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A 20 mm thick heat resistant 13CrMoV9-10 steel was welded using a multi-pass submerged arc tandem setup on a 3-D testing facility designed to prevent shrinkage both during the welding and the subsequent cooling to room temperature. The effects of variations in pre-heating and interpass temperatures on the local stresses were monitored by in situ measurement of reaction forces and bending moments during welding and the subsequent dehydrogenation heat treatment. The austenite to bainite transformation and its effects on the overall loads were monitored through the use of a high sampling rate. Increasing the pre-heating and interpass temperatures led to a rise in reaction forces and bending moments. The bending moments originated from the eccentric force transmission over the backing, with a concomitant risk of fracture, especially in the critical root zone. Although the pre-heating and interpass temperatures had a strong effect on the reaction forces, their effect on the bending moments upon cooling to room temperature was negligible.
Realization and safe operation of modern welded structures are progressively requiring for base and filler materials to cope with continually increasing loads, Analyses with a view to crack prevention therefore need to accommodate particularly the structural design (restraint intensity) and the thermomechanical effects in terms of stresses introduced during welding, Against this background, multi-run welding experiments were carried out in an IRC - (Instrumented Restraint Cracking) Test under defined restraint intensity in order to examine the influence of heat control (preheating and interpass temperatures) on the weldinq-specific forces and stresses, The experiments revealed significant rises in the reaction force and stress after welding with increasing preheating and interpass temperature, Furthermore, various concepts for calculating the preheating temperature are discussed, It is demonstrated that the hitherto existing concepts for high-strength finegrained structural steels can lead to divergent results.
The avoidance of failures during the fabrication or operation of petrochemical reactors made of creep-resistant, low-alloy steels as 13CrMoV9-10 requires still research despite over 60 years of international investigations in the field of stress relief cracking. The quality of modern base materials and filler metals leads to the fact that previously known crack causes, such as impurities of S or P, recede into the background. Rather, the causes are increasingly to be found in the fabrication process. Investigations on the influence of heat control on the stresses in welded components and thus on the stress relief cracking sensitivity under realistic manufacturing conditions are not yet available. This work is subdivided in two parts. Part 1 of this study focused on the effect of heat control during submerged arc welding on the stresses. For this purpose, a testing facility was applied, which allows to observe the forces and moments accumulating during welding or heat treatment in a component-like specimen under shrinkage restraint. The stress acting in the specimen increases with higher preheat/interpass temperatures and higher heat input. During the heat treatment, the stresses are relieved. Nevertheless, cracks are formed already during heating. The total crack length correlates with the heat input.
Welding of 13CrMoV9-10 vanadium steel requires care due to an increased susceptibility to stress relief cracking during post weld heat treatment. Previous research into the crack formation in creep-resistant steels has focused on thermal and metallurgical factors; however, little knowledge has been gathered regarding the crack formation during post weld heat treatment considering real-life restraint conditions. This work is subdivided in two parts. Part I showed that an increasing heat input during submerged arc welding under restraint led to an increasing stress level in the joint prior to the post weld heat treatment. The magnitude of stress relief cracking observed in the heat-affected zone after the post weld heat treatment is affected by the heat input. In Part II of this work, the cracks and the associated microstructure which occurred under restraint were studied. The application of a Special acoustic emission analysis indicated that the cracks formed in a temperature range between 300 and 500 °C during the post weld heat treatment. The toughness in the heat-affected zone of the restrained welds was affected by the welding heat input.
Microstructural analyses of all specimens revealed accelerated aging due to precipitation of carbides during post weld heat treatment under restraint.
For higher operational temperatures and pressures required in petrochemical plants, the modified 13CrMoV9-10 steel was developed providing high resistance against creep and compressed hydrogen. Extreme care during the welding procedure is necessary for this steel, attributed to low toughness, high strength in as-welded state, and increased susceptibility to stress relief cracking (SRC) during post-weld heat treatment (PWHT). Previous research of SRC in creep-resistant steels discussed mainly thermal and metallurgical factors. Few previous findings addressed the influences of welding procedure on crack formation during PWHT considering real-life manufacturing conditions. These investigations focus on effects of welding heat control on stresses during welding and subsequent PWHT operations close to realistic restraint and heat dissipation conditions using a special 3D testing facility, which was presented in parts I and II of this contribution. Part III addresses investigations on residual stress evolution affecting crack formation and discusses the transferability of results from large-scale testing to laboratory-scale. Experiments with test set-ups at different scales under diverse rigidity conditions and an assessment of the residual stresses of the weld-specimens using X-ray (surface near) and neutron diffraction analysis (bulk) were performed. This study aims to provide a way of investigating the SRC behaviour considering component-specific residual stresses via small-scale testing concepts instead of expensive weld mock-ups.
Residual stresses are crucial when assessing the performance of welded components. The present work deals with the possibilities of transferring the real-life boundary conditions of welding, which influence the residual stress, into the laboratory. The possibilities of a test system specifically developed for this purpose with a maximum capacity of 2 MN are shown. Due to the structural design, global process, geometry and material-dependent stresses are induced, which can be simulated and quantified within the system. Additionally, X-ray diffraction can be applied to determine the resulting local residual stress distribution precisely with high spatial resolution. Two examples are presented how the conditions to be found during production are simulated in the laboratory. It is shown how welding residual stresses in high-strength steels are affected by the heat control. It was possible to clarify why elevated working temperatures significantly increase the bending stresses in the welded joint and therefore the tensile residual stresses in the heat affected zone (HAZ). The effect of a heat treatment applied under mechanical stress resulting from welding is demonstrated by the example of a creep resistant steel. Reheat cracking is significantly increased in this case compared to small scale laboratory based tests.