Welding in the World

https://doi.org/10.1007/s40194-021-01135-x

RESEARCH PAPER

All-positional flux cored wire with lower trace element contents

and improved ambient temperature toughness for welding P91
steels
Zhuyao Zhang 1 & Sorin Craciun 1 & Vincent van der Mee 1

Received: 15 February 2021 / Accepted: 16 April 2021

# International Institute of Welding 2021

Abstract
The productivity benefits of utilizing flux cored wire for welding P91 steels have been recognized for many years. However, due
to the moderate ambient temperature impact toughness and relatively high level of the Bruscato factor (X-factor) of the weld
metal from the flux cored wire consumables, the application range of the FCAW in welding P91 steels has been limited when
compared with other processes, e.g., GTAW, SMAW, and SAW. Consequently, the development for continuous improvement of
the P91 flux cored wire has been an active area. Efforts have been focused on optimizing weld chemical composition to control
the levels of trace elements and improve the impact toughness.
The present paper introduces the latest advances achieved in the improvement of a rutile-based all-position flux cored wire for
P91 steels. The progress has resulted in an optimized weld metal chemical composition with a substantially lower X-factor, better
mechanical properties with significantly improved impact toughness at ambient temperature, and further enhanced out of position
welding performance.

Keywords Thermal power generation . P91 steels . FCAW . Flux cored wire . X-factor . Impact toughness

1 Introduction T91 tubes. After appropriate post-weld heat treatment

(PWHT), satisfactory weldment mechanical and creep
As one of the advanced and most successful creep properties have been consistently achieved under both
resisting alloys in recent three decades, T/P91 (modified workshop and on-site welding conditions.
9Cr-1Mo) steels have been widely used for the modern In response to the continuous demand for improving engi-
fossil fuel power plants. In the fabrications of T/P91 steel neering productivity/efficiency and reducing fabrication/
components, the most commonly used welding processes maintenance costs, both metal cored wire (MCW) and flux
include gas tungsten arc welding (GTAW), shielded metal cored wire (FCW) for P91 steels have been developed, and
arc welding (SMAW), and submerged arc welding the flux cored arc welding (FCAW) process is used for
(SAW). Gas metal arc welding (GMAW) using solid wire welding P91 components, such as steam pipework in thermal
has also been used but mostly only for the tube-to-fin power plant boilers. Up to current date, the majority usage has
fillet joint welding when fabricating panels made from been rutile-based FCW [1–5]. The main benefits of rutile-
based flux cored wire are its significant productivity advan-
Recommended for publication by Commission II - Arc Welding and tages and welder-friendly operability. Figure 1 shows the
Filler Metals comparison of the deposition rate between SMAW, GMAW
(using solid wire) and FCAW processes. Equally importantly,
* Zhuyao Zhang rutile FCW can also be used for all-positional welding, partic-
[email protected]
ularly for ASME 5G/6G fixed pipework where the application
Sorin Craciun of SAW becomes impracticable. These features provide sig-
[email protected] nificant benefits for the fabrications of P91 steel structures. On
the contrary, the application of metal cored wire has been
Vincent van der Mee
[email protected] limited to mainly casting repairing at flat positions (e.g., 1G,
1F, and 2F) [6] only, although the deposition rate advantage of
1
Lincoln Electric Europe, Sheffield, UK MCW would be even higher than FCW.
 Weld World

6
designed for welding the P91 steels which produces simulta-
5 neously satisfactory operative performances in all welding
Deposition rate, kg/h

