NAUKAISTRAIVANJERAZVOJ J. Pecha, J. Hakl, T.

Vlask

SCIENCERESEARCHDEVELOPMENT Prevod: Sonja Papak

ZAVARIVANJE OPREME ZA ENERGETIKU SADANJOST I BUDUNOST WELDING IN POWER EQUIPMENT - PRESENT AND FUTURE
Originalni nauni rad / Original scientific paper UDK / UDC: 621.791:621.31 Rad primljen / Paper received: Mart 2008. Kljune rei: Membranski zid, zavarivanje pod prakom, termika obrada, otpornost na puzanje, sekundarno ojaavanje. Adresa autora / Author's address: Jozef Pecha, Jn Hakl Slovensk energetick strojrne, Tovrenska 210, Tlmae, Slovaka Tom Vlask Sttny vskumn stav materil, Praha-Bchovice, Republika eka Keywords: Membrane wall, submerged arc welding, postweld heat treatment, creep resistance, secondary hardening.

Izvod
U radu je prikazan kratak pregled automatskog zavarivanja u prizvodnji membranskih zidova za delove pod pritiskom kod energetske opreme. Analizirani su problemi trenutnog stanja i mogue perspektive u ovoj kljunoj tehnologiji zavarivanja. Analizirani su aspekti zavarivanja savremenog elika tipa 23. Ispitivani su efekti termike obrade zavarenog spoja na otpornost na puzanje. Prikazani su problemi zavarljivosti cevi od elika T23 sa primerima iz prakse. UVOD Iako se zavarivanje opreme za energetiku suoava sa razliitim tehnolokim problemima, reavanje svakog problema poveava nivo svih ljudskih delatnosti. U radu e biti prikazan nivo koji su tehnologije zavarivanja dostigle u oblasti opreme pod pritiskom. Kako su poveavani energetski parametri ureaja, tako se razvijala i osnova za poveanje legirajuih dodataka primenjivanih elika otpornih na puzanje. Usavravanje elika otpornih na puzanje je praeno problemima njihove zavarljivosti. Kako se dolo do reenja tih problema? Ovaj rad e to ukratko pokuati da objasni. elici za energetsku opremu se primenjuju na povienim temperaturama i to uglavnom u zonama gde se javlja puzanje. Zavareni spojevi kojima se spajaju delovi pod pritiskom su izloeni istim uticajima kao i osnovni materijal, stoga se pokuavaju dobiti njihova svojstva to priblinija osnovnom materijalu. To predstavlja razlog zbog kojeg je razvoj u tehnologiji zavarivanja sledio gore pomenuti cilj. Na poetku su cevni sistemi skoro iskljuivo bili runo spajani korienjem obloene elektrode, naravno, sem tehnologije zavarivanja sa gasnim plamenom. Pokuaj da se postigne vea produktivnost rezultirala je razvojem sueonog otpornog zavarivanja u
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (2/2008), str. 51-60

Abstract
A brief summary of automatic welding in manufacture of membrane walls for pressure parts of power equipment is presented. Problems of current state and possible expectation in this key technology of welding were analyzed. Analyses of material aspects of welding the progressive steel type 23 are presented. Weld heat treatment effect on creep resistance were examined. Problems of T23 steel tube weldability and conclusions from practice are shown. INTRODUCTION Even welding in power equipment faces various technological problems. However, solving any problems helps to increase the level of every human activity. This presentation will show the level reached by welding technologies of pressure parts. So as the power unit parameters were increased, it was also developed basis of alloying additions to applied creep resisting steels. Development of creep resistant steels has been accompanied with problems how to manage their weldability. How were the problems succeeded to be managed? This paper will try to answer it briefly, too. Steels in power equipment are applied for increased temperatures, mostly in creep zone. The weld seams forming the pressure part shall face the same exposition as base material. Their properties try to be as close to the base material properties as possible. This is the reason why the welding technology development has followed the target mentioned above. In the very beginning, tube systems were connected almost exclusively manually by coated electrode, of course except for flame technology. An attempt to achieve higher productivity resulted in dynamical start of resistance butt welding in pressure systems. The technology was widely used in ll0 and 200 MW boilers

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NAUKAISTRAIVANJERAZVOJ sistemima pod pritiskom. Tehnologija je iroko primenjivana u kotlovima od 110 i 200 MW i zastupljena je kod oko 90 % zavarenih cevi. Usled nesavrenosti koje su se uglavnom ogledale u pojavi visoke tvrdoe, stvaranja suvinog metala spoja i problema vezanih za protok fluida, ta tehnologija je postepeno izbegavana. Tokom sedamdesetih godina prolog veka, lansirani su metodi zavarivanja sa zatitnim inertnim gasom, koji su postali dominantni. ak i kod cevovoda sa debelim zidovima, oni su bili nezamenljivi za zavarivanje korenog prolaza. Podesna geometrija zavarenog spoja i dobra mogunost formiranja podruja korenog prolaza garantuju minimum defekata koji predstavljaju presudni faktor za ivotni vek zavarenog spoja. Za zavarivanje relativno manjih debljina, razvijeno je mehanizovano zavarivanje u zatitnom gasu argonu, ime su ograniene ljudske greke, iako to ne znai da su smanjene potrebe za strunou operatera. Sa stanovita automatizacije zavarivanja, zanimljiva je proizvodnja sabirnih i distributivnih cevi sa debelim zidovima. Dok se spoljanji avovi debelih delova zidova zavaruju spomenutom kombinacijom 141 (GTAW) + 111 (REL), cevi brizgaljke se takoe zavaruju kombinacijom 141 (GTAW), ali se prolazi popune rade pomou automatskog zavarivanja pod prakom 121 (EPP), ako prostorni uslovi to omoguavaju. Ako to nije mogue, ovi zavari se takoe prave pomou kombinacije 141 (GTAW) + 111 (REL). Poetkom ezdesetih godina, delovi isparivaa energetskih ureaja su konstruisani iskljuivo od solo zasunskih cevi. Ovo su bile cevi sa navarenim ravnim delovima, meusobno spojeni zavarivanjem. Zidovi isparivaa koji su bili zavarivani su na taj nain formirali kompaktne komore za sagorevanje, ali one nisu bile toliko nepropustljive na gas. Idealizovani Karnotov ciklus je primorao traenje naina poveanja efikasnosti jo u prvoj fazi, to jest kod pretvaranja vode u paru. Umesto do tada korienih takvih komora, zavarivanjem pod prakom su izraivani zidovi koji su bili nepropusni za gas. Komoru za sagorevanje koja se sastoji od membranskih zidova karakterie mala teina (iskljuujui teke delove od opeke), ali uglavnom sa mogunou sagorevanja pod izvesnim preoptereenjem i predstavlja bitan doprinos poveanju efikasnosti energetskog ureaja kao celine. Dananja tehnologija zavarivarivanja spojenih cevi sa ravnim limovima od gvoa izmeu predstavlja ekskluzivnu osnovu za stvaranje zidova bilo koje veliine, slika 1. Jasno je da automatsko zavarivanje pod prakom (121, EPP) dominira u proizvodnji zidova. Geometrija zavara, posebno veliina dela cevi gde nema provara se redovno proverava makro pregledom. Kao dodatni materijal se dugo vremena koristila puna ica 2 mm.

