Strip Cladding. We are part of voestalpine AG. Lewis Ashby 7 th December Special Steel Division

Transcription

1 Strip Cladding Lewis Ashby 7 th December We are part of voestalpine AG Tool steel & leading position for high-speed steel & special forged parts Special Steel Division Turnouts, rails, processed wire, seamless tubes & welding consumables Metal Engineering Division Welding: 545 Mio EUR 2,397 Employees Steel Division Premium steel strip, electrical steel strip, heavy plate, cast products Metal Forming Division High-quality metal processing solutions, precision steel strip & special components 11,2 Billion EUR 47,418 Employees 2 1

2 More than 145 years of know-how mergers & acquisitions of best-in-class welding companies: Thyssen, Böhler, UTP, Avesta Welding, Soudokay, Fontargen, Fileur, Maruti in the steel industry since 1870 in the welding consumables business since 1926 a voestalpine company since Production sites in Europe Hamm Germany 55,000 tons annual capacity Stick electrodes, solid wire, flux Eisenberg Germany 400 tons annual capacity Filler metals and fluxes for brazing and soldering Seneffe Belgium 7,500 tons annual capacity Hardfacing flux cored wire for maintenance & repair, Welding fluxes for maintenance & repair, Strips for strip cladding process Malmö Sweden 1,200 tons annual capacity Filler metals and fluxes for brazing and soldering Bad Krozingen Germany 3,000 tons annual capacity Stick electrodes, Thermal spraying powders Kapfenberg Austria 27,000 tons annual capacity Flux cored wire, stick electrodes, solid wire Cittadella Italy 6,000 tons annual capacity Seamless flux cored wire 4 2

3 voestalpine Bohler Welding UK Ltd Oldbury Nr Birmingham Sales Customer Service Technical Support Product Distribution 3 Business Units - 3 Brands 6 3

4 Comprehensive portfolio Products Covered electrodes Solid wires/tig rods Flux cored wires Sub arc wire and flux Strips for strip cladding Solders, pastes, fluxes Post-weld cleaning chemicals and pickling pastes Thermal spraying powders Alloys / Grades Unalloyed and low alloyed Aluminium Nickel-based alloys Special alloys (nickel, copper, cobalt) Stainless steel High strength High / low temperature Corrosion resistant Heat resistant 7 Certificates 8 4

5 ASME NCA Corporate Presentation Why cladding? One single material cannot comply with all the requirements Solution : combining two materials Frame : un or medium alloyed construction steel to support the main mechanical loads of the vessel (base metal) Side subjected to wear : alloyed or medium alloyed cladding with anti-wear properties Strip cladding Cladding Electroslag 10 Corrosion High temperatures Metal to metal Compression loads Abrasion Base metal 5

6 Methods of protecting a vessel inside structure from corrosion 1. High alloyed steel inner sleeves CRA Sleeve Vessel shell US Patent 11 Methods of protecting a vessel inside structure from corrosion 2. Roll-bonded clad plates 12 6

7 Methods of protecting a vessel inside structure from corrosion 3. Explosive bonded cladding Vd=2-3.5 km/s Vc= km/s Some Explosives used for bonded cladding 13 Detonation velocity (km/s) RDX (Cyclotrimethylene trinitramine C 3H 6N 6O 6) PETN (Pentaerythritol tetranitrate C 5H 8N 4O 12) TNT (Trinitrotoluene C 7H 5N 3O 6) Tetryl (Trinitrophenylmethylinitramine C 3H 6N 6O 6) Lead azide (Pb(N 3)N 2) Amonium nitrate (NH 4NO 2) Laminar transition Wavy transition Vd = 1.8 km/s Vd = 2.1 km/s Vd = 2.5 km/s Vd = 2.8 km/s Vd=explosive detonation velocity Turbulent transition Methods of protecting a vessel inside structure from corrosion 3. Explosive bonded cladding Open air explosion cladding: Entrapped Intermetallic oxides Hammer bend tests Lower costs, Lower bonding quality Explosion cladding under vacuum: Vacuum EXW Open air EXW Zones of potential risk of crack formation depending of oxides and/or intermetallics entrapments in wave crests Highest costs Best bonding quality Cladding 14 Base metal Clad material Fine grain region Amorphous structure High dislocation density Base metal microns microns microns EXW Superduplex Heat exchanger Onzawa explosion bonded model. 7

