NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES

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NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES
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A. Dhooge1, J. Vekeman2 Belgian Welding Institute/University Ghent, e-mail: alfred.dhooge@ugent.be, 2 Belgian Welding Institute, e-mail: johan.vekeman@soete.ugent.be (Belgium)

ABSTRACT
Creep resistant steels for high temperature service are a vital part in the construction of power stations. The possibilities to increase steam parameters of new boilers are restricted if pressure and temperature in the membrane waterwalls cannot be simultaneously increased. The increase of steam parameters requires the development of new high strength and creep resistant materials. This paper gives data on weldability, mechanical properties, toughness and high temperature behaviour (creep) of new materials T/P 24 (7CrMoVTiB10-10) which have been developed by Vallourec & Mannesmann Tubes, and T/P 23 (7CrWVMoNb9-6). It is the outcome of a research project of the Belgian Welding Institute in collaboration with Laborelec and with industrial partners. Both base metals and weldments in tubes and thick walled pipes have been investigated.

IIW-Thesaurus keywords: Boilers; Tubes and pipes; Creep resisting materials; Weldability; Toughness; Mechanical properties; Creep strength; Strength; Hardness; Coarse grained heat affected zone; Heat affected zone; Weld zone; Simulating; Post weld heat treatment; Heat treatment; Reheat cracking; Cracking; Defects; GTA welding; Arc welding; Gas shielded arc welding; MMA welding; Submerged arc welding; Practical investigations.

1 INTRODUCTION
Creep resistant steels for high temperature service are a vital part in the construction of power stations. The possibilities to increase steam parameters of new boilers are restricted if pressure and temperature in the membrane water-walls cannot be simultaneously increased. The increase of steam parameters requires the development of new high strength and creep resistant materials. Conventional ferritic-bainitic steels such as ASTM A 213 T12 (13CrMo4-4) and ASTM A 213 T22 (10CrMo910) do not have enough creep strength for the use as membrane water-walls of USCB (Ultra Super Critical Boilers). Moreover, the maximum hardness in the HAZ of steel T22 (10CrMo9-10) is too high in the as welded condition and a post-weld heat treatment is necessary to reduce the hardness below 350 HV. For some time, two modified versions of the standard 21/4Cr-1Mo steel (P22) are on the market. The new grades T23 and T24 are ideal candidates for water-wall tubes of USCB. They are also used for superheater and re-heater components of conventional boilers and Heat Recovery Steam Generators (HRSG) [1, 2]. Moreover, thick walled pipes can nowadays be pro-

duced for piping applications in headers and main steam pipes, in both conventional and HRSG plants. This paper gives data on weldability, mechanical properties, toughness and high temperature behaviour (creep) of these new materials T/P 24 (7CrMoVTiB1010) which have been developed by Vallourec & Mannesmann Tubes [1, 2], and T/P 23 (7CrWVMoNb96). It is the outcome of a research project of the Belgian Welding Institute in collaboration with Laborelec and with industrial partners (Carnoy Industrial Piping, Cockerill Mechanical Industries, Fabricom, Stork Mec, SAF Oerlicon, Thyssen Welding Germany, Vallourec & Mannesmann Tubes, AIB Vinotte, WTCM). Both base metals and weldments in tubes and thick walled pipes have been investigated.

2 BASE MATERIALS
Chemical compositions of steel grades T/P23 and T/P24 are compared per ASTM A 213/A335 (ASTM A 335 for P24 in preparation) in Table 1 to other standard steel grades (T/P22, T/P91) used for high temperature application in power plants. The investigated materials in this study were both tubes and pipes. The T23 and T24 tubes have an outside diameter of 51 mm and a wall thickness of 7.1 mm. The P23 pipes have an outside diameter of 219 mm and a wall thickness of 30 mm. The P24 pipes have an outside diameter of 370 mm and a wall thickness of 25 mm.

Doc. IIW-1693-05 (ex-doc. XI-810-04) recommended for publication by Commission XI Pressure vessels, boilers and pipelines.
Welding in the World, Vol. 49, n 9/10, 2005

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Table 1 Chemical composition of ferritic creep resistant base materials and of martensitic T/P 91
T/P 22 21/4Cr-1Mo ASTM A 213/A335 T/P23 7CrWVMoNb9-6 ASTM A 213/A335 T/P24 7CrMoVTiB10-10 ASTM A 213 T/P 91 X10CrMoVNb 91 ASTM A 213/A335 Min Max Min Max Min Max Min Max C .15 C .04 .10 C .05 .10 C .08 .12 Si .25 1.00 Si .50 Si .15 .45 Si .20 .50 Mn .30 .60 Mn .10 .60 Mn .30 .70 Mn .30 .60 Cr 1.9 2.6 Cr 1.9 2.6 Cr 2.2 2.6 Cr 8.0 9.5 Mo .87 1.13 Mo .05 .30 Mo .90 1.10 Mo .85 1.05 Ni Ni Ni Ni .40 V V .20 .30 V .20 .30 V .18 .25 W W 1.45 1.75 W W Al Al .030 Al .020 Al .040 B B .0005 .0060 B .0015 .0070 B N N .030 N .012 N .030 .070 Nb Nb .02 .08 Nb Nb .06 .10 Ti Ti Ti .05 .10 Ti -

The chemical composition according to the certificates is given in Table 2. The required and actual measured mechanical properties are shown in Table 3.

3 BASIC WELDABILITY STUDY WELD SIMULATION

Weld simulation tests were performed to study the weldability of the 21/4Cr steels and to be used as input data for making the welded joints under field conditions. An extensive simulation program was carried out to determine the influence of the welding parameters and a Post Weld Heat Treatment (PWHT) on the microstructure, hardness and the toughness of the Heat-Affected Zone (HAZ).

Conclusion
The delivered base metals show acceptable hardness, strength and toughness and fulfil the requirements of the standards.

