Faisal Awad | January 2012

Contents

1 Definition
2 Principal methods of manufacturing clad plate

3 Loose Lining
4 Requirements of ASME VIII Div.1, Part UCL

5 Requirements of ASME VIII Div.2

6 Requirements of some Specifications

7 Required tests for clad/ weld overlaid plates

8 References
 1- Definition

Cladding refers to the application of relatively thin layer of an alloy (as the cladder) onto a
substrate or backing material ( as the backer). The cladder would be selected from resistant
materials to the environment. They referred generically to Corrosion Resistance Alloys or CRAs.

:AWS hand book

Cladding: A surfacing variation that deposits or applies surfacing material usually to improve
.corrosion or heat resistance

:API 5LD (2.1.a)

Clad steel pipe is a bimetallic pipe composed of an internal CRA layer metallurgically
.bonded to the base metal

ASME VIII Div.1 (3-2)

clad vessel: a vessel made from a base material having a corrosion resistant material either
.integrally bonded or weld metal overlaid to the base of less resistant material
2- Principal methods of manufacturing clad plate

2.1 Hot Roll bonding

integrally bonded

2.2 Explosive bonding

2.3 Weld overlaying

2.1 Hot Roll bonding

Hot Roll bonding is the most widely adopted production method where large clad areas are
. needed and accounts for about 85% of all clad plate production
Hot Roll bonding Process
 2.2 Explosive bonding

”The explosive bonding process, also known as "cladding by the explosive welding process

Explosive bonding is considered to be a solid-state welding process that uses controlled

explosive energy to force two or more metals together at high pressures. The energy of an
explosive detonation accelerates the cladder and base metal plates together causing a high
. velocity collision to fuse them together and make metallurgical joining

The force of the explosion sets up an angular collision which

produces an ejected plasma. The plasma jet acts to remove
impurities from both metals’ surfaces in front of the collision point,
leaving behind clean metal for joining. The pressures at the
collision point, which can be from 100,000 – 600,000 psi, are
enough to squeeze the metals into behaving like viscous fluids.
The fluid-like behavior is responsible for creating the wave pattern
.bond line in an explosive weld
Explosive bonding Process

See video
2.3 Weld overlaying

It is a welding process where a weld layer is applied to a base metal in order to improve its
.properties, e. g., corrosion resistance
.Overlay - A layer, either permanent or temporary, that is superimposed on a substrate

:There are several different welding methods that can be used

Submerged arc welding using a solid wire electrode, often Twin Arc double wire
Submerged arc welding using a broad but thin strip electrode
Strip electrode welding with a flux that enables the process to be carried out using the
.electroslag principle

The aim is to achieve a sound weld, but with little melting of the underlying material. In
this respect, the electroslag method is preferable to ordinary submerged arc welding, as it
.penetrates less into the substrate material and so results in less mixing of the weld metal
Several of the ordinary submerged arc welding methods can of course be used, but it
may be necessary to apply two or more layers until a sufficiently pure layer of weld
.metal is produced
Cladding is often performed by mechanised methods, as there are often larger areas to be
.covered
SAW strip cladding ESW strip cladding

The well-known SAW method has been widely ESW strip cladding relates to the resistance
used with strip electrodes since the mid-1960s. welding processes and is based on the ohmic
A strip electrode, normally measuring 60 x 0.5 resistance heating of a molten electrically
mm or 90 x 0.5 mm, is used as the (usually conductive slag. There is no arc between the strip
positive) electrode and an electric arc is electrode and the parent material. The heat
formed between the strip and the workpiece. generated by the molten slag melts the surface of
Flux is used to form a molten slag to protect the base material, and the edge of the strip
the weld pool from the atmosphere and helps .electrode is submerged in the slag and flux
.to form a smooth weld bead surface The penetration achieved with ESW is less than
that with for SAW because the molten slag pool is
used to melt the strip and some of the parent
material

See video
Weld overlaying inside a pipe

See video
Weld overlaying inside a pipe

. 68”) 17 mm
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Hot Roll Bonding versus other methods
3- Loose Lining

The loose lining isn't metallurgically bonded to the backing steel over most of its surface but
is normally fully sealed to form a complete barrier between the backing steel and the
corrosive environment.

