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Oxidation Behaviour of Welded ASTM-SA210 GrA1 Boiler Tube Steels under Cyclic Conditions at 900°C in Air

  • Ravindra Kumar EMAIL logo , V. K. Tewari and Satya Prakash
Published/Copyright: October 16, 2018
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High Temperature Materials and Processes
From the journal High Temperature Materials and Processes Volume 38 Issue 2019

Abstract

ASTM-SA210-Grade A1 boiler tube steels were welded by shielded metal arc welding (SMAW) and tungsten inert gas processes. The oxidation behaviour of the welded steels was evaluated under cyclic conditions at 900°C. Visual observations and thermogravimetric data were measured at the end of each cycle. Finally, the scale was analysed using X-ray Diffraction, Scanning-Electron Microscopy/Energy-Dispersive X-Ray studies. A SEM Back scattered image analysis of the cross-section of the oxide scale thickness has been made to measure the oxide scales formed over the welded steels. SMAW welded steel showed the more oxidation rate (in terms of weight gain) as compared to TIG welded at the test temperature of 900°C and it was due to the formation of more cracks in oxide scale, and a thick oxide scale was found on HAZ and weld region.

Keywords: oxidation; GrA1 boiler tube steel; shielded metal arc welding (SMAW); tungsten inert gas (TIG)

Introduction

The Ferritic steels used in wide range of applications in boilers, especially in the construction of their water walls because of their low cost, good mechanical properties and resistance to corrosion at elevated temperature. A large number of welds were found in typical thermal power plants, the weldment specially consists of weld metal and heat-affected zone (HAZ). HAZ is the region of base metal that affected during welding. The welded components of steels suffer deleterious micro- structural degradation, most of the service failures are reported to occur in the HAZs. However, no alloy is perfect to resist the corrosion. Any welding techniques that can reduce or eliminate the corrosion increase the life of welded components and its reliability [1, 2, 3, 4, 5, 6]. During the weld thermal cycle, extremely high temperatures are reached within the HAZ and this can cause the carbide distribution to differ significantly from that of the original, unaffected base metal. The initial carbides may coarsen, transform to subsequent carbide species in situ or completely dissolve and be replaced by a dispersion of new carbides. The manner in which the carbides are affected depends upon factors such as peak temperature, dwell time and cooling rate. In tungsten inert gas welding process a much narrower HAZ is produced [7]. HAZ is the regions which oxides at much higher rate due to the formation of much more extensive internal oxidation and void formation in the subscale regions than in the subscales of the weld metal and base metal regions [8]. For most of the materials the cyclic testing was performed for 50 cycles as this duration is considered to be adequate to achieve the steady state of oxidation The aim of cyclic loading was to create severe conditions for testing as these conditions constitute more realistic approach towards solving the metal corrosion problem in actual industrial environment [9, 10, 11, 12].

This study is an attempt to compare oxidation behaviour of welded Gr A1 boiler tube steels subjected to cyclic conditions in air at 900°C. The X-ray diffraction (XRD) and scanning electron microscopy/energy-dispersive X-ray analysis (SEM/EDX) have been used to characterize the corrosion product after high temperature oxidation at 900°C.

Experimental procedures

Selection of materials and preparation of weldments

ASTM SA 210-GrA1 (GrA1) boiler tube steel was selected as a candidate material in experimental work. This steel has a wide range of application in boilers, especially in the construction of their water walls. The boiler tube (5 mm thickness×33 mm diameter) was cut into approximate length of 150 mm each. Each tube was machined to obtained a single conventional V-groove, with 37.50 bevel angle, constant root gap 1 mm and root face 1 mm. Prior to welding the tube was thoroughly cleaned with brush and acetone so as to remove any oxide layer and dirt or grease adhering to the tube. Tubes were welded together by shielded metal arc welding (SMAW) using basic coated electrode E7018 and tungsten inert gas welding techniques using 99% pure argon gas with filler wire ER 70S-2 with constant arc current 95 A. Details of welding parameters are given in Table 1. The specimens, each measuring approximately 20×15×5 mm3, were cut from the weldments portions. The specimens were polished with (220 grade) silicon carbide paper and emery paper (1/0, 2/0. 3/0, 4/0) then wheel polished before being to oxidize. The chemical composition of the base metal and the electrode/filler metal are given in Table 2.

