Flux Cored Wires for LNG Applications
Transcript of Flux Cored Wires for LNG Applications
Metrode Welding Consumables
Flux Cored Wires for LNG Applications
9 October 2013
ESOPE 2013, Paris
Zhuyao Zhang, Mark Golding and Pierre Gerard
www.lincolnelectric.eu
Content
• Controlled ferrite flux cored wires for low
carbon austenitic stainless steel piping
systems
• 625 type nickel base flux cored wire for 9%Ni
steel storage tanks
ESOPE 2013, Paris
www.lincolnelectric.eu
Content
• Main base alloys for LNG facilities
• Advantages of flux cored wire welding
• Flux cored wires for stainless steels
• Microstructure control – δ ferrite
• Mechanical properties
• Flux cored wire for 9%Ni steel
• Choice of filler alloy – NiCrMo-3 type nick base
• Mechanical properties
• Summary
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Why LNG?
ESOPE 2013, Paris
• Natural gas is mainly methane
• LNG is produced by cooling natural gas to -161C
at atmospheric pressure
• Remains liquid by autorefrigeration (cryogen)
• Liquefaction reduces volume by a factor of 600
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Why LNG?
Rapid increase in natural gas consumption:
world consumption and forecast 1965 - 2015
Ref: Energy Insightes
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Why LNG?
Cost of natural gas transportation
Ref: Institute of Gas Technology
LNG vs gas through pipelines
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LNG transpiration and storage
LNG transportation
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LNG transpiration and storage
Storage tank
SS pipe work
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Main base alloys for LNG facilities
Base alloys for LNG
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Base alloys for LNG
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Temp. °C Base Alloys
-50 CMn
-60 CMn (+Ni)
-75 3%Ni
-101 3/5%Ni
-196 9%Ni
-196 304L
-196 316L
-269 304L/316L
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Base alloys and consumables for LNG
ESOPE 2013, Paris
Temp. °C Base Alloys Consumable
-50 CMn
Low alloy -60 CMn (+Ni)
-75 3%Ni
-101 3/5%Ni
Ni-base -196 9%Ni
-196 304L
Control ferrite
-196 316L
-269 304L/316L Non-ferrite
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Welding processes for site-construction
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• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
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Base alloys and consumables for LNG
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Temp. ˚C Alloy Consumable Solid Wire SMAW SAW
-50 CMn
Low alloy
1Ni E8018-C3 (Tufmet 1Ni.B) --
-60 CMn (+Ni) 2Ni E8018-C1 (Tufmet 2Ni.B) --
-75 3%Ni 2Ni E8018-C2 (Tufmet 3Ni.B) --
-101 3/5%Ni
Ni-base
82 ENiCrFe-3 (Nimrod 182KS) --
-196 9%Ni 625 or C276 ENiCrMo-6 (Nyloid 2) C276 or 625 wire
+ flux
-196 304L
Control ferrite
ER308L(CF) E308L-16
Ultramet 308LCF
E308L-15
Ultramet B308LCF --
-196 316L ER316L(CF) E316-16
Ultramet 316LCF
E316L-15
Ultramet B316LCF --
-269 304L/316L Non-ferrite ER316MnNF
(nil ferrite)
E316L-16
(nil ferrite)
E316L-16
(nil ferrite) --
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Welding processes for site-construction
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• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
• Why flux cored wire?
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Welding processes for site-construction
ESOPE 2013, Paris
• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
• Why flux cored wire?
• High productivity
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Base alloys for LNG
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50 100 150 200 250 300 350 400
Welding Current, A
0
2
4
6
8
10
Dep
osit
ion
Rate
, kg
/hFCAW (1.2mm)
GMAW (1.2mm)
SMAW
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Welding processes for site-construction
ESOPE 2013, Paris
• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
• Why flux cored wire?
• High productivity
• Possibility for fully automated welding
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Automated welding mock up: 9%Ni steel + ENiCrMo-3 FCW
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Welding processes for site-construction
ESOPE 2013, Paris
• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
• Why flux cored wire?
