Corrosion-Resistant Alloys Conference
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The Welding of Corrosion-Resistant Alloys |
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As an added benefit, AWS Conference
attendees are awarded 1
PDH (Professional Development Hour) for each hour of conference
attendance. These PDH’s can be applied toward AWS recertifications and
renewals.
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November
18, 2009 — Chicago, Illinois
Facility: McCormick Place, Fabtech Int'l and AWS Welding Show
Chairs: Robert R. Irving and Ralph Davison
The
interest level is extraordinarily high when it comes to the welding of
corrosion-resistant alloys. There are many reasons for this. One is the
entry of the duplex stainless steels and other high-performance grades.
Another is the unstable prices in nickel, molybdenum and titanium. When
the price of nickel hit the roof, many fabricators switched from 316 to
201 stainless because the latter grade’s lower nickel content. Research
is feverish throughout the world in the development of new and cheaper
methods of producing titanium. Will a lower-cost titanium make the
metal more popular?
The overall activity is immense. Cladding and strip overlay processes
have become a more popular means of protecting parts exposed to heavy
corrosion. Duplex stainless is now being welded for over-the-road
tankage. New processes like friction stir welding and the more advanced
thermal stir welding out of NASA will be discussed as well. Also,
improvements in weld properties are being realized by increasing the
weld interpass temperatures for conventional austenitic stainless
steels.
Each presentation will be followed by a 5-minute question-and-answer
session.
Conference Registration Fees
AWS/FMA/SME/PMA/NAM Member – $345Nonmember – $480
- Each nonmember
attendee will receive
a two-year complimentary membership in AWS.
- The registration fee does not include hotel accommodations. Hotel accommodations are subject to hotel regulations and are the responsibility of the attendee.
- You will receive a CD containing copies of all presentations.
- Each participant will also earn 5 Professional Development Hours (PDHs) for attending the conference. These PDH’s can be applied toward AWS recertifications and renewals.
Program Schedule
WEDNESDAY, NOVEMBER 18, 2009
9:00-9:30
AM
Lean Duplex Stainless Steel Chemical Cargo Tanks
Ralph Davison, Vice President, Technical Marketing Resources
A lean duplex stainless 2101 has been developed with low addition of nickel in order to reduce and stabilize the cost. The low nickel content is compensated by an increased amount of manganese and nitrogen to assure a balanced microstructure with approximately equal amounts of ferrite and austenite. This helps to give the stainless a yield strength more than twice that of 316 and 304 stainless steels, and the yield strength continues even at high temperatures. Lean duplex is also highly resistant to stress corrosion cracking and has better pitting resistance. This alloy is being welded by the gas metal arc process.
9:35-10:05 AM
The Thermal Stir Welding Process
Jeff Ding, Aerospace Welding Engineer, NASA Marshall Space Flight Center
The thermal stir welding (TSW), developed by the National Aeronautical and Space Administration’s Marshall Space Flight Center, is a solid state joining technique. The process is similar to the friction stir welding (FSW) in that the weld seam is consolidated without liquefying the parent material. However, unlike "FSW-ing", the heating, stirring, and forging elements of the process are decoupled allowing independent, dynamic control of each process element. With the separation of heating, stirring, and forging elements during the joining process there are more degrees of freedom allowing greater process control. In this study the TSW process was used to join .250-in thick Haynes 230 alloy in a butt joint configuration. Metallographic samples have been mounted, polished, and analyzed using optical microscopy to document the microstructure. Mechanical property data will also be presented.
10:10-10:40 AM
Evaluation of Higher Interpass Temperatures When Welding 304L and 316L Austenitic Material
Matthew Yarmuch, co-authors are Iulian Radu and Ken Armstrong of PCL Industrial Constructors.Yarmuch is Program Leader, Welding Engineering, Advanced Materials Business Unit
The objective of the evaluation is to reassess maximum interpass temperature limits, while welding 304L and 316L pressure equipment materials, to significantly improve welding productivity. The findings confirm that higher interpass temperatures can be tolerated without compromising the sensitization-corrosion resistance of the weldment. Additional investigations of the weld metal pitting performance are also presented. The results indicate that not exceeding the critical threshold of “time at the sensitization temperature” is paramount to ensure weldment quality.
10:45-11:15 AM
Strip Overlay Weld Cladding of Specialty Stainless Steel Alloys Sandvik
Frank S. Babish, Technical Manager Welding Products, Sandvik Materials Technology, Welding & Wire Products Division
The topic will cover strip overlay welding of specialty stainless steel alloys using the electroslag welding process. This process allows high deposition rates of metallurgically clean weld deposits. Alloys will include duplex and superaustenitic alloy. Applications for the nuclear industry will be included.
11:20-11:50 AM
Alternative Welding Processes for the Fabrication of Titanium Structures
Nick Kapustka, Applications Engineer, Arc Welding, Lasers & Automation, Edison Welding Institute; co-authors: Suhas Vaze and Chris Conrardy
Work is under way at Edison Welding Institute to make the gas metal arc welding (GMAW) process a useful and effective means for welding Ti-6Al-4V. To do this, it was necessary to provide adequate inert gas shielding, arc stability, and contact tip life. This presentation will provide the steps that have been taken to achieve this level of performance. Other processes evaluated in the study included friction stir welding and hybrid laser welding.