ASME VIII Div.1 (3-2)

lined vessel: a vessel having a corrosion resistant lining attached intermittently to the vessel
.wall

:ASME VIII Div.2

Corrosion resistant or abrasion resistant linings are those not integrally attached to the
.vessel wall, i.e., they are intermittently attached or not attached at all

:API 5LD (2.1.a)

Lined pipe is a pipe in which a CRA layer is affixed inside the carbon steel pipe by
.expanding the liner and/or shrinking the pipe or any other applicable processes
 4- Requirements of ASME Sec.VIII Div.1, Part UCL
Requirements for welded pressure vessels constructed of material with corrosion resistant integral
cladding, weld metal overlay cladding, or with applied linings

When the cladding or overlay thickness is not included in the design thickness, no specific
.design provisions of part UCL are applicable
In this case the design calculations are based on the base material thickness, exclusive of
the thickness of the cladding material, may consist of any base material satisfying the code
requirements and any metallic corrosion resistant integral or weld metal overlay cladding
material of weldable quality that in the judgment of the user is suitable for the intended
.service

Clad material used in constructions in which the design calculations consider the thickness
:of cladding

Clad material used in constructions in which the design calculations including the
excess thickness of cladding, design calculations shall be based on the total thickness
of the clad material less the specified nominal minimum thickness of cladding. A
reasonable excess thickness of the actual cladding may be included in the design
1 calculation as an equal thickness of base material. The maximum allowable stress
.value shall be that given for the base material
The cladding must be subjected to the bond shear test and must show a minimum shear strength
.of 140 MPa (20,000 psi)
 Clad material used in constructions in which the design calculations are based on the
total thickness including cladding, if integrally clad material “ Roll or Explosive Bonding”
:shall conform to one of the following specifications
SA-263, stainless chromium steel-clad plate )1(
SA-264, stainless chromium–nickel steel-clad plate )2(
SA-265, nickel and nickel-base alloy-clad steel plate )3(
In addition to the above, the cladding must be subjected to the bond shear test and must show a
.minimum shear strength of 140 MPa (20,000 psi)
2 A shear or bond strength test is not required for weld metal overlay cladding
The thickness of the corrosion resistant weld metal overlay cladding deposited by manual
processes shall be verified by electrical or mechanical means. One examination shall be made
for every head, shell course, or any other pressure retaining component for each welding process
.used
t : design thickness
tb: nominal thickness of base material
tc: nominal thickness of cladding ( in the corroded condition)
t = tb + Sc/Sb * tc
Sc: maximum allowable stress value for the integral cladding at design temperature
Sb: maximum allowable stress value for the base material at design temperature

If Sc > Sb , the value of Sc/Sb shall be taken equal to unity

 Radiographic Examination

Vessels or parts of vessels constructed of base material with corrosion resistant integral or )a(
weld metal overlay cladding and those having applied corrosion resistant
linings shall be radiographed when required by the rules in UW-11, UCS-57, UHT-57, and UCL-36. The
material thickness specified under these rules shall be the total material thickness for clad construction
.and the base material thickness

Base Material Weld Protected by a Strip Covering. When the base material weld in clad or )b(
lined construction is protected by a covering strip or sheet of corrosion resistant material
applied over the weld in the base material to complete the cladding or lining, any radiographic
examination required by the rules of UW-11, UHT-57, and UCS-57 may be made on the
.completed weld in the base material before the covering is attached
Base Material Weld Protected by an Alloy Weld. The radiographic examination required by )c(
the rules in UW-11, UHT-57, and UCS-57 shall be made after the joint, including the corrosion
.resistant layer, is complete
Except that the radiographic examination may be made on the weld in the base material before
.the alloy cover weld is deposited, provided the following requirements are met
The thickness of the base material at the welded joint is not less than required by the design )1(
.calculation
.The corrosion resistant alloy weld deposit is non-air hardening )2(
.The completed alloy weld deposit is spot examined by any method that will detect cracks )3(
The thickness of the base material shall be used in determining the radiography requirement )4(
.in (a) above
 Post Weld Heat Treatment