• High productivity
• Possibility for fully automated welding
• Good weld cosmetic profile – particularly when involves nickel base filler
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Welding 9%Ni steel with nickel base filler metal
FCAW (3G) SMAW (3G)
9%Ni steel
Ni base
FCW
9%Ni steel
Ni base
SMAW
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Welding processes for site-construction
ESOPE 2013, Paris
• Conventionally: GTAW + SMAW or
GTAW + SAW in the case of LNG tank 2G joint
• Why flux cored wire?
• High productivity
• Possibility for fully automated welding
• Good weld cosmetic profile – particularly when involves nickel base filler
• Good weld metal integrity
• Excellent mechanical properties, particular low temperature impact toughness
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Base alloys and consumables for LNG
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Temp. ˚C Alloy Consumable Solid Wire SMAW FCAW
-50 CMn
Low alloy
1Ni E8018-C3 (Tufmet 1Ni.B) E71T1-21
Metcore DWA55E
-60 CMn (+Ni) 2Ni E8018-C1 (Tufmet 2Ni.B) --
-75 3%Ni 2Ni E8018-C2 (Tufmet 3Ni.B) --
-101 3/5%Ni
Ni-base
82 ENiCrFe-3 (Nimrod 182KS) --
-196 9%Ni 625 or C276 ENiCrMo-6 (Nyloid 2) ENiCrMo3T1-4
Supercore 625P
-196 304L
Control ferrite
ER308L(CF) E308L-16
Ultramet 308LCF
E308L-15
Ultramet B308LCF
E308LT1-4
Supercore 308LCF
-196 316L ER316L(CF) E316-16
Ultramet 316LCF
E316L-15
Ultramet B316LCF
E316LT1-4
Supercore 316LCF
-269 304L/316L Non-ferrite ER316MnNF
(nil ferrite)
E316L-16
(nil ferrite)
E316L-16
(nil ferrite)
E316L-T1-4
Supercore 316NF
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Base alloys and consumables for LNG
ESOPE 2013, Paris
Temp. ˚C Alloy Consumable Solid Wire SMAW FCAW
-50 CMn
Low alloy
1Ni E8018-C3 (Tufmet 1Ni.B) E71T1-21
Metcore DWA55E
-60 CMn (+Ni) 2Ni E8018-C1 (Tufmet 2Ni.B) --
-75 3%Ni 2Ni E8018-C2 (Tufmet 3Ni.B) --
-101 3/5%Ni
Ni-base
82 ENiCrFe-3 (Nimrod 182KS) --
-196 9%Ni 625 or C276 ENiCrMo-6 (Nyloid 2) ENiCrMo3T1-4
Supercore 625P
-196 304L
Control ferrite
ER308L(CF) E308L-16
Ultramet 308LCF
E308L-15
Ultramet B308LCF
E308LT1-4
Supercore 308LCF
-196 316L ER316L(CF) E316-16
Ultramet 316LCF
E316L-15
Ultramet B316LCF
E316LT1-4
Supercore 316LCF
-269 304L/316L Non-ferrite ER316MnNF
(nil ferrite)
E316L-16
(nil ferrite)
E316L-16
(nil ferrite)
E316L-T1-4
Supercore 316NF
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Controlled ferrite FCW
• Controlled ferrite flux cored wires for low
carbon austenitic stainless steel piping
systems
ESOPE 2013, Paris
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Stainless in a LNG facility
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• Typically 304L and 316L types
• Base materials have excellent cryogenic toughness
• Pressure equipment
• Pipe to connect plant and also connect plant to jetty
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Stainless in a LNG facility
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• For simplicity cryogenic Charpy tests are normally carried out
at -196C, liquid nitrogen temperature
• A common requirement is 0.38mm lateral expansion (ASME
B31.3)
• Some European projects (TÜV) do have a minimum Charpy
energy requirement, for example 40J/cm2
Property requirements: Toughness
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Stainless in a LNG facility
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0
0.1
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0.8
0.9
1
0 10 20 30 40 50 60
La
tera
l E
xp
an
sio
n,
mm
Impact Energy, J
LE=0.38mm
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Stainless in a LNG facility
ESOPE 2013, Paris
Weld metal toughness
• Base materials are carefully processed.
