Indian Welding Journal

Open Access Open Access  Restricted Access Subscription Access
Open Access Open Access Open Access  Restricted Access Restricted Access Subscription Access

Exploring the Weldability of Austenitic Stainless Steels in Advanced Ultra-Supercritical Power Plant Applications: An Extensive Review


Affiliations
1 Mechanical Engineering Department, Techno Main Saltlake, Kolkata- 700091, West Bengal, India
2 Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani-741235, West Bengal, India
3 Power Engineering Department, Jadavpur University, Kolkata- 700098, India
     

   Subscribe/Renew Journal


Despite continuous efforts to enhance the operational efficiency of power plants dependent on these fuels, fossil fuels are expected to remain a significant global energy source in the coming decades. India has initiated a mission program to establish Advanced Ultra Super Critical (AUSC) power plants operating at temperature and pressure exceeding 720°C and 30.4kPa respectively. These plants are anticipated to utilize specialized materials with high resistance to corrosion and deformation at elevated temperatures. Among the materials considered, Nickel-base alloys, Creep Strength Enhanced Ferritic (CSEF) Steels and Austenitic Stainless Steels have emerged as the primary candidates. The prime emphasis of this paper is directed towards examining the weldability of Austenitic Stainless Steels utilized in AUSC power plants. It encompasses various aspects such as the choice of filler materials, welding techniques, and the attributes of welds involving both similar and dissimilar metals. The paper provides a comprehensive review of weldability challenges encountered in Austenitic Stainless Steels, including issues like liquation cracking in the heat-affected zone (HAZ), hot cracking, and stress relaxation cracking induced by tramp elements. Additionally, it investigates the performance of different filler wires, namely ER304HCu, ERNiCrCoMo-1, and ERNiCrMo-3, in weld joints involving 304HCu SS tubes, as well as ERNiCrCoMo-1 in dissimilar tube weld joints between 304HCu Stainless Steel and Alloy 617M.

Keywords

Weldability, Austenitic Stainless Steel, AUSC, Advanced Ultra-Supercritical Power Plant.
User
Subscription Login to verify subscription
Notifications
Font Size

  • Masuyama F (2001); History of power plants and progress in heat resistant steels. The Iron and Steel Institute of Japan International, 41(6), 612–625.

  • Abe F (2008); Precipitate design for creep strengthening of 9% Cr tempered martensitic steel for ultra-supercritical power plants. Science and Technology of Advanced Materials, 9(1), 9-15.

  • Abe F, & Tabuchi M (2004); Microstructure and creep strength of welds in advanced ferritic power plant steels. Science and Technology of Welding and Joining, 9(1), 22–31.

  • Bhadeshia H (2001); Design of ferritic creep-resistant steels. The Iron and Steel Institute of Japan International, 41(6), 626–640.

  • Guidelines and specifications for high-reliability fossil power plants, Report no. 1023199, EPRI, Palo Alto, CA, USA, 2011.

  • T24 Experience: A Hitachi Power Europe Perspective, 38–40, Modern Power Systems, Kent, United Kingdom, 2012, 38–40.

  • Fishburn JD, Henry JF & Zhou G (2001); Proc. 9Cr Materials Fabrication and Joining Technologies, Myrtle Beach, SC, USA, July 2001, EPRI, 7–11.

  • Nevasmaa P, Laukkanen A & Häkkilä J (2005); Assessment of hydrogen cracking risk in multipass weld metal of 2.25Cr-1Mo-0.25V-TiB (T24) boiler steel. Welding in the World, 49(7-8), 45-58.

  • Dobrzanski J, Pasternak J & Zielinski A (2006); Proceedings to the 8th Liege Conference on Materials for Advanced Power Engineering, 2006 (Liege, Belgium), Forschungszentrum Jülich GmbH, 390–399.

