MPWT19-14343

High Quality CRA solutions by Electro Slag Process for Austenitic

Stainless Steels, 625 & 825 Single & Multiple Layer Solutions
JP Van Nieuwenhoven,
Head of Application Engineering & Technology
Voestalpine Bohler Welding Belgium s.a.

ABSTRACT

Within many features of the Electro Slag Strip Cladding (ESSC) technique, one of the most
attractive is the opportunity to achieve a required clad metal chemical analysis in one single
layer. All these CRA 308L, 316L, 347, 625 & 825 types frequently concern fabricators who are
constantly demanding for ways to reduce production costs & thicknesses of CRA. Hence, new
low dilution and high-travel speed solutions have been developed with the aim to reduce the
thickness and/or the number of layers in order to answer to industry expectations in terms of
productivity. Through controlling dilution with the parent metal and balancing the chemistry by
means of the new fluxes, it has been possible to achieve high quality results with an iron content
Fe <7% & Fe < 10% for 625 cladding in a single layer where traditional ESSC requires two layers
for the same objective. Also, for Alloy 825, single and thin layer solutions have been achieved.
This subject presents an overview of these new developments with details on the applied welding
conditions and the quantitative results achieved, showing benefits in terms of material savings
and productivity gains.

Keywords: ESSC, CRA, Single Layer Cladding, Thin Layer Cladding

INTRODUCTION

Inner surfaces of heavy wall pressure vessels (such as nuclear reactors or oil refinery plants)
are weld overlaid with stainless steel or nickel alloy to prevent corrosion or hydrogen attacks.
Overlay welding is performed by means of various methods, such as Shielded Metal Arc,
Submerged Arc, Gas Metal Arc or Plasma Arc Welding. However, these large-sized pressure
vessels, with large overlay areas & tons of deposition, require an efficient welding process. In
overlay welding, not only a high efficiency, but also low penetration into the base metal i.e. less
dilution is achieved. Therefore, we can conclude that Electro Slag Strip Cladding (ESSC) is the
most preferred process for overlay welding. The principal object of such a product is to combine
at low-cost, hold the desirable properties of the Corrosion Resistant Alloy steel and the backing
material for applications where full thickness alloy construction is not required.

I. Industrially clad plates are manufactured by 3 processes

1) Roll Bonded Plates

Fig 1: Roll Bonding of Corrosion Resistant Clad Plates

2) Explosion Bonded Plates

Fig 2 : Explosion Bonding of Corrosion Resistant Clad Plates

3) Strip Cladded Plates

Fig 3: Strip Cladding by Corrosion Resistant Strips

As compared to Roll Bonded Plates, Explosion Bonded plates are less used in the Fabrication
Industries because of issues related to disbonding/disfigurement of plates during the explosion.
The main issue with the usage of Roll Bonded plates is that they have a restriction of rolling
above a certain thickness. Hence, for higher thickness, fabricators go with the Electro Slag Strip
Cladding process for internal cladding of vessels.

II. ESSC PROCESS PRINCIPLE

Electro Slag Strip Cladding basically works according to Joule’s Heating Law. The heat required
to melt the strip, the slag-forming flux and the surface layer of the base metal is generated by
resistance heating due to the welding current flowing through the molten conductive slag. The
dilution levels resulting from this welding technique are quite low (up to 10%) and hence the heat
input generated during the entire process is quite low. This is because much of the heat
generated during the process is used up to melt the conductive flux, leaving only enough heat
to fuse the base metal. However, enough heat is generated to ensure a fine bonding between
the base metal and the cladding.

Fig 4 : Principle Representation of an ESSC Process

III. IMPROVING PRODUCTIVITY WITH ESSC

1) By increasing the width of the Strip Cladding:

With increase in the width of the strip, the current (amperage) required in melting the
strips increases and the deposition rate increases as well. This increase in current does
not mean an increase in the Heat Input since the Heat Input calculation also takes into
consideration the width of the strip.
60

50

120mm
40
Deposition rate [kg/h]

30 90mm

20
60mm

10
30mm

0
200 700 1200 1700 2200 2700
Welding current [A]

Fig 5: Graphical representation of Deposition Rate for different strip sizes

2) By reducing the number of layers:

The traditional sequence of a Strip Cladding process involves depositing a buffer layer
followed by a subsequent pass of the required strip chemistry using a Submerged Arc
Strip Cladding Process.
 For e.g.: In an Austenitic Stainless Steel Strip Cladding Technique, the Cladding
sequence includes:
a) Depositing a buffer layer of EQ309L followed by a second layer of EQ308L strip which
would give a 308L chemistry on the top surface
b) Depositing a buffer layer of EQ309L or EQ309LMo followed by a second layer of
EQ316L strip which would give a 316L chemistry on the top surface
c) Depositing a buffer layer of EQ309L or EQ309LNb followed by a second layer of
EQ347 strip which would give a 347 chemistry on the top surface

The height of each layer achieved will be around 4.5-5 mm thick thereby depositing an
overall clad thickness of 9-10 mm.