Table 2 Chemical composition of investigated tubes and pipes

C T23 P23 T24 P24 .060 .070 .063 .060 Si .220 .280 .220 .290 P .014 .008 .006 .014 S .002 .004 .003 .003 Mn .470 .540 .510 .410 Cr 2.05 2.08 2.45 2.31 Mo .08 .08 .97 .95 V .230 .220 .255 .228 W 1.510 1.650 Al .017 .018 .003 .010 B .0019 .0020 .0043 .0046 N .009 .011 .0075 .0080 Nb .050 .030 Ti .051 .079

Table 3 Mechanical properties of investigated tubes and pipes

Rp0.2 (MPa) ASTM A 213/A335 T23 P23 > 400 > 557 > 537 > 552 > 553 Rp0.2 (MPa) ASTM A 213 T24 P24 > 450 > 528 > 521 > 560 > 569
* Subsized specimen, value in J/cm2.

Rm (MPa) > 510 > 644 > 628 > 633 > 634 Rm (MPa) > 585 > 639 > 640 > 640 > 654

A5 (%) > 20 > 25 > 26 > 22 > 23 A5 (%) > 20 > 20 > 20 > 24 > 24

Hardness (HV10) < 230 > 201 > 203

CVN (J) 232* 219

Hardness (HV10) < 263 HV10 > 200 > 212

CVN (J) > 41 (T) > 68 (L) 245* 260

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3.1 Experimental procedure

In weld simulation, impact test specimens are subjected to weld thermal cycles by computer controlled dynamic resistance heating and simultaneous cooling via water cooled jaws. A programmed heating and cooling thermal cycle is thereby applied to the central working zone of the specimen. The microstructures obtained in the central zone correspond to the microstructures of the HAZ obtained in welded joints under field conditions. Single weld cycles were simulated with different peak temperatures (Tp1 = 1 350 oC, 1 200 oC and 1 000 oC). The desired cooling time t8/5 between 800 and 500 oC depends on the welding process one wants to simulate. Cooling times t8/5 between 800 and 500 oC of 10, 30 and 60 seconds for the tubes and 10, 20, 40 and 60 seconds for the pipes were chosen. When welding the thin walled tubes (wall thickness 7.1 mm) without preheat, the cooling time t8/5 is about 10, 35 and 60 seconds for a heat input of respectively 5, 10 and 15 kJ/cm. Applying a higher heat input will result in lower cooling rates. When welding the thick walled pipes (wall thickness 25 30 mm) with a preheat of 150 oC, the cooling time t8/5 is much faster compared to the thin walled tubes. Cooling times of 10, 20 and 60 seconds correspond to a heat input of respectively 15, 18 and 26 kJ/cm. Applying a higher heat input will also here result in lower cooling rates. Besides the single weld thermal cycles, also double cycles were applied with Tp1 = 1 350 oC and a second peak temperature of either 750 oC or 1 000 oC.

After simulation of four specimens at the same condition, one specimen was used to measure the Vickers Hardness HV10 and to perform micro structural investigations. The other three specimens were used for Charpy V impact tests at room temperature to determine the impact toughness. The impact tests on the fullsize specimen, with a notch of 2 mm, were performed conform to EN 10045-1 and the tests on the sub-size specimen, with a notch of 1 mm, conform to ASTM E23. The need for a PWHT was evaluated using the following criteria: maximum hardness 350HV10 (power generation application); minimum impact toughness at room temperature: 27 J [Pressure Equipment Directive (PED)]. The PWHT was performed in a furnace. The specimens were heated to the desired temperature at a rate of 125 oC/hour and after the holding time was expired, they were air cooled.

3.2 Test results and discussion

The test results are summarised in Figures 1 to 6. Some different behaviours were found between tubes and pipes, especially concerning the toughness after double thermal cycles and after PWHT. In the as welded condition, the lowest toughness and highest hardness can be expected in the coarse grained HAZ of both tubes and pipes. The highest hardness is associated with the fastest cooling rate although the

Figure 1 Weld simulation test results on T23

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Figure 2 Weld simulation test results on T24

hardness variation with different cooling rates is not very pronounced. For the tubes, fulfilling the hardness criteria (< 350 HV) seems to be easily achievable even without preheat and PWHT. Indeed, in nearly all simulated conditions, the hardness is below 350 HV10. Applying a PWHT reduces the hardness considerably (see Figures 1 and 2). Obtaining sufficient toughness in the as welded condition requires an adequate heat input. The lowest toughness is found with the fastest cooling rate (t8/5 = 10 seconds), but in practice cooling rates will always be lower in these thin walled tubes, if normal heat input for TIG welding is used, giving rise to adequate toughness. Applying a PWHT has a positive effect on the toughness in the coarse grained HAZ of T24 but for the T23 steel, a slight drop in toughness is found (see Figures 1 and 2). Applying a double weld cycle with Tp2 = 1 000 oC improves the coarse grained HAZ toughness considerably in T23 but Tp2 = 750 oC has a negative effect (see Figure 1). Also for the thick walled pipes, the hardness stays mostly below 350 HV, even in the as welded condition and not much variation is found with different cooling rates. Applying a PWHT reduces the hardness considerably. Toughness in the as welded condition is low in the coarse grained HAZ of both steels (see Figures 3 and 5). For the P23 steel, this can be improved by applying

a PWHT at 740 oC for 1.5 hours (see Figure 4) although no improvement was found for T23. For the P24 steel, the improvement by such a PWHT is quite low (see Figure 6). Such a heat treatment was beneficial for the T24. Both steels do not show any improvement in toughness by applying a second weld thermal cycle with a peak temperature of 750 oC or 1 000 oC as was the case for the T23 steel with a second peak temperature of 1 000 oC. Applying a PWHT at 740 oC for 2 hours on these microstructures has a positive effect especially when a high second peak temperature is applied (Figures 4 and 6). Indeed, much higher toughness was found for a second peak temperature of 1 030 oC compared to 1 000 oC indicating that a second peak temperature of 1 000 oC is too low for toughness improvement. One can conclude that the overall HAZ toughness will improve and be adequate after PWHT.

