Facing crack in during overlay welding of Stellite 12 on Duplex material

SURESH

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Nov 20, 2020, 4:46:41 AM11/20/20

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Dear Experts

During welding of Duplex grade material we are facing crack on the weld metal as attached in the photo. Below is the detailed process for reference

Process: PTAW

Base Material: ASTM 182 Gr.F55

Consumable: Stellite 12 (Powder)

PreHeat: Nil

Interpass: <200*C

Current: 128 to 145

Gas: Ultra Pure ARGON

Job Size: OD544 X ID 472 X Thk 36mm

Welding: Overlay weld on OD Surface alone

We are welding deposition thickness of 3mm. So as per this we are doing welding of 2 layer with multi pass, On welding second layer we found crack. Can anyone suggest where it is went wrong and why this crack is propagated. Please advice

In First layer- Total of 12 weld pass

In second layer- Total of 12 weld pass

Regards

Suresh

Raghuram Bathula

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Nov 20, 2020, 4:53:45 AM11/20/20

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https://www.valvemagazine.com/magazine/sections/materials-q-a/7461-hardfacing-stainless-steel.html

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Srinivasan Jagannathan

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Nov 20, 2020, 6:17:34 AM11/20/20

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Dear Suresh

Are you getting the crack during the deposition? Or after the job is cooled?

Srinivasan

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SURESH

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Nov 20, 2020, 11:07:36 AM11/20/20

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Dear sir

While welding itself I am getting crack.

Ring is holded in the positioner by means of clamps at 90 degree and we are proceeding the welding.

Regards

Suresh

d...@btinternet.com

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Nov 20, 2020, 11:07:47 AM11/20/20

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Stellite12 deposits are prone to cracking due to local residual stress and limited ductility.

Thus, preheat has to be applies in order to minimise this susceptibility.

Sincerely,

David Harvey, 20 11 2020.

D Harvey, Director & Welding Metallurgist,
Eclipse Welding Metallurgy & Associates,
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Srinivasan Jagannathan

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Nov 20, 2020, 11:39:56 AM11/20/20

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Dear Suresh,

Grind the surface just before the deposition and try. This might be due to Chromium oxide which has already formed on the surface. Also slow cool by wrapping the entire job with an asbestos cloth.

Srinivasan

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Vanchinath S.A.

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Nov 21, 2020, 3:41:59 AM11/21/20

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Nickel barrier maybe required for stellite deposit on duplex steel.

Vanchinath

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pgos...@rogers.com

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Nov 21, 2020, 11:35:42 PM11/21/20

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ASTM 182 Gr.F55 is Zeron 100 forged product. The base metal hardness could be anything close to 28HRC or less. It’s reasonably high hardness value. Although PTAW is widely followed for depositing Stellite overlay, it could embrittle Duplex , if the heat input is high. What is the Preheat temperature(if at all) adopted, and the calculated Heat Input. For Zeron 100, Q should be typically 1.0-12.Kj/mm.

In your, case the cracks are visible after depositing 2^nd layer(i.e. Stellite over Stellite), which is an indicator that hard products like Stellite are not able to accommodate the shrinkage stress. In case of Stelllite hardfacing application of buffer layers with Nickel base alloys(Alloy 625) could be of help.

Refer the provided guidance in this literature as a reference.

Thanks.

P.Goswami.P.Eng, IWE.

Independent & Consulting Welding & Metallurgical Specialist

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