8 Methods of protecting a vessel inside structure from corrosion 3. Strip cladding Wire : solid or cored Derived from common SAW Agglomerated Flux Heat source : Subarc = Electric arc Electroslag = Slag ohmic resistance Electrical Power Source Base metal 15 Submerged Arc Strip Cladding (SASC) Flux hopper 1 Driving rolls Contact shoes Strip Travel direction Flux hopper 2 Liquefied slag layer Agglomerated flux Solidified slag layer Base metal Clad metal Electrical arc heating the weld pool 8

9 Electroslag Strip Cladding (ESSC) Single flux hopper Contact shoes Strip Driving rolls Travel direction Agglomerated flux 17 Weld pool heated by RxI 2 Base metal Liquefied electroconductive slag layer Solidified slag layer Clad metal ESSC Process explained 18 12/12/2016 Corporate Presentation 9

10 Cladding Nozzles 19 12/12/2016 Corporate Presentation Magnetic Steering 20 12/12/2016 Corporate Presentation 10

11 Comments on Heat Input Expressed in Joules/cm Processes using wires* or SMAW* HI = Amperage x Voltage x 60 Travel speed (cm/min) Processes using strips HI = Expressed in Joules/cm 2 Amperage x Voltage x 60 Travel speed (cm/min) x strip width (cm) Welding process I (Amps) U (volts) speed HI (J/cm²) SMAW (1) SAW (2) SAW strip (3) ESW strip (3) (1) Stick electrode 3,25 mm diameter, bead width = +/- 10 mm (2) Submerged arc welding wire, bead width = +/- 20 mm (3) 21 * : 60 only mm valid strip for stringer width; bead weld beads width = +/-63mm Characteristics of strip cladding : Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity Very flat surface High reproducibility Low flux consumption Highly flexible cladding process 22 11

12 Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Cladding with Wire Low crack sensitivity Single layer cladding with wire stringer beads Multiple layers cladding with wire stringer beads Very flat surface Multiple layers cladding with wire weaved beads High reproducibility Single layer cladding with strip Low flux consumption Cladding with stringer beads Highly flexible cladding Multiple layers process cladding with strip Strip stringer beads 23 Very uniform penetration Low dilution levels High deposition rates Typical values: A Homogeneous weld metal Low crack sensitivity Very flat surface High reproducibility Low flux consumption SASC: 18% ESSC: 10% B Dilution Base metal 0.20 wt% C, Dilution level : 10 % Strip wt% C Highly flexible cladding process C in 1st layer = 0.20 x 10% x 90% = wt% A B B 24 C en 2nd layer = x 10% x 90% = wt% 12

13 Subarc SC deposition rate spectrum SMAW SAW with 1 single wire SAW with 2 wires FCAW PLASMA SPRAYING PLASMA MIG GMAW SASC with 60mm strip SASC with 90mm strip Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity Very flat surface High reproducibility SASC 120mm strip ESSC with 60mm strip ESSC with 90mm strip ESSC with 120mm strip Electroslag SC deposition rate spectrum kg/h Low flux consumption Highly flexible cladding pro 25 Very uniform penetration Low dilution levels High deposition rates 625 GMAW wire overlay cladding Homogeneous weld metal Low crack sensitivity Very flat surface High reproducibility Single layer 625 strip cladding Low flux consumption Highly flexible cladding process C-steel base metal Percentage in alloying elements Evolution of the content in alloying elements for a single layer 625 cladding made with Electroslag SC -100 Base metal st layer weld metal Distance from the fusion line [µm] Nb Cr Fe Mo Ni Si Mn 26 Fusion line 13

