Metals and how to Weld Nickel Alloys like Inconel 718, Hastelloy
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Metals and how to weld them ...Welding nickel alloys Before I
get in too deep, I have been asked for the parameters for the welds
in the video..here they are..**the 15-5ph stainless joint was ,050"
thick and with a .030-.050" gap took 40-45 amps.**the inconel 718
joint was .032" thick and only took 23-25 amps**the 4130 chromoly
was .048" thick and required 45-50 amps**no pulse was used, just
straight current on a miller syncrowave 250.**I was using an
oversize cup 15/16" with a gas lens and screen diffuser with 35cfh
and the tungsten extended about 3/4" to allow the camera to get the
arc.Ok, exactly what are nickel alloys?Most technical guides define
nickel alloys as metals that contain more nickel than anything
else.Some books state that nickel alloys contain more than 50%
nickel.The nickel alloys we will talk about today have more than
50% nickel. Like:Inconel 718 --- 19Cr 3Mo .9Ti 5.1Cb .5Al 18Fe
balance NiInconel 625 --- 21.5Cr 9Mo 3.7Cb balance NiInconel 82 ---
20Cr 2.5Cb 3.2Mn balance NiHastelloy X --- 22Cr 1.5Co 9Mo .6W
18.5Fe balance NiNichrome V --- 20 Cr balance NiWaspaloy --- 19.5Cr
13.5Co 4Mo 3Ti 1.4Al .006B balance NiHASTELLOY S --- 16Cr 15Mo .3Al
.06La balance NiC263 --- 20Cr 20Co 6Mo 2.2Ti .45Al balance NiAs you
can see all the nickel alloys listed above contain more than 50%
nickel.Some of them contain fairly large amounts of iron but some
of them dont contain any iron all Properties of nickel alloys:Low
conductivity this is why nickel alloyed with chromium is often used
for heating elements. Because of a low conductivity heating
elements made from nickel alloys get red hot quickly when electric
current is applied.Resistance to oxidation and scaling nickel
alloys can be heated to red hot temperatures repeatedly without
scaling.Corrosion resistance nickel alloys dont rust and are very
corrosion resistant to certain acids and alkaline
solutions.Strength and hardness - alloy additions of aluminum and
titanium allow some heat treatable nickel alloys to be strengthened
substantially by heat treatment.Nickel alloys will not harden from
heating and quenching. Only certain nickel alloys can be hardened
by heat treatment and it involves holding the metal at an elevated
and controlled temperature for a long time. This heat treatment is
known as aging or precipitation hardening.The two main properties
of nickel alloys that most determine what welding techniques to use
are:1. Low thermal conductivity2. Sluggish puddleA low thermal
conductivity means that heat does not dissipate easily. Another way
of saying that is that heat builds up very easily. Stainless steels
have low thermal conductivity also and we know one of the tricks to
prevent heat build up is to get in , and get out you know, dont
fart around .hit it, get moving, and get out.Chill blocks to pull
the heat out are good for stainless, and good for nickel alloys
too.The sluggish puddle is another property of nickel alloys ,
especially when tig welding. That is why aerospace welders who tig
weld nickel alloys often use an oversized tig cup. The extra argon
shielding you get with a big cup helps keep the hot tip of the
filler rod shielded and that keeps the puddle more fluid. A more
fluid puddle needs less amperage to move the puddle. Less amperage
means less heat input, less distortion, less likelihood for
cracking, and less heat affected zone.all good things.3 of the most
widely used nickel alloys in the aerospace industry are :1. Inconel
713c turbine blades2. Inconel 718 engine cases, compressor blades3.