positions, optimized chemical composition, and mechanical

4
properties.
3

2 2 Status of the existing P91 FCW

FCW
FCAW
1 SMAW
GMAW 2.1 Chemical composition and trace elements
0
0 50 100 150 200 250 300
Commonly used P91 flux cored wire used to be manufactured
Current, A
by primarily using high alloyed steel strip which inherently
Fig. 1 Deposition rate comparison: FCAW vs SMAW and GMAW presented certain limitations in achieving low levels of certain
(solid wire)
trace elements, phosphorous in particular. This formed the
basis of the weld metal phosphorous content limit for P91
It has been nearly 20 years since the flux cored arc welding FCW. The relevant AWS classification [10] for P91 FCW
(FCAW) process was first introduced for joining P91 steel was drawn up based on this situation. The equivalent ISO
components in the early 2000s [4, 5]. One of the very first standard, ISO 17634 [11], also followed the same require-
applications was 5G fixed P91 main steam pipe welding in an ments. Table 1 shows the weld metal chemical composition
actual power plant construction project in Florida, USA in range in the latest edition of AWS A5.29/A5.29M [10] stan-
year 2001 (Fig. 2) [7]. Since then, the benefits of rutile flux dard for classification E91T1-B91M/E621T1-B91M and one
cored wire have been recognized by many P91 projects. example of a typical composition from a representative com-
Nevertheless, the application range of FCAW has been limited mercial product.
when compared with other processes, e.g., GTAW, SMAW, As can be seen from Table 1, the typical phosphorous con-
and SAW. This was mainly due to the moderate ambient tem- tent of all weld deposits was around 0.016%. This, together
perature impact toughness and relatively high level of with the contents of other trace elements, As, Sn, and Sb,
Bruscato factor (X-factor = (10P+5Sb+4Sn+As)/100 ppm) resulted in a Bruscato Factor (X-factor) of around 20–
[8, 9] of the weld metals from the flux cored wires. 22ppm. This value has been satisfactory for general power
Consequently, the development for continuous improvement plant applications since temper embrittlement tendency has
of P91 flux cored wire has been an active area. Efforts have not been considered as a critical issue for P91 power steam
been focused on optimizing the flux design, chemical compo- pipework. Indeed, FCW consumables meeting this require-
sition balance, and controlling the level of trace elements, ment have benefited large numbers of super critical (SC) and
thereby improving the impact toughness and lowering the ultra-super critical (USC) power plant projects, and mainly for
X-factor. joining of thick wall P91 steel pipework. By now, the in-
(Photo courtesy of Euroweld Ltd, USA; Florida Power & service duration of the first portion of P91 steam pipework
Light & J.A. Jones/Lockwood-Greene [7]) welded with FCAW process has reached more than 160,000
The present paper introduces the latest progress in the im- h. On the other hand, for the applications in the oil refining
provements achieved for a rutile-based all-positional flux industry, API 938-B [13] recognized the relatively high X-
cored wire conforming to classification of AWS A5.29/ factor of the FCW consumables. Although, FCAW is recom-
A5.29M: E91T1-B91M/E621T1-B91M [10]. The wire is mended for welding P91 steels, it only allows for less critical
welds such as welding non-pressure containing components.

2.2 Mechanical properties – toughness

In terms of mechanical properties of P91 weld metals after

appropriate post weld heat treatment (PWHT), tensile strength
has never been an issue in meeting the classification require-
ments and matching the base materials. On the contrary, the
impact toughness often needed more attention and has
attracted much more discussions. Nevertheless, it is worth
pointing out that P91 steel is an alloy designed for applications
Fig. 2 Use of the all-positional FCAW in 5G fixed P91 pipework (dou- at temperatures ranging from 550–600°C. It can be argued that
ble-up) a high weld metal toughness should be an irrelevant
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Table 1 All-weld metal chemical composition for P91 flux cored wire

Element (wt%)b C Mn Si S P Cr Ni Mo Nb V N

E91T1-B91M/ 0.08 1.20 0.50 0.015 0.020 8.0 0.80 0.85 0.02 0.15 0.02
E621T1-B91M [9]a, b 0.13 10.5 1.20 0.10 0.30 0.07
Previous designc,d 0.10 0.80 0.30 0.010 0.016 9.0 0.50 1.00 0.04 0.20 0.05
Element (wt%) Cu Al Ti Sn As Sb Mn+Ni Mn/S N/Al X-factor J-factorf
E91T1-B91M/ 0.25 0.04 –e – – – 1.40 – – – –
E621T1-B91M [9]a, b
Previous designc,d 0.01 0.01 0.040 0.008 0.010 0.003 1.3 80 5 21.7 264