  • Perrin IJ & Fishburn JD (2005); A perspective on the design of high temperature boiler components, Proceedings of the International Conference on Creep and Fracture in High Temperature Components in Design and Life Assessment Issues, EPRI, Keynote paper 4, Institute of Mechanical Engineers, Central London, UK.

  • Creep strength enhanced ferritic (CSEF) steel welding guide, Report No. 1024713, EPRI, Palo Alto, CA, USA, 2011.

  • DuPont JN, Marder AR, Nawrocki JG, Puskar JD & Robino CV (2003); The mechanism of stress-relief cracking in a ferritic alloy steel. Welding Journal, 82(2), 25–35.

  • Auerkari P, Holmstrom S, Nevasmaa P, Rantala J & Salonen J (2010); Proceedings to the 9th Liege Conference on Materials for Advanced Power Engineering, Liege, Belgium, 229–238.

  • Fuchs R, Hahn B & Heuser H (2004); Proceedings of the Sixth International Conference on Welding and Repair Technology for Power Plants, EPRI/ASM International, 1–26.

  • Park K, Kim S, Chang J & Lee C (2012); Post-weld heat treatment cracking susceptibility of T23 weld metals for fossil fuel applications, Materials and Design, 34, 699–706.

  • Welding Handbook (1987), American Welding Society, 8th edition, 1, 111.

  • Messler Jr RW (1999); Principles of Welding: Processes, Physics, Chemistry, and Metallurgy, New York, John Wiley & Sons.

  • Dupont JN & Lippold JC (2009); Welding Metallurgy and Weldability of Nickel Base Alloys, New York, John Wiley & Sons.

  • Stout RD (1987); Welding and weldability of steels, 4th edition, New York, Welding Research Council.

  • Viswanathan R, Henry J, Tanzosh J, Stanko G, Shingledecker J, Vitalis B & Purgert R (2005); U.S. Program on Materials Technology for Ultra-supercritical Coal Power Plants, Journal of Materials Engineering and Performance, 14(3), 281–292.

  • Wu Q, Song H, Swindeman R, Shingledecker J & Vasudevan V (2008); Microstructure of long-term aged IN617 Ni-base super alloy. Metallurgical and Materials Transactions, 39(11), 2569–2585.

  • Dittrich F, Mayr P & Siefert JA (2019); Thermodynamic simulation of ferritic to ferritic dissimilar metal welds, Welding in the World, 64(1), 95-103.

  • Blum R & Bugge J (2010); Proceedings of 6th International Conference on Advances in Materials Technology for Fossil Power Plants, EPRI, ASM International, Santa Fe, NM, USA, August–September, 1–10.

  • Fukuda M, Saito E, Tanaka Y, Takahashi T, Nakamura S, Iwasaki J, Takano S & Izumi S (2010); Advanced USC technology in Japan. Proceedings of International Conference on Advances in Materials Technology for Fossil Power Plants, EPRI, ASM International, Santa Fe, NM, USA.

  • Masuyama F (2010); Proceedings of 6th International Conference on Advances in Materials Technology for Fossil Power Plants, EPRI, ASM International, Santa Fe, NM, USA, August–September, 11–29.

  • Xie X, Chi C, Yu H, Yu Q, Dong J & Zhao S (2010); Structure stability study on fossil power plant advanced heat-resistant steels and alloys in China, Proceedings of 6th International Conference on Advances in Materials Technology for Fossil Power Plants, EPRI, ASM International, Santa Fe, NM, USA, August–September, 30–52.

  • Siefert JA, Thomson R & Parker J (2018); Microstructure features contributing to heat affected zone damage in Grade 91 steel feature type cross-weld tests. Proceedings of the ASME 2018 Symposium on Elevated Temperature Application of Materials for Fossil, Nuclear, and Petrochemical Industries, ETAM, April 2018.

  • State of knowledge for advanced austenitics, Report No. 1020241, EPRI, Palo Alto, CA, USA.