3.3 Conclusions
The weld simulation tests indicate that adequate hardness and toughness can be obtained in tube welds of both T23 and T24 materials without preheat and without PWHT. Also for the thick walled pipes, the hardness stays below 350 HV, even in the as welded condition. However, for toughness reasons, a PWHT at a temperature of about 740 oC is necessary.

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Figure 3 Weld simulation test results on P23

Figure 4 Weld simulation test results on P23

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Figure 5 Weld simulation test results on P24

Figure 6 Weld simulation test results on P24

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4 REHEAT CRACKING
Reheat cracking, also called stress relief cracking, is a possible cause of weld failures in creep-resistant, precipitation-strengthened alloys such as ferritic alloy steels. Reheat cracking is defined as an intergranular cracking phenomena occurring in the heat-affected zone (HAZ) and occasionally in the weld metal of a welded joint, being initiated during a post-weld heat treatment (PWHT) or during high temperature service. A susceptible microstructure is a coarse prior austenite grain size with strong grain interiors that resist plastic deformation and weak grain boundaries. Therefore the coarse-grained heat-affected zone (CGHAZ) is the most susceptible region of a weldment.

Susceptibility to reheat-cracking Extremely susceptible Highly susceptible Slightly susceptible Not susceptible

% Reduction in area <5% 5 - 10 % 10 - 20 % > 20 %

The tests were performed using a Gleeble 1500/20 thermo mechanical simulator. Cylindrical test samples, 110 mm long and with a diameter of 6 mm (tubes), respectively 12 mm (pipes), with threaded ends were used. The samples were taken in axial direction. After simulation, a zone of 10 mm in the centre of the specimen was reduced to 4 mm (tubes), respectively 6 mm (pipes) so that specimen fracture during tensile testing occurred in the simulated zone. The longitudinal cross-section of the specimen with the lowest reduction of area was investigated using light optical micrographs. A second specimen was tested under the same conditions, but with inert gas (argon) protection to prevent oxidation of the fracture surface, to examine the fracture surface using scanning electron microscopy (SEM). The influence of double weld cycles, second peak temperature Tp2 = 750 or 1 000 oC, has been compared to single weld cycles.

4.1 Experimental procedure

At the Research Centre of the Belgian Welding Institute, a lot of experience has been gathered with the isothermal slow strain rate tensile test. In this test, cylindrical specimens are given a weld simulation cycle with peak temperature Tp1 = 1 350 oC to simulate the CGHAZ. After cooling to room temperature (t8/5 = 20 seconds), the specimen is heated to and held at the test temperature between 550 oC and 750 oC. As soon as this temperature is obtained, the specimen is slowly strained to fracture at a tensile velocity of 0,5 mm/min. After fracturing the specimen, its reduction in area is measured to assess the ductility. Steels are classified as follows:

4.2 Test results and discussion

Figure 7 summarizes all test results and shows the reduction in area as a function of the peak temperature. Both T24 and P24 materials have a reduction in area of more than 20 % for single cycled specimens in the whole

Figure 7 Reheat cracking test results

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P23

P24

Figure 8 SEM pictures or fracture surface (reheat cracking test) test temperature range, indicating that there is no susceptibility to reheat cracking in this particular simulated CGHAZ. Also the double cycled specimens have microstructures which are not susceptible to reheat cracking. The situation is different for the T23 and P23 materials. Here, T23 shows some susceptibility to reheat cracking in the particular simulated coarse grained HAZ at PWHT temperatures above 675 oC. This means that when T23 is used without PWHT, no reheat cracking problems are expected during service (temperature limited to 585 oC). The P23 simulated coarse grained HAZ shows a high susceptibility to reheat cracking in a broad test temperature range above 575 oC. Important to note is that applying a double weld cycle with a second peak temperature of 1 000 oC increases the reduction in area to a value above 20 %, indicating that multi-pass welding gives rise to fine grained microstructures that are not susceptible to reheat cracking. Typical SEM pictures for P23 and P24 are shown in Figure 8. One can recognize a fully intergranular fracture along the prior austenite grain boundaries for the P23 coarse grained HAZ and a mixed ductile/intergranular fracture with ductile characteristics on the grain boundaries for the P24 steel. The reheat cracking results for T23 and P23 agree with test results by J.G. Nawrocki [3]. In this study, the reheat cracking susceptibility was based on the ductility and the resultant microstructures. HCM2S (Japanese designation of T/P23) was found to be extremely to highly susceptible to reheat cracking at each energy input and post weld heat treatment. HCM2S experienced brittle intergranular failure along prior austenite grain boundaries for single-pass simulations. For double-pass simulations, the ductility increased and the samples failed along grain boundaries (prior austenite or packet) normal to the tensile axis and exhibited extensive plastic deformation, indicating that reheat cracking was avoided with the use of multi-pass simulations. It is clear that some caution has to be taken in welding the T23 and P23 steel due to their possible susceptibility to reheat cracking. This is particularly the case for highly stressed joints for which the following recommendations can be formulated: Avoid too coarse grained HAZ microstructures by: limiting the heat input (below 2.5 kJ/mm), using multiple layer welding (renormalizing effect), use of tempering beads. Eliminate stress raisers at coarse grained HAZ areas by using: an adequate welding technique, smooth transitions (grinding).

4.3 Conclusions
Both investigated T24 and P24 materials show no susceptibility to reheat cracking in this particular simulated CGHAZ. Also the fine grained microstructures (double cycled specimens) are not susceptible to reheat cracking. T23 shows some susceptibility to reheat cracking in the particular simulated coarse grained HAZ at PWHT temperatures above 675 oC. The P23 simulated coarse grained HAZ shows a high susceptibility to reheat cracking in a broad test temperature range above 575 oC. However, the simulated fine grained microstructures are not susceptible to reheat cracking indicating that reheat cracking can be avoided by using an appropriate welding technique (avoiding coarse grained microstructures in highly stressed areas).

