40mm thick SA515 with 3mm Inconel 600 Clad Reactor
amso...@gmail.com
We seek your valuable insights regarding the welding, shell rolling, and dish forming processes for a clad steel reactor comprising 40mm thick SA515 Gr.60 base material with 3mm Inconel 600 cladding ( Produced by Explosion Bonding Method).
Preliminary references suggest that pre-heating may be necessary during rolling, forming, and welding operations due to the dissimilar material combination. Additionally, maintaining inter-pass temperatures between 100°C and 250°C is advised to prevent clad layer disintegration.
ENiCrFe-3 has been recommended as a suitable filler metal for both cladding and transition layer welds.
As we are new to this material combination, we would greatly appreciate expert opinions on critical considerations, best practices, and potential challenges associated with these fabrication steps.
Looking forward to your guidance.
sridhar cn
No doubt, a lot of considerations are required and citing a few steps to take these into your WPS/PQR
development and supplier discussions. I have collected few information from the Nickel Institute and
other available literature.
The practical considerations are: Collect the mill test certificate for both base,clad plates and the
explosion bonding report, including macro photos, peel/shear test results, and lab test (if available)
results. Shell rolling, dish forming/pressing, welding, including WPS, PQR, and final NDT (PT/MT/UT)
are important.
Consumables: ER NiCrFe-3 for buttering, transition and welding of Inconel 600.
Potential problems: Use a slow incremental forming, UT checks between passes to avoid delamination
during forming. Poor weld fusion at the interface, clad cracking could be avoided with controlled heat
input and proper preheating and interpass temperature. If PWHT is carried out, use controlled parameters.
Recommendations: Run a small (coupon plate) forming trial to check the bond to validate the forming parameters. Develop WPS & PQR for clad welding. Maintain interpass temperature (100–250 °C) and
check HAZ properties and bond integrity using PT/UT checks.
Trust the above details will help you to a large extent.
Sridhar.
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