SCIENCERESEARCHDEVELOPMENT and applied in about 90 % of workshop tube welds. Due to imperfections manifested mainly in high peaks of hardness, creation of excess welding metal and related problems in medium flowing, that technology was gradually avoided. In 70-ties of the last century there were launched methods of shielded inert gas metal arc welding that became dominant. Even in thick wall piping they were indispensable for welding the root areas. Suitable weld geometry and good capability to form the root area guarantee minimum of defects being a crucial factor for service life of weld. For welding relatively smaller thicknesses, argon shielded welding has succeeded to be mechanized and consequently, human errors are limited, although it does not mean reduced requirements for operators qualification. From the point of welding automation it is interesting manufacture of thick wall collecting and distribution headers. While circumferential seams of thick wall parts are welded by the mentioned combination 141 (GTAW) + 111 (SMAW), nozzle tubes are also welded by the combination 141 (GTAW), but with filling passes done by automatic submerged-arc welding 121(SAW), if possible due to spatial conditions. If it is not possible, then these welds are welded by the combination 141 (GTAW) + 111 (SMAW), too. At the beginning of 60-ties the evaporator parts of power units were constructed exclusively of solo register tubes. There were tubes with welded-on flat parts, mutually interconnected by welding. The evaporator walls welded in that way formed combustion chambers being compact, but less gastight. The idealized Carnot cycle forced to look for ways of increasing the efficiency still in the first phase i.e. at changing water into vapour. Instead of register combustion chambers used till then, there were manufactured gas-tight walls by submerged-arc welding. The combustion chamber consisting of membrane walls is characterized by small weight (excluded heavy brickwork), but mostly by possible combustion under a certain overpressure and it is an important contribution to increased efficiency of power unit as a whole. Today welding technology of tube couple with flat iron in-between is an exclusive basis for creation of walls of any size, fig.1. Automatic submerged-arc welding (121, SAW) dominates clearly in manufacture of walls. The weld geometry, particularly the size of tube part lacking fusion is checked regularly on macrosections. For a long time it was used a solid wire 2 mm as filler material. Recently, it has been an attempt to increase welding rates. A possible way to increase the welding rate is to use a tubular wire. To achieve the required effect it is important to optimalize the combination of wire and flux. Having done a lot of tests of wire and flux
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NAUKAISTRAIVANJERAZVOJ U zadnje vreme pokuava se sa poveanjem brzine zavarivanja. Jedan od mogui naina poveanja jeste korienje punjene ice. Da bi se postigao traeni efekat, bitno je optimizovati kombinaciju ice i punjenog jezgra. Posle mnogobrojnih obavljenih ispitivanja uticaja ice i jezgra na poroznost i geometriju sva etiri ava popune, brzina zavarivanja punjenom icom se ustalila u opsegu od 1,1-1,4 m/s. U svetu, posebno u Japanu, za zavarivanje membranskih zidova koristi se MAG postupak. Firma Kusakabe nudi liniju sa 12 glava za zavarivanje, dok 6 glava zavaruje u horizontalnoj poziciji od gore, a 6 glava zavaruje u suprotnoj poziciji. Za ovaj raspored glava za zavarivanje, brzine zavarivanja su 1,5 m/s. U Evropi za proizvodnju membranskih zidova prevladava postupak zavarivanja pod prakom. Vodea finska firma PEMA za proizvodnju linija za zavarivanje membranskih zidova nudi opremu sa 6 glava za zavarivanje i dodatnom opremom za okretanje limova, kao i potpunu automatizaciju tokom operacija zavarivanja. Garantovana brzina zavarivanja iznosi 1,2 m/s. UTICAJ TOPZ NA OTPORNOST NA PUZANJE DEBELOZIDNIH ZAVARENIH SPOJEVA OD ELIKA P23 Neki od rezultata ispitivanja su prikazani u literaturi [21]. Prezentovani su rezultati ispitivanja zavarenih spojeva na spoljnoj temperaturi. Poto je u pitanju novi elik, bitna je otpornost na puzanje zavarenih spojeva. Ovaj zahtev je od velike vanosti

