Technical Report

On

Properties
and
Welding
Procedure for Grade 91 Alloy
Steel

Prepared By:
Siddharth Pant
Roll No. 10MEU073
Mechanical Department
ITM University

ABSTRACT:
New Martensitic Alloy Steel Grade 91 (9Cr-1Mo-V
enhanced) was studied and detected to have
exceptionally high creep strength. It was found to
have a complex microstructure which was
extremely vulnerable to convert into Austenite
form near the temperature for heat treatment.
The variation in the properties of Grade 91 and
Grade 22 alloy steel (presently used for boiler
pipes and fittings) was studied. Differing
properties on using various methods of welding
were noticed, especially GTAW, SMAW and SAW.
Final conclusion was drawn to justify the correct
procedure for welding of 9Cr-1Mo-V Alloy steel.

ACKNOWLEDGEMENTS:
I am highly obliged to S & G Engineers Pvt Ltd.
for inspiring me and allowing me to conduct the
experiment in their facility. I am highly indebted
to the chairperson Mr Siddharth Makkar,
Managing Director Mr Jeewan Pant and their
technical head Mr Jayesh Narang for their support
and guidance.
I would like to extend my gratitude to Itm
University to grant us this platform to present our
research in various upcoming sectors of
mechanical industry.
Some external sources were used to gather the
knowledge used for this project. The mentions
have been done respectively in the references.

CONTENTS:
1.Introduction
2.About the Material
3.About the Welding Electrode
4.Basic Welding Procedure
5.Post Weld Heat Treatment (PWHT)
6.Stress Corrosion Cracking (SCC)
7.Results and Discussions
8.Conclusions
9.References

INTRODUCTION
During this era of energy, there is need of material
which enables us to generate maximum power. Hence,
the experiments on new alloys are being conducted.
Alloy Steel provides good creep strength and can be
used to generate power in high pressure boilers where
temperatures are extreme. Amongst these, Grade 91 is
specially modified 9% Chromium, 1% Molybdenum,
Vanadium enhanced (9Cr-1MoV). Development of 9Cr1MoV began in 1978 by Oak Ridge National Labs for
breeder reactor and has been further developed by
other researchers since then. [1] It was used in Germany
in large scale from 1990 onwards. Generally used for
Superheater sections in boilers. Superheaters are prone
to more creep damage because of high temperature at
which they operate. Other Alloy Steels (Ferritic Alloy
Steels; used previously) have less strength as
compared to Grade 91. Thus, the pressure vessels were
made of thicker section. Because of this, thermal
gradients in them were large and thus, they were more
prone to thermal fatigue cracking. But, Grade 91 has
much higher strength than others. Due to which,
pressure vessels can be made with thinner sections and
hence, thermal gradients are low and resistant to
thermal fatigue cracking. Also, they require less time to
attain thermal equilibrium across the section.

ABOUT THE MATERIAL

The properties of Grade 91 wholly depend on its
chemical composition and microstructure. As per the
chemical composition the minimum Carbon content is
to be 0.08%, minimum Niobium content is to be 0.03%
and minimum Nitrogen of 0.02% is specified to ensure
adequate creep strength. It requires 9% Chromium, 1%
Molybdenum and minimum 0.18% Vanadium with 0.30.6% Manganese, 0.02% Phosphorous maximum,
0.01% Sulfur maximum and 0.2-0.5% Silicon. Niobium
level can be taken slightly lower if Titanium is added. [3]
Titanium is an effective substitute for niobium, but its
level should not exceed 0.010%. This is because of
tendency of titanium to combine with nitrogen. This
reduces the efficiency of nitrogen to act as creep
strength enhancer. Also, it must be kept in mind the
sum of Mn+Ni should not exceed 1.5%. This is because
they depress lower transformation temperature below
1450o F, which makes it difficult to perform Post Weld
Heat Treatment safely. This, in turn, increases the
possibility of conversion to Austenite after PWHT.
Grade 91 is a Martensitic Alloy Steel and thus, it is very
important that its microstructure doesnt convert to
Austenite during or after the welding. Any action that
changes the microstructure adversely affects the
performance of Grade 91. Processes like hot bending,
forging and welding, if not done properly, can destroy
the carbide matrix which gives high creep strength to
the material.

Fig.1 Microstructure of Grade 91 Alloy Steel

ABOUT
ELECTRODE

THE

[4]

WELDING

There are norms to ensure correct welding procedure.

