African Fusion March 2015

Microstructural study of turbine rotors

mechanical values for this weld joint were satisfied.

steel and different interlayers were investigated – B1 and B2 weldments with interlayers of 2.5Cr1Mo steel (Union I) and 2.5Cr1MoVNb steel (P24) respectively. The Interlayers were depositedon the 28CrMoNiVbasematerial. The temperatureof postweld heat treatment (PWHT) of the variant B2was slightly higher than that of the B1 variant. Microstructures as well as mechanical properties of both variants are similar. Themicrostructure of theweldments cor- responded to tempered bainite that can be described based on LM and SEM observations as carbides spread more or less homogeneously in a ferritic matrix. The density of the carbide particles was different in individual zones of the weld joint, ie, it was higher in the base materials than in the weldmetal and interlayers. The size of precipitates was higher in 28CrMoNiV base material than in 27NiCrMoV base material. The higher temperature of tempering in the case of 28CrMoNiV steel was the cause. No significant coarsening of the structure in the heat affected zones (HAZ) was observed in either of the base materials. Microstructures in of B2 variant were more tempered in compliance with the rather higher temperature of PWHT in comparison to the B1 variant. Nevertheless, precipitates in the P24 interlayer of the B2 weld joint were finer and more regularly spread than in the Union I interlayer of the B1 weld joint. In addition, carbon enrichment at the interface of the interlayer and the weld metal was observed in the B1 variant. This fact revealed itself in the significantly higher density of precipitates in the interlayer near the fusion line (Figure 5). The microstructure of the B2 weld joint seemed to be better than the B1 weld joint. The crossweld hardness profile (Fig- ure 6) showed more balanced hardness values in the case of the B2 variant. Mechanical tests revealed that the interlayer was the weakest zone of both theweld variants. Fracture during tensile tests occurred in central parts of the interlayer. Both B1 and B2 variants satisfiedmechanical requirements. Due to its slightly better mechanical properties and more favourable micro- structure, the B2 weld joint was selected for real production. Dissimilar weld joint C Themicrostructure of dissimilar weld joint Cof 27NiCrMoV and COST F steels with NiCrMo2.5 weld metal and P24 interlayers is very heterogeneous. After PWHT the microstructure of the COST F base material corresponded to temperedmartensite, while other parts of the weldment consisted mainly of tem- pered bainite with possible small amount of martensite in the 27NiCrMoV base material. Seven main zones were observed in the cross section of the weldment – two base materials (Figures 7 and 8), three heat affected zones, the interlayer (Figure 9) and the weld metal (Figure 10). Bands of coarse- grained and fine-grained structures could be distinguished within the interlayer and in the weld metal. The structure of the COST F basematerial unaffected bywelding is significantly coarser than that of 27NiCrMoV basematerial. Near the fusion line at the interface between the high-alloyed COST F base material and the low alloyed P24, carbon enriched bands were observed. As could be expected, carbon enrichment oc- curred in the basematerial, which resulted in a local increase in hardness (Figure 11). The crossweldhardness profile is shown in Figure 12. Mean hardnesses of the COST F base material and the weld metal were the same – 265 HV. Hardness of 220 HV and 300 HV were

Dissimilar weld joint B Two variants of the weld joint of 27NiCrMoV and 28CrMoNiV steelswith the sameweldmetal on thebasisof 2.5Cr0.4Mo2.5Ni

Figure 5: LM micrographs of Weld B1 showing a carbon enriched interface between the weld metal and the interlayer.

Figure 6: The crossweld hardness profile of Weld B after the PWHT: a) B1 variant, b) B2 variant.

Figure 7: LM micrograph showing the Bainitic structure in Weld C’s 27NiCrMoV base material.

Figure 8: LM micrograph of Weld C showing a tempered martensite of the COST F base material.

Figure 9: LM micrographs of Weld C showing the Bainitic structures of the interlayer: a) coarse-grained and b) fine-grained microstructures.

Figure 10: LM micrograph of Weld C showing the Bainitic structure of the weld metal.

Figure 11: LM micrograph of the COST F/ P24 base material for Weld C showing carbon enrichment at the fusion line.

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March 2015

AFRICAN FUSION