SCIENCERESEARCHDEVELOPMENT influence on porosity and geometry of all 4 fillet welds, the welding rate with tubular wire settles within the range of 1.1-1.4 m/s. In the world, particularly in Japan, for membrane walls welding it is use MAG method. Kusakabe offers a line with 12 welding heads, while 6 heads weld in the horizontal position from above and 6 heads weld in opposite position overhead. In the company presentation there are given welding rates of 1.5 m/s for this welding heads arrangement. Within Europe, the submerged-arc welding method prevails for membrane wall manufacture. The Finnish PEMA that is a leading company producing welding lines for manufacture of membrane walls supplies equipment with 6 welding heads and accessories for turning the panels and complete mechanization during welding operations. The guaranteed welding rate is 1.2 m/s. PWHT INFLUENCE ON CREEP RESISTANCE OF THICK WALL WELDS P23 Some results about P23 steel welding were previously presented in the literature [21]. There were presented test results of weld seams at ambient temperature. As it is concerning new steel, the creep resistance of weld seams is important. This requirement is important because there are just a few records of long-term properties of weld seams. I would also like to mention experience with welding the tubes of this steel. Creep resistance of weld seams P23 has been

Slika 1: Zavarivanje membranskog zida isparivaa Figure 1: Welding of evaporator membrane wall ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (2/2008), str. 51-60

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NAUKAISTRAIVANJERAZVOJ jer postoji mali broj podataka o osobinama zavarenih spojeva nakon dugotrajnog rada. Takoe e biti pomenuta iskustva sa zavarivanjem cevi od ovog elika. Otpornost zavarenih spojeva od elika P23 na puzanje je prouavana u saradnji sa SVM iz Praga (Nacionalni institut za istraivanje materijala) i VUZ PI iz Bratislave (Insititut za istraivanje zavarivanja Industrijski institut). Ovi rezultati ispitivanja prikazani u radu Vlask, Hakl i Pecha [1] u kojem se spominju neka od prvih saznanja zavarivanju ovih elika u Slovakoj [2]. Rad spomenutih autora ispituje uticaj termike obrade na otpornost na puzanje zavarenih spojeva. Ispitivane su tri alternative parametara termike obrade, uzevi prvu opciju kao osnovnu. Rezultati ostalih alternativa testova su predstavljeni u radu [21]. Parametri termike obrade zavarenih spojeva za ispitivanje otpornosti na puzanje su sledei:

SCIENCERESEARCHDEVELOPMENT studied in cooperation with SVM Praha (National Research Institute for Materials) and VUZ PI Bratislava (Welding Research Institute Industrial Institute). These test results are included in the paper of Vlask, Hakl and Pecha [1] referring to the first knowledge of this steel welding in Slovakia [2]. The paper of the mentioned authors examines heat treatment influence on creep resistance of weld seams. There were tested three alternatives of post-weld heat treatment parameters and the first alternative was taken as a basis. The results of the other tests of this alternative are given in the paper at the conference in Zlatibor. The parameters of weld heat treatment for creep resistance tests were as follows:

Prva alternativa - termika obrada na temperaturi 750-760 C/2h, (TO1) Druga alternativa - termika obrada na temperaturi 740-750 C/2h, (TO2) Trea alternativa - termika obrada na temperaturi 730-740 C/1h, (TO3)

1st alternative - scope of heat treatment temperatures 750-760 C/2h, (HT1) 2nd alternative - scope of heat treatment temperatures 740-750 C/2h, (HT2) 3rd alternative - scope of heat treatment temperatures 730-740 C/1h, (HT3)

Ispitivanje otpornosti na puzanje je vreno na ipkama, na temperaturama od 500, 550 i 600 C i pritisku. Radi poreenja uticaja temperatura termike obrade na otpornost na puzanje, korien je dijagram otpornosti na puzanje osnovnog materiala P23. U testovima na puzanje kod prve alternative (TO1) vreme do loma predstavlja neto vie od jedne desetine vrednosti za osnovni materijal. Rezultati testova otpornosti na puzanje kod druge alternative (TO2) su bili neznatno vii, ali ne mogu se smatrati zadovoljavajuim. Nia temperatura termike obrade nakon zavarivanja je potvrdila trend poboljanja otpornosti na puzanje. Stoga je odlueno da se pretpostavka potvrdi smanjivanjem temperature termike obrade i vremena dranja na zadatoj temperaturi. Fine modifikacije parametara termike obrade (slika 2) ne bi bile mogue bez tane kontrole i instrumenata za beleenje na elektro pei HN 27/12. Probleme tanog merenja temperatura unutar pei reio je Macko sa saradnicima, Institut za istraivanje opreme u elektranama iz Levica [3]. Alternativa (TO3) sa TOPZ sa parametrima termike obrade prema slici 2 potvrdila je sa testovima otpornosti na puzanje, pretpostavku o moguem postizanja zadovoljavajueg vremena do loma sa navedenim parameterima, slika 3. U poreenju sa prethodnim, alternativa termike obrade (TO3) je postigla najbolje rezultate. Rezultati ispitivanja se nalaze unutar dozvoljene granice od -20 % od rezultata otpornosti na puzanje osnovnog materijala koji se koristio za zavarene spojeve. Postignute vrednosti otpornosti zavara na puzanje se

