Journal of Metals, Materials and Minerals, Vol.21 No.1 pp.

93-99, 2011

Effect of Postweld Heat Treatment on Microstructures and Hardness of TIG

Weldment between P22 and P91 Steels with Inconel 625 Filler Metal
Nattaphon TAMMASOPHON1*, Weerasak HOMHRAJAI2,
Gobboon LOTHONGKUM1*
1
Department of Metallurgical Engineering, Faculty of Engineering,
Chulalongkorn University, Bangkok 10330, Thailand
2
Electricity Generating Authority of Thailand (EGAT), Nonthaburi 11130, Thailand

Abstract

This research aims at searching for the optimal postweld heat treatment condition of the TIG weld
joint between P22 (2.25Cr) and P91 (9Cr) steels using Inconel 625 as filler metal. The postweld heat
treatment at 750C for 2, 4 and 6 hours was applied in order to reach the proper microstructure and hardness
for high performance in mechanical properties at elevated temperatures. It is recommended that postweld
heat treatment at 750C for 2 hours is the proper condition to reduce the hardness of heat affected zone
(HAZ) of P91 steel.

Key words: P22, P91, Post weld heat treatment, Microstructure, Hardness

Introduction Material and Experimental Procedures

In steam power plants of the Electricity The chemical compositions of P22 steel,
Generating Authority of Thailand (EGAT), the P91 steel and Inconel 625 are exhibited in Tables
dissimilar TIG weld joints between P22 (2.25Cr) 1, 2 and 3, respectively. Table 4 shows the TIG
steel and P91 (9Cr) steel using Inconel 625 as welding parameters used in this work. All section
filler metal were used (1). After welding, high P22 steel samples were TIG welded with
hardness values of the heat affected zone (HAZ) sectioned P91 steel samples using Inconel 625 as
of those dissimilar weld joints were possibly filler metal as shown in Figure 1, followed by
obtained (1). This high hardness HAZ comes from PWHT at 750C for 2, 4 and 6 hours.
the austenite transformation to martensite due to Subsequently, they were ground and polished
the high cooling rate. The improper postweld heat using standard metallographic technique, and
treatment (PWHT) can result in a considerable afterwards etched in a Nital 10% etchant. The
difference in hardness between P91 steel and weld microstructures of all samples except Inconel 625
metal leading to prior crack and failure during were viewed using optical microscopy.
high temperature operation (1). There are many
research works studying and evaluating the Table 1. Chemical composition of P22 (2.25Cr)
microstructures and hardness of the dissimilar steel.
weld joints between P22 steel and P91 steel (2-5).
However, very few researchers dealt with the Composition (wt%)
effect of PWHT conditions on the weldment C Mn Si S P Cr Mo
microstructure using Inconel 625 as filler metal. 0.07 0.6 0.3 0.02 0.02 2.25 1.0
Inconel 625 is a popular nickel base superalloy,
and used for high temperature service (6-9). It is Table 2. Chemical composition of P91 (9Cr)
utilized as a filler metal in welding because of its steel.
high strength and toughness. The aim of this
research work is to determine the suitable PWHT Composition (wt%)
conditions, which provide the proper C Mn Si S P Cr Ni Mo Nb V N
microstructure and hardness to avoid earlier 0.1 0.5 0.3 0.01 0.02 9.0 0.1 1.0 0.08 0.2 0.05
component failure for long-term high temperature
service.

*Corresponding author E-mail: [email protected] , [email protected]

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TAMMASOPHON, N. et al.

Table 3. Chemical composition of Inconel 625.

Composition (wt%)
Ni Cr Fe Co Mo W Nb Ti Al C Mn Si B Other
58.0 20.0-30.0 5.0 1.0 8.0-10.1 - 3.15-4.15 0.40 0.40 0.1 0.50 0.50 - -

Table 4. TIG welding parameters.

Voltage 130-160 V
Current 11-13 A
Preheat Temperature 300C
Interpass Temperature 330-350C
Postweld Heat Treatment Temperature 750C
Travel Speed 3-5 cm/min
Welding pass 10

P91 P22 P91 P22

(a) Before welding ( b) After welding

Figure 1. Weld joint between P91 and P22 steels (a) Before welding (b) After welding.