a. The chemical composition range specified by AWS A5.29/A5.29M: E91T1-B91M/E621T1-B91M; The composition requirement of ISO 17634-B:
T69T1-1C/M-9C1MV [11] is very similar to AWS; The only differences are Ni ≤ 1.00% and no limitation to Mn+Ni total
b. Single values = maximum
c. Example of typical all-weld metal composition from a production batch; Shielding gas: M21 (80%Ar-20%CO2) mixed gas
d. Chemical analysis was conducted to the all-weld deposit pad. C and S were measured using solid-state infrared absorption method (ELTRA CS800), N
content was measured using LECO (LECO TC 400), and all the other elements were measured using OES (Bruker Q8 Magellan)
e. - = not specified
f. Watanabe J-factor [12]: J = (Mn + Si) (P + Sn)×104

consideration since the potential operating temperatures of the weld metal with similar CTOD properties (Fig. 3 [4]). This
weldments would be far above the temperature range at which conclusion gave rise for the acceptance of rutile all-positional
any possible risk of fast brittle fracture could occur. However, flux cored wire for practical applications in P91 steel welding.
there are situations where components might be pressurized or Consequently, the all-positional rutile FCW has been widely
loaded structurally at ambient temperatures during testing and/ used since early 2000s, particularly for thermal power plant
or construction. projects which followed ASME/AWS codes.
To cater to these situations, it is considered by some au-
thorities that the weld metal should have a minimum level of
impact toughness at +20°C. The AWS specifications for P91 3 Desire for further improvement
welding consumables, including A5.29/A5.29M for flux
cored wire, do not specify impact toughness requirements, With the continuous evolvement of P91 steel applications in
but the non-mandatory appendix does propose that a suitable the power generation industry during the past decade, and
testing procedure and acceptance requirements can be agreed lately in the petrochemical industries, there have been grow-
by the purchaser and supplier. Although, the A-sections of ing necessities for further optimisating the P91 flux cored
relevant ISO classifications, ISO 3580 [14], ISO 21952 [15], wires. These include the following two typical aspects:
and ISO 24598 [16], do specify minimum required impact
toughness, typically minimum average of 47J and minimum (1) Improving the ambient temperature impact toughness for
single value of 38J at +20°C for consumables of SMAW, power generation projects which call for consumables
GTAW, and SAW processes after the specified PWHT. But meeting ISO classifications.
in the case of FCW standard, ISO 17634 [11], only the B- (2) Increasing demands for allowing the higher efficiency
section includes wire for P91 steel as 9C1MV and no tough- FCAW process to be used for welding of more critical
ness requirements are specified. petrochemical equipment. This means multi-cycle ther-
Only rutile type flux cored wires could have practical use mal processes under working pressure during services
for the welding of P91 structures due to the welding perfor- requires a higher resistance to temper embrittlement.
mance and the capability of accomplishing 5G/6G fixed Accordingly, an X-factor of around 20–22ppm would
pipework welding. However, rutile flux systems impose a be considered less adequate when the applications were
significantly larger challenge in achieving good weld metal intended for facilities in the petrochemical industry, such
impact toughness than other processes, and the all-weld as equipment for oil refineries, of which many specifica-
Charpy V-notch impact toughness had been typically average tions require at least an X-factor ≤ 15ppm. The latest
28J at +20°C after PWHT at 760°C for 2 h and 35J after technical specifications for P91 consumables from some
760°C for 6–8 h. Based on these toughness values, CTOD test major fabricators of power and petrochemical equipment
and maximum tolerable flaw size examination using TWI’s have introduced controls to sensitive trace elements, such
Crackwise® software [17] were conducted. The calculated as As, Sn, and Sb, and require X-factor ≤ 15ppm for all
maximum tolerable flaw sizes using the lowest CTOD values processes including FCAW. Currently, new industrial
at 0°C and +20°C were comparable to the values of SMAW specifications have tightened the limits of sulfur and
 Weld World

Fig. 3 Illustration of a boiler

header with maximum tolerable Flaw
surface breaking flaw in a 450mm
longitudinal seam weld with a 125mm
CTOD value of 0.018mm at
+20°C [4] Plan view