5 PROPERTIES OF TUBE WELDS

5.1 Welding data
The 7.1 mm thick T23 and T24 steel tubes were welded with the GTAW process. Welding was performed with and without preheating, but in all cases without PWHT. Both homogeneous and heterogeneous welds (to T91 and AISI 316L tubes) were investigated. The T23 homogeneous welds and the heterogeneous welds to T91 were welded with filler metal Union 1Cr2WV (diameter 2 mm) from Thyssen Welding. The heterogeneous welds to AISI 316L were welded with SAF filler metal Inconel 82 (diameter 2 mm). The chemical composition of the wires (according to the fabricator) and of the all-weld metal is given in Table 4.

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Table 4 Chemical composition of welding wires and all-weld metal (homogeneous welds)
C T23 Union 1Cr2WV - wire T23/All-weld metal T24 Union 1CrMoVTiB T24/All-weld metal .07 .069 .05 .064 Si .3 .384 .3 .285 P .007 .004 S .004 .004 Mn .5 .528 .5 .488 Cr 2.2 2.15 2.2 2.37 .029 1.0 .95 Mo V .22 .22 .22 .251 W 1.7 1.32 .013 .009 .011 Al B .002 .002 .003 .003 N .01 .010 .008 Nb .05 .026 Ti .004 .005 .051

The welded joints were tested according to EN 288-3: Specification and approval of welding procedures for metallic materials Part 3: Welding procedure tests for the arc welding of steel. The destructive tests on the welds included: transverse tensile test according to EN 895; bend tests according to EN 910; impact tests according to EN 875; macroscopic and microscopic examination according to EN 1321; hardness test according to EN 1043-1.

For the homogeneous welds, all welded joints fulfilled the strength requirements. Also root and face bending could be performed without cracking. The impact toughness (measured on subsize specimens) and the hardness are closely related to the applied welding procedure and especially to the applied heat input. Lower toughness is mostly correlated with a high heat input (Welds no. 1 and 2 in Table 5 were welded with only 3 weld passes and a heat input up to 35 kJ/cm). Hardness in excess of 350 HV can be encountered when low heat input is applied (e.g. in weld no. T24-3, welded with a heat input of 12 - 22 kJ/cm). The heterogeneous girth welds T23 or T24 to T91, welded with T23 or T24 filler metals, with a preheat of 150 oC and with a PWHT (740 oC 2 hours) showed all acceptable strength, hardness and toughness in spite of the high heat input used (up to 35 kJ/cm).

5.2 Mechanical test results

The mechanical test results are summarized in Tables 5 to 8.

Table 5 Test results on T23 homogeneous tube welds

Test results on T23 tubes (OD 50.8 7.1 mm) Weld no. T23-1 Manual GTAW 3 layers Filler: Union 1Cr2WV 2 mm No preheat, no PWHT Weld no. T23-2 Orbital GTAW 3 layers Filler: Union 1Cr2WV 2 mm Heat input: 35 kJ/cm No preheat, no PWHT Weld no. T23-3 Manual GTAW 7 layers Filler: Union 1Cr2WV 2 mm Heat input: 10-20 kJ/cm Preheat: 150 oC, no PWHT

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa specified in ASTM A213 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location 645 / outside weld in base metal 635 / outside weld in base metal 644-628 617 / outside weld in base metal 637 / outside weld in base metal 645 / outside weld in base metal 639 / outside weld in base metal

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Root bends Face bends 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks

Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm )
2

232 240 225 / 232 177 216 265 / 219 25 25 27 / 26 226 30 27 / 94 123 182 123 / 143 179 211 255 / 215 228 226 108 / 187

Impact weld metal (J/cm2)

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root 340 298 343 283 201 314 349 308 325 334 287 360 297

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Table 6 Test results on T24 homogeneous tube welds

Test results on T24 tubes (OD 50.8 7.1 mm) Weld no. T24-1 Manual GTAW 6 layers Filler: Union 1CrMoVTib 2 mm No preheat, no PWHT Weld no. T24-2 Orbital GTAW 3 layers Filler: Union 1CrMoVTib 2 mm Heat input: 26.4 kJ/cm No preheat, no PWHT Weld no. T24-3 Manual GTAW 7 layers Filler: Union 1CrMoVTib 2 mm Heat input: 12-22 kJ/cm Preheat: 150 oC, no PWHT

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 585 MPa specified in ASTM A213 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location 638 / outside weld in base metal 643 / outside weld in base metal 639-640 631 / outside weld in base metal 623 / outside weld in base metal 635 / outside weld in base metal 632 / outside weld in base metal

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Root bends Face bends 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks

Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm )
2

240 250 240 / 243 233 253 307 / 264 91 108 105 / 101 272 91 388 / 250 39 7 17 / 21 98 226 211 / 178 255 253 255 / 254

Impact weld metal (J/cm2)

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root 340 343 331 336 200 339 360 339 343 363 313 366 298

Table 7 Test results on heterogeneous tube welds T23 and T24 to T91
Test results on T23 and T24 tubes to T91 (OD 50.8 7.1 mm) Weld no. T23-4 Manual GTAW 3 layers Filler: Union 1Cr2WV 2 mm Heat input: 30 - 35 kJ/cm Preheat: 150 oC, PWHT: 740 C 2 hours Weld no. T24-4 Manual GTAW 3 layers Filler: Union 1CrMoVTib 2 mm Heat input: 26 - 35 kJ/cm Preheat: 150 oC, PWHT: 740 C 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa for T23 specified in ASTM A213 min. 585 MPa for T24 specified in ASTM A213 min. 585 MPa for T91 specified in ASTM A213 Tensile strength girth welds (MPa) / fracture location 564 / outside weld in T23 578 / outside weld in T23 599 / outside weld in T24 588 / outside weld in T24

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Root bends Face bends 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks

Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact HAZ T23/T24 (J/cm2) Impact HAZ T91 (J/cm2) Impact weld metal (J/cm2) 258 265 258 / 260 194 189 182 / 188 179 196 191 / 189 253 250 260 / 254 204 228 196 / 209 216 187 238 / 214

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) Max. HV10 face HAZ T91 root 275 257 308 275

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Table 8 Test results on heterogeneous tube welds T23 and T24 to 316L
Test results on T23 and T24 tubes to 316L (OD 50.8 7.1 mm) Weld no. T23-5 Manual GTAW 5 layers Filler: Inconel 82 2 mm Heat input: 8 - 15 kJ/cm No Preheat, no PWHT Weld no. T24-5 Manual GTAW 4 layers Filler: Inconel 82 2 mm Heat input: 5 - 11 kJ/cm No Preheat, no PWHT

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa for T23 specified in ASTM A231 min. 585 MPa for T24 specified in ASTM A213 min. 585 MPa for 316L Tensile strength girth welds (MPa) / fracture location 599 / outside weld in T23 593 / outside weld in 316L 621 / outside weld in 316L 621 / outside weld in 316L

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Root bends Face bends 180o - no cracks 180o - no cracks 180o - no cracks 180o - no cracks

Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact HAZ T23/T24 (J/cm2) Impact HAZ 316L (J/cm2) Impact weld metal (J/cm2) 238 226 235 / 233 307 289 289 / 295 189 177 174 / 180 277 307 / 292 238 245 245 / 243 135 155 118 / 136

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) Max. HV10 face 318 333 329 380 in HAZ T23/24 root

Also the heterogeneous girth welds T23 or T24 to AISI 316L, welded with Inconel 82 filler metal, without preheat and PWHT but with lower heat input (maximum 15 kJ/cm) showed all acceptable strength and toughness. The hardness in the 21/4 Cr steel HAZ can be in excess of 350 HV when too low heat input is applied (e.g. in weld no. T24-5, welded with a heat input of 6 13 kJ/cm).

erogeneous welds (to P22 and P91 pipes) were investigated. In order to define the optimum PWHT conditions, SMAW girth welded pipes were subjected to different PWHT cycles. The impact and hardness test results are summarized in Figures 9 and 10. From these data, it was decided to apply a PWHT at 740 oC for two hours. The chemical composition of the filler metals (according to the fabricator) and of the all-weld metal (measured values) is given in Table 9. The heterogeneous SMAW welds P23 and P24 to P22 were welded with filler metal Thyssen SH Chromo 2 KS. The SMAW welds P23 and P24 to P91 were welded with Thyssen CrMo9V electrodes [4]. The welded joints were tested according to EN 288-3: Specification and approval of welding procedures for metallic materials Part 3: Welding procedure tests for the arc welding of steel. The destructive tests on the welds included: transverse tensile test according to EN 895; bend tests according to EN 910; impact tests according to EN 875; macroscopic and microscopic examination according to EN 1321; hardness test according to EN 1043-1.

5.3 Conclusions
Both T23 and T24 tubes can be welded without preheat and without PWHT, providing an appropriate heat input and multiple layer welding is applied. The recommended heat input is between 15 and 25 kJ/cm. The heterogeneous girth welds T23 or T24 to T91, welded with T23 or T24 filler metals, with a preheat of 150 oC and with a PWHT (740 oC 2 hours) and the heterogeneous girth welds T23 or T24 to AISI 316L, welded with Inconel 82 filler metal, without preheat and PWHT showed all acceptable strength and toughness. The applied heat input should not be below 15 kJ/cm in order to avoid hardness in excess of 350 HV.

6 PROPERTIES OF PIPE WELDS

6.1 Welding data
P23 and P24 steel pipes were welded with the SMAW and SAW welding process. Both homogeneous and het-

6.2 Mechanical test results

The mechanical test results are summarized in Tables 10 to 15.

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Figure 9 Influence of PWHT on hardness and impact toughness of P23 SMAW welds

Figure 10 Influence of PWHT on hardness and impact toughness of P24 SMAW welds For the homogeneous P23 welds, both SMAW and SAW welds fulfilled the strength, hardness and toughness requirements. In all cases, a preheat of at least 150 oC has been applied and all welds received a PWHT at 740 oC for two hours. The heat input seems to play a minor role here. Indeed, the applied heat input varied between 8 and 27 kJ/cm. Also for the homogeneous P24 welds, welded with the same conditions as the P23 welds, both SMAW and SAW welds fulfilled the strength, hardness and toughness requirements. Only SMAW weld P24-4 showed some cracking in the side bend test due to unacceptable porosities in the weld metal. Also here, the applied heat input varied largely between 8 and 37 kJ/cm. The heterogeneous girth welds P23 to P22, welded with P22 filler metals, with a preheat of 150 oC and with a PWHT (740 oC 2 hours) showed all acceptable strength, hardness and toughness. Also the heterogeneous girth welds P23 or P24 to P91, welded with P91 filler metal, with a preheat of 150 200 oC and with a PWHT (740 oC for two hours) and heat input ranging from 18 to 25 kJ/cm showed all acceptable strength and hardness. Toughness is no problem in the HAZ but the weld metal shows low impact toughness and cracking in side bend testing. Low impact toughness at RT is not unusual for dissimilar welds with low-alloy ferritic steel. Due to the differ-

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87

Table 9 Chemical composition of welding wires and all-weld metal (homogeneous welds)
C P23 - SMAW Thyssen Cr 2 WV* P23 - 3 / SMAW All-weld metal P23 - SMAW SAF AL CROMO E223* .06 .06 .05 Si .22 .29 .38 P .017 .015 .011 S .007 .007 .007 Mn .46 .53 .55 Cr 2.28 2.33 2.12 Mo .067 .073 .08 V .28 .25 .23 W 1.72 1.23 1.38 Al B .002 N .017 Nb .043 .028 .015 Ti .001 .005 .006 Cu -