• Weld metals are as-cast and do not necessarily achieve the
required toughness.
• How to achieve weld metal impact properties?
• Solution annealing
• Fully austenitic consumables
• Gas shielded processes
• Specially designed ‘Controlled Ferrite’ consumables
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Stainless in a LNG facility
ESOPE 2013, Paris
Flux cored wires – specially designed with controlled ferrite ‘CF’
• Design philosophy
• Control ferrite
• Control alloy content
• Flux system
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
Ferrite control
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Ferrite control
Ferrite & LE – 308L weld
0
0.1
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0.6
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0.8
0.9
1
0 2 4 6 8 10 12
Late
ral E
xp
an
sio
n, m
m
Ferrite, FN
308L
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Ferrite control
Ferrite & LE – 308L & 316L welds
0
0.1
0.2
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0 2 4 6 8 10 12
Late
ral E
xp
an
sio
n, m
m
Ferrite, FN
308L
316L
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Ferrite control
Ferrite & LE – 308L & 316L welds
0
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0 2 4 6 8 10 12
Late
ral E
xp
an
sio
n, m
m
Ferrite, FN
308L
316L
LE=0.38mm
<5FN
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Ferrite control
Various standards have ferrite limits for stainless steels, for
example:
• ASME III requires 5FN minimum; 3-10FN for service
above 427C.
• API 582 has 3FN minimum, it is noted that for
cryogenic service lower FN may be required.
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Ferrite control
0
0.1
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0 2 4 6 8 10 12
Late
ral E
xp
an
sio
n, m
m
Ferrite, FN
308L
316L
LE=0.38mm
308L & 316L welds: ferrite control range
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Type C Mn Si Cr Ni Mo N
AWS/ASME
spec range 0.04 0.5-2.5 1.0
18.0-
21.0 9.0-11.0 0.75 -
Ultramet 308LCF
(E308L-16) <0.025 1.0 0.6 18.5 10.0 0.1 0.08
Ultramet B308LCF
(E308L-15) 0.03 1.2 0.3 18.5 10.2 0.1 0.04
Supercore 308LCF
(E308LT1-4) 0.03 1.4 0.6 18.5 10.5 0.1 0.03
Ferrite control – composition of the weld metals
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308L weld composition: rutile SMAW, basic SMAW, rutile FCW
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Type C Mn Si Cr Ni Mo N FN
AWS/ASME
spec range 0.04 0.5-2.5 1.0
18.0-
21.0 9.0-11.0 0.75 - -
Ultramet 308LCF
(E308L-16) <0.025 1.0 0.6 18.5 10.0 0.1 0.08 2-5
Ultramet B308LCF
(E308L-15) 0.03 1.2 0.3 18.5 10.2 0.1 0.04 2-5
Supercore 308LCF
(E308LT1-4) 0.03 1.4 0.6 18.5 10.5 0.1 0.03 2-5
Ferrite control – composition of the weld metals
ESOPE 2013, Paris
308L weld composition: rutile SMAW, basic SMAW, rutile FCW
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Type C Mn Si Cr Ni Mo N FN
AWS/ASME
spec range 0.04 0.5-2.5 1.0
18.0-
21.0 9.0-11.0 0.75 - -
Ultramet 308LCF
(E308L-16) <0.03 1.0 0.6 18.5 10.0 0.1 0.08 2-5
Ultramet B308LCF
(E308L-15) <0.03 1.2 0.3 18.5 10.2 0.1 0.04 2-5
Supercore 308LCF
(E308LT1-4) 0.03 1.4 0.6 18.5 10.5 0.1 0.03 2-5
Ferrite control – composition of the weld metals
ESOPE 2013, Paris
308L weld composition: rutile SMAW, basic SMAW, rutile FCW