Vessels or parts of vessels constructed of base material with corrosion resistant integral or )a(
weld metal overlay cladding or applied corrosion resistant lining material shall be post weld
heat treated when the base material is required to be post weld heat treated. In applying
these rules, the determining thickness shall be the thickness of the base material. When the
thickness of the base material requires post weld heat treatment, it shall be performed after
the application of corrosion resistant weld metal overlay cladding or applied corrosion
.resistant lining

Vessels or parts of vessels constructed of chromium stainless steel integral or weld metal )b(
overlay cladding and those lined with chromium stainless steel applied linings shall be post weld
heat treated in all thicknesses, except vessels that are integrally clad or lined with Type 405 or
Type 410S and welded with an austenitic electrode or non-air hardening nickel–chromium–iron
.electrode need not be post weld heat treated unless required by (a) above

CAUTION: Post weld heat treatment may be in the carbide-precipitation range for unstabilized
austenitic chromium–nickel steels, as well as within the range where a sigma phase may form,
and if used indiscriminately could result in material of inferior physical properties and inferior
.corrosion resistance, which ultimately could result in failure of the vessel
The provisions for marking and reports in UG-115 through UG-120 shall apply to vessels
that are constructed of base material with corrosion resistant integral or weld metal overlay
cladding and those having applied corrosion resistant linings, with the following
.supplements to the Data Reports
.Include specification and type of lining material )a(
Include applicable paragraph in UCL-23 under which the shell and heads were )b(
.designed
 5- Requirements of ASME Sec.VIII Div.2

Design Calculations Based on Total Thickness .3.3.6.2

Base material with corrosion resistant integral or weld metal overlay cladding used in
construction in which the design calculations are based on total thickness including cladding
(paragraph 4.1.9) shall consist of base plate listed in one of the material tables in Part 3 and
shall conform to one of the following specifications or utilize weld metal overlay cladding
.meeting the requirements of this Division
;a) SA-263 Specification for Corrosion-Resisting Chromium-Steel Clad Plate, Sheet and Strip
b) SA-264 Specification for Corrosion-Resisting Chromium-Nickel Steel Clad Plate, Sheet and
Strip; or
.c) SA-265 Specification for Nickel and Nickel-Base Alloy Clad Steel Plate
Integrally clad plates in which any part of the cladding is included in the design .3.3.6.4
calculations, as permitted in paragraph 4.1.9, shall show a minimum shear strength of 140
MPa (20,000 Psi) when tested in the manner described in the plate specification. One shear
test shall be made on each such clad plate and the results shall be reported on the certified
test report
Design Calculations Based on Base-Plate Thickness .3.3.6.3
Clad plate used in constructions in which the design calculations are based on the base-plate
thickness, exclusive of the thickness of the cladding material, may consist of any base-plate
material satisfying the requirements of Part 3 and any metallic integral or weld metal overlay
.cladding material of weldable quality
:Example

Material UNS number N06625, Supplier

select SB-444 for solid SS pipe for nozzle
.neck
As per this table, we cannot use SB-444

There is a code case no. 2468-1 allow to

use this material, this code case shall be
.referenced in vessel GA drawing/ BOM
 6- Requirements of some Specifications

”BP ETPs “ Engineering Technical Practices

Corrosion resistant weld overlay or cladding shall not be considered in calculating required
.pressure boundary thickness
.UT for bond integrity of weld overlay or clad plate to ASTM A578 S6 Acceptance level B
.PT for weld overlay with no surface-breaking defects
Chemical analysis for alloy 625 weld overlay shall be determined and specified in the weld
.procedure qualification. Iron content shall not exceed 8% at the process wetted surface
PMI in accordance with Supplier procedure of Alloy 625 and Alloy 825 materials and its weld -
.consumables is required
Chemical analysis of weld overlay deposits shall be taken to a minimum depth of 3 mm (0,125
in) below the final surface. Results shall meet the requirements of the specified wrought
.material
.Linings, made by strips fillet welded to the shell, are not permitted
Clad nozzles may be manufactured from clad plate or by weld overlay. Internal surfaces of the
.nozzle and the flange face shall be clad. Loose linings are not permissible
.Clad plate shall be purchased with shear test requirements
Welding consumables used for ASS weld overlays that are subject to PWHT shall be selected
to minimize sigma phase formation during the heat treatment; they shall be "L" grade, or
.stabilized with additions of Ti or Nb (Cb)
The ferrite content of ASS overlays, with the exception of type 904L (which is fully austenitic),
.shall be in the range 3 - 8% in the as-welded and post-weld heated condition
Clad ring type joints made as shown below are not acceptable because these are vulnerable to
.cracking at the root of the groove, particularly if thermal stresses are large