.001 .002 .002 .0009

P23 - SAW .075 Thyssen Union S1 Cr 2 WV Flux: UV 430 TTR-W* P23 - 5 / SAW All-weld metal .068

.22

.017

.001

.47

2.19

.09

.23

1.88

.022 .001

.009

.063

.048

.44 .27 .37 .44 .45 .51 .41 .24

.010 .011 .010 .008 .011 .004 .008 .004

.006 .004 .005 .005 .007 .003 .005 .002

1.32 .56 .58 .54 .51 .46 .41 .53

2.09 1.93 2.18 2.37 2.30 2.47 2.41 2.39

.03 .08 .058 .96 .91 .97 .99 1.01

.19 .23 .22 .23 .26 .22 .22 .24

1.32 1.25 1.23 .021 < .005 .016 -

.013 .001 < .0001 .024 .001 .002

.015 .017

.002

P23 - SAW .055 SAF AL CROMO SF223* P23 - 6 / SAW All-weld metal P24 - SMAW Thyssen CrMoVTiB* P24 - 3 / SMAW All weld metal P24 - SMAW SAF AL CROMO E224* P24 - 4 / SAW All-weld metal P24 - SAW Thyssen Union S1 CrMoVTiB* Flux: UV430 TTR-W P24- 5 / SAW All weld metal P24 - SAW SAF AL CROMO SF224* P24 - 6 / SAW All-weld metal
* Data from fabricators.

.052 .06 .06 .075 .08 .06

.034 -

.007

.004 .032

.006 .003 .002 .0024 .007 .002 .0037

.010 .016

.023 .063 .055 .073 .14

.014

.05

.37

.007

.004

1.17

2.23

.92

.21

.025

.017 .001

.007

.009

.19

.07

.52

.012

.006

.54

2.72

1.06

.24

.020

.038 .003

.017

.032

.05

ences in chromium contents between the materials involved, carbon diffuses during PWHT from the lowchromium material into the neighbouring high-chromium steel or weld metal. As a result, a carbon-depleted zone evolves in the low-chromium and a carbon-enriched zone in the high-chromium material. The extensions of these zones depend on tempering time and temperature. These microstructural changes have an effect on room temperature toughness. However, the creep rupture strength of such a dissimilar weld usually is not affected. The fine-grained intercritical HAZ of the low-alloy ferritic steel still remains the weak zone after long-time exposure.

Heterogeneous girth welds between P23 and P24 to P22, welded with P22 filler metals, with a preheat of 150 oC and with a PWHT (740 oC 2 hours) showed all acceptable strength, hardness and toughness. Heterogeneous girth welds P23 or P24 to P91, welded with P91 filler metal, with a preheat of 150 200 oC and with a PWHT (740 oC for two hours) and heat input ranging from 18 to 25 kJ/cm showed all acceptable strength and hardness but low weld metal toughness (low impact values and cracking in side bend testing).

7 CREEP TEST RESULTS ON PIPE BASE METAL AND WELDMENTS

To determine the creep strength, uniaxial creep tests at 575 oC with stresses between 170 MPa and 215 MPa (isothermal creep tests) were performed by LABORELEC and the Belgian Welding Institute. The time to rupture was measured and the fracture location was determined by metallographic examination.

6.3 Conclusions
The 30 and 25 mm thick P23 and P24 pipes, welded with matching filler metals, a preheat of minimum 150 oC, a heat input between 10 and 35 kJ/cm and a PWHT at 740 oC for two hours show acceptable strength, hardness and toughness.

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Table 10 Test results on homogeneous P23 pipe welds

SMAW girth weld in P23 pipes (OD 219 30 mm) Weld no. P23-3 Filler: Union Cr2WV Heat input: 8 - 27 kJ/cm Preheat 150 oC, PWHT 740 oC - 2 hours Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa specified in ASTM A335 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Side bends Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm )
2

633 634 581 / outside weld in base metal 578 / outside weld in base metal

no cracks > 3 mm

207 219 233 / 219 208 150 218 / 192 98 77 35 / 70

Impact weld metal (J/cm2) Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root

203 238 233 231 241

Table 11 Test results on homogeneous P23 pipe welds

SAW girth welds in P23 pipes (OD 219 30 mm) Weld no. P23-5 Filler: Union S1 Cr2WV Heat input: 9 kJ/cm Preheat 180 oC, PWHT 740 oC 2 hours Weld no. P23-6 Filler: AL CROMO SF 223 Heat input: 10 - 16 kJ/cm Preheat 150 oC, PWHT 740 oC 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa specified in ASTM A335 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location 577 / outside weld in base metal 566 / outside weld in base metal 633 634 563 / outside weld in base metal 578 / outside weld in base metal

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Side bends no cracks > 3 mm no cracks > 3 mm Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm2) Impact weld metal (J/cm2) 207 219 233 / 219 215 209 220 / 215 216 279 182 / 226 228 217 221 / 222 175 218 172 / 188

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root 256 231 236 222 203 227 221 207 227

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Table 12 Test results on homogeneous P24 pipe welds

SMAW girth welds in P24 pipes (OD 370 25 mm) Weld no. P24-3 Filler: Union CrMoVTiB Heat input: 8 - 27 kJ/cm Preheat 150 oC, PWHT 740 oC 2 hours Weld no. P24-4 Filler: AL CROMO E 224 Heat input: 25 - 37 kJ/cm Preheat 200 oC, PWHT 740 oC 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 585 MPa for T24 specified in ASTM A213 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location 596 / outside weld in base metal 600 / outside weld in base metal 640 654 627 / outside weld in base metal 609 / outside weld in base metal

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Side bends cracks due to porosities no cracks > 3 mm Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm )
2

260 246 273 / 260 115 228 129 / 157 70 175 80 / 108 216 114 240 / 190 42 123 104 / 90

Impact weld metal (J/cm2)

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root 247 247 228 233 212 243 256 231 227

