower-alloyed ferritic grades of tubing (T11, T22) deserve special mention because of the early failures that developed in some of these dissimilar metal welds (DMWs) soon after their introduction in superheater and reheater assemblies.  Prior to the mid-1970s, many DMWs were fabricated either as standard fusion welds using an austenitic stainless filler metal, such as TP308, or as induction pressure welds, in which the tubes were fused directly to each other without the addition of filler metal.  Some of these welds failed after less than 40,000 hours of operation, with the earliest failures being associated with DMWs that operated “hot” in units that cycled heavily and were subjected to bending stresses during operation. 

After the mid-1970s, and in response to extensive research carried out by EPRI and other organizations, an increasing number of DMWs in superheater and reheater tubes were fabricated as fusion welds using nickel-based filler metals, such as the INCO A, INCO 82, INCO 182, etc.

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