Welding Metallurgy and Weldability of Nickel-base Alloys

by Lippold, John C.; Kiser, Samuel D.; DuPont, John N.

• ISBN13: 9780470087145
• ISBN10: 0470087145
• Edition: 1st
• Format: Hardcover
• Copyright: 2009-10-05
• Publisher: Wiley

Summary

The metallurgical behavior and "weldability" of nickel-base alloy welds is of critical engineering and commercial importance. Welding Metallurgy and Weldability of Nickel-Base Alloys provides the most up-to-date treatment on how the wide variety of nickel-base alloys respond to the heat and stresses that result from welding. Many practical examples and case studies demonstrate the application of these principles, making this a value-rich reference and how-to guide for "hands-on" engineers, technicians, and scientists, as well as undergraduate and graduate students.

Author Biography

John N. DuPont, PhD, is the R.D. Stout Distinguished Professor in the Materials Science and Engineering Department at Lehigh University and Associate Director of the Energy Research Center. A Fellow of both the American Welding Society and ASM International. Dr. DuPont has won numerous awards for his research and teaching, including the Charles H. Jennings Memorial Award, the William Spraragen Memorial Award, the Masubuchi Award, the Lehigh Teaching Excellence Award, and the Mckay-Helm, Award. He and his students have published over 200 articles in the area of solidification, high-temperature corrosion, and welding metallurgy. John C. Lippold, PhD, is a Professor in the Welding Engineering Program and leader of the Welding and Joining Metallurgy Group at The Ohio State University. A Fellow of both the American Welding Society and ASM International, Dr. Lippold has received numerous awards;, for his research and teaching, including the Charles H. Jennings Memorial Award, the William Spraragen-Memorial Award, the McKay-Helm Award, the James F. Lincoln Gold Medal, the Comfort A. Adams Lecture Award, the Plummet Memorial Education Lecture Award, and the IIW Jaeger Lecture Award. Together: with his students and colleagues, he has published over 250 articles oh welding metallurgy and Weldability of structural materials. Samuel D. Kiser is Director of Technology for the Special Metals; Welding Products Co., formerly INCO. He is a professional Welding engineer, a Fellow of the American Welding: Society, and holds more than ten patients for nickel alloy welding products. Sam is the; recipient of the A.F. Davis Silver Medal and the Samuel Wylie Miller Memorial Medal Awards, and has published, more than eighty articles and lectured extensively at AWS meetings to audiences around the world.