Hastelloy X hot section parts like burner cans that operate at red
hot temperatures and withstand thousands of heating and cooling
cycles.In other industries like power generation, nickel alloys
have another application.Cladding.Tons upon tons of inconel 625
welding wire are used each year to weld cladding on steel boiler
tubes to extend their life. Inconel 625 is one of the most widely
used nickel alloy filler metals becauseIt works.Inconel 625 welding
wire is used routinely to weld layers of heat and corrosion
resistance cladding on less corrosion resistant steel .It stands to
reason that if inconel 625 can be used to clad steel or chromium
steel boiler tubes, it is also a good choice as a welding rod for
welding steel to other metals.Another property of nickel is that it
remains soft and ductile after the weld is done.Nickel welding rods
will not harden by heating and quenching. No matter what the base
alloy is, a nickel welding deposit will not be hard and
brittle.Thats some useful information.So lets recap.We know now
that nickel alloys have a low thermal conductivity, resist scaling
and oxidation at elevated temperatures, will not harden--even when
used to weld carbon steel or cast iron, and we know that nickel
alloys can retain these properties even when subjected to multiple
heating and cooling cycles.With these properties, it makes perfect
sense that inconel 625 would be used for cladding boiler tubes in
power plants.
TIP TIG superior nickel weld quality than traditional TIG
weldsIf you want all position, defect free alloy welds at superior
quality than conventional TIG, Pulsed MIG or the flux cored process
and you would like to produce all position weld deposition rates
equal to pulsed MIG and flux cored, consider the TIP TIG process. A
five minute TIP TIG demo will show any weld professional that when
welding in any weld position, thin or thick metals, any alloys and
any weld, clad or brazed application, the TIP TIG process is the
world's most cost effective process for producing defect free
welds.
THE NORTH AMERICAN, PATENT PENDING, ADVANCED TIP TIG PROCESS, IS
THE WORLD'S MOST EFFECTIVE WELD, CLAD AND BRAZING PROCESS. TIP TIG
IS AN EASY PROCESS TO USE AND ALWAYS DELIVERS SUPERIOR WELD QUALITY
THAN TRADITIONAL TIG / PLASMA WELDS. THE BONUS FOR THE WELD SHOP IS
WHILE GETTING THE ULTIMATE IN TIG WELD QUALITY, YOU ARE GETTING IT
4 TO 8 TIMES FASTER THAN A TIG WELD:
The manual or automated semiautomatic TIP TIG process can be
used with either TIG - Plasma or a laser. TIP TIG will always
result in superior weld / clad quality and superior mechanical
properties. It does not matter what the application, the weld
position, or the alloy to be welded is, TIP TIG will deliver the
ultimate attainable weld quality on all Carbon Steels, Stainless,
Aluminum, Inconel, Titanium, Hastelloy, Stellite, Duplex, Low and
High Alloy Steels, Tool Steels and Cast Steel welds and clad
applications.
The Fossil and Nuclear industry will never attain the
construction weld quality or productivity (10 to 40 times faster
than manual TIG) that the ATT manual and automated weld process can
deliver. Oil Platforms - Ship Yards - Naval Vessels and Submarines
- The Space and Aircraft Industries - Cryogenic Vessels - Petro
Chemical - Refining - Waste to Energy - Industrial Processing -
Pulp and Paper - Military Equipment - Medical Equipment - Food and
Beverage, none of the North American industries have in their weld
shops a weld process that can deliver the weld quality /
productivity attainable from the easy to use, semiautomatic ATT
process.
Why be concerned about the skilled welder shortage when the
moderate priced TIP TIG process is easy to use on the most
difficult applications. PQR's will be easy to produce as two simple
amp / wire feed weld procedures will weld most of your manual or
automated applications. It takes about one hour to learn the one
handed TIP TIG techniques. TIP TIG will dramatically reduce your
weld rework costs and reduce your product liability concerns as it
always will deliver the optimum in weld quality. There is no weld
smoke issues and no concerns for spatter. In contrast to most other
process it will provide less weld heat input. . If highly cost
effective, defect free alloy welds with superior weld appearance
are important to you. Click for TIP TIG weld information.
To watch the worlds best process weld on a pipe orbital head
copy the following link and note the untouched pipe weld quality
and unique multi-pass color without interpass temp control which
indicates the very low weld heat. http://youtu.be/byBer6EWy7s
When MIG welding nickel alloys, the welder would note many
similarities to welding carbon steels. Nickel has similar
mechanical properties to carbon steels, it's the nickel crystalline
and metallurgical structure that's very different from iron.