Table 1:

Welding process parameters.

Welding processesTypes of processArc voltage (Volts)Arc current (Amp.)Average welding speed (mm/min)No. of passAverage heat input (J/cm)Electrode/filler wireGas flow rate (l/min)Electrode/filler wire size (mm)
TIGManual129546.93414,575AWS A5.18 ER 70 S-282.4
SMAWManual2295140.4728927AWS A5.1 E7018-3.15
Table 2:

Chemical composition (wt %) for Gr A1 boiler tube steel and electrode/filler wire used in present study.

MaterialCMnSiSPFe
Base metal0.270.930.10.0580.048Balance
Electrode E70180.081.20.520.0160.015Balance
Filler wire ER70S-20.051.150.450.0180.02Balance

High temperature oxidation test

Cyclic oxidation studies in air were conducted at 900°C temperature in the laboratory silicon carbide tube furnace for 50 cycles. Each cycle consisted of 1 h heating at 900°C followed by 20 min cooling at room temperature. The aim of cyclic loading is to create severe conditions for testing. The studies were performed for welded specimens for comparison. The specimens were mirror-polished before oxidation studies. During experimentation, the prepared specimen was kept in an alumina boat and the weight of the boat and specimens was measured. The alumina boats used for the studies were preheated at a constant temperature of 1200°C for 6–8 h, and it was assumed that their weight would remain constant during the course of high temperature cyclic oxidation study. Then the boat containing the specimen was inserted into the hot zone of the furnace set at a temperature of 900°C. The holding time in the furnace was 1 h in still air at an isothermal temperature of 900°C, after which the boat with specimen was taken out and cooled at ambient temperature for 20 min. Weight-change measurements were taken at the end of each cycle using an electronic balance (model 06120) with a sensitivity of 10–3 g. Any spalled scale was also included at the time of weighing to determine the total rate of corrosion. Efforts were made to formulate the kinetics of corrosion. After the oxidation studies, the exposed specimens were analysed by XRD and SEM-EDX analysis using Bruker AXS D-8 advance diffractometer (Germany) with Cu Kα radiation at the scan rate of 1°/min for 10° to 110° and Oxford (Model-6841), respectively. The oxidized specimens were then cut using Buehler’s Precision Diamond saw (Low speed saw, 04006, USA make) across the cross section and mounted for the cross-sectional oxide scale thickness measurement.

Results and discussion

Visual observation and thermogravimetric data analysis in air

The weight gain plots of welded steels in air at 900°C is shown in Figure 1 and it can be seen in the plots the weight gain for both weldments was almost same in the initial number of cycles up to the 14th cycles then after gradually increased. It can be inferred from the plot that SMAW welded steel showed the maximum weight gain as compared to TIG welded steel. The amount of the spalled scale has also been incorporated in weight gain measurements. The colour of oxide scale during initial cycles for TIG weldment was blackish grey and turned light black after 34th cycle, cracks in the oxide scale had started appearing during 30th cycles. Where as in case of SMAW welded steel, the weld regions seen black in colour during 14th cycle and cracks seem after 27th cycle with little surface spallation. The width of cracks was comparatively more in case of SMAW welded steel than TIG welded. Oxide protrusions, blackish dark grey in colour have been observed through these cracks.

Figure 1: Weight gain plot for welded steels exposed to air at 900°C.
Figure 1:

Weight gain plot for welded steels exposed to air at 900°C.

The behaviour for welded steel was almost parabolic with parabolic rate constants, Kp (10–8 g2 cm−4 s−1) is 20.365 (SMAW) and 13.074 (TIG) as shown in Figure 2. The total cumulative weight gain of these weldments is shown in Figure 3.