Table of Contents

Preface	p. xiii
Introduction	p. 1
Ni-base Alloy Classification	p. 2
Commercially Pure Nickel Alloys	p. 2
Solid-Solution Strengthened Alloys	p. 3
Precipitation-Strengthened Alloys	p. 4
Other Specialty Alloys	p. 5
History of Nickel and Ni-base Alloys	p. 5
Corrosion Resistance	p. 11
Nickel Alloy Production	p. 12
References	p. 14
Alloying Additions, Phase Diagrams, and Phase Stability	p. 15
Introduction	p. 15
General Influence of Alloying Additions	p. 16
Phase Diagrams for Solid-Solution Alloys	p. 20
The Ni-Cu System	p. 20
The Ni-Cr System	p. 21
Ni-Mo System	p. 22
The Ni-Fe-Cr System	p. 22
Ni-Cr-Mo System	p. 24
Phase Diagrams for Precipitation Hardened Alloys-?'Formers	p. 26
Phase Diagrams for Precipitation-Hardened Alloys-?"Formers	p. 30
Calculated Phase Stability Diagrams	p. 33
Phacomp Phase Stability Calculations	p. 40
References	p. 43
Solid-Solution Strengthened Ni-base Alloys	p. 47
Standard Alloys and Consumables	p. 47
Physical Metallurgy and Mechanical Properties	p. 51
Welding Metallurgy	p. 57
Microstructural Evolution in the Fusion Zone	p. 57
Interfaces in Single Phase Austenitic Weld Metal	p. 57
Solidification Subgrain Boundaries (SSGBs)	p. 57
Solidification Grain Boundaries (SGBs)	p. 58
Migrated Grain Boundaries (MGBs)	p. 59
Elemental Segregation during Solidification	p. 59
Phase Transformation Sequence	p. 70
Heat Affected Zone	p. 81
Postweld Heat Treatment	p. 82
Stress Relief Heat Treatments	p. 83
Homogenization of Weld Metal Microstruciure	p. 87
Mechanical Properties of Weldments	p. 91
Hydrogen Effects	p. 91
Postweld Heat Treatment	p. 93
Weldability	p. 100
Fusion Zone Solidification Cracking	p. 100
HAZ Liquation Cracking	p. 118
Avoiding Solidification and Liquation Cracking	p. 123
Ductility-Dip Cracking	p. 128
Description of Ductility-Dip Cracking	p. 128
Proposed Mechanisms for Ductility-Dip Cracking	p. 130
Ductility-Dip Cracking in Ni-base Weld Metals	p. 131
Avoiding Ductility-Dip Cracking	p. 143
Corrosion Resistance	p. 143
Case Studies	p. 149
Pitting Corrosion in MONEL“ Welds	p. 149
References	p. 150
Precipitation-Strengthened Ni-base Alloys	p. 157
Standard Alloys and Consumables	p. 158
Physical Metallurgy and Mechanical Properties	p. 161
Welding Metallurgy	p. 173
Microstructural Evolution in the Fusion Zone	p. 173
Elemental Segregation during Solidification	p. 173
Phase Transformations-?' Formation	p. 175
Phase Transformations-Carbide Formation	p. 182
Phase Transformations-?"Formation	p. 184
Effect of Nb and C	p. 187
Fusion Zone Microstructure Predictions using New Phacomp	p. 196
Heat-Affected Zone	p. 201
Postweld Heat Treatment	p. 204
Mechanical Properties of Weldments	p. 206
Weldability	p. 207
Solidification Cracking	p. 208
Effect of Minor Element Additions-B and Zr	p. 208
Effect of Nb Additions	p. 210
Cast Pin Tear Test Results	p. 220
Summary of Solidification Cracking	p. 222
HAZ Liquation Crackin	p. 223
Composition Effects	p. 224
Effect of Grain Size	p. 226
Effect of Heat Treatment	p. 228
Effect of Thermal Stress/Strain	p. 234
Summary of HAZ Liquation Cracking	p. 235
Strain-Age Cracking	p. 235
Mechanism for Strain-Age Cracking	p. 237
Effect of Residual, Thermal and Aging Stresses, and Joint Restraint	p. 242
Composition Effects	p. 244
Grain Size	p. 245
Preweld Condition of the Base Metal	p. 245
Effect of Welding Procedure	p. 246
Effect of Postweld Heat Treatment	p. 246
Summary of Strain-Age Cracking	p. 248
References	p. 248
Oxide Dispersion Strengthened Alloys and Nickel Aluminides	p. 255
Oxide Dispersion Strengthened Alloys	p. 255
Physical and Mechanical Metallurgy	p. 255
Welding Metallurgy	p. 259
Summary of the Weldability of ODS Alloys	p. 268
Nickel Aluminide Alloys	p. 268
Physical and Mechanical Metallurgy	p. 268
Weldability of the Ni-Aluminides	p. 272
Elevated Temperature Cracking	p. 272
Hot Ductility Behavior	p. 274
Brazing	p. 276
Summary of the Weldability of Nickel Aluminide Alloys	p. 276
References	p. 278
Repair Welding of Ni-base Alloys	p. 281
Solid-Solution Strengthened Alloys	p. 281
Precipitation-Strengthened Alloys	p. 283
Alloy 718	p. 284
Effect of ?-phase Formation	p. 284
Rejuvenation Heat Treatments	p. 292
Summary of Repair Weldability of Alloy 718	p. 294
Waspaloy	p. 295
Single Crystal Superalloys	p. 298
Control of Single Crystal Weld Repairs	p. 302
Solidification Cracking	p. 314
Optimizing Processing Parameters	p. 317
References	p. 324
Dissimilar Welding	p. 327
Application of Dissimilar Welds	p. 327
Influence of Process Parameters on Fusion Zone Composition	p. 328
Carbon, Low Alloy and Stainless Steels	p. 331
Determining Weld Metal Constitution	p. 332
Fusion Boundary Transition Region	p. 334
Weldability	p. 342
Solidification Cracking	p. 342
Clad Disbonding	p. 345
Creep Failure in the HAZ of Carbon Steel or Low Alloy Steel	p. 345
Postweld Heat Treatment Cracking	p. 346
Postweld Heat Treatment Cracking in Stainless Steels Welded with Ni-base Filler Metals	p. 347
Super Austenitic Stainless Steels	p. 349
Dissimilar Welds in Ni-base Alloys-Effect on Corrosion Resistance	p. 357
9%Ni Steels	p. 357
Physical Metallurgy of 9%Ni Steels	p. 357
Hot Cracking of Ni-base Deposits	p. 361
Super Duplex Stainless Steels	p. 363
Case Studies	p. 364
Postweld Heat Treatment Cracking of Thick Section Welds in Alloy 800H Made with ENiCrFe-2 Filler Metal	p. 364
Alloy 925 Welded with ERNiCrMo-15 (INCO-WELD 725NDUR) for Manufacturing Vacuum Insulated Oil Patch Tubing	p. 367
Corrosion-Fatigue of Alloy 625 Weld Overlays	p. 369
Overlay of "Safe-End" Welds using High-Cr, Ni-base Filler Metals	p. 373
References	p. 376
Weldability Testing	p. 379
Introduction	p. 379
Weldability Testing Approaches	p. 380
Types of Weldability Test Techniques	p. 380
The Varestraint Test	p. 381
Technique for Quantifying Weld Solidification Cracking	p. 383
Technique for Quantifying HAZ Liquation Cracking	p. 386
Modified Cast Pin Tear Test	p. 388
The Sigmajig Test	p. 392
The Hot Ductility Test	p. 394
The Strain-to-Fracture Test	p. 399
Other Weldability Tests	p. 401
References	p. 402
Composition of Wrought and Cast Nickel-Base Alloys	p. 403
Composition of Nickel and Nickel Alloy Consumables	p. 409
Corrosion Acceptance Testing Methods	p. 415
Etching Techniques for Ni-base Alloys and Welds	p. 419
Author Index	p. 423
Subject Index	p. 431
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