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Ni-rich filament
Composition:
Location p
Cr Ni Fe O
Base metal 20 32 48 ---
Oxide layer >50 <20 <30 +++
Metallic filament <5 >55 35 ---
cavities
250
after 6.000h service at 650°C
225
200
as welded
175
150
125
weld metal Heat Affected Zone base metal
100
-5 0 5 10 15 20 25
Distance (mm) 99-015661125-02-WOR
33 Failed material
2 Failed material
1 New material
Outcome:
Severe relaxation cracking due to welding stresses only!
Control of Relaxation Cracking: EFC-WP 15, April 26th, Paris
13
Metallic filament
cavities
275
Vickers hardness (HV10)
250
HV 140
225
200
175
150
125
weld metal Heat Affected Zone base metal
100
-5 0 5 10 15 20 25
Distance from fusion line in mm
300
275
Vickers hardness (HV1)
250
after 6.000h service at 650°C
225
200
HV 210 as welded
175
150
125
weld metal Heat Affected Zone base metal
100
-5 0 5 10 15 20 25
Distance (mm) 99-015661125-02-WOR
• base materials
• welding consumables
• heat treatments
• Equipment manufacturer
OUTLOOK
160
120
80
5
40
0
600 650 700 750 800 850 900 950
operating temperature, °C
Control of Relaxation Cracking: EFC-WP 15, April 26th, Paris
38
Cost effectiveness new base material not
susceptible for relaxation cracking
Ø 2200mm
dT=670°C
1800mm
• Based on a Alloy 800H
46mm
heat exchanger,
178
dT=680°C
• Weight 86 tonnes 33mm
dT=760°C
• Diameter 2.2 meter
• Height 8 meter 57mm
178
1000mm
between 625 and 825°C 25mm
dT=625°C
Alloy 800H
Control of Relaxation Cracking: EFC-WP 15, April 26th, Paris
39
Calculations performed by an
equipment manufacturer
Cost benefit
Cost Relative cost Relative cost new material
item Alloy 800H new material relative to
Alloy 800H
Material 100 % 69 % 31 %
Labour 100 % 98 % 2%
Various 100 % 90 % 10 %
Total 100 % 75 % 25 %