Figure 2: Weight gain square (mg/cm2)2 plot for welded steels exposed to air at 900°C.
Figure 2:

Weight gain square (mg/cm2)2 plot for welded steels exposed to air at 900°C.

Figure 3: Cumulative weight gain of weldments.
Figure 3:

Cumulative weight gain of weldments.

Measurements of oxide scale thicknesses

The thickness of the oxide scale formed on the weldment (i.e. on weld metal and HAZ) measured from the BSEI, taken along the cross-section of the mounted specimens, images for all the specimens are shown in Figure 4. The average scale thickness values measured for weld region of SMAW and TIG weldment in steels are 1.110 mm and 0.704 mm, respectively. Whereas average scale thickness measured for HAZ region of SMAW and TIG weldment are 1.196 mm and 0.843 mm, respectively. Minimum scale thickness is indicated by TIG weld metal. There were the cracks in the scale of HAZ of SMAW. The cross sectional image for the oxide scale of HAZ of SMAW weldment indicates cracks right through scale, whereas the oxide scale debonding at metal/scale interface is evident from Figure 4 (b), (c) & (d) for HAZ of SMAW and TIG welded steels, respectively.

Figure 4: SEM back scattered image of the cross section of welded steels after cyclic oxidation in air at 900°C for 50 cycles (a) weld metal (SMAW) (b) HAZ (SMAW) (c) weld metal (TIG) (d) HAZ (TIG).
Figure 4:

SEM back scattered image of the cross section of welded steels after cyclic oxidation in air at 900°C for 50 cycles (a) weld metal (SMAW) (b) HAZ (SMAW) (c) weld metal (TIG) (d) HAZ (TIG).

X-ray diffraction studies

In the given environment, both the weldment had Fe2O3 as the main constituent of scale, as shown in Figure 5. High intensity peaks were observed in case of SMAW welded steel than that of TIG welded.

Figure 5: X-ray diffraction profiles for welded GrA1 steel exposed to air at 900°C for 50 cycles.
Figure 5:

X-ray diffraction profiles for welded GrA1 steel exposed to air at 900°C for 50 cycles.

Surface morphology of the scales

SEM photographs showing surface morphology of the welded steel after cyclic oxidation at 900°C in air for 50 h are shown in Figure 6. It was observed that the scale containing distorted grains consists of mainly iron oxide. SMAW welded steel shows more oxidation along boundaries of globules. The top scale contains larger amount of iron oxide (99.44%) as compared to boundary region having 99.11% iron oxide. Whereas the oxide scale of HAZ region consists of mainly iron oxide (99.01%) with small amount of MnO (0.65%) at Point 2 in Figure 6(b). The weld region of TIG weldment indicates a scale rich in Fe2O3 (99.60%) as revealed by EDX. Oxide protrusions from inside consisting mainly of Fe2O3 (99.83%) indicated point 1 Figure 6 (c). The upper oxide scale on HAZ region consists of iron oxide Fe2O3 and SiO2 (2.56%) at point 2, whereas the inner scale (Point 1) consists of 99.20% Fe2O3 with small amount of MnO Figure 6 (d).

Figure 6: Surface morphology and EDX analysis of the scale on welded GrA1 steels exposed to air at 900°C (a) weld metal (SMAW) (b) HAZ (SMAW) (c) weld metal (TIG) (d) HAZ (TIG).
Figure 6:

Surface morphology and EDX analysis of the scale on welded GrA1 steels exposed to air at 900°C (a) weld metal (SMAW) (b) HAZ (SMAW) (c) weld metal (TIG) (d) HAZ (TIG).