11:50 AM - 1:00 PM
Lunch on your own
1:00-1:30 PM
Welding Metallurgy of Duplex Stainless Steels
Damian Kotecki, President, Damian Kotecki Welding Consultants, Inc.
Duplex stainless steel weld metal solidifies as 100% ferrite, and the HAZ near the fusion boundary also forms 100% ferrite. It is essential that austenite nucleates and grows in both areas in order for proper properties to be obtained. The critical role of nitrogen in this process is explained. Then remaining ferrite can transform to undesirable phases such as sigma, and this is explained.
1:35 - 2:05 PM
Explosion Welding to Join Dissimilar Metals
Michael Blakely , Director of Market Development, Dynamic Materials Corp.
Explosion welding focuses on joining both similar and dissimilar metals. A value proposition exists when certain materials are required in specific applications for corrosion resistance, light weighting or temperature distribution and solid material is either impractical, ineffective, or expensive. This talk will focus on the process of explosion welding and discuss some examples of cost savings opportunities when the process is used.
2:10-2:40 PM
The 200 Series Stainless Steels and the Lean Duplex Stainless Steels: Why They Should Be Considered
Cheryl A. Botti, Manager, Market and Product Development, ATI Allegheny Ludlum
Popularity in the use of 200 series stainless steels where 300 series stainless have been traditionally specified continues. Advantages exist with respect to raw material volatility. This talk will address the major material, welding and fabrication, application, codes and standards and commercial issues involved with switching to another grade of stainless steel. In addition to the 200 series stainless steels, the popularity of lean duplex stainless steels to replace 300 series stainless steels continues to grow. More stable raw material costs, improved corrosion resistance and strength advantages are among the major advantages over the 300 series stainless grades. The talk will provide information on chemistry, mechanical and physical properties, corrosion resistance, welding and fabrication, and cost comparisons of these new lean duplex stainless steels.
2:45-3:15PM
PCBN Tools for Friction Stir Welding
Jeff Defalco, Business Manager, ESAB Welding & Cutting Products
Most of the initial work using friction stir welding has been conducted on a wide variety of nonferrous alloys including aluminum, copper, and lead. With the development of pin tools produced from polycrystalline cubic boron nitride (PCBN) and its associative composites, the range of corrosion resistant, high melting temperature materials joined by FSW has grown considerably. Austenitic stainless steels, superduplex stainless steels, and various nickel-base alloys are a few of these alloys worth mentioning. Friction stir welding pin tool technology and its impact on joining these alloys is presented.
3:20-3:55 PM
Corrosion Resistance of New Ni-Cr-Mo and Ni-Mo-Cr Alloys
Henry J. White, Senior Staff Engineer, Welding Metallurgist, Haynes International, Inc.; co-authors: N. S. Meck, N. Koon, and P. Manning
Alloys Ni-21Cr-17Mo and Ni-22Mo-17Cr are two new materials from Haynes International for use in the chemical process and oil and gas industries, respectively. We will discuss the corrosion properties of the base materials, arc weldments, and laser weldments, each being exposed to a variety of conditions. The behavior of these materials will be ranked against competing alloys typically used in these environments.”
Note: Each presentation will be followed by a 5-minute question-and-answer session.
Lean Duplex Stainless Steel Chemical Cargo Tanks
Ralph Davison, Vice President, Technical Marketing Resources
A lean duplex stainless 2101 has been developed with low addition of nickel in order to reduce and stabilize the cost. The low nickel content is compensated by an increased amount of manganese and nitrogen to assure a balanced microstructure with approximately equal amounts of ferrite and austenite. This helps to give the stainless a yield strength more than twice that of 316 and 304 stainless steels, and the yield strength continues even at high temperatures. Lean duplex is also highly resistant to stress corrosion cracking and has better pitting resistance. This alloy is being welded by the gas metal arc process.
9:35-10:05 AM
The Thermal Stir Welding Process
Jeff Ding, Aerospace Welding Engineer, NASA Marshall Space Flight Center
The thermal stir welding (TSW), developed by the National Aeronautical and Space Administration’s Marshall Space Flight Center, is a solid state joining technique. The process is similar to the friction stir welding (FSW) in that the weld seam is consolidated without liquefying the parent material. However, unlike "FSW-ing", the heating, stirring, and forging elements of the process are decoupled allowing independent, dynamic control of each process element. With the separation of heating, stirring, and forging elements during the joining process there are more degrees of freedom allowing greater process control. In this study the TSW process was used to join .250-in thick Haynes 230 alloy in a butt joint configuration. Metallographic samples have been mounted, polished, and analyzed using optical microscopy to document the microstructure. Mechanical property data will also be presented.