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Type C Mn Si Cr Ni Mo N FN
AWS/ASME
spec range 0.04 0.5-2.5 1.0
17.0-
20.0
11.0-
14.0 2.0-3.5 - -
Ultramet 316LCF
(E316L-16) <0.03 1.0 0.6 18.0 12.0 2.2 0.08 2-5
Ultramet B316LCF
(E316L-15) <0.03 1.2 0.3 18.5 12.2 2.2 0.04 2-5
Supercore 316LCF
(E316LT1-4) 0.03 1.4 0.6 18.5 12.4 2.2 0.03 2-5
Ferrite control – composition of the weld metals
ESOPE 2013, Paris
316L weld composition: rutile SMAW, basic SMAW, rutile FCW
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Ferrite control – composition of the weld metals
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0
Creq = %Cr+%Mo+0.7x%Nb
Nie
q =
Ni+
35x
%C
+2
0x
%N
+0
.25x
%C
u
0
2 4 6 8 10 12 14 1618
20 2224
2628
3035
4045
50
55
60
65
70
80
85
90
95
100
A
A+F
F+A
F
75
First solidifying phase: A
First solidifying phase: -F
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Ferrite control & Suutala diagram
308LCF
range 308LCF & 316LCF
range P+S=~0.03wt%
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Ferrite control & weld microstructure
Predicted ferrite
WRC = 4FN
5FN
measured
4FN
measured
Supercore 308LCF
weld cap
weld mid
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
Alloy control
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Alloy control – 308L weld
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 2 4 6 8 10
Ferrite, FN
Late
ral ex
pan
sio
n,
mm
High alloy
LE=0.38mm
www.lincolnelectric.eu
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 2 4 6 8 10
Ferrite, FN
Late
ral ex
pan
sio
n,
mm
Medium alloy
High alloy
Alloy control – 308L weld
LE=0.38mm
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Alloy control – 308L weld
0.3
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0.6
0.7
0.8
0.9
0 2 4 6 8 10
Ferrite, FN
Late
ral ex
pan
sio
n,
mm
Low alloyMedium alloyHigh alloy
LE=0.38mm
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Alloy control
ESOPE 2013, Paris
• Composition balanced to achieve the optimised ferrite level.
• More critical for 316L than 308L.
• For 316L FCW it means that Mo is in the range 2.0-2.5%.
• The controlled FCWs conforms to AWS 308L and 316L specifications; but the 316L type does not meet the EN ISO specification (EN ISP 17633-A) because it requires 2.5%Mo minimum.
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Controlled ferrite FCWs for stainless steel in a LNG facility
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Flux system
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
• For all-positional welding, fast freezing rutile flux system is used for the wires.
Designations;-
•E308LT1-1/4 (Supercore 308LCF)
•R316LT1-1/4 (Supercore 316LCF)
• Low N2 helps achieving good toughness:
•FCW ~0.03%
•SMAW (-15) ~0.08%
•SMAW (-16) ~0.04%
•SAW ~0.06%
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
Mechanical properties
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Controlled ferrite FCWs – mechanical properties
0,1
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10 15 20 25 30 35 40 45
Late
ral
Exp
an
sio
n, m
m
Impact Energy, J
308L
LE=0.38mm
LE vs Impact Energy @-196C
www.lincolnelectric.eu
Controlled ferrite FCWs – mechanical properties
0,1
0,2
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0,4