  • Viswanathan R, Henry JF, Tanzosh J, Stanko G, Shingledecker J, Vitalis B & Purgert G (2015); The design and research of a new low cobalt-molybdenum niobium-containing Ni-base superalloy for 700° ̊C advanced ultra-supercritical power plants, Procedia Engineering, 130, 617-627.

  • Shibli IA, Holdsworth SR & Merckling G (2005); Creep & Fracture in High Temperature Components-Design & Life Assessment Issues, Proceedings of ECCC Creep Conference, September 2005, UK.

  • Shibli IA & Le MHN (2001); Creep crack growth in P 22 & P 91 welds-Over view from SOTA and HIDA projects, International Journal of Pressure Vessels and Piping, 78(11-12), 785-793.

  • David SA, Siefert JA & Feng Z (2013); Welding and weldability of candidate ferritic alloys for future advanced ultra-super critical fossil power plants, Science and Technology of Welding and Joining, 18(8), 631-651.

  • Viswanathan R, Gandy D & Coleman K (2004); Proceedings of The 4th International Conference on Advances in Materials Technology for Fossil Power Plants, EPRI, ASM International, Hilton Head Island, SC, USA.

  • Viswanathan R, Henry JF, Tanzosh J, Stanko G, Shingledecker J, Vitalis B & Purgert R (2005); U.S. Program on Materials Technology for Ultra-Supercritical Coal Power Plants, Journal of Materials Engineering and Performance, 14(3), 281–292

  • Weitzel PS (2011); Proceedings of ASME Power Conference, Denver, CO, USA, ASM International, 281–291.

  • Sourmail T & Bhadeshia H (2005); Microstructural evolution in two variants of NF709 at 1023 and 1073 K, Metallurgical and Materials Transactions A, 36(1), 23–25.

  • Masuyama F (2004); Effect of heat treatment on the microstructure and properties of cold worked Inconel 740H boiler tubes, Proceedings of 4th International Conference on Materials Technology for Fossil Power Plants, Hilton Head, SC, USA, EPRI/ASM International.

  • Masuyama F (2010); R&D program for A-USC material development with creep strength degradation assessment studies. Proceedings of 6th International Conference on Materials Technology for Fossil Power Plants, Santa Fe, NM, USA, EPRI/ASM International, August, 11–29.

  • Lippold J & Kotecki D (2005); Welding Metallurgy and Weldability of Stainless Steels, New York, John Wiley and Sons Inc.

  • Chi C, Yu H & Xie X (2011); Alloy Steels-Properties and USC. In E. Morales (Ed.), Intech, London, UK.

  • Senba H, Sawaragi Y, Ogawa K, Natori A & Han T (2002); Development of high strength 18-8 series super 304H steel pipe for high efficiency thermal power boiler. Materia Japan, 41(2), 120–125.

  • Matsuda F (1989); Proceedings of 2nd International Conference on Trends in Welding Research, Gatlinburg, TN, USA, ASM International, 127–136.

  • Lippold JC (2005); Joining of Advanced and Specialty Materials VII, No. 05116G, Materials Park, OH, ASM International.

  • Dhooge A & Vinckier (1992); Reheat cracking–Review of recent studies (1984–1990). Welding World, 30(3/4), 44–71.

  • Thakur P & Chapgaon A (2016); A review on effects of GTAW process parameters on weld, International Journal for Research in Applied Science & Engineering Technology, 4(1), 136-140.

  • Arivazhagan B & Vasudevan M (2014); A comparative study on the effect of GTAW processes on the microstructure and mechanical properties of P91 steel weld joints. Journal of Manufacturing Processes, 16, 305–311.

  • Sawaragi Y, Hirano S, Hayase Y & Masuyama F (1991); Proceedings of 3rd International Conference on Improved Coal-fired Power Plants, San Francisco, CA, USA, EPRI, 14-1–14-15.

  • Siefert JA & David SA (2014); Weldability and weld performance of candidate austenitic alloys for advanced ultra-supercritical fossil power plants. Science and Technology of Welding and Joining, 19(4), 631-651.