14 Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity CaO + MgORaw + CaF materials 2 + Kwith 2O + Basic Na2Obehaviour + 1 FeO + MnO = MCaO MMgO MCaF MK O MNa O 2 MFeO MMnO I B(%mol.) Raw SiO materials with TiO Acid 2 + Al behaviour 2O3 M SiO 2 2 MTiO 2 MAl2O3 Very flat surface High reproducibility Typical SC Flux basicity indexes The higher the basicity index, the better the metallurgical cleaning efficiency of the weld pool Low flux consumption Subarc : I B = Highly flexible cladding process Electroslag : I B = 4 Vertical molten metal solidification pattern 27 Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity Very flat surface High reproducibility Low flux consumption Heavy influence on post weld machining costs Highly flexible cladding process 28 14

15 Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity ESSC Nominal Absolute variation Relative variation Voltage 24V +/- 0.5V +/- 2% Amperage 1250A +/- 50A +/- 4% Very flat surface High reproducibility Low flux consumption Highly flexible cladding process Typical values observed in cladding applications: SAW wire: kg melted flux /kg melted wire SASC strip: 0.8 kg melted flux /kg melted strip 29 ESSC strip: kg melted flux /kg melted strip Very uniform penetration Low dilution levels High deposition rates Homogeneous weld metal Low crack sensitivity Very flat surface Immediately applicable on vessels during manufacturing operations even on complex and narrow areas & shapes Allows to restore an existing cladding on bonded clad plates after forming & joint welding High reproducibility Low flux consumption Most flexible cladding process 30 Virtually no limit of accessible chemical compositions in stainless Steels, Ni-bases, Cu-bases Co-bases thanks to judicious choices in strip & flux combinations & composition adjustments by the flux 0.5Mo, 1,25Cr-0.5Mo, 2.25Cr-1Mo,410, 308L,309L,316L,347,22 9 3L, L Alloy 625, Alloy 825, Monel

16 Main paramètres & essential différences 60 x 0,5mm strip 4.5mm thick of dep. met. SASC ESSC Electrical arc Yes No Source of heat Electrical arc Joule-effect in molten slag Current 750 A 1250 A Typical welding parameters Voltage 28 V 24 V Travel speed 12 cm/min 18 cm/min Current density in strip 25 A/mm² 42 A/mm² Dilution 18 % 10 % Deposition voestalpine rateböhler Welding 31 Magnetic control 14 kg/h, 0.4 m 2 /h No 23 kg/h, 0.6 m 2 /h Yes Standard SA strip cladding solutions for 347 Using standard stainless steel strips at conventional travel speeds 1 st L 2 nd L Two layers : alloy 347 Soudotape 309 L Record INT 109 Soudotape 347 Record INT 109 C Mn Composition Si Cr Ni Nb mm FN layers 60 mm strip: 750 A - 28 V - 14 cm/min [ 5.9 inch/min] kg/h [ 31.7 lbs/h] m 2 /h [ 898 inch 2 /h] RECORD INT 109 : Neutral flux 32 16

17 Standard ES strip cladding solutions for 347 Using standard stainless steel strips at conventional travel speeds Two layer alloy 347 Composition C Mn Si Cr Ni Nb mm 1 st l Soudotape 309 L Record EST nd l Soudotape 347 Record EST st l Soudotape 347 Record EST mm strip: 1250 A - 24 V - 16 to 18cm/min [7.1 inch/min] - 24 kg/h [ 52.8 lbs/h] m 2 /h [ 1160 inch 2 /h] FN layers 1 single layer 33 RECORD EST 122 : Neutral flux RECORD EST : Cr,Ni,Nb compensated flux Standard ES strip cladding solutions for 347 Using over alloyed stainless steel strips at conventional or high travel speeds 1 st L 1 st L 1 st L RECORD EST 122 & 136 : Neutral fluxes RECORD EST HS : Cr,Ni,Nb compensated flux 34 Single layer alloy 347 Soudotape LNb Record EST 122 (1) Soudotape LNb Record EST 136 (2) Soudotape LNb Record EST HS (3) C Mn Composition 60 mm strip: (1) : 1250 A - 24 V - 16 cm/min [6.3 inch/min] kg/h [ 52.8 lbs / h] m 2 /h [ 967 inch 2 /h] (2) : 1450 A - 24V - 35 cm/min [13.8 inch/min] kg/h [ 61.3 lbs / h] m 2 /h [ 1737 inch 2 /h] (3) : 1650 A - 24V - 35 cm/min [13.8 inch/min] kg/h [ 69.7 lbs / h] m 2 /h [ 2188 inch 2 /h] Si Cr Ni Nb mm FN Single Layer 17

