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Use of Computational and Experimental Techniques to Predict Susceptibility to Weld Cracking

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Cracking Phenomena in Welds IV

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Abstract

A range of computational and experimental techniques has been employed to determine relative susceptibility to various types of weld metal cracking. These techniques can be valuable tools that facilitate both filler metal selection and filler metal development. A combination of thermodynamic and kinetic modeling is employed alongside experimental validation. In some cases, a design of experiment can be used to reduce the number of experiments and optimize a filler metal composition. Two examples will be given; one regarding solidification cracking in Ni-base alloys, and the other on local brittle zone formation in dissimilar metal overlay of a Ni-base alloy on carbon steel. High-chromium, Ni-base filler metals are used for construction and repair applications of nuclear power plants based on their exceptional corrosion resistance. Niobium is added to these alloys to improve resistance to ductility dip cracking by formation of NbC. Additions of Nb also cause low melting point eutectics to form at the end of solidification, which increases susceptibility to solidification cracking. Alternative carbide formers have been investigated using a design of experiment methodology along with ThermoCalc-Scheil simulations to determine the potential for solidification cracking based on the magnitude of the solidification temperature range. Compositions were optimized and then verified using a combination of button melting and small scale weldability testing. Dissimilar metal welds are widely used in the petrochemical industry to improve corrosion resistance and facilitate field fabrication of welded structures. For some metal combinations, such as Ni-base alloys to steels, service failure can occur at the fusion boundary. This failure is related to a brittle zone that forms due to carbon diffusion from the steel towards the interface during postweld heat treatment (PWHT). Carbon diffusion during PWHT has been modeled using DICTRA®. Hypothetical alloy combinations have been simulated with this model in order to demonstrate the influence of carbon content and PWHT conditions. Examples will be given of dissimilar combinations that reduce the potential for carbon migration during PWHT that avoid brittle zone formation at the interface.

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Authors and Affiliations

  1. The Ohio State University, Ohio, USA

    A. T. Hope & J. C. Lippold

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  1. A. T. Hope
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  2. J. C. Lippold
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Correspondence to A. T. Hope .

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Editors and Affiliations

  1. forschung und -prüfung, BAM Bundesanstalt für Material-, Berlin, Berlin, Germany

    Thomas Boellinghaus

  2. The Ohio State University, Columbus, Ohio, USA

    John C. Lippold

  3. Los Alamos National Laboratory, Los Alamos, New Mexico, USA

    Carl Edward Cross

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Hope, A.T., Lippold, J.C. (2016). Use of Computational and Experimental Techniques to Predict Susceptibility to Weld Cracking. In: Boellinghaus, T., Lippold, J., Cross, C. (eds) Cracking Phenomena in Welds IV. Springer, Cham. https://doi.org/10.1007/978-3-319-28434-7_4

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