0,5
0,6
0,7
0,8
0,9
10 15 20 25 30 35 40 45
Late
ral
Exp
an
sio
n,
mm
Impact Energy, J
308L
SC308LCF
LE=0.38mm
LE vs Impact Energy @-196˚C
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Controlled ferrite FCWs – mechanical properties
LE=0.38mm
LE vs Impact Energy @-196˚C
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Controlled ferrite FCWs – mechanical properties
Gas Position Heat Input
kJ/mm
Charpy energy
J
Lateral expansion
mm
Ar-20%CO2 1G 1.1 38 0.64
100%CO2 1G 1.0 33 0.68
Ar-20%CO2 3G 1.2 32 0.57
Ar-20%CO2 3G 1.8 36 0.67
100%CO2 3G 1.1 36 0.64
Procedural effects on FCAW toughness -196˚C
Welding position, shielding gas and heat input
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Controlled ferrite FCWs – mechanical properties
Consumable Supercore 308LCF Supercore 316LCF
Specification, AWS A5.22 E308LT1-4 E316LT1-4
Specification, EN ISO 17633-A T 19 9 L P M 2 --
Shielding gas Ar-20%CO2 Ar-20%CO2
Tensile strength, MPa 544 546
0.2% Proof stress, MPa 393 410
Elongation, % 4d 50 42
5d 47.5 38.5
Reduction of area, % 54 44
Impact properties -196°C:
impact energy, J 36 34
lateral expansion, mm 0.72 0.55
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Controlled ferrite FCWs – mechanical properties
Process FCAW SMAW FCAW SMAW
Consumable Supercore 308LCF
Ultramet 308LCF
Supercore 316LCF
Ultramet 316LCF
Specification, AWS A5.22 E308LT1-4 E308L-16 E316LT1-4 E316L-16
Specification, EN ISO 17633/EN 1600
T 19 9 L P M 2 E 19 9 L R 3 2 -- --
Shielding gas Ar-20%CO2 -- Ar-20%CO2 --
Tensile strength, MPa 544 583 546 565
0.2% Proof stress, MPa 393 452 410 461
Elongation, % 4d
50 53 42 52
5d 48 47 39 47
Reduction of area, % 54 52 44 63
Impact properties -196°C:
impact energy, J 36 32 34 33
lateral expansion, mm 0.72 0.49 0.55 0.46
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Controlled ferrite FCWs – mechanical properties
FCAW SMAW SAW FCAW SMAW SAW
Supercore 308LCF
Ultramet 308LCF
ER308LCF Supercore 316LCF
Ultramet 316LCF
ER316LCF
E308LT1-4 E308L-16 ER308L E316LT1-4 E316L-16 ER316L
T 19 9 L P M 2 E 19 9 L R 3 2 S 19 9 L -- -- S 19 12 3 L
Ar-20%CO2 -- LA491 Ar-20%CO2 -- LA491
544 583 552 546 565 563
393 452 398 410 461 402
50 53 49 42 52 48.5
48 47 45 39 47 44
54 52 55 44 63 67
36 32 45 34 33 32
0.72 0.49 0.69 0.55 0.46 0.49
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
Project examples
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
SAGE terminal - UK
• First use of ‘CF’ consumables, early 1990’s.
• ExxonMobil/Ralph M Parsons.
• 6G fixed pipe.
• SMAW.
• GTAW.
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Controlled ferrite FCWs for stainless steel in a LNG facility
ESOPE 2013, Paris
Isle of Grain, UK
• First use of the ‘CF’ flux
cored wire.
• 304L pipe.
• 10mm wall thickness.
• 915mm OD.
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Controlled ferrite FCWs for stainless steel in a LNG facility
Isle of Grain, UK
STT root
FCAW fill & cap
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Controlled ferrite FCWs for stainless steel in a LNG facility
Isle of Grain, UK: Project procedure data
Contractor P M Associates UK Ltd
Project Grain-LNG importation facility, Isle of Grain, UK
Material 304L 36in Schedule 10S
Root welding process and consumable.
