Ni-Base Filler Thermanit 625

in joining & cladding

V. Gross
Böhler Schweisstechnik Deutschland GmbH
Germany, Hamm
Tehran, 25.05.2010
BÖHLER WELDING Group
 content

A. basics and features of

filler metal grade Thermanit 625
IC
G EN
S ION
RYO RRO S CA L E RESIST.
C CO
B. Applications in the offshore industry.
Essentials for:
B1. claddings
B2. clad pipe welding
H T EMP ER.
HIG
BÖHLER WELDING Group 2
General Aspects

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 thermal conductiv. thermal conductiv.
thermal expan. thermal expan.

Basic microstructures

Ferrite +
Ferrite Martensite Austenite
Austenite
516 / 70 13 % Cr (S) / DSS 6 Mo (Ni-basic)

strength .+. .+++ . . ++ . .+.

toughness .+. .+. . ++ . .+++ .

sensibility to
.+. .+++ . . ++ (+) . .+++ .
heat input

+Cr, Mo, Ni; N increasing corrosion resistance (price)

BÖHLER WELDING Group

- 625 has a single phase microstructure, no second phase
like ferrite in some austenitic grades
- structure is very much loaded by Cr, Mo, Nb

which behaviour can be expected by thermal

treatments in terms of melting, forming, heat treatment,
cooling, welding??? The influence of trace elements (e.g. S)

Seggregations, precipitations, hardening, hot cracking

affecting mechanical and corrosion properties and later
on the service

Special procedures have to be developped

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exposure to higher temperatures

90

0
80
1000
70 3000
10000
60 30000

50

40

30

20

10

0
550 650 exposure750
temp. (°C) 850 950

Drop in toughness to be considered at

exposure to 580°C to 900°C in service

BÖHLER WELDING Group

 behaviour of 625 weld metal after pwht
tests done by SMAW strength properties Rpo.2
Rp1.o
Rm
900

strength (MPa)
Some low alloyed base metals require 800
pwht after cladding (e. g. grade 11, 12, 700
22V). 600
500
Impact on mechanical properties 400
as 600°C 650°C 700°C
welded pwht temp. (14hrs/air cooling)

toughness
impact energy (J)

70
60
50
Mechanical properties are not
40
30
affected by pwht in the indicated
20
10
ranges.
0
as
welded
600°C 650°C 700°C Corrosion properties have
pwht (14hrs/aircool.) to be rated seperately!

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Hot cracking tendency/ MVT-Test
SMAW
SAW
GMAW
GTAW
Base metal

MVT-Test (7,5 kJ/cm)

30
Base metal: alloy 625
Filler metal: Thermanit 625
25
Total cracking length [mm]

20
III

II
15

10
I
I = not critical, easy (area of e.g.316L)
5

II = to be welded with care

0
0 0,5 1 2 3 4
Total strain [%]
III = very critical

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 Influence of dilution on the hot cracking
tendency
BM: 6Mo (S31254)

Filler metal in the weld seam

Filler metal: 625

20 80
30 70
Dilution

40 60
[%]

[%]
50 50
60 40
70 30
80 20
Hot crack tendency

10 20 30 40 50 60 70
[%]
Ni in the weld seam

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general aspects of usual welding processes

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 filler metal processes

• „slag processes“ SMAW/ SAW/ FCAW

– weld pool is protected by slag, not affected by wind on site

– SAW high rate of deposit, but high heat input, restricted dia (<2,5mm)
– FCAW , advantages in positional welding

• „solid processes“ GTAW/ GMAW

– very sensitive to turbulances (for weld pool protection)

– low rate of deposit for GTAW (increase by using GTAW hot wire
equipment to sensitive for site conditions). Optimum properties!
– GMAW good compromise for shop fabrication in terms of quality and
rate of deposit.

