Professional Documents
Culture Documents
Effect of Welding Parameters On Tungsten Carbide - Metal Matrix Composites Produced by GMAW
Effect of Welding Parameters On Tungsten Carbide - Metal Matrix Composites Produced by GMAW
28, 2010
Abstract
Wear of materials in the oil sands industry includes severe low stress sliding abrasion
and various types of slurry erosion. Tungsten carbide metal matrix composite materials
are one of the various wear-resistant materials used in mining applications to combat
these problems. The application of these coatings is used to extend the service life of
production-critical components, reduce maintenance costs and avoid production
outages. Tungsten carbide composite overlays are most commonly applied to the
component surface by plasma transferred arc welding (PTAW) with the use of powder
consumables. Although PTAW is the most common and efficient method for shop-
production, this process cannot be used in all situations. Due to the required substrate
geometry and immobility of the equipment or component, it is impractical to use PTAW
for field welding applications.
The present work examines the performance of tungsten carbide wire consumables
during gasManuscript
metal for
arcthewelding (GMAW).
Canadian Welding Although
Association the Sept.
Conference, GMAW process provides the
28, 2010
flexibility and mobility required for field repair welding applications, the wire consumables
are currently Manuscript
not widelyfor the Canadian Welding Association Conference, Sept. 28, 2010
used in industry due to inferior wear performance compared to
PTAW overlays. The influence of welding parameters on the resulting microstructure and
wear performance are evaluated. Specifically, the properties will be investigated,
including macro and microstructures of the carbides, percent dilution, percent carbide
area, mean free path and scanning electron microscopy with Auger Electron
Spectroscopy. Strategies for optimizing welding parameters to improve the wear
properties of wire-based overlays will be discussed.
i
MSc Graduate Student, University of Alberta and Research Engineer, Alberta Innovates -
Technology Futures (formerly Alberta Research Council).
ii
Research Engineer, Alberta Innovates - Technology Futures (formerly Alberta Research
Council)
iii
Team Leader, Welding Engineering, Alberta Innovates - Technology Futures (formerly Alberta
Research Council)
iv
Assistant Professor, Chemical and Materials Engineering, University of Alberta
Effect of Welding Parameters on Tungsten Carbide -
Metal Matrix Composites Produced by GMAW
By: Leonard Choi, Tonya Wolfe, Matthew Yarmuch, Adrian
Gerlich
Background
Wear in the Oil Sands Industry
The oil sands deposits in Northern Alberta are the second largest in the world,
behind only Saudi Arabia, and contain over 175 billion barrels of oil (DOE, 2010).
Current production from the oil sands is 55% of western Canada’s total crude oil
production, and is expected to grow from approximately 1.3 million barrels per day (bpd)
in 2009 to 2.2 million bpd in 2015 and 3-3.5 million bpd by 2020-2025 (DOE, 2010,
CAAP, 2010). Oil sands are processed either by in-situ operations (e.g., thermal or other
assisted recovery methods) or open pit mining operations (e.g. bucket and truck
methods). A general overview of the open pit mining process and hydrotransport
systems are illustrated in Figure 1. Oil sands mining operations present very unique
challenges; for example, the equipment and machinery must be tolerant enough to
withstand the extreme conditions present when handling two tonnes of oil sands ore for
every barrel of refined oil produced (Harper et al., 2002). The sands in oil sands are
mainly composed of quartz sand, silt, clay, water and bitumen (Flores et al, 2009).
Quartz particles comprise 80% to 95% of the total solids in oil sands in varying sizes and
forms. These hard particles are the main causes of wear attack on oil sands equipment,
primarily by the low stress abrasion, high stress abrasion, gouging abrasion, and impact
wear mechanisms, such as in Steps 2 through 5 in Figure 1. The introduction of water,
during hydrotransport operations, has lead to significant maintenance and reliability
issues due to the synergic erosion-corrosion damage mechanism (Step 6 in Figure 1).
For example, this is seen by the increased wear rates of separating screens, inclined
settling plates, slurry pumps, and tailing pipelines. (Flores et al, 2009; Llewellyn, 1997).
Wear attack of equipment is responsible for higher production costs resulting in
hundreds of millions of dollars being spent yearly on maintenance activities, not to
mention the loss of production (Llewellyn,1995). For example, the annual budget for
repair and maintenance of equipment at a major oil sands producer was in excess of
$450 million in 2003 (Anderson et al, 2004). A major portion of this budget is due to wear
damage to machinery and equipment. The lost time in production due to maintenance
and unplanned shut-downs also amounts to hundreds of millions of dollars. Production
goals and investment returns would be difficult to achieve without protective overlays
and coatings for key production equipment.
1 2 3 4 5 6
Hydrotransport
Piping to Extraction
Plant
Figure 1 - General Overview of the Oil Sands Open Pit Mining Process
For this study, all overlays were double pass overlays were produced. Many
demanding oil sands applications require multi-pass overlays as the thicker protective
layer extends component life. However, the heat input must be minimized to prevent
significant (detrimental) changes to the base metal HAZ and overlay macro and
microstructure.
A2
% Dilution
A1 A2
Figure 2 - Cross-Section of Overlay Bead Schematic
Figure 3 – Image of an MMC microstructure (left), and an Example of Utilizing the Image
Analysis to Determine %Carbide area (right)
Figure 4 – Image of an MMC Microstructure (left), and an Example of Image Analysis
Software Measurement Grid to Determine the Mean Free Path (right)
Considering the %dil. and %carbide values of Table 5, the data suggest that
welding an overlay with short-circuiting mode (Sample A and D) will yield the lowest
dilution and the highest fraction of primary carbides in the metal matrix. According to the
manufacturer, the original ratio between carbides and metal matrix in the wire
consumable was ~50 vol%, and the as-deposited MMC %carbide approached this level.