Lincoln STT GMAW LNM 304Si
Filling process and consumable. FCAW Supercore 308LCF
Transverse tensile strength, MPa 621, 621
Weld impact properties -196˚C: 10x7.5mm
- impact energy, J 32, 29, 34 (32)
- lateral expansion, mm 0.81, 0.70, 0.73 (0.75)
HAZ impact properties -196˚C: 10x7.5mm
- impact energy, J 107, 74, 70 (84)
- lateral expansion, mm 1.44, 1.02, 1.04 (1.17)
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Content
• Controlled ferrite flux cored wires for low
carbon austenitic stainless steel piping
systems
• 625 type nickel base flux cored wire for 9%Ni
steel storage tanks
ESOPE 2013, Paris
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LNG Tank Construction
ESOPE 2013, Paris
Storage tank
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LNG Tank Construction
ESOPE 2013, Paris
Concrete pre-stressed outer shell
Steel vapor barrier 304L cryogenic piping work
9%Nickel steel inner tank
Suspended Aluminum deck
Insulation
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LNG Tank Construction: 9%Ni steel
ESOPE 2013, Paris
Concrete pre-stressed outer shell
Steel vapor barrier 304L cryogenic piping work
9%Nickel steel inner tank
Suspended Aluminum deck
Insulation
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Background of 9% Nickel steel
ESOPE 2013, Paris
Two principle types of 9% Nickel steel used to build LNG
storage tanks:
• Double normalized + Tempered (NN+T)
- ASTM A353 / A353M
• Quenched & Tempered (Q+T)
- ASTM A553 / A553M
• Both NN+T & Q+T steel have a martesitic microstructure
containing Nickel rich ferrite and stable high carbon Austenite
provides good strength and low temperature impact
toughness
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Background of 9% Nickel steel
ESOPE 2013, Paris
Tensile @ambient:-
•Yield Strength: >430 MPa
•UTS: 690-825 MPa
•Elongation: >35 %
Toughness @-196°C
•Impact (CVN): 47-70 J
•Lateral Expansion: >0.38mm
•Shear Fraction: >80 %
•CTOD: >0.30mm
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LNG tank construction: 9%Ni steel
ESOPE 2013, Paris
9%Nickel steel inner
tank construction
A: 9%Ni Inner tank 2G joint: 625 SAW or HAS C276 SAW B: 9%Ni Inner tank 3G joint:
ENiCrMo-6 SMAW ENiCrMo3T1-4 FCAW
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Nickel base FCW for 9%Ni steel LNG
ESOPE 2013, Paris
• AWS A5.34:2007: ENiCrMo3T1-4
• ISO 12153:2011: T Ni 6625 P M 2
* Single values are maximums
Type C Mn Si Cr Ni Mo Nb+Ta Ti Fe Cu
AWS/ASME
spec range 0.10 0.50 0.50
20.0-
23.0 58.0min
8.0-
10.0
3.15-
4.15 0.40 5.0 0.50
ISO
spec range 0.10 0.50 0.5
20.0-
23.0 58.0min
8.0-
10.0
3.15-
4.15 0.40 5.0 0.50
SC625P:
typical 0.020 0.30 0.20 20.5 66.0 8.2 3.30 0.18 1.0 0.016
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
* Single values are maximums
• All position rutile flux cored wire
• Designed for either M21 or 100%CO2 shielding gases
• Diameter 1.2mm
• Minimal spatter
• Very stable arc
• Self releasing slag
General features
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
* Single values are maximums
Operating parameters
• Polarity: DC+
• Gas flow: 15-20 litre/min
• ESO: 15-20mm
• Parameters: G/3F: ~25-26V
~150-170A (6-8m/min)
1G/2F: ~28-29V
~180-210A (8-10m/min)
• Metal recovery: 90%
• Very similar to welding with all-positional stainless steel FCWs
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
* Single values are maximums
Semi-auto: Root pass (60° V) Full-auto: Capping (60°V)
Operability
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
Operating parameters
Optimum
range
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
Deposition rate
~4.5kg/h
~2.5kg/h
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
Deposition rates comparison: FCAW vs. SMAW
De
po
sitio
n r
ate
kg
/h
160% Metal recovery & 99%Ni core wire
1,09 1,15
1,65 1,68
2,03
2,25
0,5
0,7
0,9
1,1
1,3
1,5
1,7
1,9
2,1
2,3
2,5
2.5 low 75A 2.5 high 90 A 3.2 low 130A 3.2 high 145A 4.0 low 150A 4.0 high 180A
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
~4.5kg/h
MMA high: ~2.25kg/h
MMA low: ~1.1kg/h
~2.5kg/h
Deposition rates comparison: FCAW vs. SMAW
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