In contrast to carbon steels, when welding nickel, the nickel
does not undergo a crystalline / phase change up to its melt
temp.To change the grain size requires cold working and annealing.
Nickel has great solubility for elements that's why we see alloys
such as Nickel - Chrome, Nickel - Iron,
Nickel - Copper, Nickel - Moly and other commercial alloys. In
small amounts carbon, manganese, silicon, aluminum and columbian
are added, some of the these have a positive influence on the weld
and some have a negative influence.
Manganese in the range of 3 to 9 percent is added to nickel
copper alloys to improve crack resistance.
Titanium is sometimes added to the filler metals as a deoxidizer
for weld porosity reduction.
ED'S MIG GAS FOR NICKEL ALLOYS: Typically straight argon is the
gas of choice, and when more weld energy is required argon with 40%
helium have been use for MIG and pulsed MIG.
Note for those that having been using gas mixes with Argon -
< 30% helium, the weld energy benefits will be minuscule from
that helium content, and that's why the 40% helium is recommended.
Also be aware that with pulsed MIG, you can tweak the pulsed
parameters to put more weld energy in the pulsed droplets, so you
won't need the helium mix. I did this many times when establishing
cladding procedures for the power and waste management
industries.
For decades CO2 or oxygen in the MIG gas was not recommended for
Nickel alloys as these alloys are very sensitive to oxidation. In
the eighties while carrying out MIG gas research I discovered the
value of a small amount of CO2 for MIG welding nickel alloys. Visit
the MIG gas section at this site for the gas data. With MIG Nickel
alloys, the addition of 0.5 to 1 percent (max) CO2 to argon not
only improves the arc stability it will also allow the use of
higher, more spray transfer wire feed rates.
INFO ON COMMON NICKEL ALLOYS
Nickel. Solid Solution. 200 series, typically not strengthened
by heat treat.
Nickel 200 - 201 used food and chemical processing equipment and
pipes. The 201 is used on applications over 600F. Nickel 201 99.5%
nickel - Nickel. Precipitation Hardenable. 300 series. Strengthened
by heat treatment.Nickel Copper Alloys. Solid Solution. 400 series.
High strength. High toughness and great corrosion resistance. 405
is free machining. 405 = 66.% Ni - 31% Cu - 1.25% Fe - 1%
Mn.Nickel. Copper Precipitation Hardenable. 500 series. These
alloys (K-500) are strengthened with Al and Ti. Used when high
strength / hardness and corrosion resistance required. K500 66.5%
Ni - 28% Cu - 3% Al.
Nickel Chrome. Solid Solution. 600 series.These are the common
alloys we see in use today. 600 - 601 - 625, Good corrosion
resistance at high temperature.Good resistance to chloride-ion
stress corrosion cracking and corrosion from high purity water.
Used in reactors, power plant water wall cladding etc.Alloy 625
good MIG weldability, using pulsed or spray transfer.625 = 61% Ni -
21.5% Cr - 9% Mo - 3.65% Cb - 2.5% Fe -Nickel Chrome. Precipitation
Hardenable. 700 series. Strengthen by Al - Ti - Cb additions.
Common alloys 713 c - 706 - 718 - X750 - U500 - U700 - R41 -
Astoloy - Waspaloy. When Cb is used for strengthening rather than
Al - Ti the weldability is improved. Gas Turbines and Aircraft
parts. X750 = 73% Ni - 15.5% Cr - 7% Fe - 2.5% - Ti -0.95% Cb.