Cracking usually takes place due to high stress concentration in the RTJ groove
”Cladding re-instatement “ Restoration

0.8mm MAX. 12mm MIN. 0.8mm MAX. 5mm MIN.

(1/32 in) (1/2 in) (1/32 in) (3/16 in)
AFTER GOUGING
CHIPPED OR
GOUGED SURFACE

(a) MACHINING (b) ROOT PASS

CHIPPED OR
GOUGED SURFACE

COMPLETED WELD 12mm MIN. 2 ND PASS 1 ST PASS

IN BASE MATERIAL. (1/2 in) ELECTRODE ELECTRODE
GRIND FLUSH BEFORE
DEPOSITING ALLOY
(c) MAIN FILL & (d) BACK FILL &
BACK GOUGE CLADDING
Attachment of supporting ring to a clad vessel

Lightly and moderately loaded internal Moderately loaded attachments may be made
supports may be welded directly to clad by cutting back the cladding and welding to the
plate where the plate has been clad by base material. Cladding re-instatement shall be
.weld overlay .made over any remaining unlined areas
CLAD PLATE CLAD PLATE

CLAD STRIP CLAD STRIP

CLAD PLATE OR
WELD OVERLAID

SOLID ALLOY CLIP

SOLID STRIP STRIP, SHEET OR

WELD OVERLAY

Heavily loaded internals where thermal stress

.is present shall be integral with the shell
Lightly loaded supports may be considered to be those where the average shear stress across the section does not
exceed 25 MPa (3 625 psi). Moderately loaded are those where it lies between 25 MPa (3 625 psi) and 50 MPa
(7 250 psi), and heavily loaded where it exceeds 50 MPa (7 250 psi). These stress values are approximate and, where
.custom and practice indicates otherwise, designs shall follow satisfactory precedent
ARAMCO

.The base material nominal thickness shall be used for strength calculations
Unless otherwise specified on the data sheet, the minimum thickness of cladding shall be 3.0
.mm
.Non-integral strip linings shall not be used
.Loose sleeve liners are not permitted
Integrally clad plates shall be supplied in accordance with: ASME SA-263, or ASME SA-264,
.or ASME SA-265, as applicable
.Larger than NPS 4 solid alloy nozzles are not permitted
Integrally clad plates shall be ultrasonically tested at the mill in accordance with ASME SA-
578. Any un-bonded areas are to be repaired in accordance with the supplementary
requirement S6, Level I of ASME SA-578. A report on all repairs that have taken place shall
.be supplied by the mill
Attachments supporting light loads, which will result in tensile or shear stress less than 6.9
.MPa (1,000 psi), may be welded directly to the cladding
When heat treatment is required, the procedure shall be such that it will not impair the
.mechanical properties of the base material or the corrosion resistance of the cladding
7- Required tests for clad/ weld overlaid plates

Nondestructive Testing Destructive Testing

Ultrasonic Testing (UT) -1 Tension test -1

Magnetic Particle (MT) -2 Shear test -2
Dye penetrant (PT) -3 Bend Test -3
Positive Material Identification (PMI) -3 Hydrogen Disbonding test -4
Ferrite content test (FN) -4
 Positive Material Identification (PMI)

The MTRs “material test reports “ may not be always trusted.