  • Mathur A, Bhutani OP, Jayakumar T, Dubey DK & Chetal SC (2013); India's National A-USC Mission-Plan & Progress. Proceedings from 7th International Conference on Advances in Materials Technology for Fossil Power Plants, USA.

  • Srinivasan G, Dey HC, Ganesan V, Bhaduri AK, Albert SK & Laha K (2016); Choice of welding consumable and procedure qualification for welding of 304HCu austenitic stainless steel boiler tubes for Indian advanced ultra-super critical power plant. Welding World, 60(5), 1029-1036.

  • Benafia S, Retraint D, Brou S, Panicaud B & Poussard J (2018); Influence of surface mechanical attrition treatment on the oxidation behaviour of 316L stainless steel. Corrosion Science, 136, 188-200.

  • Kumar MV & Balasubramanium V (2018); Hot tensile properties and constant load stress corrosion cracking test data of autogenous weld joints of Super 304HCu stainless steel in boiling MgCl2 solution. Data in Brief, 18, 102-110.

  • Kumar MV, Balasubramanium V, Rajakumar S & Albert SK (2015); Stress corrosion cracking behaviour of gas tungsten arc welded super austenitic stainless steel joints. Defence Technology, 11(3), 282-291.

  • David SA, Siefert JA, DuPont JN & Shingledecker J (2015); Weldability and weld performance of candidate nickel base superalloys for advanced ultra-supercritical fossil power plants Part I: Fundamentals. Science and Technology of Welding and Joining, 20(7), 532-552.

  • Siefert JA, Shingledecker J, DuPont JN & David SA (2016); Weldability and weld performance of candidate nickel based superalloys for advanced ultra-supercritical fossil power plants Part II: Weldability and cross-weld creep performance. Science and Technology of Welding and Joining, 21(5), 397-427.


Abstract Views: 132

PDF Views: 4




  • Exploring the Weldability of Austenitic Stainless Steels in Advanced Ultra-Supercritical Power Plant Applications: An Extensive Review

Abstract Views: 132  |  PDF Views: 4

Authors

Subhodwip Saha
Mechanical Engineering Department, Techno Main Saltlake, Kolkata- 700091, West Bengal, India
Santanu Das
Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani-741235, West Bengal, India
Subrata Mondal
Power Engineering Department, Jadavpur University, Kolkata- 700098, India

Abstract


Despite continuous efforts to enhance the operational efficiency of power plants dependent on these fuels, fossil fuels are expected to remain a significant global energy source in the coming decades. India has initiated a mission program to establish Advanced Ultra Super Critical (AUSC) power plants operating at temperature and pressure exceeding 720°C and 30.4kPa respectively. These plants are anticipated to utilize specialized materials with high resistance to corrosion and deformation at elevated temperatures. Among the materials considered, Nickel-base alloys, Creep Strength Enhanced Ferritic (CSEF) Steels and Austenitic Stainless Steels have emerged as the primary candidates. The prime emphasis of this paper is directed towards examining the weldability of Austenitic Stainless Steels utilized in AUSC power plants. It encompasses various aspects such as the choice of filler materials, welding techniques, and the attributes of welds involving both similar and dissimilar metals. The paper provides a comprehensive review of weldability challenges encountered in Austenitic Stainless Steels, including issues like liquation cracking in the heat-affected zone (HAZ), hot cracking, and stress relaxation cracking induced by tramp elements. Additionally, it investigates the performance of different filler wires, namely ER304HCu, ERNiCrCoMo-1, and ERNiCrMo-3, in weld joints involving 304HCu SS tubes, as well as ERNiCrCoMo-1 in dissimilar tube weld joints between 304HCu Stainless Steel and Alloy 617M.

Keywords


Weldability, Austenitic Stainless Steel, AUSC, Advanced Ultra-Supercritical Power Plant.

References





DOI: https://doi.org/10.22486/iwj.v56i4.223541