12.5mm
50mm

Transvers view
125mm
12.5mm
50mm

Longitudinal view

phosphorous to the same levels of the SMAW electrode, Full chemical analysis was carried to the all-weld deposit
i.e., S ≤ 0.01% and P ≤ 0.01%, and the petrochemical pads. Various mechanical tests were conducted including ten-
industry calls for higher impact toughness. sile tests at ambient and elevated temperatures, Charpy V-
notch impact toughness test, and Vickers hardness test using
Accordingly, development work was conducted and rele- 10kg load.
vant improvements have been achieved after optimisation of
the formula and alloying design for the FCW. 3.2 Welding operability and parameter tolerance

For the new modifed design, the welding operability, particu-

3.1 Evaluations, weld assembly preparation, and larly out of position welding performance, was carefully eval-
parameters uated, and satisfactory results were achieved with various
welding positions inclusing 1G, 1F, 2F, 3G, 4G, and 4F.
The modified flux cored wire was manufactured to a final size The majority of Grade 91 welding is for P91 pipe joints.
of ∅1.2mm. The welding operability was evaluated with both One of the most profound advantages of the FCAW process
plate joints and fixed pipe 5G butt joints. In the cases of plate in this application is the capability of 5G/6G fixed pipework
joint, the types of joints and welding positions included welding and possibilities of employing full-mechanized oper-
ASME 1G, 1F, 2F, 3G, 4G, and 4F [6]. For the 5G pipe joint, ation. The operability examination of the 5G orbital welding
fully mechanized orbital welding was conducted. demonstrated stable spray arc and produced good weld bead
Deposit pads for chemical analysis of all-weld metal and profile with excellent slag removal (Fig. 5).
test assemblies for all-weld metal mechanical tests were pre- Moreover, it was noted that the modified flux system and
pared in accordance to the requirements specified by AWS steel sheath demonstrated a wider optimum operating param-
A5.29/A5.29M [10]. The dimensions and locations of test eter box. With a voltage as low as 20 V (with a M21 shielding
specimens are illustrated in Fig. 4. gas), a good spray arc transfer can still be achieved. This
The base plate used was A285 Grade C carbon steel and the would particularly benefit positions where welding with lower
groove was buttered with the same FCW as shown in Fig. 4a. parameters are desirable.
Shielding gas used was M21 (80%Ar-20%CO2) with a flow
rate of 18 l/min. Pre-heat temperature was 250°C. Interpass 3.3 Improvement in all-weld chemical composition
temperature was controlled to 250–275°C. The welding was
conducted with a polarity of DC+ (DCEP) using parameters of For the chemical analysis, carbon and sulfur contents were
28V and 180–190A. Travel speed was 25cm/min with an measured using solid-state infrared absorption method
electrode stick out of 20mm, giving a heat input of 1.2–1.3 (ELTRA CS800), nitrogen content was measured using
kJ/mm. The welding was conducted at 1G position with two LECO (LECO TC 400), and all the other elements were ana-
passes per layer and finished with seven layers. After the com- lyzed using OES (Bruker Q8 Magellan). Table 2 lists the all-
pletion of welding, the weld assemblies were cooled down to weld metal chemical composition from the improved design,
room temperature before being subjected to different planned the composition from the previous wire, and the relevant
PWHTs. AWS classification is also listed for comparison.
Weld World

Buttering
layers

a. Illustraon of buered groove b. Locaons of test specimens

Fig. 4 Test assembly for mechanical properties and soundness tests of all-weld metal (after ref [10]), (θ = 22.5°, D = 9, F = 6mm, L = 300mm, R =
12mm, T = 20mm, V = 10mm, Z = 25mm), a. Illustration of buttered groove, b. Locations of test specimens