18 Developed ES fluxes for single layer cladding at conventional* travel speeds * : cm/min Alloy Grades Layers Welding Strip Single layer flux AISI 308L 1 Soudotape 308L RECORD EST AISI 309L 1 Soudotape 309L RECORD EST AISI 316L 1 Soudotape 316L RECORD EST AISI 317L 1 Soudotape L RECORD EST AISI Soudotape 347 RECORD EST AISI Soudotape LCu RECORD EST Ni-alloy Soudotape 625 RECORD EST Ni-alloy Soudotape 825 RECORD EST Duplex 2209 / Soudotape L RECORD EST Developed ES combinations for single and multilayers high* speed cladding * : 35 cm/min Alloy Grades Layers Welding Strip High speed flux AISI 308L 2 Soudotape 309L/308L RECORD EST 136 AISI 316L 2 Soudotape 309L/316L RECORD EST 136 AISI 316L 1 Soudotape L RECORD EST 316-1HS AISI 317L 2 Soudotape L RECORD EST 136 Mo AISI Soudotape LNb RECORD EST 136 AISI Soudotape 347 RECORD EST 347-1HS Ni-alloy Soudotape NiCr3 RECORD EST 236 Ni-alloy Soudotape 625 RECORD EST

19 Comparison between flux technologies * : Based on a 2 layer deposit Comparison by process : Based on 60x0,5mm strip SAW ESW ESW HS ESW SL Voltage (Volts) Current (Amps) Speed (cm/min) Thickness/layer (mm) 4, ,0 4,5 Deposition rate (kg/h) Covering rate (m²/h) 0,45 0,69 1,1 0,7 Min. required number of layers Need of magnetic steering No Yes Yes Yes C % in 1 st layer on mild steel metal 0,045 0,030 0,055 0,020 Consumables voestalpine costs Böhler Welding 100% 80% 85% 65% 37 Working time 100%* 66%* 42%* 33% Single layer strip cladding of 316L at high speed Flux : RECORD EST HS (6717) Strip : SOUDOTAPE L (95937, EF2065, 60x0,5 mm) Base metal : ST 52 (thickness : 30 mm) Welding position: 1G/PA Flat Polarity: DC (+) Welding current: 1700 A Arc voltage: 24 V Travel speed: 30 cm/min Preheat/ interpass temperature: none / Max. 150 C Stick out: 40 mm Number of layers: 1 Number of runs: 2 % STRIP ANALYSIS WELD OVERLAY AWS A5.4: E316L C ,034 0,04 Mn ,16 0,5-2,5 Si ,30 1,00 S ,005 0,03 P ,017 0,04 Cr ,4 17,0-20,0 Ni ,2 11,0-14,0 Mo 2.9 2,96 2,0-3,0 Cu ,03 0,75 FN - 8,7 - Bead voestalpine overthickness Böhler Welding Bead width 5 mm 65 mm 19

20 39 12/12/2016 Corporate Presentation 40 12/12/2016 Corporate Presentation 20

21 41 12/12/2016 Corporate Presentation 42 12/12/2016 Corporate Presentation 21

22 43 12/12/2016 Corporate Presentation 44 12/12/2016 Corporate Presentation 22

23 45 12/12/2016 Corporate Presentation Thanks for your kind attention Please visit our website using the below links to download our Nuclear Industry Brochures. s+for+the+nuclear+industry+%28en%29.pdf ear+industry+%28en%29.pdf ANY QUESTIONS? 46 23