All weld metal properties
Tensile at ambient temperature:
Toughness:
Position Rp0.2, MPa Rm, MPa A4, % A5, % Z, %
All-weld 1G 496 770 44.0 42.5 41
All-weld 3G 498 772 42.5 40.5 41
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
All weld metal properties
Tensile at ambient temperature:
Toughness:
Position Rp0.2, MPa Rm, MPa A4, % A5, % Z, %
All-weld 1G 496 770 44.0 42.5 41
All-weld 3G 498 772 42.5 40.5 41
AWS - - >690 >25 - -
EN SIO - >420 >690 - >22 -
9%Ni steel
weld typical: - >430 690-825 >35 - -
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
All weld metal properties
Toughness:
Toughness:
Position RT
J
-100°C
J
-196°C J
LE at -196°C
mm
All-weld PF/3G 104 98 86 1.44
All-weld PF/3G 87 83 76 1.32
9%Ni steel
weld metal typical
requirement - - - 47-70 >0.38
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Hot cracking susceptibility test: T-joint test
Test set-up (JIS Z 3153 – 1993):
40
70
12
Weld 2:
Test weld
Weld 1:
Restraining weld
45˚
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Hot cracking susceptibility test: T-joint test
Test welds:
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Hot cracking susceptibility test: T-joint test
Test welds: layer by layer dye penetration assessment
Cross section of test weld (height=~5mm)
Test weld
Restraining
weld
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Hot cracking susceptibility test: T-joint test
Cross section of test weld
(height=~5mm)
Test Weld
(top surface)
Test welds: layer by layer dye penetration assessment
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Test Weld:
(1.0mm below top surface)
Test Weld:
(2.5mm below top surface)
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
Procedure test: 9%Ni 3G joints
Root on ceramic
Root on ceramic + seal weld
Root on round ceramic
1 3
2
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
ESOPE 2013, Paris
Procedure test: joint 3
Weld metal
microstructure
Weld cap
Joint macro image
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Procedure test: joint impact toughness @-196°C
Joint CLW CLW* HAZ HAZ* BM BM*
1 59 78 116 154 127 196
2 57 76 120 160 120 160
3 79 (2/3) n.a. 165 n.a. - n.a.
74 (1/3) n.a. 136 n.a. - n.a.
71 (root) n.a. 96 n.a. - n.a.
* 7,5mm sub size CVN values converted to full size values
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Procedure test: joint impact toughness @-196°C
HAZ
165J
96J
136J
Weld
79J
71J
74J
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Procedure test: tensile properties
AWS type and 9%Ni steel joints tensile properties
Joint Position Rp0.2, MPa Rm, MPa A4, % A5, % Z, %
AWS type coupon 1G 496 770 44.0 42.5 41
AWS type coupon 3G 498 772 42.5 40.5 41
9%Ni joint
All-weld
3G
(2/3 thickness) 438 737 49.5 49.5 43
9%Ni
X-weld tensile
3G
(2/3 thickness) - 787 - - -
3G
(2/3 thickness) - 785 - - -
9%Ni steel
weld typical >430 690-825 >35
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Nickel base FCW for 9%Ni steel LNG – SUPERCORE 625P
Procedure test: bend test – side and transverse
Root (transvers) Face (transverse)
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FCWs for LNG applications
ESOPE 2013, Paris
• All-positional flux cored wires are now available for applications of LNG facility constructions;
• FCW for 304L and 316L grade stainless steels are controlled ferrite 308L and 316L types;
• FCW for LNG storage tank 9%Ni steel is 625 type which enables full automated 3G welding;
• These flux cored wires demonstrated very good weldability; satisfactory strength; excellent cryogenic (-196˚C) toughness. The impact properties are compatible and in most cases better than equivalent SMAW electrode welds;
• Benefiting from its nature of continuous welding and capability of fully automated welding, FCW process offers considerable advantages in producing weld joints with sound microstructure quality and low rate in defects;
• Applications of FCWs in the LNG construction offer significant productivity benefit, hence provide potential to substantially reduce the project cost.
Summary
Metrode Welding Consumables
ESOPE 2013, Paris
Thank you for your attention