From Figure 2 it can be inferred that both weldments shows same weight gain during initial number of cycles up to 14th but subsequently increase in weight is gradual and almost follow parabolic oxidation rate law. The oxidation resistance in air was more of TIG welded steel as compared to SMAW. The XRD analysis revealed mainly the presence of Fe2O3 in the scale of both the weldments with high intensity peaks in case of SMAW welded steel. Fe2O3 might be formed due to the interdiffusion of oxygen and interaction with the metal surface. Fe2O3 formation has also been reported as the main oxide in base steel by Sidhu and Prakash [12]. In terms of scale thickness measurements the weld region and HAZ of SMAW welded specimen shows more oxidation than that of weld and HAZ regions of TIG welded, the reason was the development of internal oxidation, more cracks and spallation of oxide scale during oxidation run. Spalling of the oxide scale was due to different values of thermal expansion coefficients of the metal and oxides as discussed by Young [13]. The result of XRD was in accordance with the surface EDX analysis. In case of SMAW welded steel, EDX analysis revealed the top and inner scale was richer in iron oxide of weld and HAZ regions, whereas in case of HAZ region of TIG welded steel Si was observed in small amount with main iron oxide. The presence of Si in the oxide of HAZ region of TIG weldment may result of less oxidation in the given environment.

Conclusions

Based on thermogravimetric studies under cyclic condition the following conclusions have been drawn:

Fe2O3 has been found as main oxide in the welded GrA1 steels as revealed by XRD, and EDS analysis. SMAW welded steel showed the more weight gain than that of TIG welded and it was due to the formation of internal oxidation, more cracks and spallation of oxide scale, and a thicker oxide scale was found on HAZ and weld region (as confirmed by oxide scale thicknesses measurements BSEI).

Both the weldments in GrA1 steel follows the parabolic rate law in air at 900°C. Maximum cracking was observed in the case of SMAW weldment during air oxidation which provides the easy diffusion path for corrosive elements, whereas it was least in TIG weldment.

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Received: 2017-09-01
Accepted: 2018-08-12
Published Online: 2018-10-16
Published in Print: 2019-02-25

© 2019 Walter de Gruyter GmbH, Berlin/Boston

This work is licensed under the Creative Commons Attribution 4.0 Public License.

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https://doi.org/10.1515/htmp-2018-0017
Keywords for this article
oxidation; GrA1 boiler tube steel; shielded metal arc welding (SMAW); tungsten inert gas (TIG)
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Articles in the same Issue