Table 13 Test results on homogeneous P24 pipe welds

SAW girth welds in P24 pipes (OD 370 25 mm) Weld no. P24-5 Filler: Union S1 CrMoVTiB Heat input: 9 kJ/cm Preheat 180 oC, PWHT 740 oC 2 hours Weld no. P24-6 Filler: AL CROMO SF 224 Heat input: 10 - 20 kJ/cm Preheat 150 oC, PWHT 740 oC 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 585 MPa for T24 specified in ASTM A213 Tensile strength BM (MPa) Tensile strength girth welds (MPa) / fracture location 627 / outside weld in base metal 632 / outside weld in base metal 640 654 632 / outside weld in base metal 617 / outside weld in base metal

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Side bends no cracks > 3 mm no cracks > 3 mm Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact base metal (J/cm2) Impact HAZ (J/cm2) Impact weld metal (J/cm2) 218 36 222 / 159 260 246 273 / 260 277 255 109 / 214 235 242 254 / 244 89 204 85 / 126

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) HV10 base metal HAZ max. HV10 face HAZ max. HV10 root Weld metal max. HV10 face Weld metal max. HV10 root 284 260 247 222 212 258 254 239 235

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NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES

Table 14 Test results on heterogeneous pipe welds P23 and P24 to P22
SMAW girth welds P23 and P24 pipes to P22 Weld no. P23-7 P22 Filler 2.5 and 3.25 mm Heat input: not available Preheat 150 oC, PWHT: 740 oC 2 hours Weld no. P24-7 P22 Filler 2.5 and 3.25 mm Heat input: not available Preheat 150 oC, PWHT 740 oC 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa for P23 specified in ASTM A335 min. 585 MPa for T24 specified in ASTM A213 min. 415 MPa for P22 specified in ASTM A335 Tensile strength girth welds (MPa) / fracture location 489 / outside weld in P22 496 / outside weld in P22 514 / outside weld in P22 487 / outside weld in P22

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Root bends no cracks > 3 mm no cracks > 3 mm Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact HAZ P23/P24 (J/cm2) Impact HAZ P22 (J/cm2) Impact weld metal (J/cm2) 182 193 203 / 193 265 257 212 / 245 192 196 201 / 196 91 75 91 / 86 294 294 294 / 294 202 201 207 / 203

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) Max. HV10 face in HAZ T91 root 240 233 271 253

Table 15 Test results on heterogeneous pipe welds P23 and P24 to P91
SMAW girth welds P23 and P24 tubes to P91 Weld no. P23-8 24 layers P91 Filler 2.25 and 3.25 mm Heat input: 18 - 25 kJ/cm Preheat 200 oC, PWHT: 740 oC 2 hours Weld no. P24-8 21 layers P91 Filler 2.25 and 3.25 mm Heat input: 18-23 kJ/cm Preheat 200 oC, PWHT 740 oC 2 hours

Transverse tensile testing (EN 895) Required: greater than specified minimum BM (EN 288-3): min. 510 MPa for P23 specified in ASTM A335 min. 585 MPa for T24 specified in ASTM A213 min. 585 MPa for P91 specified in ASTM A335 Tensile strength girth welds (MPa) / fracture location 623 / outside weld in P23 623 / outside weld in P23 623 / outside weld in P24 617 / outside weld in P24

Side bending (EN 910) Required: 120o without cracks of 3 mm in each direction (EN 288-3) Side bends 2 cracks > 3 mm at 180 cracks > 3 mm at 180 Charpy-V impact testing (EN 875) Required: 27 J (34 J/cm2) in WM at room temperature (PED) Impact HAZ P23/P24 (J/cm2) Impact HAZ P91 (J/cm )
2

187 143 89 / 140 145 211 145 / 167 60 30 60 / 50

160 125 135 / 140 179 194 216 / 196 29 29 42 / 33

Impact weld metal (J/cm2)

Hardness testing (EN 1043-1) Required: max. 350 HV10 (power plant applications) max. 320 HV10 (EN 288-3) Max. HV10 face 256 263 261 271 in weld metal root

Creep rupture tests were performed on the delivered P23/P24 base materials and the homogeneous SMAW and SAW welded joints (preheat 150 oC; PWHT 740 oC 2 hours). For the welded joints, creep specimens were taken transversely from the weld.

Stress levels were based on isothermal creep data at 575 oC from Sumitomo data sheet for HCM2S (P23) and from Vallourec & Mannesmann own analysis for P24. A scatter band of 20 % is assumed on the average stress values.

NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES

91

The results are also plotted in the Larson-Miller diagram with a constant C in the Larson Miller parameter taken equal to 20. In the Larson-Miller diagram the creep results are compared with the mean and minimum creep rupture curves for the base material according to the standards. For P23, the mean and minimum creep rupture curves are calculated on basis of the maximum allowable stresses in the ASME Code Case 2199. According to ASME Boiler & Pressure Vessel Code the maximum allowable stress must be smaller than 67 % of the mean creep curve for rupture in 105 hours or 80 % of the minimum creep curve for rupture in 105 hours. For P24, the mean creep rupture values for a 105 hours rupture time are found in the VdTV Data Sheet 533. The minimum stress is around 20 % below the specified mean stress.

7.1 Creep test results and discussion on P23(-joints)

The isothermal (575 oC) creep test results are shown in Figures 11 and 12. The P23 base material from Vallourec & Mannesmann has a higher creep rupture strength at 575 oC than Sumitomos HCM2S and the test results are above the mean rupture curve in the Larson-Miller diagram. The welded joints have lower creep strength than the P23 base material, but fall within the 20 % scatter band on the average stress values for the HCM2S base material. Only the SAW joint (Weld no. P23 - 5) shows a negative trend. The specimens from the SMAW joint (Weld no. P23 - 3) ruptured in the Sub Critical HAZ. The SAW joints

Figure 11 Creep test results

Figure 12 Creep test results

92

NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES

showed ruptures in the weld metal or Sub Critical/Inter Critical HAZ. Ruptures in the weld metal can be the result of the relative high stresses used. Also the fact that for some welds, a low Nb content was found in the weld metal could have contributed: Nb content P23-6 Nb content P23-3 and P23-5 SAW: 0.015 % SAW: 0.007 % SMAW: 0.028 %

7.2 Creep test results and discussion on P24 (-joints)

The isothermal (575 oC) creep results are shown in Figures 13 and 14. The creep rupture strength of the delivered P24 base material confirms the results obtained by Vallourec & Mannesmanns own analysis and is between the minimum and mean creep rupture curve in the Larson-Miller diagram. The SMAW and SAW welds no. P24-4 and P24-6, have a lower creep strength than the base material with rup-

Creep data on welded joints are all above the minimum required in the ASME Code Case 2199 as can be seen in the Larson-Miller plot (see Figure 12).

