Alloy 625 Weld Metal Cracking on Alloy 825 Cladded Carbon Steel Piping What is the Problem? Multiple cracks were observed on the weld metal during production ‘welding at one of our sub-contractor's spool fabrication shop. The concerned pipe material size involved was 8° OD x 18.26mm thick with Alloy 825 clad (API SL Gr.B to A234 Gr.WPB). The welding processes were GTAW and SAW and the filler metal combination as below: coy St] ERNICrM3,Dia, 24mm Wire ER NiCrMo, Dia, 24mm Manufacturer-Westbrook Manufacturer ~ Westbrook (Wire) & Bavaria (Flux) Trade Name -NW-1740 Trade Name ~ NW-1740 & WP380 During solidification of the weld metal, cracks were observed on the weld surface and confirmed subsurface by Non destructive testing (Liquid Penetrant and Radiographic Testing). These cracks were localized and found within the SAW weld metalHow did it Happen? + Use of different SAW wire and flux combination. = Use of unrecognized flux and wire manufacturers. = SAW flux used is a Neutral flux with low basicity index (1.3), Lower basicity flux has better slag detachability and good bead appearance, but poor weld metal crack resistance. - Review of the SAW flux material certificate (WP 380) indicated that the SiO, content in the flux was three times higher when compared to a basic flux from recognized SAW flux ‘manufacturers. = Although the SAW flux (WP 380) was reported as a Neutral flux, there was evidence of silicon pickup into the final solidifying weld metal from the higher SiO. containing SAW flux. This was detected via chemical analysis of weld metal against specification permissible limits. Code Limit (See. I! Part C) Filler Wire Weld Metal (ater for ER NiCrMo-3 (Manufacturer Westbrook) Interaction with Flux) 05% 0.3% 0.75% = The values of Siicon and Sulphur contents reported in the weld metal chemical analysis were higher than acceptable levels. ~ Lab test reports confimed the presence of inter-dendri: Lave's phases rich in Silicon in a matrix of Austnite + Higher silicon and sulphur content in the weld metal forms a low melting eutectic phase which due to solifying shrinkage stress promotes micro fissures or cracks, Fit was clearly evident that the SAW wire and flux used from diferent manufacturers were not ‘compatible and the combination was nat proven.Alloy 625 Weld Metal Cracking on Alloy 825 Cladded Carbon Steel Piping What must be done to prevent it happening again? itis recommended to use SAW flux and wie from the same manufacturer and with proven flux and wie compatibility. The SAW flux and wire used shouldbe supported with an appropriate flux and wire combination consumable certificate. Although the bead appearance and slag detachabilty ofa basic flux are not so good as with a Neutral fx, itis recommended tose a basic fu for better crack resistance. The weld metal chemistry reported on the consumable batch test certfiate shouldbe verified fr control of low melting eutectic phase forming elements (e.g, slcon, sulphur) to be as low as possible itis recommenced to qual new welding procedures wth SAIN flux and wire from recognized manufacture for use in production welding. SAW wire and flux used should be fee from oll and grease contamination (considered a major source of sulphur) leading to weld metal cracking.