Through a series of Research & Developments, single layer strip chemistry was
developed for all the above grades of Austenitic Stainless Steel Strips. This means
depositing only one layer of strip cladding to achieve the required chemistry.

By modifying the chemistry of the strip to a chemistry nearing the 309L/309LMo/309LNb

grades and with the same neutral flux, the required chemistry of 308L/316L/347 grades
could be achieved respectively. The advantages achieved by this single layer Strip
Cladding solution are as below:

a) The height of the single layer Strip Cladding comes to around 4.5-5 mm, thereby
reducing the thickness of the weld overlay almost by half as compared to the
Submerged Arc Strip Cladding Process
b) Respective Austenitic Stainless Steel chemistries could be achieved not only on
the top surface but also 3 mm below the surface. Since the dilution levels in an
ESSC process is around 10% maximum, a favorable chemistry can be achieved
very close to the fusion line.
c) An Increase in Productivity by almost 50% compared to a 2-layer Strip Cladding
since only one layer needs to be welded.
d) A substantial saving in terms of cost, taking into consideration the reduced quantity
of strips for cladding & reduced man-hours for production.

This technique has now been accepted widely in most of the pressure vessel
manufacturing specifications for the Austenitic Stainless Steel Range.

3) By Increasing the Deposition Rates & lowering the thickness per each layer for Inconel
strip cladding chemistries of 625 and 825, single layer strip cladding using neutral fluxes
is not yet possible. To make the Strip Cladding economical for 625 & 825 chemistries
using a neutral flux application, our R&D team developed several neutral fluxes which
could be used at higher welding speeds and thereby reducing the thickness of the clad.
These fluxes are known as the High-Speed Fluxes.

The benefit of this High-Speed Flux can best be explained by an example. A normal Strip
Cladding speed for a 60 mm wide strip is 160-180 mm/minute. For an Inconel 625 Strip
Cladding at this speed, a height of 4.5 mm-5 mm could be achieved.
 Using a High-Speed flux, the speed of Strip Cladding could be increased to 250-270
mm/minute and hence bring the cladding height of each layer to 3 mm-3.5 mm. For 2
layers of Inconel 625 this cladding height comes to around 7 mm-8 mm.
Undiluted Inconel 625 chemistry can very well be achieved at the surface of the weld as
well as 3 mm from the top surface.

The cladding height in the range of 7 mm-8 mm is almost 20% lesser than the traditional
cladding height with 2 layers (9 mm-10 mm). This is a substantial saving considering the
high cost of Inconel 625. Also to be taken into consideration is the savings due to the
reduced man-hours.

This 2-layer High-Speed Strip Cladding process can also be used for all grades of
Stainless Steel Strip Cladding as well as Alloy 825 Strip Cladding.

There has been some Research and Development going on in developing a single layer
Strip Cladding solution for 625 and 825 grades. Through this paper, we wish to highlight
the economic benefits of 625 and 825 cladding solutions using a single layer Inconel
625/825 or a very thin 2 layer 625/825 solution.

EXPERIMENTAL PROCEDURE

Development of 625 innovative strip cladding solutions:

As Inconel 625 is a high-priced product, voestalpine Bohler Welding has received many
requests from fabricators to provide a single layer solution for Inconel 625 by the ESSC
process. Unlike Austenitic Stainless Steel Strip Cladding, the main challenge in an Inconel
625 Strip Cladding is to achieve the required Iron (Fe) content to less than 10% or, as per
ASME requirements, to less than 7%. Although the dilution by the ESSC process is less
compared with other processes, there is a substantial pick up of Fe from the base metal,
making it essential to weld a 2nd layer to reduce the dilution from base metals and achieve
the required undiluted chemistry of Inconel 625

To achieve this chemistry in a single layer, our R&D team developed a flux which could be
used at a lower amperage as shown below in Trial 1

1) Single layer with flux Record EST 625-1LD at conventional travel speed

Record EST 625-1 LD is a specifically modified Low Dilution enhancing flux. Trials were
made in comparison with the standard Record EST 625-1 fluxes at the below parameters

 Trial – 1 Welding parameters (60x0,5 mm strip) :