However, a dilution level of <1% is likely too low for some oil sands applications,
especially those involving impact loading or mechanical bending, and such an overlay
would likely be prone to spallation failure. Hence, although the short-circuiting mode
promoted low carbide losses, the low level of base metal fusion would potentially be
problematic during actual service. Further testing would be necessary to quantify the
actual wear performance of these samples, and investigate if mechanical loading could
cause an alternative failure mechanism. Conversely, on the other extreme, Sample F
achieved excessively high %dil. and low %carbide, which indicates that the heat input
was far too high to retain the desired metallurgical properties. This supports the
hypothesis that when welding MMC overlays, selection of parameters within the
appropriate “operating window” (i.e., not too far above or below the optimized values) will
cause a detrimental effect on the microstructure and resulting wear properties.
In the case of the mean free path (O) values shown in Table 5, Samples C and D
achieved the lowest and most consistent primary carbide space (i.e., considering
average and standard deviation, respectively). However, the microstructures were
substantially different, as Sample C (Figure 6c) typically exhibited small, closely-packed
carbides, while sample D (Figure 8a) was comprised of mainly large carbides. This
implies that the O measurements do not take into account variations in the primary
carbide size due to dissolution, but the %carbide values does indentify this variation.
Hence, O alone does not provide a complete indication of the quality of the MMC overlay.
In future studies, it may be beneficial to measure the average as-deposited carbide size
(width). Additional future work could include wear testing of Samples C and D, to
determine the performance difference between smaller and large carbides, respectively.
The heat input levels of the “high” productivity overlays, particularly Sample F
achieved high O values, with sparsely and unevenly space carbides, as confirmed in the
microstructure shown in Figure 8c. This is likely due to the very high temperatures and
long solidification time-at-temperature associated with the higher arc energy when using
spray transfer. This is consistent with previous work examining GMAW using
NiCrBSi/Wc-W2C wire consumables, where severe dissolution of the WC/W2C particles
was noted with increasing arc current (Badisch et al, 2008). Based on the development
of an un-optimized combination of dilution, carbide area and spacing, as a function the
elevated heat input, the MMC would be expected to have reduced wear resistance. This
is because the abrading particles can preferentially remove the matrix material before
fracturing and/or removing the remaining exposed tungsten carbide due to insufficient
matrix binding-material to ensure proper resistance to wear, impact, chipping, and micro-
fracturing. Additional wear testing and analysis would be necessary to verify this
concept.
(a) (b)
Figure 9 – SEM micrographs of Sample A and B respectively
Ni dendrites
3
4
Primary Carbide
2 Ni+Ni3B eutectic -
lamellae structure of Ni
1 (light phase) and Ni3B
(dark phase)
Fine precipitates or
secondary carbide
phases containing W
Figure 10 – SEM micrograph of a tungsten carbide particle and surrounding metal matrix
from Sample B
“Halo Region” around a
primary carbide where
the WC phase remains
intact and the W2C phase
has undergone
preferential dissolution.
(note: spot 4 & 5 are WC
and spot 3 is W2C)
Anderson, M., Chiovelli, S., Hoskins, S. (October 2004) Improving Reliability and
Productivity at Syncrude Canada Ltd. Through Materials Research: Past, Present, and
Future, CIM Bulletin, Volume 97, pages 1-6.
ASM Handbook, Volume 3, Alloy Phase Diagrams (2002) B-Ni (Boron-Nickel), ASM
International.
ASME Boiler and Pressure Vessel Code (2010) Section IX: Welding and Brazing
Qualifications, American Society of Mechanical Engineers, July 2010
DOE/EIA – 0484 (2010) International Energy Outlook 2010, July 2010, U.S. Energy
Information Administration, Office of Integrated Analysis and Forecasting, U.S.
Department of Energy, Washington, DC 20585
Flores, J. F., Neville, A. (2009) Materials Selection in the Oilsands Industry Based on
Materials Degradation Mechanisms, Exploration & Production: Oil and Gas Review,
Volume 7, Issue 1, pages 42-45.
Harper, D., Gill, M., Hart, K.W.D., Anderson, M. (2002), Plasma Transferred Arc
Overlays Reduce Operating Costs in Oil Sands Processing, in International Thermal
Spray 2002, Essen Germany
Liyanage, T., Fisher, G., and Gerlich, A.P., (2010) The Influence of Alloy Chemistry on
Microstructure and Properties in NiCrBSi Overlay Coatings Deposited by Plasma
Transferred Arc Welding (PTAW), in press, Surface Coatings and Technology
Llewellyn, R. (July 1997) Resisting Wear Attack in Oil Sands Mining and Processing,
CIM Bulletin, Volume 90, Issue 1012, pages 75-82.
Llewellyn, R., Tuite, C., (1995), Hardfacing Fights Wear in Oil Sands Operation,
Welding Journal, 74, 3, pp.55-60
Melfi, T., (2010), Implementing New Changes to ASME Section IX Heat Input
Calculations, IIW Paper XI-933-10, IIW Annual Assembly, July 2010, Istanbul, Turkey
Nagender Naidu, S. V., Sriramamurthy, A.M., Rama Rao, P. (1991). Phase diagrams of
binary tungsten alloys: C-W (Carbon-Tungsten), Monograph series on alloy phase
diagrams, 7. Calcutta: Indian Institute of Metals, pages 37-50.
Yarmuch, M., Patchett, B.M., Ivey, D.G., Anderson, M., (2008), Effect of Welding
Parameters and Gas Composition on PTAW Behaviour, Trends in Welding Research, 8th
International Conference, June 1-8, 2008, AWS, ASM.