Data shows that the new improved design meets the most Another important compositional index of P91 filler metals
stringent chemical composition requirements for the P91 flux is the total Mn+Ni total content, and there has been a trend to
cored wire weld. The X-factor achieved 9–10ppm, consider- reduce Mn+Ni total to a lower level, preferably ≤ 1.0%, in-
ably below the new required 15ppm maximum as stated in stead of what the formal classification stated ≤ 1.40% [10]. In
Section 3.2. Likewise, the J-factor is also substantially re- fact, the latest edition of AWS A5.29/A5.29M, the 5th Edition
duced. The calculated value of the J-factor was considerably which was just issued early 2021, specially addressed this
below 150ppm with a typical level of around 100ppm and matter by including two sub-classifications for P91 FCW.
Mn+Si < 1%. These will significantly reduce the susceptibility These are B91 (1.2) which requires Mn+Ni ≤ 1.20% and
to temper embrittlement of the weld metal and improve the B91 (1.0) which requires Mn+Ni ≤ 1.00%. The new design
resistance to brittle fracture of the joint. of the wire has taken into account, and the Mn+Ni is

Fig. 5 The modified all-

positional FCW in fully mecha-
nized 5G fixed P91 pipe welding,
a. Mechanized orbital welding in
action, b. Weld bead profile and
slag removal, c. Weld bead profile
of lower fill – full weave passes,
d. Weld bead profile of upper fill
and cap – split passes

a b

c d
 Weld World

Table 2 All-weld metal chemical composition of the improved P91 flux cored wire and comparison with relevant classification requirements

Element (wt%) C Mn Si S P Cr Ni Mo Nb V N

E91T1-B91M/ 0.08 1.20 0.50 0.015 0.020 8.0 0.80 0.85 0.02 0.15 0.02
E621T1-B91M [10]a 0.13 10.5 1.20 0.10 0.30 0.07
Previous designb 0.10 0.80 0.30 0.010 0.016 9.0 0.50 1.00 0.04 0.20 0.05
New designb 0.10 0.70 0.28 0.008 0.008 8.8 0.24 1.00 0.04 0.20 0.05
Element (wt%) Cu Al Ti Sn As Sb Mn+Ni Mn/S N/Al X-factor J-factor
E91T1-B91M/ 0.25 0.04 –c – – – 1.40 – – – –
E621T1-B91M [9]a
Previous designb 0.01 0.01 0.040 0.008 0.010 0.003 1.3 80 5 21.7 264
New designb 0.01 0.01 0.018 0.002 0.003 0.001 0.9d 91 5 9.6e 98f

a. Single values = maximum

b. Examples of typical all-weld metal composition from production batches; Shielding gas: M21 (80%Ar-20%CO2) mixed gas
c. - = not specified
d. Maximum Mn+Ni value ≤1.00%
e. Maximum X-factor value ≤15ppm
f. Maximum J-factor value ≤150ppm

controlled to 1.00% maximum with a typical value range from weld, as shown in the Schneider diagram [19] and in compar-
0.8 to 0.9%. That means the new wire meets the most restric- ison with P91 typical composition (Fig. 7).
tive Mn+Ni limitation. Accordingly, the Ac1 temperature of
the weld metal could be expected to be above 795°C. With the 3.4 Radiographic inspection
typical Mn+Ni = 0.8–0.9%, the anticipated Ac1 temperature is
estimated to be approx. 800°C (Fig. 6). This will safeguard After PWHT, radiographic inspection was conducted to all the
against the possibilities of austenite reformation when PWHT test assemblies after removing the backup strip. The test welds
temperature is incidentally above the highest allowed temper- showed sound quality and free from porosities and defects.
ature (i.e., 775°C [10]), hence benefiting the weld properties The assemblies were then machined to different specimens
after PWHT. for further testing.
The chromium equivalent is controlled to below 10 and
typically in the range of 8.5–9.5, (chromium equivalent is 3.5 Mechanical properties – weld metal tensile
calculated using the formula: Creq = Cr+6Si+4Mo+1.5W+ strength and hardness
11V+5Nb+9Ti+12Al-40C-30N-4Ni-2Mn-1Cu [7]). This ef-
fectively ensures the formation of a single martensitic micro- Table 3 shows the tensile and hardness properties of the
structure and avoidance of the undesirable δ-ferrite in the weld metals from the previous design and the new

