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Low heat input gas metal arc welding for dissimilar metal weld overlays part I: the heat-affected zone

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Abstract

Dissimilar metal weld overlays of nickel base alloys on low alloy steel components are commonly used in the oil and gas, petro-chemical, and power generation industries to provide corrosion and oxidation resistance in a wide range of service environments and temperatures. Traditionally, weld overlays are produced using cold or hot wire gas tungsten arc welding (GTAW). Potential advantages of cold metal transfer (CMT) welding, a low heat input gas metal arc welding process, over the conventional GTAW in production of weld overlays were evaluated. Metallurgical characterization was performed on CMT overlays of Alloy 625 filler metal on Grade 11 and Grade 22 steels. Significant grain refinement was found in the high temperature HAZ compared to the traditional coarse-grained HAZ in arc welding. Evidences of incomplete carbide dissolution, limited carbon diffusion, and incomplete transformation to austenite were also found. These phenomena were related to high heating and cooling rates and short dwell times of the high-temperature HAZ in austenitic state. Tempering effects in the steel HAZ were identified, showing a potential for development of CMT temperbead procedures. Based on the results of this study, the steel HAZ regions in CMT overlays were classified as high-temperature HAZ and intercritical HAZ.

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Notes

  1. NACE SP0472, Methods and controls to prevent in-service environmental cracking of carbon steel weldments in corrosive petroleum refining environments.

  2. Standard specification for seamless ferritic alloy-steel pipe for high-temperature service

  3. Standard specification for forged or rolled alloy and stainless steel pipe flanges, forged fittings, and valves and parts for high-temperature service

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Acknowledgments

This study was supported by ExxonMobil and Fronius International by provision of materials, welding equipment, and technical support, and was performed at the Welding Engineering Laboratory of the Ohio State University.

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Authors and Affiliations

  1. Department of Joining and Coating Technology, Fraunhofer Institute for Production Systems and Design Technology IPK, Berlin, Germany

    Julian Frei

  2. Welding Engineering Program, Department of Material Science and Engineering, The Ohio State University, 1248 Arthur E. Adams Drive, Columbus, OH, 43221, USA

    Boian T. Alexandrov

  3. Fraunhofer Institute for Production Systems and Design Technology IPK | BAM - Federal Institute for Materials Research and Testing, Berlin, Germany

    Michael Rethmeier

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  1. Julian Frei
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  2. Boian T. Alexandrov
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  3. Michael Rethmeier
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Correspondence to Boian T. Alexandrov.

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Recommended for publication by Commission IX - Behaviour of Metals Subjected to Welding

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Frei, J., Alexandrov, B.T. & Rethmeier, M. Low heat input gas metal arc welding for dissimilar metal weld overlays part I: the heat-affected zone. Weld World 60, 459–473 (2016). https://doi.org/10.1007/s40194-016-0306-z

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  • DOI: https://doi.org/10.1007/s40194-016-0306-z

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