BÖHLER WELDING Group 11

 Features of different processes

rate of deposit Dilution % equipment local

welds
SMAW + 20 +++ +++

GTAW +(+) 0-100 + +

GMAW ++ 25 + +

SAW +++ 35 + -

FCAW ++ 25 + +

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 Properties related to process

corrosion strength toughness heat input welders skills

SMAW + + + + ++

GTAW +++ ++ +++ +(++) +++

GMAW ++ ++ +++ ++ ++(+)

SAW + + + +++ +

FCAW + + + ++ +

best quality to be achieved with the GTAW and GMAW process

attention: but qualified welders are required too for this job!!!

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All weld metal properties, chemistry of 625

process C Si Mn Cr Mo Nb Fe O
SMAW 0,02 0,7 1,0 22 9 3,5 3(<1)** 0,04*

GTAW 0,02 0,2 0,2 22 9 3,5 <1 0,005

(core wire)

GMAW 0,02 0,2 0,2 22 9 3,5 <1 0,01

SAW 0,02 0,2 0,2 22 9 3,5 <1 0,04*

FCAW 0,02 0,2 0,2 22 9 3,5 2** 0,04*

* higher O-content is „normal“ due metal-slag reaction under atmosphere

** very low Fe-content in stick electrodes in highly corrosive media
required

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all weld metal, mechanical properties

tensile test Impact test

rt
process Rpo.2 Rm A5 RA (J) (J)
(MPa) (MPa) (%) (%) rt -196°C
SMAW 500 780 43 40 90 80

GTAW 500 770 40 50 180 130

GMAW 520 820 45 45 190 150

SAW 480 750 42 50 120 100

FCAW 468 762 36 42 75 60

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GMAW, “ a fine process”
Why GMAW became popular for Ni-base wires??? history

specific behaviour of Ni-base wires:

Ni-base wires show low Si-content which decrease the
viscosity & surface tension of the weld pool.
Welding with conventional GMAW process and gases not
possible. High degree of oxidation, spatters.

But:
Improvement was achieved, when Thyssen Edelstahlwerke
(electrode division) developped mixed gases (Arg+He+low
CO2 content) in the mid ´80ies. In combination with the
pulse technique spatterfree welds have been made
possible. Properties close to the TIG process are achieved!

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 qualification tests SMAW Thermanit 625 3,2mm

Passed corrosion
tests

Stringer beads !!! Parameters reflect low heat input !!!

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 Böhler Schweißtechnik
GTAW - Welding Parameters
Deutschland GmbH
Base material Alloy 625 Blechdicke 5 mm

Filler metal Thermanit 625 - FM 625 Drahtdurchmesser 2,4 mm Ø

Chem. Composition Cr Ni Mn Si Mo Nb Fe Ti C Cu other

Base Material 22.3 bal. 0,08 0,12 9,10 3,40 3,70 0,18 0,024 0,05
Filler Metal 22.4 bal. 0,08 0,10 9,17 3,48 0,70 0,21 0,014 0,03

Weldingparameter root hot pass final layer

Stromart / Polung (current / polarity) DC / - DC / - DC / -

Stromstärke (amperage) I 100 130 130
Spannung (voltage) U 10 12 13
Schweißgeschw. (welding speed) cm /min 12 14 15
Zwischenlagentemp. (interpass temp.) °C 80 100 100
Streckenenergie (heat input) kJ/cm 5 6,7 6,7
Schutzgasmenge (gas flow) l/min 8 8 8
Schutzgas (shielding gas) R1 / Argon 4.6 +2% H2

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 Influence of shield. gas components on wetting

Ar
poor
Ar/He/CO2 wetting of the parent metal
good

Reduction of surface tension and viscosity

O2 und CO2 : through oxidation
He : through higher temperature
"Preheating effect"
Dissociation endothermic
CO2
CO + ½ O 2
Recombination exothermic