Creep resistance tests were carried out with bars at temperatures of 500, 550 and 600 C and pressure. To compare the weld heat treatment temperatures effects on creep resistance it was used the creep resistance diagram of the base material P23. In creep testing of the first alternative welds the time to rupture represented just about one tenth of base material values. The creep resistance results achieved in the 2nd alternative were slightly higher, but they cannot be considered to be satisfactory. The lower post-weld heat treatment temperature confirmed the trend of creep resistance improving. Therefore it was decided to confirm the assumption by reducing the heat treatment temperature and the holding time at the temperature. Sensitive modification of heat treatment parameters (fig. 2) would not be possible without exact control and recording instrumentation provided in z common electric box furnace HN 27/12. The issues of precise measurement of temperatures within the furnace were solved by Macko et al., Research Institute of Power Engineering Equipment Levice [3]. The alternative III with PWHT at the parameters according to the previous figure confirmed in creep resistance testing the assumption of possible reaching of satisfactory time to rupture with the specified testing parameters, fig. 3. Comparing to previous ones, the alternative III reached the best results. The test results are within the permissible range of variations -20 % of results of creep resistance tests of base material used for weld seams. The achieved values of weld creep resistance are comparable to the results of Metrode, Vallourec (Thyssen), Air Liquide [4, 5]. During creep tests the testing specimens were mostly ruptured in case of low-heated heat affected zone
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NAUKAISTRAIVANJERAZVOJ
Program: COST 536 WELD D219*30m m materil P23 hodnota vdre 735C -

SCIENCERESEARCHDEVELOPMENT

Teplota [C] 745 743 741 739 737 735 733 731 729 727

han: 21.04.2006

725 04:44:00

TIR1.1-teplota materilu v bode1 TIR2.1-teplota materilu v bode 2 iadan hodnota Priemer hodnt vdre (TIR1.1+TIR2.1)/2
04:54:00 05:04:00 05:14:00 05:24:00 as [hh:mm:ss] 05:34:00 05:44:00 05:54:00

TIR1.1 temperature materijala u taki 1 / temperature of material in point 1; TIR2.1 temperatura materijala u taki 2 / temperature of material in point 2; iadan hodnota zahtevana vrednost / required value; Priemer hodnt vdre proseno vreme dranja / holding time average Slika 2: Temperature tokom TOPZ zavarenih spojeva P23, TO3 , (TIR1.1, TIR2.1 temperature na uzorku zavara) Figure 2: Progress of temperature during PWHT of welds P23, HT3, (TIR1.1, TIR2.1 temperatures at the sample weld)

100000 600C 550C 500C

Doba do lomu [h]

10000

Alternativa Alternativa Alternativa Alternativa Alternativa

III-550C III-600C III-500C III-550C III-600C

1000

100

Przdn symboly znzoruj pokraujc zkouky

10 50 100 150 200 250 Napt [MPa] Naptie [MPa] 300 350

Doba do lomu vreme do loma / time to rupture; Naptie napon / stress; Przdn symboly znzorujce pokraujce skky prazni simboli predstavljaju testove koji traju / empty symbols represent tests in progress Slika 3: Rezultati testiranja karakteristika otpornosti na puzanje zavarenih avova od P23, TOPZ, TO3 Figure 3: Results of testing of creep-resistance properties of welds of P23, PWHT, HT3

mogu porediti sa rezultatima iz literature [4, 5]. Tokom ispitivanja puzanja, uzorci koji su testirani su se uglavnom lomili u sluaju da je zona pod uticajem toplote (ZUT) bila izloena niim temperaturama termike obrade. Tokom termiko-deformacionog ciklusa zavarivanja, zona je nekoliko puta zagrevana do temperatura izmeu Ac1 i Ac3. Zone koje su zagrevane na temperature iznad Ac1 su bile predmet viestrukih martenzitnih transformacija. Sa druge
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (2/2008), str. 51-60

(HAZ). During the thermal-deformation cycle of welding the zone was several times heated up to the temperatures between Ac1 and Ac3. The zones heated up to the temperatures above Ac1 were subject to multiple martensitic transformations. On the other side, the zones heated under Ac1 were subject to multiple high-temperature tempering resulting in a drop of hardness accompanied by carbidic phase increase.

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NAUKAISTRAIVANJERAZVOJ strane, zone koje su zagrevane do ispod Ac1 su bile podvrgnute viestrukim visoko-temperaturnim otputanjima, to je dovodilo do pada tvrdoe koju je pratilo poveanje udela karbidne faze. Termika obrada posle zavarivanja je rezultirala daljim otputanjem ovih zona. Rezultat gore pomenutih procesa jeste omekavanja u mikrostrukturi. Stoga, lom usled puzanja se prvenstveno inicira u mekoj zoni pod uticajem toplote kao to je prikazano na slici 4. Termiki obraeni uzorci spojeva prema alternativi (TO3) su bili predmet daljih ispitivanja obzirom na povoljne rezultate otpornosti na puzanje. Ispitivanja energije udara su pokazala vrednosti od 94, 111 i 120 J iz centra zavarenog spoja. Tvrdoa zavarenog spoja (pre testova puzanja) je dostigla maksimalne vrednosti od 250 HV. ZAVARIVANJE ELIKA T23 TANKOZIDNIH CEVI OD

SCIENCERESEARCHDEVELOPMENT Post-weld heat treatment resulted in further tempering of these zones. The result of the above mentioned processes is a softer microstructure. Consequently, creep rupture is initiated preferentially in a softer HAZ as shown in fig. 4. Samples of heat treatment representing the 3rd alternative were subject to further tests with regard to favourable creep resistance results. Impact strength testing showed the impact work values 94, 111, 120 J from the centre of weld seam. The weld seam hardness (before creep tests) reached the maximal values of 250 HV. WELD SEAMS OF THIN-WALL TUBES T23 Testing welds were made by an automatic TIG welding machine. At welding the welding torch is in a stable position and tube is rotating. Tube end preparation is simple alignment of end faces, but there are high requirements for perpendicularity of aligned ends to the tube centre line. When the ends are moved to contact each other (zero gap), the automatic welding machine will make one weld layer up to the tube wall thickness of 5.6 mm. For testing there were used tubes D 42.2 x 3.6 mm of above mentioned quality. As filler it was used a wire D 1.0 mm on a spool marked WZ CrWV 2 1.5 from Bhler Thyssen Welding (Union I P23). What made us