Figure 13 Creep test results

Figure 14 Creep test results

NEW GENERATION 21/4CR STEELS T/P 23 AND T/P 24 WELDABILITY AND HIGH TEMPERATURE PROPERTIES

93

tures in the Sub Critical- HAZ, but fall within the 20 % scatter band of the P24 base material and show a positive trend in creep strength. For the SMAW joint P244, the specimen tested at 180 MPa broke with a low reduction of area in the weld metal, due to a weld defect. When plotting the results of the welded joints in the Larson-Miller diagram, one can see that the creep rupture strengths fall outside the minimum creep rupture curve for P24 base material defined in VdTV data sheet 533 for the higher stresses used. At the lowest stress-levels the creep rupture strength is near the minimum curve for P24 base material. The SMAW and SAW welds no. P24-3 and P24-5, have a creep strength which falls out the 20 % scatter band of the P24 base material. A large scatter in rupture times occurred. This is probably due to the Ti which is not always homogeneously distributed in the weld metal at different locations in the welded joint, resulting in rupture in the weld metal with a scatter in rupture times. The joints P24-4 and P24-6 showed a higher Ti content in the weld metal than welds no. P24-3 and P24-5, resulting in a better creep strength. Ti-content P24-4 and P24-6: SMAW: 0.055 % Ti-content P24-3 and P24-5: SMAW: 0.023 % SAW: 0.032 % SAW: 0.009 %

Creep results within the 20 % scatterband of the P24 base material can be obtained in P24 SMAW and SAW welded joints, if the Ti in the weld metal can be kept at an acceptable level (above 0.030 %), otherwise the joint has not enough creep strength with rupture in the weld metal and with a large scatter in rupture times. For the relatively high stresses used, ruptures occurred in the weld metal. This is an indication that the weld metal has a lower creep strength than the base materials. For lower, service related stresses (and thus longer rupture times) the fracture location of the creep specimen will probably move to the intercritical HAZ.

8 OVERALL CONCLUSIONS
Both investigated new 21/4Cr-Steel tubes and pipes are very promising high temperature materials for use in power plants. The base metals fulfil the standard requirements and appropriate welding consumables are available. Care must be taken when welding T23 and P23 due to the susceptibility to reheat cracking but this type of embrittlement can easily be avoided by using an appropriate welding technique. Weld simulation tests and tests on real weldments have shown that adequate hardness and toughness can be obtained in tube welds of both T23 and T24 material without preheat and without PWHT. Also heterogeneous tube welds (T23 and T24 to T91 with T23 or T24 filler metal, or to 316L with Inconel 82 filler) showed all acceptable strength and toughness. Also for the thick walled pipes, the hardness stays below 350 HV, even in the as welded condition. However, for toughness reasons, a PWHT at a temperature of about 740 oC is necessary. Both homogeneous and heterogeneous welds (P23 or P24 to P22), welded with P22 filler metal, showed acceptable strength, hardness and impact toughness. Heterogeneous welds (P23 and P24 to P91), welded with P91 filler metal, showed acceptable strength and hardness, but low weld metal toughness. Adequate creep strength can be obtained in the homogeneous pipe welds, providing the Nb and Ti level is kept sufficiently high in the deposited weld metal.

7.3 Fracture location

For lower service related stresses (and thus longer rupture times) the fracture location of the creep specimen will probably move to the intercritical HAZ (IC-HAZ). As with all welded joints in ferritic/martensitic CrMo steels, a lower hardness of the microstructure and lower creep strength is expected due to the thermal weld cycle. In the IC-HAZ, between the Fine Grained HAZ and the uninfluenced base material, of CrMo welds there is only a partial austenitic transformation due to the heat-input during welding. As a result, not all carbides go in solution and during the temperature treatment after welding occurs over-ageing: this means that there is a carbide coarsening and the carbides will coagulate. The result is a softer microstructure with lower creep properties.

7.4 Conclusions
Lower creep rupture strengths are obtained in the P23 SMAW and SAW welded joints than the delivered P23 base material, but with creep rupture strengths above the minimum required for P23 base material in the ASME Code Case 2199. Ruptures occurred either in the weld metal or SC-HAZ. Lower creep rupture strengths are obtained in P24 SMAW and SAW welded joints than the delivered P24 base material, but within the 20 % scatterband of the base material. For lower stresses, the creep rupture strengths move towards the minimum requirements for P24 base material in the VdTV data sheet 533 with ruptures in the SC-HAZ.

REFERENCES
[1] Arndt J., Haarman K., Kottmann G., Vaillant J.C., Bendick W., Kubla G., Arbab A., Deshayes F.: The T23/T24 Book. New grades for waterwalls and superheaters, Information book from Vallourec & Mannesmann Tubes, 1998. [2] Gabrel J.: Development of T and P23 steel grade, Vallourec and Mannesmann Tubes, Cost 522 Steam Power Plant Progress Report No. 04, 2003. [3] Nawrocki J.G.: Stress relief cracking of a ferritic alloy steel, IIW Document IX-2001-01. [4] Heuser H., Jochum C.: Characterization of matching filler metals for new ferritic-bainitic steels like T/P 23 and T/P 24, Thyssen Welding Germany.