Thermal conductivity λ He ∼ 8
λ Ar 1
α He 5
Heat transfer coeff. ∼
α Ar 1

BÖHLER WELDING Group

Shield. gas influence on penetration/ welding speed

Parent and filler

metal:
Alloy 625 /
Filler Tht. 625

Welding
process:
GMAW pulsed
arc (t-MAGp)

Plate thickness:
5 mm

Shielding gas Argon VARIGON® He 50 CRONIGON® He 30 S

(Ar + 50% He) (Ar + 0,05% CO2 + 30% He + 2% H2)

vS 25 cm/min 35 cm/min 50 cm/min

vD 5 m/min

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 Typical GMAW parameter for Thermanit Nimo C 24

Böhler Schweißtechnik
GMAW - Welding Parameters
Deutschland GmbH
Base metal Nicrofer 5923 hMo - Alloy 59 Thickness 16 mm

Filler metal Thermanit Nimo C 24 Welding wire 1.2 mm Ø

Analysis Cr Ni Mn Si Mo Nb Fe Ti C Cu V
Base metal 22.50 60.65 0.15 0.02 15.90 1.00 .002 0.01 0.15
Filler metal 22.65 60.80 0.15 0.03 15.60 0.29 .005 0.01 0.14

Welding parameters Filler passes Cover pass

Current / polarity DC / + DC / +
Amperage 175 A 175 A
Voltage 30 V 30 V
Welding speed 45 cm/min 45 cm/min
Interpass temperature 130 °C 130 °C
Heat input 7 kJ/cm 7 kJ/cm
Wire feed rate 6.2 m/min 6.2 m/min
Drop transfer frequency 90 Hz 90 Hz
Shielding gas Cronigon Ni 10 (Argon + 30% He + 2 % H2 + 0.05 % CO2)

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Cladding

BÖHLER WELDING Group

 625 filler metal for clad pipe joining

Filler metal selection reflects:

•clad material
•cast structure of the weld metal
•strength of pipe material
•dilution with pipe material

Clad filler

316L 309LMo
317L 625
825 625
625 625
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 Cladding in general

Criteria
•in principle all usual welding techniques are applicable
•low dilution with the lower alloyed base metal
•economical aspects
•quality aspects (what is necesary?)
•disposal of welding equipment (incl. operator!)
•geometry of the weld
•site/ shop welding

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 Quality criteria

•dilution to be considered in
order to achieve requ. Quality
•bead geometry
Dilution %
•optimized bead overlap (50%)
SMAW 25
•restricted travel speed GTAW 0-100
GMAW 25
Risk in lack of fusion SAW 35
FCAW 25

NO YES

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 SMAW cladding

electrode cladding
Strip cladding

~6mm

SMA weld C Cr Mo Nb Fe SAW C Cr Mo Nb Fe

All weld ,04 21,3 9,6 3,0 1,2 strip
Surface ,04 21,6 9,0 3,3 1,4 Surface ,016 20,3 9,0 3,0 4
-1mm -1mm
Surface ,04 20,4 9,4 2,9 3,4 Surface ,016 20,1 9,0 3,0 4
-2mm -2mm
Surface ,04 20,0 9,0 2,9 6,8 Surface ,016 20,6 9,0 2,8 4
-3mm -3mm

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 SAW clad joints

825 clad
2 layers
3mm

suff. radius avoids lack of fusion Parameters:

wire: Thermanit 625, dia 2mm
flux: Marathon 444
weld C Cr Mo Nb Fe current: DC+, 290A
volts: 28 V
All weld ,01 21,6 9,1 3,6 0,7
speed: 55 cm/min
Surface ,02 21,6 9,0 3,3 1,4
interpass: max 100°C
Surface - ,02 20,9 8,6 3,2 4,4 bead overlap: 50%
1.5mm

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 GMAW Thermanit 625 claddings