Alloy Steel Grade 91 can be welded using methods
such as GMAW, GTAW, SAW and FCAW. The most
important thing is electrode used for welding Grade 91.
The electrode preferred for welding this material is E9015-B9-H4. This welding electrode consists of 0.080.13% C, 1.25% Mn, 0.3% Si, 0.01% P and S each, 1%
Ni, 8-10.5% Cr and 0.85-1.2% Mo. [5] It requires DCEP
type of current. Additional elements present in small
amounts are V, Cu, Al, Nb, and N.
Another important thing to notice is the presence of
Hydrogen. Grade 91 is easily hardened, hence it
produces hydrogen cracks. Thus, it must be ensured
that the level of hydrogen is minimum.E-9015-B9-H4
has very low hydrogen; and hence is best suited for
welding of such a critical metal. Similar is the
requirement with wire/flux core as well. Also, the
electrodes are recommended to be stored in heated
portable rod boxes to ensure inclusion of undesirable
hydrogen.

BASIC WELDING PROCEDURE

Welding of such material is done at elevated
temperature. The preheat temperature and Interpass
temperature is kept in the range of 400-550 oF. Under
these mentioned conditions, the welding was done. The
edge preparation was done through band-saw followed
cleaning of prepared edge. Then, the material was
heated before the process. The heating can be done
through localized heating method or induction heating
machine. Though, Induction heating is recommended
being faster method and it saves energy. A wide, flat
bead is considered best suited. Thus, a slight weave
technique with high travel speed is specified. After the
welding, the material is kept at elevated temperature to
keep it dry before Post Weld Heat Treatment (PWHT).
Die Penetration Test was conducted to check for any
flaw in the welding. This was done to protect the
material from the action of contaminants especially
Hydrogen. During welding Heat Affected Zones (HAZ)
occur and they are handled very carefully. These are
the soft spots on the material and most prone to
breakage or rupture.

POST WELD HEAT TREATMENT

(PWHT)
PWHT is required for Grade 91 sheets. Grade P91
(Seamless Pipe of grade 91; SA-335 [3]) is to be
normalized at 1900oF [1040oC] minimum and then
tempered at 1350oF [730oC] minimum as a final heat
treatment.
Alternatively,
liquid
quenching
and
tempering is allowed for thicknesses above 3 in. The
location and attachment of thermocouples, the extent
of insulation needed etc. are done as specified. [6] The
temperature was taken to 710oC with heating rate of
100oC per hour and was held for 10 hrs. The metal
reached in red hot phase. Then the material is allowed
to cool down in air

STRESS
(SCC)

CORROSION

CRACKS

In some cases, cracks occur in the fine grained section

of the heat affected zone of a weldment. This happens
if the welding process is not followed as recommended.
[6]

Fig.3 Stress Corrosion Cracking in P91 [2]

These are Stress Corrosion Cracks (SCC) occurring in
as-welded state of material. The cause of SCC is not
identified yet. They may not happen for days after the
material has cooled down to ambient temperature. But,
they certainly occur. Though, the action of
contaminants, such as moisture, after welding and
before PWHT might be a probable reason. If the
material is kept dry in that period, there are great
chances in reduction of SCC. Also, if there are any signs
of SCC after welding and before PWHT, then it can be
checked using Liquid Penetration Test or MagneticParticle Testing before PWHT. Also, it is kept in mind
while performing hydrostatic test, there is danger of
brittle failure due to presence of flaws and inadequate
toughness of material. So, to reduce the danger,
hydrostatic testing is performed at temperature of 70 oF

or higher. There should be allowance for lateral

expansion as well. This ensures failure by leak before
break rather than brittle failure. Other Non-Destructive
Testing Methods are not possible because of the
constraints to keep the material in heated temperature
and away from the moisture.