  1. Frontmatter
  2. Review Article
  3. Research on the Influence of Furnace Structure on Copper Cooling Stave Life
  4. Influence of High Temperature Oxidation on Hydrogen Absorption and Degradation of Zircaloy-2 and Zr 700 Alloys
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  25. Casting Defects in Transition Layer of Cu/Al Composite Castings Prepared Using Pouring Aluminum Method and Their Formation Mechanism
  26. Effect of Current on Segregation and Inclusions Characteristics of Dual Alloy Ingot Processed by Electroslag Remelting
  27. Investigation of Growth Kinetics of Fe2B Layers on AISI 1518 Steel by the Integral Method
  28. Microstructural Evolution and Phase Transformation on the X-Y Surface of Inconel 718 Ni-Based Alloys Fabricated by Selective Laser Melting under Different Heat Treatment
  29. Characterization of Mn-Doped Co3O4 Thin Films Prepared by Sol Gel-Based Dip-Coating Process
  30. Deposition Characteristics of Multitrack Overlayby Plasma Transferred Arc Welding on SS316Lwith Co-Cr Based Alloy – Influence ofProcess Parameters
  31. Elastic Moduli and Elastic Constants of Alloy AuCuSi With FCC Structure Under Pressure
  32. Effect of Cl on Softening and Melting Behaviors of BF Burden
  33. Effect of MgO Injection on Smelting in a Blast Furnace
  34. Structural Characteristics and Hydration Kinetics of Oxidized Steel Slag in a CaO-FeO-SiO2-MgO System
  35. Optimization of Microwave-Assisted Oxidation Roasting of Oxide–Sulphide Zinc Ore with Addition of Manganese Dioxide Using Response Surface Methodology
  36. Hydraulic Study of Bubble Migration in Liquid Titanium Alloy Melt during Vertical Centrifugal Casting Process
  37. Investigation on Double Wire Metal Inert Gas Welding of A7N01-T4 Aluminum Alloy in High-Speed Welding
  38. Oxidation Behaviour of Welded ASTM-SA210 GrA1 Boiler Tube Steels under Cyclic Conditions at 900°C in Air
  39. Study on the Evolution of Damage Degradation at Different Temperatures and Strain Rates for Ti-6Al-4V Alloy
  40. Pack-Boriding of Pure Iron with Powder Mixtures Containing ZrB2
  41. Evolution of Interfacial Features of MnO-SiO2 Type Inclusions/Steel Matrix during Isothermal Heating at Low Temperatures
  42. Effect of MgO/Al2O3 Ratio on Viscosity of Blast Furnace Primary Slag
  43. The Microstructure and Property of the Heat Affected zone in C-Mn Steel Treated by Rare Earth
  44. Microwave-Assisted Molten-Salt Facile Synthesis of Chromium Carbide (Cr3C2) Coatings on the Diamond Particles
  45. Effects of B on the Hot Ductility of Fe-36Ni Invar Alloy
  46. Impurity Distribution after Solidification of Hypereutectic Al-Si Melts and Eutectic Al-Si Melt
  47. Induced Electro-Deposition of High Melting-Point Phases on MgO–C Refractory in CaO–Al2O3–SiO2 – (MgO) Slag at 1773 K
  48. Microstructure and Mechanical Properties of 14Cr-ODS Steels with Zr Addition
  49. A Review of Boron-Rich Silicon Borides Basedon Thermodynamic Stability and Transport Properties of High-Temperature Thermoelectric Materials
  50. Siliceous Manganese Ore from Eastern India:A Potential Resource for Ferrosilicon-Manganese Production
  51. A Strain-Compensated Constitutive Model for Describing the Hot Compressive Deformation Behaviors of an Aged Inconel 718 Superalloy
  52. Surface Alloys of 0.45 C Carbon Steel Produced by High Current Pulsed Electron Beam
  53. Deformation Behavior and Processing Map during Isothermal Hot Compression of 49MnVS3 Non-Quenched and Tempered Steel
  54. A Constitutive Equation for Predicting Elevated Temperature Flow Behavior of BFe10-1-2 Cupronickel Alloy through Double Multiple Nonlinear Regression
  55. Oxidation Behavior of Ferritic Steel T22 Exposed to Supercritical Water
  56. A Multi Scale Strategy for Simulation of Microstructural Evolutions in Friction Stir Welding of Duplex Titanium Alloy
  57. Partition Behavior of Alloying Elements in Nickel-Based Alloys and Their Activity Interaction Parameters and Infinite Dilution Activity Coefficients
  58. Influence of Heating on Tensile Physical-Mechanical Properties of Granite
  59. Comparison of Al-Zn-Mg Alloy P-MIG Welded Joints Filled with Different Wires
  60. Microstructure and Mechanical Properties of Thick Plate Friction Stir Welds for 6082-T6 Aluminum Alloy
  61. Research Article
  62. Kinetics of oxide scale growth on a (Ti, Mo)5Si3 based oxidation resistant Mo-Ti-Si alloy at 900-1300∘C
  63. Calorimetric study on Bi-Cu-Sn alloys
  64. Mineralogical Phase of Slag and Its Effect on Dephosphorization during Converter Steelmaking Using Slag-Remaining Technology
