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The low carbon 46Ni-35Cr-9Mo alloy is a solid solution strengthened cast Ni-Cr-Mo alloy additionally containing Cu and N. This work reports on the properties achievable for a centrifugally cast low carbon 46Ni-35Cr-9Mo alloy tube of 4500 mm length and 55 mm wall thickness.
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High-strength materials with excellent corrosion resistance and mechanical properties are highly sought after for use in light water reactor (LWR) type nuclear power plants (NPP). In western pressurized water reactors (PWR), nickel-base alloys are often the main structural materials for the steam generator (SG) tubes, while in Russian PWRs or water-water energetic reactor (VVER) high-nickel alloys, for example XH35BT (35 wt.% Ni), can be found in some primary side high strength applications, such as reactor pressure vessel internals (RVI).
Weld overlay has been successfully used to mitigate high temperature corrosion issues in coal-fired boilers since the1990s, such as in waterwall and superheater/reheater area. Weld overlay is typically applied in shop or field by using Gas Metal Arc Welding (GMAW) process for boiler waterwall application, and the overlay welding is performed in vertical down welding mode (3G welding position) in subcritical and supercritical boiler waterwall applications. With the rapid development of coal-fired boiler market in China, ultra-supercritical boilers are becoming the dominated boiler type which often has spiral waterwall design. Most of ultra-supercritical coal-fired boiler waterwall consists of CrMo steel tubes, which could suffer severe high temperature corrosion attack after the installation of low NOx burners. It is expected that weld overlay could provide a long-term high temperature corrosion protection for ultra-supercritical boiler waterwall based on previous weld overlay study and application experience. However, for the spiral waterwall with inclined tube design, its field overlay welding is highly challenging and significantly different from typical vertical boiler waterwall overlay welding. The challenge and difference include welding position, welding sequence, welding parameters, and overlay properties, etc. This paper presents a successful field application of 309L stainless steel and 622 Ni-based alloy weld overlay on the spiral waterwall of an ultra-supercritical coal-fired boiler, including the welding development, simulation, and experience of overlay welding on the inclined tubes, along with the characterization of the weld overlay applied.
Many industrial processes contain H2, CO, CO2, and H2O gas mixtures, such as syngas production and processing in hydrogen, ammonia, and methanol plants. These process environments have high carbon activity, i.e. ac > 1, and low oxygen partial pressure at their elevated operating temperatures, such as in the temperature range of 400-800 °C (752-1472 °F). The high carbon activity could result in a catastrophic material degradation, i.e. metal dusting. The resulting corrosion products consist of carbon or graphite and metal particles, along with possible carbides and oxides, and cause material disintegration.