Fig. 6 Effect of Mn+Ni content

on the Ac1 temperature [18] and
the anticipated typical and the
highest Ac1 temperatures of the
weld metal from the modified
design
Weld World

Fig. 7 Composition–
microstructure locations of
undiluted weld metals in the
Schneider diagram [20]

improved design. Data indicates that the new design pro- specified requirements with a steady increase when the
duced all-weld metal meeting the tensile strength require- holding time extends from 2 to 8 h (Fig. 9).
ments specified by the relevant AWS classification after For weld metal hardness, neither AWS nor ISO clas-
appropriate PWHT. The strength levels were slightly low- sifications specify the requirement. Neverthless, it has
er than those from the previous design but similar to the been suggested that the P91 weld hardness should be
values from the SMAW weld metals, such as a Chromet in the range of 200 to 275HV [22]. The hardness values
9MV-N (AWS A5.5/A5.5M: E9015-B91/E6215-B91) achieved were between 235 and 250HV (10kg load)
electrode [21], as shown in Fig. 8 in which the 0.2% proof after different holding durations at 760°C. These values
strength Rp0.2 and tensile strength Rm are plotted against were slightly lower than the previous design and within
tempering parameter P (P is Larson Miller parameter with the middle of the recommended range. This reduction
a constant 20). With increased holding time at 760°C, the was one of the targeted design modifications since it
strength demonstrated a steady reduction but the values was considered that the previous weld metal had a hard-
were satisfactory. After an 8-h hold at 760°C, the tensile ness (typically 260HV) nearer to the higher side of the
properties still meet the minimum required tensile preferred range. Figure 10 shows the plots of weld
strength, and the yield strength is above the minimum hardness comparison between the welds from the design
required for SMAW electrode by AWS A5.5/A5.5M: and the previous designs after different PWHT.
E90xx-B91/E62xx-B91 [17], i.e., Rp0.2 ≥ 530MPa after Figure 10 also compares the hardness results from the
760°C×2h. The weld elongation level also meets the welds of FCAW with those from the welds of other

Table 3 All-weld metal tensile and hardness properties for P91 flux cored wire

PWHTa Test temp Rp0.2 (MPa) Rm (MPa) A5 (%)b HV (10kg load)

E6215-B91M 760±15°C×2h +20°C 540 620 – 830 14 –d

(E91T1-B91M) [9]c (78ksi) (90 – 120ksi)
Previous design 760°C×2h 660 (96ksi) 790 (115ksi) 18 260
760°C×4h 621 (90ksi) 754 (109ksi) 19 255
760°C×8h 590 (86ksi) 710 (103ksi) 20 245
New design 760°C×2h 613 (89ksi) 734 (107ksi) 20 250
760°Cx4h 567 (82ksi) 694 (101ksi) 20 246
760°C×8h 539 (78ksi) 672 (98ksi) 23 238

a. Furnace cool
b. ISO 17634 specifies elongation A5 ≥14% (AWS A5.29/A5.29M specifies A4 ≥ 16%)
c. Single values = maximum
d. - = not specified
 Weld World

800 1000
FCAW-E91T1-B9 (Supercore F91, pre) FCAW-E91T1-B9 (Supercore F91, pre)

FCAW-E91T1-B9 (Supercore F91, new) FCAW-E91T1-B9 (Supercore F91, new)

SMAW-E9015-B91 (Chromet 9-B9) SMAW-E9015-B91 (Chromet 9-B9)

900 GTAW-ER90S-B9 (9CrMoV)
700 GTAW - ER90S-B9 (9CrMoV)
SAW-EB91 (9CrMoV) AWS spec max.
SAW-EB91 (9CrMoV)
Proof stress Rp0.2, MPa