Zavareni spojevi za ispitivanje su napravljeni ureajem za automatsko TIG zavarivanje. Prilikom zavarivanja, brener za zavarivanje se nalazi u fiksnom poloaju, a cev se rotira. Priprema kraja cevi predstavlja jednostavno poravnanje zadnjih strana, ali postoje visoki zahtevi za upravnost poravnatih krajeva sa centralnom linijom cevi. Kada se krajevi pokreu

Slika 4: SEM analiza izabranog uzorka posle testa puzanja [6] gore mikrostruktura uzorka posle testa puzanja; a)-mikrostruktura osnovnog materijala (1000x); b)-mikrostrukture zone uticaja toplote (1000x); c)-mikrostruktura metala ava (1000x) Figure 4: SEM analysis of selected sample after creep test [6] above microstructure of the sample after creep test; a)-microstructure of parent material (1000x); b)-microstructure of heat-affected zone (1000x); c)-microstructure of weld metal (1000x)

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ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (2/2008), str. 51-60

NAUKAISTRAIVANJERAZVOJ da bi dotakli jedni druge (nema meuprostora), aparat za automatsko zavarivanje e napraviti jedan sloj zavara do debljine zida cevi od 5,6 mm. Za ispitivanje su koriene cevi dimenzija 42,2 x 3,6 mm kvaliteta T23. Kao dodatni materijal je koriena ica 1,0 mm oznake WZ CrWV 2 1.5 od proizvoaa Bhler Thyssen Welding (Union I P23). Razlog zbog kojeg je iz tehnoloke procedure zavarivanja izostavljeno predgrevanje, jesu navodi iz literature [7], sopstveno iskustvo sa zavarivanjem elinih cevi T24 [8], kao i neophodnost da zavarivanje cevi za supergrejae bude efikasnije. Heuser sa saradnicima [9] opisuje rezultate ispitivanja T23 zavarenih cevi sprovedenih orbitalnom glavom na zidu debljine 7,5 mm bez predgrevanja. Uticaj predgrevanja se manifestuje na tvrdoi zavarenih spojeva. Rezultati testova tvrdoe zavarenih spojeva T23 bez predgrevanja i termike obrade posle zavarivanja koja se spominje u radu nisu dokazali poveanje vrednosti iznad 310 HV. Slini rezultati su postignuti ispitivanjima pri zavarivanju cevi od T24 (debljina zida 6,3 mm) kod proizvoaa opreme za energetiku [8]. Pitanje da li zavareni spojevi trebaju biti podvrgnuti termikoj obradi ili ne i dalje predstavlja predmet irih prouavanja mnogih autora i programa istraivanja [10-12]. Zavareni spojevi slinih, prethodno razvijenih Cr Mo V elika trebaju biti podvrgnuti termikoj obradi [13] usled veeg sadraja ugljenika i rezultujue tvrdoe. Vrednost doputene tvrdoe (maks. 350 HV10) je bio jedan od razloga zbog kojeg se poelo sa razmatranjima o izostavljanju mekog arenja zavarenih spojeva modernih CrMo modifikovanih tipova elika T23 i T24 [14, 15]. Izostavljanje mekog arenja zavarenih spojeva ovih elika predstavlja siguran debalans u mikrostrukturi. estice sekundarne faze ojaavaju vrsti rastvor (Cr23C6 i Cr7C3) i poseduju visoku dimenzionalnu stabilnost koja je postignuta otputanjem pri proizvodnji poluproizvoda. Zavarivanje u zoni pod uticajem toplote osnovnog materijala stvara privremene uslove da se ne postigne potpuno taloenje ojaavajuih estica. Ako se prelazni uslovi dre tako da zavareni spoj nije bio izloen mekom arenju, onda je tokom rada pri visokim temperaturama dolo do pojave dodatnog taloenja ovih estica [10, 12]. Pojava sekundarnog ojaavanja zavara sa CrMoV legirajuim dodacima u osnovi praeno je smanjenjem njihovih plastinih osobina to znai poveanje granice poputanja i smanjenje udarne ilavosti. Iako je primarni zahtev za karakteristike zavara kod ovih elika dovoljna otpornost na puzanje, pojava sekundarnog ojaavanja ne moe biti potcenjivana poto moe da se pojavi tokom poetnih faza rada energetskog postrojenja. Pucanje zavarenih spojeva u CrMo, CrMoV elicima na poetku dugotrajnog rada moe izazvati obimne tete ak i kada su zavari zadovoljavajui sa take gledita otpornosti na puzanje. Prelazni reimi rada
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SCIENCERESEARCHDEVELOPMENT to leave out preheating from the technological procedure of welding, it was literary knowledge [7], our own experience with welding of tube steel T24 [8] and a necessity to make tube welding for superheaters more efficient. Heuser et al. [9] describes the test results of T 23 tube welds carried out by an orbital head on a wall thickness of 7.5 mm without preheating. Preheating influence is manifested in weld seam hardness. Hardness test results of weld seams T23 without preheating and post-weld heat treatment mentioned in the paper did not prove increase of values above 310 HV. Similar results were achieved at tests of T24 tube welding (wall thickness 6,3 mm) at a manufacturer of power engineering equipment [8]. The issue if weld seams are to be subject to heat treatment or not, is still a subject of large studies of a lot of authors, research programmes [10-12]. Weld seams of similar, previously developed Cr Mo V steels shall be subject to heat treatment [13] due to a higher content of carbon and resulting hardness. The value of permissible hardness (max. 350 HV10) was one of reasons why it started to consider about leaving out stress annealing of weld seams of modern CrMo modified steels type T23, T24 [14, 15]. Leaving the weld seam annealing for these steels means a certain type of unbalance of microstructure. Secondary phase particles hardening the solid solution (Cr23C6 and Cr7C3) are of high dimensional stability achieved by tempering at manufacture of semi-finished products. Welding in heat-affected zone of parent material creates transient conditions at there is not occurred complete precipitation of hardening particles. If the transient conditions are kept so that a weld seam was not subject to annealing, then during operation at high temperatures there is occurred additional precipitation of these particles [10, 12]. The event of secondary hardening of weld seams CrMoV of alloying additions basis is accompanied by reduction of their plastic features and it means increase of ultimate strength and decrease of impact strength. Although the primary requirement for weld properties in these steels is sufficient creep strength, the occurrence of secondary hardening cannot be underestimated as we can meet with it during the initial stages of power plant operation. Weld cracking in CrMo, CrMoV steels at the beginning of long-term operation can cause extensive damages even when the welds from the creep resistance point of view are satisfactory. Transient modes of boilers are the most critical from the point of secondary hardening i.e. shutdown of plant when welded nodes made of these steels reach ambient temperature and there is not enough plasticity reserve in a hard weld to transfer stress of thermal expansion at shutdown as well as at subsequent starting-up. Assessment of hazard level of this phenomenon should consider several factors e.g. tightness of