This is becoming more common in the stainless steel and nickel
alloy fabrication industries. the implementation of Positive
Material Identification (PMI) to validate raw materials before
.manufacturing begins

PMI refers to the identification and analysis of metal alloys

based on their elemental composition. Measurement results are
shown either in form of elemental concentration in percentage
.and/ or by specific alloy name
PMI is a typically field method, occasionally in office/ lab
: environment. Typically used to
Verify that the alloy used is correct and grade name is what
.supposed to
Verify possible impurities (unwanted elements)

Example of a typical analysis

Techniques used on portable PMI analyzers
XRF based on X-Ray Fluorescence OES based on optical Emission Spectroscopy

XRF works by exposing a sample to be In the OES atoms are also excited, excitation
measured to a beam of x-rays. The atoms energy comes from a spark formed between
of the sample absorb energy from the x- sample and electrode. The energy from spark
rays, become temporarily excited and causes the electrons in the sample to emit
they fluoresce, and then emit secondary light, this light is converted into spectral
.x-rays .pattern
By measuring the intensity and By measuring the intensity of the peaks in this
characteristic energy of the emitted x- spectrum, the OES analyzer can produce
rays, an XRF analyzer can provide .qualitative and quantitative analysis
.qualitative and quantitative analysis

XRF units are smaller and much easier to .If C,S,P are needed, OES is the only choice
.operate OES requires always sample preparation by
.XRF requires no sample preparation .grinding
 Ferrite content test

stainless steel clad metals contain ferrite, which is

expressed in terms of Ferrite Number (FN). The
amount of ferrite present in the deposit is a function of
chemical composition of the filler and base metals,
welding process, type of shielding gas, welding
procedure, and heat input during cladding process.
Hence, control of ferrite in stainless steel cladding is
essential to obtain the required mechanical and
.corrosion-resistant properties

If the ferrite content is too low, then the welded material is susceptible to hot-cracking, if the
ferrite content is too high, the toughness, ductility as well as the corrosion resistance of the steel
are reduced. For duplex steel, a ferrite deficit in the area of the weld seam results in stress
corrosion cracking and reduction in strength

Magnetic induction method

A magnetic field generated by a coil begins to interact with the magnetic portions of the
specimen. The changes in the magnetic field induce a voltage proportional to the ferrite
.content in a second coil. This voltage is then evaluated
 Disbonding

Weld overlay disbonding has been observed, in some

cases, during cool down of reactors. Crack propagation
occurs in a narrow zone at the interface and along grain
boundaries in the overlay close to the interface (Fig. 2).
The microstructure in this region is very complex as a
consequence of carbon migration during PWHT and
.incomplete mixing of melted parent and filler materials

Mechanisms

The exact mechanism of disbonding is under discussion, but it is thought to occur,

essentially, as a result of hydrogen embrittlement. During operation, atomic hydrogen
diffuses into the reactor wall and the hydrogen concentration can build up to levels around 4
– 7 ppm in thick wall reactors. Following shutdown, hydrogen tends to accumulate at the
transition zone between the ferritic parent material and the austenitic weld overlay. This
occurs because hydrogen is about one order of magnitude more soluble in the austenitic
weld overlay than in the base metal, but its diffusivity in the overlay is much slower than in
the base material. Therefore, as the hydrogen diffuses from the base metal it tends to
.accumulate at the weld overlay interface
 Hydrogen disbonding test

Autoclave testing method

The most common method is by exposure of the test coupon in
an autoclave at high temperature and high hydrogen pressure.
: Typical exposure conditions are
Temperature: 300 – 500°C, usually 425°C •
Hydrogen partial pressure: 14 – 20 MPa •
Exposure time: 48±1 h •
Cooling rate: 150°C/h •
Holding time at 24±2,5 °C: 7 days •
The test temperature and hydrogen pressures are chosen with
reference to the actual service conditions. Following exposure,
the specimens are cooled to ambient temperature at a
controlled rate, A cooling rate of 150°C/h is commonly used
for qualification testing. The specimens are then held at room
temperature for a designated period to allow for development
of cracking between the stainless overlay and the steel.
Following the hold period, the specimens are evaluated for
disbonding by ultrasonic methods often combined with
metallographic examinations. The size and distribution of the
.disbonded region(s) are then characterized (Figs. 7 and 8)
Various specimen geometries are used but recent configurations utilise a round geometry,
.overlayed on the top and side surfaces