• Standard 625 single layer with RECORD EST 625-1: 1250 A / 24 V / 20 cm/min

• Development RECORD EST 625-1 LD: 900 A / 24V / 18 cm/min

 Trials were also done using Record EST 625-1 LD with slightly lower speeds and in a single
layer with adjusted parameters. The trials were then compared with the standard Record
EST 201 double layer flux for Inconel 625

 Trial – 2 Welding parameters (60x0,5 mm strip) :

• RECORD EST 201 two layers: 1100 A / 24 V / 16 cm/min

• RECORD EST 625-1 LD : 1150 A / 24 V / 16 cm/min

2) Two thin layers with flux Record ES6625 at high travel speed

Many welding specifications restrict fabricators to go with single layer solutions for strip
cladding. Conventional Inconel 625 strip cladding solution in 2 layers gets the height of up to
9-10 mm overlay height.

With the new modified Record ES6625 high speed flux, this height can be restricted to 6.5-7
mm of overlay height. A saving of 25-30% of strip and fluxes can be achieved.

 Trial – 3 Welding parameters (60x0,5 mm strip):

• RECORD ES6625: ~1400A / 24V/ 30cm/min

Development of 825 innovative strip cladding solutions:

Few fabricators and end users around the world even have an expertise in strip cladding of
Alloy 825 and this can also be achieved in a single layer or two layers. Conventional single
layer 825 strip cladding gives a clad height of 5 mm and a 2-layer cladding achieves a height
of up to 9 mm. Modifying the flux to be used in a higher travel speed or reducing the amperage
for lesser deposition helps in lowering down the height of the cladding, reducing the overall
project cost.

1) One single layer with flux RECORD EST 138+ at conventional travel speed.

New flux Record EST 138+ was tried at the below parameters for single layer with the strip
Soudotape 825HS

 Trial 4: Welding Parameters (60x0,5 mm strip):

• Record EST 138 +: 975A/24V/16cm/min

2) Two thin layers with flux RECORD EST 825H-HS at high travel speed.
This is a 2-layer strip cladding solution modified to suit the 825 cladding at a very high travel
speed which is almost double the travel speed of the conventional strip cladding process.

 Trial 5: Welding Parameters (60x0,5 mm strip):

• Record EST 825H-HS: 1400A/29V/39cm/min

RESULTS

Development of 625 innovative strip cladding solutions:

Trial – 1: One single layer with flux RECORD EST 625-1LD at conventional travel speed

Chemical Analysis:

Table-1
Chemical Analysis at top surface of overlay using a standard Record EST 625-1 vs. newly developed low
dilution flux Record EST 625-1 LD

For requirements with 1layer

Fe<10% C Mn Si Cr Ni Nb Mo Fe
thickness
Standard 625 single layer
0.025 0.20 0.30 21.5 - 3.5 9.0 7.9 5.0 mm
flux RECORD EST 625-1

RECORD EST 625-1 LD

0.022 0.12 0.35 22.4 - 3.6 9.7 8.0 3.6 mm
Single layer (Fe < 10%)

Trial -2: One single layer with flux Record EST 625-1LD at slightly slower travel speed

Chemical Analysis:

Table-2
Chemical Analysis at top surface of overlay using a standard 2-layer flux Record EST 201 vs.
Newly developed single layer low dilution flux Record EST 625-1 LD

For requirements with Total

C Mn Si Cr Ni Nb Mo Fe
Fe<7% in single layer thickness
Standard 625 two layers
0,020 0,10 0.30 21.5 - 3.0 8.8 2.5 8.4 mm
flux RECORD EST 201
RECORD EST 625-1 LD
0.019 0.12 0.32 22.3 - 3.6 9.6 6.1 5.0 mm
Single layer (Fe < 7%)
Corrosion Test:

Table 3
Corrosion Test Results (Inconel 625 + Record EST 625-1 LD single layer)

Corrosion test Corrosion rate

ASTM G48A 1
0 mm/year
(72h @ 50°C)
ASTM G28A (120h) 2
Middle of the bead 0,42 mm/year

ASTM G28A (120h)

Overlap betwen beads 0,53 mm/year

Side Bend Test:

Table 4
Side Bend Tests: (Inconel 625 + Record EST 625-1 LD single layer)

As welded PWHT 24h@670°C

Sample thickness 10 mm 10 mm

Bending angle 180° 180°

Mandrel diameter 40 mm 40 mm

Remark No crack No crack

Fig 6: 180° Side Bend Specimens for cladded Inconel 625 using Record EST 625-1 LD flux
Chemical Analysis Survey:

Inconel 625 + Record EST 625-1 LD single layer

Fusion Chemical analysis survey from base material to top surface of
100 line cladding Mn (%)
RECORD EST 625-1 LD < 7% Fe scenario Cr (%)
Ni (%)
80 Mo (%)
Element concentraion [%]

NICrMo Nb (%)
Base
cladding Fe (%)
60

40

20

0
-500 -250 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 5000
Distance from the fusion Line (0) in µm

Fig 7 : Chemical Analysis Survey of major elements up to the top surface

Macro photograph:

Inconel 625 + Record EST 625-1 LD single layer

Fig 8: Macro photograph with height at regular intervals from the fusion line

Discussion on Trial 1 & 2:

Electro Slag flux RECORD 625-1 LD allows to achieve (at standard travel speed) a weld metal with:
• Fe < 7% in one single layer where at least 2 layers were required in conventional processes
• Fe < 10% in a thin single layer using adapted cladding parameters whereas per conventional
practices a minimum of 5mm weld clad height was required to achieve the required chemistries
 • This flux has been tested for corrosion tests including pitting corrosion and crevice corrosion and
has exhibited excellent resistance to corrosion
• Side Bend Tests were carried out with no cracks or disbondment

This new flux and strip combination provides the advantages listed below:
• The bead profile is flat at the surface and is a uniform fusion line
• It is free from a lack of Fusion
• Total Thickness of 5.16 mm (from the fusion line)
• Geometrical dilution of only 5.8%. The dilution of chemicals is uniform from the top surface
to undiluted lower layers as shown in Figure 7

Trial – 3 Two thin layers with flux Record ES6625 at high travel speed

Chemical Analysis:

Table 5
Chemical Analysis achieved with thin layer flux Record ES6625

Standard
C Cr Ni Mo Nb Mn Si Fe
class
SOUDOTAPE 625 (typical
0,01 22 65 8,7 3,7 0,03 0,04 0,2
chemical analysis strip)
RECORD ES 6625 @
0.018 21.2 REM 8.3 3.35 0.05 0.42 4.5
30cm/min - 7 mm
Base metal 0.10 20.0-23.0 58.0 min. 8.0-10.0 3.15-4.15 0.5 0.5 5.0
Weld metal as per ASME Sec
0.10 20.0-23.0 55.0 min. 8.0-10.0 3.15-4.15 1.0 0.75 7.0
II Part C 3 SFA 5.11
Weld metal as per SAES
0.10 20.0-23.0 58.0 min. 8.0-10.0 3.15-4.15 0.5 0.5 10
W-014 4

Discussion:

Increasing travel speed reduces the height of the weld clad, but not all fluxes can support weld
overlay at high speeds. Record ES6625 flux is specially modified to be operated at high travel
speeds of up to 30cm/min.
For a 2-layer strip cladding solution, a clad height of 6-7mm could be achieved against the
conventional height of 9-10mm. A fabricator achieves a saving of 25-30 percent in terms of
Inconel 625 strips which is a significant saving for such a high-value consumable.
Development of 825 innovative strip cladding solutions:

Trial – 4 : One single layer with flux RECORD EST 138+ at conventional travel speed

Chemical Analysis:

Table-6
Chemical Analysis at the top surface of overlay using a Record EST 138+ flux

C Mn Si S P Cr Mo Fe Cu Ti Al Ni
0.01
Strip chemistry 0.014 0.70 0.30 0.001 22.30 3.00 28.3 3.00 0.70 0.04 Bal.
0
ASME SFA 5.14 19.5- 2.5- 1.5- 0.6- 38-
0.05 1.0 0.50 0.03 0.03 >22 0.20
ERNiFeCr-11 23.5 3.5 3.0 1.2 46
19.5- 2.5- 1.5- 0.6- 38-
UNS N08825 0.05 1.0 0.50 0.03 0.03 >22 0.20
23.5 3.5 3.0 1.2 46
1layer deposit, <0.00 0.01 0.03
0.024 0.59 0.72 21.7 2.84 32.3 1.98 0.06 Bal.
Height : 5mm 5 3 6

Corrosion Test

Table-7
Corrosion Test Results using a Single Layer Record EST 138+ flux

ASTM G28-A (intergranular corrosion test)

Sensitization heat treatment 10h-630°C
Test solution 400 ml H2O + 236ml H2SO4 + 25g Fe2(SO4)3
Test temperature & duration Boiling during 120 h.
Sample Corrosion
Weight Corrosion Requirement
thickness [ rate [
Soudotape 825HS + loss [g] rate [mils/yr] [ mm/yr]* / [mpy]**
mm] mm/yr]
Record EST 138+
Max. 0,45 mm/yr * /
3.07 0.099 0.30 11.81
18 mpy*