  65. Controllability of joint integrity and mechanical properties of friction stir welded 6061-T6 aluminum and AZ31B magnesium alloys based on stationary shoulder
  66. Cellular Automaton Modeling of Phase Transformation of U-Nb Alloys during Solidification and Consequent Cooling Process
  67. The effect of MgTiO3Adding on Inclusion Characteristics
  68. Cutting performance of a functionally graded cemented carbide tool prepared by microwave heating and nitriding sintering
  69. Creep behaviour and life assessment of a cast nickel – base superalloy MAR – M247
  70. Failure mechanism and acoustic emission signal characteristics of coatings under the condition of impact indentation
  71. Reducing Surface Cracks and Improving Cleanliness of H-Beam Blanks in Continuous Casting — Improving continuous casting of H-beam blanks
  72. Rhodium influence on the microstructure and oxidation behaviour of aluminide coatings deposited on pure nickel and nickel based superalloy
  73. The effect of Nb content on precipitates, microstructure and texture of grain oriented silicon steel
  74. Effect of Arc Power on the Wear and High-temperature Oxidation Resistances of Plasma-Sprayed Fe-based Amorphous Coatings
  75. Short Communication
  76. Novel Combined Feeding Approach to Produce Quality Al6061 Composites for Heat Sinks
  77. Research Article
  78. Micromorphology change and microstructure of Cu-P based amorphous filler during heating process
  79. Controlling residual stress and distortion of friction stir welding joint by external stationary shoulder
  80. Research on the ingot shrinkage in the electroslag remelting withdrawal process for 9Cr3Mo roller
  81. Production of Mo2NiB2 Based Hard Alloys by Self-Propagating High-Temperature Synthesis
  82. The Morphology Analysis of Plasma-Sprayed Cast Iron Splats at Different Substrate Temperatures via Fractal Dimension and Circularity Methods
  83. A Comparative Study on Johnson–Cook, Modified Johnson–Cook, Modified Zerilli–Armstrong and Arrhenius-Type Constitutive Models to Predict Hot Deformation Behavior of TA2
  84. Dynamic absorption efficiency of paracetamol powder in microwave drying
  85. Preparation and Properties of Blast Furnace Slag Glass Ceramics Containing Cr2O3
  86. Influence of unburned pulverized coal on gasification reaction of coke in blast furnace
  87. Effect of PWHT Conditions on Toughness and Creep Rupture Strength in Modified 9Cr-1Mo Steel Welds
  88. Role of B2O3 on structure and shear-thinning property in CaO–SiO2–Na2O-based mold fluxes
  89. Effect of Acid Slag Treatment on the Inclusions in GCr15 Bearing Steel
  90. Recovery of Iron and Zinc from Blast Furnace Dust Using Iron-Bath Reduction
  91. Phase Analysis and Microstructural Investigations of Ce2Zr2O7 for High-Temperature Coatings on Ni-Base Superalloy Substrates
  92. Combustion Characteristics and Kinetics Study of Pulverized Coal and Semi-Coke
  93. Mechanical and Electrochemical Characterization of Supersolidus Sintered Austenitic Stainless Steel (316 L)
  94. Synthesis and characterization of Cu doped chromium oxide (Cr2O3) thin films
  95. Ladle Nozzle Clogging during casting of Silicon-Steel
  96. Thermodynamics and Industrial Trial on Increasing the Carbon Content at the BOF Endpoint to Produce Ultra-Low Carbon IF Steel by BOF-RH-CSP Process
  97. Research Article
  98. Effect of Boundary Conditions on Residual Stresses and Distortion in 316 Stainless Steel Butt Welded Plate
  99. Numerical Analysis on Effect of Additional Gas Injection on Characteristics around Raceway in Melter Gasifier
  100. Variation on thermal damage rate of granite specimen with thermal cycle treatment
  101. Effects of Fluoride and Sulphate Mineralizers on the Properties of Reconstructed Steel Slag
  102. Effect of Basicity on Precipitation of Spinel Crystals in a CaO-SiO2-MgO-Cr2O3-FeO System
  103. Review Article
  104. Exploitation of Mold Flux for the Ti-bearing Welding Wire Steel ER80-G
  105. Research Article
  106. Furnace heat prediction and control model and its application to large blast furnace
  107. Effects of Different Solid Solution Temperatures on Microstructure and Mechanical Properties of the AA7075 Alloy After T6 Heat Treatment
  108. Study of the Viscosity of a La2O3-SiO2-FeO Slag System
  109. Tensile Deformation and Work Hardening Behaviour of AISI 431 Martensitic Stainless Steel at Elevated Temperatures
  110. The Effectiveness of Reinforcement and Processing on Mechanical Properties, Wear Behavior and Damping Response of Aluminum Matrix Composites
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