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NAUKAISTRAIVANJERAZVOJ kotlova su najkritiniji sa take sekundarnog ojaavanja, to jest iskljuivanje postrojenja kada zavari napravljeni od ovih elika dostignu spoljnu temperaturu, a nema dovoljno rezerve plastinosti u zavaru da bi preneo naprezanje termalnog irenja pri iskljuivanju kao i pri naknadnom pokretanju. Za procenu nivoa opasnosti od ovog fenomena bi trebalo da uzeti u razmatranje nekoliko faktora, na primer zaptivenost zavara, debljinu zavara, period i trajanje iskljuenja itd. Mohyla i Koukal [12] su objavili rezultate merenja tvrdoe zavarenog spoja i pokazali da je u krupnozrnoj zoni uticaja toplote zavarenih spojeva od T23 i T24 materijala koji nisu bili podvrgnuti termikoj obradi dolo do jaeg sekundarnog ojaavanja tokom dugotrajnog izlaganja (500C) u relativno kraim vremenskim periodima (T23-100 h, T24-2000 h), vrednosti tvrdoe zavarenih spojeva bez termike obrade nakon zavarivanja iznose od 410-430 HV10, a to nije dopustivo sa stanovita standarda. S druge strane, rezultati testova zavarenih spojeva prouavanih elinih cevi tokom rada, ali koji nisu bili izloeni termikoj obradi nakon zavarivanja nisu dokazali pojavu sekundarnog ojaavanja niti njegove posledice. Publikacije Lunda i Halda [16] i japanskih autora [15] su to dokazale. Opsena ispitivanja zavarivanja slinog elika T24 su sprovedena od strane Pecha i saradnika [8, 17]. U saradnji sa Institutom za istraivanje materijala slovake Akademije nauka, takoe je provereno sekundarno ojaavanje ovih zavarenih spojeva od elika T24 [18]. Istraivane su karakteristika zavarenih spojeva cevi koji su bili izloeni dugotrajnom mekom arenju na 550 C, tj. za 50 C vie nego u ovom radu [12]. Ova temperatura se smatra maksimalnom temperaturom za primenu elika T24 u sistemima super-grejaa. Trajanje mekog arenja pri temperaturi od 550 C je iznosilo 1000 i 3000 asova, jer se tada mogu oekivati maksimalne vrednosti sekundarnog ojaavanja. Uz metalografsku analizu, proveravana je i tvrdoa i udarna ilavost zavarenih spojeva nakon razliitih perioda izlaganja visokoj temperaturi pod uslovima sa i bez arenja. Rezultati pokazuju da je u ovom sluaju nakon 1000 asova izlaganja toploti tvrdoa u zoni pod uticajem toplote pala za 60 jedinica HV, ali nakon 3000 asova tvrdoa je dostigla vrednosti uslova nakon zavarivanja bez arenja. U ovom sluaju nije dolo do pojave ekstremnog ojaavanja. Vrednosti tvrdoe od 280-290 HV 10 su prihvatljive, a za CrMo elike ak i oekivane. areno stanje pokazuje logino nie vrednosti nakon oba perioda izlaganja visokim temperaturama. Pojava sekundarnog ojaavanja moe delovati opasno, ako je kombinovano sa uslovima i veliinom zaptivenosti odreenog elementa. Na primer, ako debljina zavarenog spoja koji nije bio izloen termikoj obradi prelazi 10 mm, onda moe da se oekuju komplikovani uslovi zaptivenosti i ekstremi tvrdoe