800

UTS, Rm, MPa

600

700

500 AWS spec min.

600
AWS spec min.

AWS specified PWHT range AWS specified PWHT range

400 745 - 775°C/2h 745 - 775°C/2h
500
760oC/2h 760oC/2h

300 400
20.00 20.50 21.00 21.50 22.00 20.00 20.50 21.00 21.50 22.00

P = °K(log t + 20)10-3 P = °K(log t + 20)10-3

a b
Fig. 8 All-weld metal tensile strength after differenet PWHT; also compares the FCAW weld metal tensile strength with welds from other processes
including SMAW, GTAW, and SAW (all welds had Mn+Ni < 1.00%), a. Comparison of proof stress Rp0.2, b. Comparison of tensile strength Rm

welding processes after standard 760°C×2h PWHT. It can be consumables (SMAW and SAW), i.e., minimum average of
seen that the new design gave hardness moved closer to values 47J and a minimum single value of 38J at +20°C [12, 15]. If a
from welds produced by SMAW and SAW processes. further safe margin is considered, extending the holding dura-
tion to 4 h would give adequate toughness with a tested aver-
age impact value of 69J (65J minimum single value).
3.6 Mechanical properties – weld metal Charpy impact At 760°C, a further extension of the holding time from 4 to
toughness 8 h did not show further increase of toughness, with a 68 aver-
age at +20°C (64J minimum single value). The voided highest
Table 4 shows the Charpy V-notch impact toughness of all-weld value was 76J, similar to the maximum value achieved after 4-h
metal after PWHT at 760°C with holding durations of 2, 4, and 8 holding. The recorded lowest value was 63J which was higher
h, respectively. The results demonstrated that significant im- than the lowest value after a 4-h hold. This indicates that ex-
provement was achieved in the weld metal toughness, and the tending PWHT duration beyond 4 h helped to reduce the im-
impact values produced were very close to those typically de- pact energy scatter for the lower values. It is resonable to con-
livered by the weld metals produced from the SMAW process. clude that if the highest impact toughness is to be reached, a
After PWHT at 760°C for 2 h, the Charpy impact values PWHT of 760°C×4h should be the optimum and effective pa-
reached the level that just met the toughness requirements by rameters to apply to the weldment using the wire from the
typical ISO classifications for flux related P91 welding current design. The weld toughness improvement is shown in

Fig. 9 Comparison of all-weld 40

FCAW-E91T1-B9 (Supercore F91, pre)
metal elongation (all welds had
FCAW-E91T1-B9 (Supercore F91, new)
Mn+Ni < 1.00%)
SMAW-E9015-B91 (Chromet 9-B9)
GTAW-ER90S-B9 (9CrMoV)
30
SAW-EB91 (9CrMoV)
Elongation A5, %

20
AWS spec A4 16% min.

ISO spec A5 14% min.

10
AWS specified PWHT range
745 - 775°C/2h

760oC/2h

0
20.00 20.50 21.00 21.50 22.00
P = °K(log t + 20)10-3
Weld World

Fig. 10 Comparison of all-weld 400

FCAW-E91T1-B9 (Supercore F91, pre)
metal hardness (all welds had
FCAW-E91T1-B9 (Supercore F91, new)
Mn+Ni < 1.00%) 350
SMAW-E9015-B91 (Chromet 9-B9)
GTAW-ER90S-B9 (9CrMoV) Typical industrial recommend
300 SAW-EB91 (9CrMoV) range max. 275HV

Weld metal hardness, HV10

250

200
Typical industrial recommend
range min. 200HV
150

100
AWS specified PWHT range
745 - 775°C/2h

50
760oC/2h

0
20.00 20.50 21.00 21.50 22.00
P = °K(log t + 20)10-3

Fig. 11 and compared with historical data obtained from all- modified and previous designs is identical at elevated tempera-
weld metal test and welding procedure qualifications. tures of 550°C, 600°C, and 650°C. Both welds demonstrated
This toughness improvement is particularly significant for considerably higher strength than the reported minimum Rm of
expanding the applications of P91 FCAW applications to a P91 base material. At temperatures of 20°C and 550°C, the Rm
much wider range, especially for the industrial segments such of the FCW welds are within the P91 base metal range. At
as the petrochemical industry. higher temperatures, i.e., 600°C and 650°C, the weld metal
Rm values are slightly higher than the base metal maximum.