RESULTS AND DISCUSSIONS:

PWHT plays a vital role determining the strength of the
alloy steel. Even after welding and during PWHT, the
microstructure of material can be destroyed. If this
happens, then the material loses all its creep strength
at once. In worst conditions, it may even have lower
creep rupture strength as compared to Grade 22.
If the complete procedure is carried out successfully,
then the material shows higher creep strength as
compared to generally used alloy steel. Though,
different welding methods exhibit different mechanical
properties. Mechanical properties of Filler metals for
Proc Fill Defor Yiel Ten Elon
P91 are given as in
ess er matio d
sile gatio table: [7]
Me n
Stre Stre n
tal (mm) ngt ngt (%)
h
h
(MP (MP
a)
a)
SM E9 3.2
620 730 19.5
AW 01
5B9
GTA ER 2.5
670 770 19.7
W
90
SB9
SA ER 3.0
580 740 20.1
W
90
SB9

Table.2 Table comparing mechanical properties in

various processes and the filler metal used
The weld hardness should be in the range of 200-275
Brinell or maximum upto 300 Brinell. But, hardness
above 300 Brinell indicates insufficient PWHT and
hardness below 175 Brinell indicates overheating of the
joint.
It must be kept in mind that the material should neither
be under-tempered nor over-tempered. If the material
remains under-tempered, then some complications
arise like Brittle Fracture and Stress Corrosion Cracking.
And if the material gets over-tempered, then its carbide
matrix is destroyed and it loses its basic molecular
properties. This happens, when the material is at a
temperature
between
lower
transformation
temperature and higher transformation temperature for
Austenite Steel. In this case, it neither stays in
martensite form nor it has completely transformed to
austenite form. This inter-critical heating, rather than
over tempering, causes substantial reduction in
strength of the material. [2]
If by any chance, the material gets transformed into
austenite form, then it is not possible to restore the
normalized and tempered microstructure through
localized heating. In that case, the affected weld joint is
cut out and replaced including a minimum of 2-3 inches
of base metal on all sides surrounding the affected
joint. Alternate solution is to normalize and temper the
entire assembly.
When the welding is done between high Chromium
alloys and low Chromium alloys, carbon migration from
high Chromium Alloys to low Chromium Alloys takes
place. This results in loss of Carbon at the joints and

hence, forms a soft zone. The higher the PWHT

temperature and holding time, the more diffusion takes
place resulting in larger soft zone area. This can be
controlled by restricting the PWHT temperature and
holding time for dissimilar joints. In case of similar
joints of Grade 91, the temperature can be kept high.
Even the heat treatment for the dissimilar joints should
not be done for longer period as mentioned in the
Codes.
In summary, below is the graph showing the complete
process
at
a
glance:

Grade 91 Welding Procedure

Temperature (in oC)

800
700
600
500
400
300
200
100
0

Grade 91 Welding
Procedure

Fig.4 Welding of Grade 91 seamless pipe (P91)

summarized at a glance

CONCLUSIONS:
Grade 91 Alloy Steel is a complex material to work
upon. The most important and difficult task is to
maintain its unique microstructure. If not done as per

the specified guidelines given in the codes, the material

properties can be ruined permanently. The conditions of
failure and the methods to prevent them must be
followed in order to ensure safe and successful hot
working on the material without disturbing its
microstructure. Grade 91 is an upgrade to the regular
Grade 22 alloy steel. In comparison with grade 22 alloy
steel, following observations are made: [2]
1. Reduction in wall thickness by two third; reduction in
weight by 60%.
2. Increase in allowable strength in 950-1100 oF range
by 150%.
3. Increase in oxidation limit by 100 oF, enabling lower
corrosion allowance.
4. Increase in thermal fatigue life by a factor of 1012.

REFERENCES:
[1] Welding Grade 91 Alloy Steel, Sperko engineering
Services,
http://www.sperkoengineering.com/html/Grade
%2091%20R%2010-05.pdf, 2005
[2] Growing experience with P91/T91 forcing essential
code changes, Henry Jeffrey F, Alstom Power Inc and
ASME Task group, Industry Alert, Combined Cycle
Journal, 2005
[3] ASME Section IIA Ferrous Material Specification,
ASME, 2004
[4] Dutt B. Shashank, Babu M. Nani, Shanthi G.,
Venugopal S., Sasikala G., Bhaduri A.K.,

Influence of microstructural inhomogeneities on the

fracture toughness of modified 9Cr1Mo steel at 298
823 K,
http://www.sciencedirect.com/science/article/pii/S00223
11511009901
[5] ASME Section IIC, Specifications for Welding rods,
Electrodes and Filler Metals, 2004
[6] Recommended Practice for local heating of welds in
piping and tubing, AWS D10.10, AWS
[7] Welding Filler Metals for power plant engineering, TPUT, Bohler Welding Group Brochure