SCIENCERESEARCHDEVELOPMENT welded node, weld thickness, period and duration of shutdown, etc. Mohyla and Koukal [12] published results of weld seam hardness measurement and showed that in coarse-grained heat affected zone of weld seams of T23 and T24 materials not subject to post-weld heat treatment there was occurred stronger secondary hardening during long-term exposition (500C) in relatively shorter time periods (T23 100h, T24 2000h), the hardness values of welds without postweld heat treatment range within 410-430 HV10, and that is not permissible from the point of standards. On the other hand the test results of weld seams of studied steel tubes in operation, but not subject to post-weld heat treatment proved neither the occurrence of secondary hardening nor its consequences. It is proved by publications of Lunda and Halda [16] and Japanese authors [15]. Extensive testing of similar T24 steel welding was carried out by Pecha et al. [8, 17]. In cooperation with the Research Institute of Material of the Slovak Academy of Science there was also checked secondary hardening of these steels welds [18]. There were examined properties of weld seams of T24 tubes subject to long-term annealing at 550 C, i.e. by 50 C higher than in paper [12]. This temperature is considered to be the maximal temperature at application of T24 steel in superheater systems. Annealing duration at 550 C was 1000 and 3000 hours, because then the maximal values of secondary hardening can be expected. In addition to metallographic analysis it was also checked hardness and impact strength of weld seams after various periods of high-temperature exposition under the conditions with / without annealing. The results show that in this case after 1000 hours of thermal exposition the hardness in HAZ dropped by 60 units HV, but after 3000 hours the hardness achieved the values of the conditions after welding without annealing. That is to say, no extreme hardening occurred in this case. The hardness values of 280-290 HV 10 are acceptable and for CrMo steels they are even expected. The annealing state shows logically lower values after both periods of high-temperature exposition. Occurrence of secondary hardening can seem to be hazardous, if it is joined with the conditions and size of tightness of a particular node. For example if a thickness of weld seam not subject to heat treatment will exceed 10 mm, then there can be expected complicated conditions of tightness and extremes of hardness can be hazardous. Therefore weld seams of bigger thicknesses of studied steels must be subject to annealing. Transient modes of thermal equipment (shutdown, starting-up) can seem to be risky due to secondary hardening. During initial operation of thermal
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NAUKAISTRAIVANJERAZVOJ mogu biti opasni. Stoga zavareni spojevi veih debljina prouavanih elika moraju biti podvrgnuti arenju. Prelazni reimi rada termoenergetske opreme (iskljuenje, pokretanje) mogu delovati rizino usled sekundarnog ojaavanja. Pri poetku rada opreme ovi reimi su kratkotrajni (optimizacija parametara), nisu esti, dok temperatura cevi, usled izolacije ne pada ispod 20 C. Dua iskljuivanja iz rada postaju redovna tokom kasnijih perioda rada postrojenja, nakon maksimuma sekundarnog ojaavanja. Takoe, zbog toga nisu zabeleeni kvarovi postrojenja sa zavarenim spojevima prouavanih elika koji nisu bili podvrgnuti termikoj obradi. Ipak je neophodno dalje obraati panju na istraivanja sekundarnog ojaavanja poto je naophodno posebno za membranske zidove termoenergetskih postrojenja. REZULTATI ISPITIVANJA Tvrdoa HV 10 je merena u centru zavarenog spoja. Maksimalne vrednosti su postignute u zoni pod uticajem toplote i u metalu ava. U ovim zonama su izmerene vrednosti HV10 od 297 do 309. U poreenju sa osnovnim materijalom, tvrdoa je poveana za oko 100 jedinica. Tvrdoa zavarenog spoja elika koji nisu bili izloeni termikoj obradi je ograniena poznatom vrednou od 350 HV [19]. Standard proizvoda [20] prihvata ak i tvrdou od 380 HV za zavarene spojeve elika koji nisu bili izloeni termikoj obradi. vrstoa zavarenog spoja proverena zateznim ispitivanjem je pokazala vrednosti od 620-652 MPa, dok su zahtevi za osnovni materijal min. 510 MPa. Karakteristike plastinosti zavarenih spojeva su ispitivane savijanjem. Uzorci savijani oko korenog zavara kao i oko pokrivnih slojeva su izdrali savijanje od 180 bez ikakvih znakova oteenja. Obzirom na gore pomenute rezultate, zavareni spojevi e biti podvrgnuti dugotrajnom izlaganju temperaturi od 550C, nezavisno od njihove primene u radu i ispitivae se njihova vrstoa i karakteristike plastinosti. Uz to, zavareni spoj e biti podvrgnut ispitivanju otpornosti na toplotu. ZAKLJUAK Obavljena su ispitivanja na zavarenim spojevima od savremenog elika T/P23 na delovima sa debelim i tankim zidovima za komponente pod visokim pritiskom u energetskim postrojenjima. Rezultati ispitivanja potvruju da su primenjeni tehnoloki parametri zavarivanja bili ispravni. Meutim, potrebno je znati ponaanje zavarenih spojeva tokom eksploatacije. Poznato je da postoji vrlo malo rezultata ispitivanja na puzanje zavarenih spojeva modifikovanog CrMo elika. Rezultati ovog rada e doprineti poveanju baze podataka o ispitivanju puzanja. Optimizacijom termike obrade uspeo se pronai kompromis izmeu ilavosti i dobre otpornosti na puzanje zavarenog spoja cevovoda sa debelim
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SCIENCERESEARCHDEVELOPMENT equipment these modes are short (optimalization of parameters), not very frequent, while the tube temperature due to insulation does not drop under 20C. Long operation shutdowns become regular during later periods of plant operation, after the maximum of secondary hardening. Also due to that reason there were recorded no failures of plants with weld seams of studied steels not subject to heat treatment. However, it is necessary further to pay attention to research of secondary hardening as it is required particularly by membrane walls of thermal plants. TEST RESULTS Hardness HV 10 was measured in the weld seam centre. The maximal values were reached in heat affected zone and weld metal. In these zones the values of 297 up to 309 HV 10 were measured. Comparing to the parent material, the hardness was increased by about 100 units. Hardness for weld seams of these steels not subject to heat treatment is limited by the known value of 350 HV [19]. The product standard [20] accepts even the hardness of 380 HV for welds of these steels not subject to heat treatment. Weld seam strength checked by tensile test showed the values of 620-652 MPa, while the requirement for the parent material is min. 510 MPa. Plastic properties of weld seams were tested by bending test. The samples stressed from the side of root as well as from the side of covering layers withstood the bend of 180 without any marks of damage. With regard to the above mentioned issues the weld seams will be subject to long-term application of temperature 550C, independently from their application in operation and their strength and plastic features will be examined. Additionally, the weld will be subject to heat resistance testing. CONCLUSION There were carried out a lot of tests of weld seams of modern steel T/P23 of thick-wall and thin-wall parts for high-pressure components of power engineering plants. The test results confirm that the applied technological parameters of weld execution were correct. However, it is necessary to know behaviour of weld seams during exploitation. It is known that there are very few results of creep test of weld seams of modified CrMo. Results of this paper will contribute to extension of database of creep tests. By optimalization of heat treatment it succeeded to find a compromise between toughness and good creep resistance of weld seam of thick-wall piping. It was confirmed that steel type 23 requires special technology for large thickness welding. To manage weldability, it is necessary to observe strictly the technological principles, particularly heat mode and technique of welding. Recommendations for practice