Nickel Iron Chrome. Solid Solution. 800 series. Common alloys
are 800 and 825 and 20Cb. Alloy 800 is used typically in high temp
applications, has good carburization / oxidation resistance. The
825 and 20 Cb in strong corrosive situations, good resistance to
chloride-ion stress corrosion cracking and reducing acids.825 = 42%
Cr - 30% Fe - 21.5% Cr - 35 Mo - 2.5% Cu - 0.9% Ti
Nickel Iron Chrome. Precipitation Hardenable. 900 series. Most
common 901 (Incoloy 901). Welds similar to X750, mostly used for
forgings that are not welded.901 = 42.7% Ni - 34% Fe - 13.5% Cr
-6.2% Mo - 2.5% Ti.
Nickel Moly Alloys. Known as Hastelloy B - N - W. Contains 16 -
28% Mo with some Chrome and iron. B used for hydrochloric acids. N
for molten fluoride salts, W for dissimilar metals with good
corrosion and oxidation resistance.
Nickel Chrome Moly Alloys. Known as Hastelloy. C - C276 - F - G
-X. Alloy C good corrosion and high temp properties. C-276 lower
carbon and silicon than C to reduce grain boundary precipitates
enables the alloy to be used in as weld condition.
Nickel Silicon Alloy. Hastelloy D. This is a cast alloy with
good resistance to sulfuric acid at all temperatures.
Base AlloyAWS Filler Metals. Need more info contact Haynes
Alloys. Kokomo IN.
Nickel 200 ERNi 3
Monel 400 ERNi Cu 7
Inconel 600ERNiCr-3 -- ERNiCrFe 6
Inconel 718 718
Inconel X-750 718
For dissimilar applications think about minimum weld
dilutionShort circuit and the pulsed mode are recommended for
cladding. For nickel chrome welds on carbon steels ERNiCr-3 is a
common consumable.
Inconel 600 - 800 to steel or stainless / monel 400.ERNiCr -3 -
ERNiCrFe-6
WELDING TIPS, NINE PERCENT NICKEL. CRYOGENIC APPLICATIONS.A
common application in which austenitic stainless and 9% nickel
steels is in the construction of cryogenic, liquefied natural gas
(LNG) containers. These containers can carry liquid argon, natural
gas, helium, oxygen, nitrogen etc. These liquid gases are usually
in an approximate temp range of -300 to -450F. Carbon steels and
alloy steels have poor toughness and ductility at low temperatures.
The alloy steels with nickel, austenitic steels typically 304 -
304L 316 - 316L - 347 and aluminum alloys all have excellent low
temperature toughness. Please note, TIP TIG will provide superior
weld quality than traditional TIG or any MIG transfer mode.
Strict welding regulations are applied to welding cryogenic
applications. The weld metal properties should contain low
nitrogen, low ferrite, low carbon and high nickel. Filler metals
such as Nickel Chrome Molybdenum, Nickel Chrome Iron or high alloy
austenitic electrodes.
The Nickel alloy consumables have a coefficient of thermal
expansion that is close to the 9% nickel this reduces the risk of
thermal fatigue in applications subject to thermal cycling.
Typically the mechanical properties of nine percent nickel will be
higher than those of the weld consumables utilized. This requires
special consideration to weld qualification tests. Note that with
the 30X in centrast to the 30XL (low carbon grades).
The higher the carbon content the lower the impact
toughness.Shop built stainless steel cryo vessels in the USA are
built to ASME Boiler Pressure Vessel Code Section V111. Field
erected vessels may use the API 620 Q. Austenitic stainless
accounts for the majority of metals used for cryo applications. The
rest of the applications use 5 to 9% nickel or aluminum. Where high
strength is required nine nickel may be chosen instead of an
austenitic steel. Its important to remember that nine percent
nickel is an alloy that can rust.
WELDING TIPS FOR NINE PERCENT NICKEL.
The best possible weld process would TIP TIG.Keep the carbon in
the rage 700 F, welds that contain high nickel to chrome ratios can
be sensitive to sulfur corrosion. This risk is reduced with filler
metals that have higher chrome / moly. Alloys 625 / 671. The 671 is
AWS (ERNiCr-4 rod)
[] The 625filler, EniCrMo-3 rod , MIG and flux cored wire should
be restricted to applications