Discussion:
This new consumable combination has replicated all the requirements of a standard 825 strip in
terms of combination along with the standard flux in a single layer itself. The conventional
process for 825 strip cladding involves 2 layers with a deposition height of 9-10mm. This single
layer combination has also successfully cleared ASTM G28 for intergranular corrosion testing.
 Trial 5 : Two thin layers with flux RECORD EST 825H-HS at high travel speed

Chemical Analysis:

Table-8
Chemical Analysis at the Top Surface and 3 mm from the Top Surface

Clad
Localisation ARL chemical analyses
Strip Strip + Flux thickn.
of chemical
[ mm] combination [ mm]
analysis
C Mo Si Cu Ni Fe Mn Cr Ti
SOUDOTAPE
Surface 2nd 0.02 2.9 1.8 38. 33. 0.6
825 + EST 825 0,81 21.1 0.10
60x0.5 layer 5 2 4 6 4 7
HS 6.6
(EM
SOUDOTAPE Surface 2nd
4542) 0.02 3.0 1.8 39. 32. 0.6
825 + EST 825 layer 0,78 21.5 0.12
3 3 7 1 4 5
HS -3 mm

Macro Photograph:

Fig 9: Macro photograph with penetration

1st Layer: Penetration – 1.2mm & Thickness from the Base Metal Surface: 3.4mm
2nd Layer: Penetration – 1.2mm & Thickness from the Base Metal Surface: 3.2mm

Side Bend Test

EM 4541

Fig 10: Side Bend Test @ 630°C +/-15°C / 840min – No Cracks

Corrosion Test

Table-9
ASTM G28 Corrosion Test Result

Maximum Corrosion Corrosion Requirement

PWHT penetration rate [ rate
[µm] mm/yr] [mpy] [ mm/yr]* / [mpy]**
610°C - Max. 0,45 mm/yr * / 18
0 0.098 3,8
1h mpy*

Discussion:

The results show a lower thickness in 2 layers using this high-speed flux compared to 2 layers
using the conventional process. A total saving of 25-30 percent in clad height could be achieved
with the use of this high-speed flux.

This new flux and strip combination provides the advantages listed below:
• Allows reduction of the total clad thickness
• Allows reduction of the total travel time
• Is a concept based on neutral flux
• Reduction in cost of weld metal & flux consumption

CONCLUSIONS

Conventional methods of strip cladding by the Electro Slag welding process are slowly giving
way to the new developments which not only reduce time, but also reduce the height of the
welding, quantity of welding consumable, and, hence, reduces the costs greatly from all aspects.

• Record EST 625-1LD flux with 625 strips can be used for a single layer Strip Cladding,
thereby reducing the overall deposition of Strip Cladding by 50%. This low dilution flux
helps in achieving the desired height of the overlay by altering the parameters and thereby
controlling the overall chemistry requirement (i.e. Fe< 10% or Fe<7%).

• For specifications restricting the use of single layer Strip Cladding for Inconel 625, a new
thin layer flux Record ES6625 flux has been developed to achieve the required chemistry
at a much lower clad thickness, reducing the strip usage by 25-30%.

• Similarly, for Alloy 825 Strip Cladding, from a 2-layer cladding technique, a single layer
Strip Cladding process using flux Record EST 138+, bringing a saving of almost 50%, is
going to be a new addition to the cladding business.

• For a 2-layer solution of Alloy 825, a high-speed neutral flux Record EST 825H-HS with
an overall thickness of 6-7 mm (depending on travel speed and dilution percentage) is
also a new development resulting in a reduced thickness from 10 mm in two layers.
 ACKNOWLEDGEMENTS

All above inputs are based on internal trials and testings carried out by the Voestalpine Bohler
Welding Belgium team & successfully implemented in production welds by customers.

REFERENCES

1. ASTM G48 : Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless
Steels and Related Alloys by Use of Ferric Chloride Solution (West Conshohocken, PA, USA)

2. ASTM G28 – 02 (Reapproved 2015) : Standard Test Methods for Detecting Susceptibility to
Intergranular Corrosion in Wrought, Nickel Rich, Chromium Bearing Alloys (West Conshohocken,
PA, USA)

3. ASME Sec II Part C SFA 5.11 : Specification for Welding Rods, Electrodes and Filler Metals

4. SAES-W-014 : Saudi Aramco Engineering Standard for Weld Overlays and Welding of Clad
Materials