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NAUKAISTRAIVANJERAZVOJ zidovima. Potvreno je da elik tipa 23 zahteva posebnu tehnologiju za zavarivanje velikih debljina. Da bi se kontrolisala zavarljivost, neophodno je da se tehnoloki principi striktno potuju, posebno toplotni reim i tehnika zavarivanja. Preporuke za zavarivanje cevi sa debelim zidovima su:

SCIENCERESEARCHDEVELOPMENT of thick-wall piping welding:

Welding shall be in heat mode under the line Ms. Strictly limited heat input. Stress annealing to be done in the range of 730740 C. Equipment for heat treatment shall be provided with precise recording and control technique.

Zavarivanje mora biti u toplotnom reimu ispod Ms temperature. Strogo ogranien unos toplote. arenje za uklanjanje naprezanja raditi u opsegu od 730-740 C. Oprema za termiku obradu mora da poseduje tehnike mogunosti preciznog zapisa i kontrole.

LITERATURE
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] Vlask, T., Hakl, J., Pecha, J.: rupevnost zkladnho materilu a svarovch spoju oceli P23, 15th Int. Conf. METAL 2007, Ostrava, 2007, s. 37. Pecha, J., Meko, J.: Weldability of new creep resistant Cr-Mo steel with tungsten content. Materials Engineering, Vol. 13, 2006, No. 2, s. 58. Macko, M. et al: Modernizcia merania teplt v hacch peciach, Technick sprva 03/2006, Vskumn stav energetickch zariaden, Levice, 2006. Heuser,H., Jochum, C.: Development of new bainitic and martensitic filler material for the use in advanced coal-fired power plants. Prezentation in Skoda Power. 2006. Baun, E. et al: Weldability and properties of new creep resistant materials for use in ultra supercritical coal fired power plants. Materials for Advanced Power Engineering 2006, Forschjungszentrum Julich, "8th Liege Conference" september 2006 p. 871. Pak, M.: tdium degradanch mechanizmov poruovania zvarovch spojov iarupevnch ocel. Bakalrsk praca. Trnava 2007. Gabrel, J.: Development of T and P 23 steel grade. Final Report COST 522, Vallourec Research Centre CEV, 2003. Pecha, J., Pele, O.: Zvranie rrok z ocele T24. Prieben sprva k eurpskemu Projektu SmartWeld. Limerick 2003. Heuser, H. Jochum, C. Meyer, F.W. : Entwicklung von Schweizusatzwerkstoffen fr moderne Kraftwerksthle. Tagungsband der 6. Werkstoffseminar TU Graz, 2003, s.1-14. Foldyna, V., Koukal, J.: Vvoj novch ocel pro energetiku a chemick strojrenstv na bzi 2 a 3% Cr. Zbornk prednok zo seminra Nov materily a technologie svaovn v prvnm desetilet novho milnia. Ostravice 2002, s.35-49. Marshall, A.W., Zhang, Z.: Development weld metals for advanced 2,5 and 9-11Cr steels. COST 536, UK 10, Louhborough, 2005 Mohyla, P., Koukal, J. Svaitelnost perspektivnch nzkolegovanch ropevnch ocel. In Sbornk konference TechMat 04 : 9.11.2004, esk Tebov. Pardubice: TU Pardubice, 2004, s. 96-101. Technick informace o vlastnostech a technologickm zpracovni vrobk z oceli 15128. Ostrava 1968. The T23/T24 Book. Vallourec & Mannesmann tubes. 2002. Sawaragi, Y., Iseda, A., Yamamoto, S., Masuyama, F.: Devolopment of High Strenght 2%Cr Steel Tubes (HCM2S) for Boilers. The Sumitomo Search No 59 Sep. 1977. Lund, E., Hald, J.: In Plant Testing of HCM 12, HCM2S and 7CrMoTiB10-10 for membrane Wals. Separt. Pecha, J. et al.: Nov materily z V. Rmcovho programu a ich zvranie. Zbornk z XXXVI. Konferencie Rozvoj zvrania na Slovensku z pohadu lenstva SR v E. Vysok Tatry, 2003, s.52. Jedinakov, M., Vrostkov, A.: Precipitcia fz vo zvarovch spojoch membrnovch stien feritickch ocel po dlhodobom han. Camin Conference, Smolenice, aprl 2005. STN EN ISO 15614-1. Stanovenie a schvlenie postupov zvrania kovovch materilov. Skka postupu zvrania. as 3. Oblkov a plameov zvranie ocel a oblkov zvranie niklu a zliatin niklu. 2006. STN EN 12952-5 Vodorrkov kotly a pomocn zariadenia. as 6: Kontrola pri vrobe, dokumentcia a znaenie asti kotla namhanho tlakom, 2005. J. Pecha, Welding of progressive steel P23 in power engineering, Zavarivanje i zavarene konstrukcije, Vol.51, No. 3, 91-100, Beograd, 2006. ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (2/2008), str. 51-60

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