10:10-10:40 AM
Evaluation of Higher Interpass Temperatures When Welding 304L and 316L Austenitic Material
Matthew Yarmuch, co-authors are Iulian Radu and Ken Armstrong of PCL Industrial Constructors.Yarmuch is Program Leader, Welding Engineering, Advanced Materials Business Unit
The objective of the evaluation is to reassess maximum interpass temperature limits, while welding 304L and 316L pressure equipment materials, to significantly improve welding productivity. The findings confirm that higher interpass temperatures can be tolerated without compromising the sensitization-corrosion resistance of the weldment. Additional investigations of the weld metal pitting performance are also presented. The results indicate that not exceeding the critical threshold of “time at the sensitization temperature” is paramount to ensure weldment quality.
10:45-11:15 AM
Strip Overlay Weld Cladding of Specialty Stainless Steel Alloys Sandvik
Frank S. Babish, Technical Manager Welding Products, Sandvik Materials Technology, Welding & Wire Products Division
The topic will cover strip overlay welding of specialty stainless steel alloys using the electroslag welding process. This process allows high deposition rates of metallurgically clean weld deposits. Alloys will include duplex and superaustenitic alloy. Applications for the nuclear industry will be included.
11:20-11:50 AM
Alternative Welding Processes for the Fabrication of Titanium Structures
Nick Kapustka, Applications Engineer, Arc Welding, Lasers & Automation, Edison Welding Institute; co-authors: Suhas Vaze and Chris Conrardy
Work is under way at Edison Welding Institute to make the gas metal arc welding (GMAW) process a useful and effective means for welding Ti-6Al-4V. To do this, it was necessary to provide adequate inert gas shielding, arc stability, and contact tip life. This presentation will provide the steps that have been taken to achieve this level of performance. Other processes evaluated in the study included friction stir welding and hybrid laser welding.
11:50 AM - 1:00 PM
Lunch on your own
1:00-1:30 PM
Welding Metallurgy of Duplex Stainless Steels
Damian Kotecki, President, Damian Kotecki Welding Consultants, Inc.
Duplex stainless steel weld metal solidifies as 100% ferrite, and the HAZ near the fusion boundary also forms 100% ferrite. It is essential that austenite nucleates and grows in both areas in order for proper properties to be obtained. The critical role of nitrogen in this process is explained. Then remaining ferrite can transform to undesirable phases such as sigma, and this is explained.
1:35 - 2:05 PM
Explosion Welding to Join Dissimilar Metals
Michael Blakely , Director of Market Development, Dynamic Materials Corp.
Explosion welding focuses on joining both similar and dissimilar metals. A value proposition exists when certain materials are required in specific applications for corrosion resistance, light weighting or temperature distribution and solid material is either impractical, ineffective, or expensive. This talk will focus on the process of explosion welding and discuss some examples of cost savings opportunities when the process is used.
2:10-2:40 PM
The 200 Series Stainless Steels and the Lean Duplex Stainless Steels: Why They Should Be Considered
Cheryl A. Botti, Manager, Market and Product Development, ATI Allegheny Ludlum
Popularity in the use of 200 series stainless steels where 300 series stainless have been traditionally specified continues. Advantages exist with respect to raw material volatility. This talk will address the major material, welding and fabrication, application, codes and standards and commercial issues involved with switching to another grade of stainless steel. In addition to the 200 series stainless steels, the popularity of lean duplex stainless steels to replace 300 series stainless steels continues to grow. More stable raw material costs, improved corrosion resistance and strength advantages are among the major advantages over the 300 series stainless grades. The talk will provide information on chemistry, mechanical and physical properties, corrosion resistance, welding and fabrication, and cost comparisons of these new lean duplex stainless steels.
2:45-3:15PM
PCBN Tools for Friction Stir Welding
Jeff Defalco, Business Manager, ESAB Welding & Cutting Products
Most of the initial work using friction stir welding has been conducted on a wide variety of nonferrous alloys including aluminum, copper, and lead. With the development of pin tools produced from polycrystalline cubic boron nitride (PCBN) and its associative composites, the range of corrosion resistant, high melting temperature materials joined by FSW has grown considerably. Austenitic stainless steels, superduplex stainless steels, and various nickel-base alloys are a few of these alloys worth mentioning. Friction stir welding pin tool technology and its impact on joining these alloys is presented.
3:20-3:55 PM
Corrosion Resistance of New Ni-Cr-Mo and Ni-Mo-Cr Alloys
Henry J. White, Senior Staff Engineer, Welding Metallurgist, Haynes International, Inc.; co-authors: N. S. Meck, N. Koon, and P. Manning
Alloys Ni-21Cr-17Mo and Ni-22Mo-17Cr are two new materials from Haynes International for use in the chemical process and oil and gas industries, respectively. We will discuss the corrosion properties of the base materials, arc weldments, and laser weldments, each being exposed to a variety of conditions. The behavior of these materials will be ranked against competing alloys typically used in these environments.”
Note: Each presentation will be followed by a 5-minute question-and-answer session.
ADJOURNMENT
Questions, to register or need additional conference information? Call
(800) 443-9353 x 455 (U.S.) or
(305) 443-9353 x 455 (Outside the U.S.)
(800) 443-9353 x 455 (U.S.) or
(305) 443-9353 x 455 (Outside the U.S.)