Results and Discussion The microstructures of P22 steel of TIG

weldment are shown in Figures 2(d)-2(f). It is
found that the base metal (Figure 2(d)) consists of
Microstructure after TIG Welding ferrite phase and ferrite with carbide precipitation
(4, 5)
. This zone is far away from weld metal. No
The microstructures of P91 steel after effect of welding heat was observed at all. Figures
TIG welding are shown in Figures 2(a)-2(c). It is 2(e) and 2(f) show HAZ microstructure and P22
found that the base metal (Figure 2(a)) is temper microstructure connected to weld metal.
martensite phase (2, 3). This zone is far away from However, it was discovered that the bainite grain
weld metal and no effect of welding heat was structure of the latter is more coarsening than that
found in any way. Figure 2(b) shows HAZ of HAZ, due to the difference in welding heat and
microstructure, the matrix of which consists of cooling rate.
martensite and retained austenite phases (3), which
occurred due to phase transformation from P91 Microstructure after Postweld Heat
martensite to austenite at higher temperature near Treatment
welding zone. Figure 2(c) shows interface zone
near Inconel 625 weld metal, which consists of Figures 3(a)-3(c) show microstructures of
bigger grain size structure than that of HAZ due P91 base metal after obtaining post weld heat
to higher temperature conductivity of Inconel 625 treatment at a temperature of 750C for 2, 4 and 6
(6-9)
. This high temperature zone also assisted in hours, respectively. No significant difference in
carbide decomposition resulting in no carbide microstructural characteristics was detected in
inhibiting grain growth (3). these specimens. However, it should be noted that
all received microstructures were temper
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Effect of Postweld Heat Treatment on Microstructures and Hardness of Dissimilar TIG Weldment between P22 and
P91 Steels with Inconel 625 Filler Metal
martensite, which consists of carbide precipitation respectively. All these microstructures consist of
along grain boundaries (2, 3). These similar ferrite and ferrite with carbides (4, 5). No
characteristics were also found in HAZ after significant effect of different PWHT durations on
PWHT; see Figures 4(a)-4(c). However, temper the microstructure was found. Figures 7(a)-7(c)
martensite grain structures of postweld heat show HAZ microstructure after PWHT at 750C
treated HAZ are finer than those of postweld heat for 2, 4 and 6 hours, respectively. These postweld
treated base metal microstructures. Figures 5(a)- heat treated HAZ microstructures are much fine
5(c) show postweld heat treated microstructures than those of postweld heat treated base metals.
of interface zone adjacent to weld metal after Ferrite grains were found in these postweld heat
heating at a temperature of 750C for 2, 4 and 6 treated HAZ. Carbide precipitation was found
hours, respectively. It is found that along grain boundaries.
microstructures in these interface areas consist of
more coarsening grain size compared to those of Figures 8(a)-8(b) show microstructures of
base metal and HAZ microstructures, due to P22 interface connecting to weld metal after
sufficient welding heat providing phase PWHT was done at 750C for 2, 4 and 6 hours,
transformation from martensite to bigger austenite respectively. These obtained microstructures are
grain structure. When these coarse austenite grain different from those of P22 HAZ and base metal
structures were cooled down, they would finally zones. In general, the microstructures consist of
retransform to coarse martensite grain structures. more coarsening grain structures occurring due to
No significant differences in microstructure a sufficient level of welding heat to transform the
characteristics were observed. They are all temper structure to coarsen austenite grain structure, and
martensite with carbide precipitation along grain cooled down later to be coarsening bainite grain
boundaries. structure instead (4-5). However, after applying
PWHT, all microstructures would transform again
P22 Microstructure after Postweld Heat to ferrite structure with carbide precipitation.
Treatment HAZ microstructure after 6-hours PWHT consists
of most coarsening ferrite grain structure.
Figures 6(a)-6(c) show microstructures of
P22 base metals after obtaining PWHT at a
temperature of 750C for 2, 4 and 6 hours,

40 m 40 m 40 m

(a) Base Metal of P91 (b) HAZ of P91 (c) Interface of P91

40 m 40 m 40 m

(d) Base Metal of P22 (e) HAZ of P22 (f) Interface of P22
Figure 2. Microstructures of TIG weldment between P91 and P22 steels with Inconel 625 filler metal.
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TAMMASOPHON, N. et al.

40 m 40 m 40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 3. Microstructures of P91 steel base metal after PWHT at 750C.

40 m 40 m 40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 4. Microstructures of P91 steel HAZ after PWHT at 750C.

40 m 40 m
40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 5. Microstructures of P91 steel in the region of Interface P91 contact with Inconel 625 weld metal
after PWHT at 750C.

40 m 40 m 40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 6. Microstructures of P22 steel base metal after PWHT at 750C.
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Effect of Postweld Heat Treatment on Microstructures and Hardness of Dissimilar TIG Weldment between P22 and
P91 Steels with Inconel 625 Filler Metal

40 m 40 m 40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 7. Microstructures of P22 steel HAZ after PWHT at 750C.

40 m 40 m 40 m

(a) 2 hours (b) 4 hours (c) 6 hours

Figure 8. Microstructures of P22 steel in the region of Interface between P22 steel and Inconel 625 weld
metal after PWHT at 750C.

550
500 P22
450 P91
400
350
HV 0.1

300
250
200
150
100 Inconel 625
50
0
-20 -10 0 10 20
Distance(mm)

Figure 9. Hardness profile of dissimilar TIG weld joint between P91 and P22 steel with Inconel 625
filler metal.
550
500 P91 P22
450
400
350
300
HV0.1

250
200
150
100 Inconel 625
50
0
-20 -15 -10 -5 0 5 10 15 20
Distance(mm)
PWHT/750/2 PWHT/750/4 PWHT/750/6

Figure 10. Hardness profiles of dissimilar TIG weld joint between P91 and P22 steels with Inconel 625 filler
metal after PWHT for 2, 4 and 6 hours.
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TAMMASOPHON, N. et al.

Hardness 2. The most suitable postweld heat

treatment condition for these TIG weld joints is at
Figure 9 shows hardness profile of 750C for 2 hours. This condition provides the
welded specimen. The hardness values of HAZ of minimum hardness of the weld zone between P91
P91 steel are over 350 HV, which is a generally steel and weld metal as well as minimum
limited hardness of carbon steel HAZ (10). This is hardness difference between P1 and weld metal.
due to the martensite microstructure as shown in
Figure 1(b). However, the hardness value of the Acknowledgements
P22 HAZ was not higher than 350 HV. P91 HAZ
has a higher hardness value than P22 HAZ The authors would like to express their
because of its higher hardenability. The thanks to the Master Research Grant Project of
interaction between the too high hardness Thailand Research Fund for the financial support
microstructure with hydrogen can result in the under the contract no. MRG-WI515E140. Thanks
crack initiation. This mechanism is well known as also go to the Electricity Generating Authority
hydrogen induced cracking (HIC) (10). Therefore, of Thailand for the sample preparation.
the postweld heat treatment is needed to reduce
this high hardness HAZ. References

Figure 10 shows hardness profiles of the 1.Electricity Generation Authority of

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Effect of Postweld Heat Treatment on Microstructures and Hardness of Dissimilar TIG Weldment between P22 and
P91 Steels with Inconel 625 Filler Metal
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