3.7 Mechanical properties – elevated temperature

tensile strength
4 Conclusions
Hot tensile tests are not representative of service conditions for
P91 weld metals owing to the short term nature of the test but Design optimisation work was conducted for the all-positional
they can provide a quick and convenient method for compari- flux cored wire (E91T1-B91M/E621T1-B91M) for the appli-
son of weld metals with base material data in a short term test. cations of P91 FCAW. Significant progresses have been
Hot tensile tests were conducted with all-weld metal samples achieved for the wire and the improvements can be summa-
after PWHT 760°C×2h. The tensile strength (Rm) results are rized as follows:
listed in Table 5. The values of the new design are compared
with those of the weld metal from the previous design and the & Significantly lowering the contents of S, P, and other crit-
reported values range from actual tests of the P91 base metal. ical trace elements, such as As, Sn, and Sb in the weld
As can be seen, the tensile strength of all-weld metals from the metal. The X-factor is now guaranteed to be ≤ 15ppm with

Table 4 All-weld metal Charpy

impact toughness PWHTb Test temp KV (individual) KV (average)

ISO requirementsa 760±15°C×2-3h [14], x2h [16] +20°C 38 47

Previous design 760°C×2h +20°C 30, 28, 27 28
760°C×4h 30, 29, 34 32
760°C×8h 45, 39, 20 35
New design 760°C×2h 55, 48, 40 47
760°C×4h 70, 73, 65 69
760°C×8h 73, 66, 64 68

a. ISO classification requirements for P91 SMAW consumables [14] and SAW consumables [16]; Single values =
minimum
b. Furnace cool
 Weld World

Fig. 11 Comparison of weld 90

metal Charpy toughness after AWS all-weld metal test (pre)
different PWHTs presented by 80 AWS all-weld metal test (new)
tempering parameter P (Larson- Examples of fabricators' PQR results

Charpy impact energy @20/22°C, J

Miller index, P = °K(log t + 70
20)103)
60

50

40

30

20
AWS specified PWHT range
10 745 - 775°C/2h
760oC/2h

0
20.00 20.50 21.00 21.50 22.00
P = °K(log t + 20)10-3

a typical range of 10–12ppm. The J-factor is below & The all-weld metal high temperature tensile strength of the
150ppm with a typical level of 100ppm. These will sig- modified design was also assessed through hot tensile test.
nificantly enhance the resistance to temper embrittlement The test results obtained were satisfactory with Rm con-
of the weld metal; siderably above P91 base metal minimum, and either
& Weld metal toughness is increased considerably to reach within the base metal range at lower temperatures or
the typical ISO classification requirements for P91 slightly above at higher temperatures.
welding consumables after a standard PWHT of
760°C×2h, i.e., 47J average and 38J single value at
+20°C; These requirements will be adequately met when
the holding duration at 760°C is extended to 4 h with a 5 Future application prospects
typical average Charpy V-notch impact energy of 69J (63J
minimum single value) at +20°C; Extending the hold time With the impact toughness improvement reported in the current
up to 8 h would further help to reduce the impact value work for the rutile P91 flux cored wire consumable, it is ex-
scatter while the average impact energy remains at the pected that the confidence on the properties of FCAW weld
similar level as the one after 4 h. These parameters are metal would be considerably reassured. This would further
also believed to be close to the optimum conditions for enhance the applications of the process for welding P91 steels
achieving the best impact toughness from the new design. in the power plant projects. Furthermore, for the petrochemical
& The all-weld metal ambient temperature tensile and hard- industry, an encouraging prospect can also be expected. The
ness properties are optimised with the strength comfort- significantly lower trace elements together with substantially
ably meeting the classification requirements and hardness increased toughness would present good justification for wid-
lowered to the middle level of the preferred range. ening the application areas of this high productivity process.

Table 5 All-weld metal tensile

strength at different temperatures Condition Rm (MPa)

20°C 550°C 600°C 650°C

P91 base material Normalized and tempereda 650–820 390–500 300–400 220–310
Tested value range [22]

Previous design 760°C×2hb 790 462 420 390

New design 760°C×2hb 734 454 450 372

a. Normalizing at 1040–1080°C; Tempering at 750–780°C

b. Furnace cool.
Weld World

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