The intention is to better simulate in-service behaviour with respect to hydrogen diffusion
during cool down. The cylindrical test specimen, according to ASTM G 146-01, is 73±2 mm
.in diameter and 45±2 mm thick, or may be reduced to plate thickness

Usually, the specimen is taken from a welding procedure qualification. A stainless overlay is
then applied to the cylindrical surface of the specimen to promote through-thickness
diffusion of hydrogen following exposure. The specimen is heat-treated in the same way as
.the reactor
Tensile requirements
Shall be determined by Tension test

Ultimate Tensile Strength is determined by dividing the highest load experienced by the specimen
.before rupture by the original cross section of the test specimen
Yield Strength is determined by the amount of stress that is required to begin plastic deformation
of the test specimen
 The tensile properties shall be determined by a The tensile properties shall be determined by
tension test of the composite plate for clad a tension test of the base steel only for clad
:plates that meet all of the following conditions :plates that meet one of the following conditions

The nominal composite gage is less than or equal to - .The composite gage is greater than 11⁄2 in (38 mm) -
.11⁄2 in (38 mm) The specified minimum tensile strength of the base -
The specified minimum tensile strength of the base - .steel is greater than 70 000 psi (485 MPa)
.steel is less than or equal to 70 000 psi (485 MPa) The specified minimum yield strength of the base -
The specified minimum yield strength of the base steel - .steel is greater than 40 000 psi (275 MPa)
.is less than or equal to 40 000 psi (275 MPa)

The tensile properties thus determined shall not be - The properties thus determined shall meet all of the
less than the minimum and not more than 5000 psi (35 .tensile test requirements for the base metal
MPa) over the maximum prescribed in the specification
for the base steel used

Tension test specimen for plates with thickness 38 mm and under. The test Tension test specimen for plates with thickness greater than 38 mm. The test
.specimen shall be the full thickness of the material fig.2 (ASME II Part A) .specimen shall be of the form shown in fig.3 (ASME II Part A)
 Test for strength of the bond

:when required, must be specified by the purchaser and shall consist of one of the following
Shear Strength test -
Bond Strength test (bend test) -

Shear test
,Shear Strength — When required by the purchaser
.The minimum shear strength of the alloy cladding and base metals shall be 20 000 psi (140 MPa) --
.The minimum cladding thickness for shear testing shall be 0.075 in. (1.9 mm) --

.The shear test, when specified, shall be made in the manner indicated in Fig. below
 Bend test
The severity of the bend test is primarily a function of the angle of bend and inside diameter to
.which the specimen is bent, and of the cross section of the specimen
Flat strap of metal is cut from the cladded plates. Next, the flat strap of a prescribed size is bent
into a U-shape, stretching the material on the outer surface of the "U," while compressing the
material on the inside surface

Cladding

Base
metal

When the composite thickness of the clad material is 3⁄4 in. (19 mm) or less, and/or when the
cladding metal thickness is nominally 0.075 in. (1.9 mm) or less, the “Bond Strength” test, as
described in SA-263, SA-264, or SA-265, may be used in lieu of the bond “Shear Strength” test
to fulfill the criteria for acceptable minimum shear strength, except that the bend test specimen
shall be 11⁄2 in. (38 mm) wide by not more than 3⁄4 in. (19 mm) in thickness and shall be bent,
at room temperature, through an angle of 180 deg to the bend diameter provided for in the
.material specifications applicable to the backing metal
At least two of the three tests shall show not more than 50% separation on both edges of the
.bent portion. Greater separation shall be cause for rejection
8- References

ASME Sec. VIII Div. 1, 2010 Edition

ASME Sec. VIII Div. 2, 2010 Edition
ASME Sec. II part A, 2010 Edition
Welding handbook AWS, 9th Edition
CASTI Handbook of cladding Technology
Companion Guide to the ASME Boiler & Pressure Vessel Code
Stainless steel sheet lining of steel tanks and pressure vessels (NiDI)
ESAB Technical handbook for Strip cladding
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