Cladding parameters

Welding pos. vertical up flat weld C Cr Mo Nb Fe

Base metal CS CS flat ,02

wire ,015 21,5 8,9 3,6 ,21
Layers 3 3
clad height 7,5 mm 8 mm at 5mm aboce CS ,02 20,9 8,7 3,6 3,2

overlap ~50 %

Filler metal Thermanit 625 1,2mm weld C Cr Mo Nb Fe

Amps, pulsed 130 A 140A vertical up, 3G ,02
Volts Pulsed, 24 V 25 V wire ,015 21,6 8,7 3,7 ,4
frequence 87 Hz 91 Hz at 5mm above CS ,02 21,5 8,6 3,6 1,4
Gas shield Arg/He/CO2(o.5%) 18 l/min
Interpass temp. max 100°C

BÖHLER WELDING Group

BÖHLER WELDING Group
Cladding on grade 11 base metal
Classification AWS A 5.14 ERNiCrMo –3
Grade Thyssen Thermanit 625
Dia 1,2 mm
Amps/ Volts DC-: 120-160A, 10-14 V
Travel speed ~14 cm/min
Interpass 1. layer acc. to base metal<150°C, other layers max 100°C
Bead overlap 50%
Gas shield* High purity Argon, min 99,996%, ~14 l/min
Bead height ~1,5 – 2mm
Nos. of layers min 5 to meet cladding thickness of 7mm
Cleaning Brushing each layer with stainless brush
Others: After welding TIG rod to be cooled in the gas shield !

weld C Cr Mo Nb Fe
wire ,015 21,6 9,2 3,7 ,6
at 3mm above CS Manual TIG ,02 21 8,6 3,4 3,2
TIG Hot wire ,02 21,7 9,0 3,5 1,8

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Improved torch
with dragging nozzle

Standard torch
without dragging
nozzle

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shielding gas flow rate/ weld bead appearance
5 l/min 10 l/min 15 l/min 20 l/min
wire Thermanit 309 L Mo; heat-no. 96236; Ø 1,2 mm
amperage 250 Amps; DC-
base metal CS
pos. 1G
preheat
none
trailing gas
Additional investigation:
Influence of the flow rate on oxygen content of surface area
100
1000 90
900
80

rel. oxide comp. [%]

800
70
700
oxides [ppm]

60 Si-Cr-Al
600
500 50 Fe-Mn
Fe
400 40
300 30
200 20
100 10
0
5 10 15 20 0
5 5 10 15 20
flow rate [l/min]
flow rate [l/min]
Oxide content of surface
area Composition of oxides

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welding of clad pipes

BÖHLER WELDING Group

back shield issues

with back shield

back shield
device

without back shield

Back shield required for:

-root pass
-base metal

350 ppm O2 <10 ppm O2 -to maintained for min 2 layers !!!

BÖHLER WELDING Group

Clad pipe welding, access from outside only

considerations:
-pick up of Fe from structure must be avoided-

X65

825

Root pass parameters:

- amperage: DC-, ~70 A
- voltage:~10 V
- travel speed: ~7-10cm/min X65
- hot pass: ~100A; 10V, 10 cm/min
- interpass: max 100°C 825
- back shield by Argon of the root to be
maintained for min 2 passes
- sufficient wire supply to be guaranteed any contact of root pass with
- after welding rod to becooled down in gas or pipe material MUST be avoided !!!
cut before restart
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 Cladd pipes

clad pipe joining

Manual TIG automatic TIG

*
9,27mm
*
X60 X70 23,8mm

3mm 317L clad

316L clad 3mm

pipe dia: 378mm

pipe dia: 219,1mm Courtesy of Butting
Fe-content
* Filler passes alternatively b SMAW BÖHLER WELDING Group
 range of fabrication parameters
(e.g. amperage, preheating, interpass temp., pwht)

Ni-base, 6Mo,Superduplex
•thickness
•restraint condition
Duplex
•yield strength

30x grades, eg. 316L

Low alloy-steel

- optimum
parameters +

QA activities have to be developped accordingly !!!

BÖHLER WELDING Group