Specification
WELDING MATERIAL FOR Ni BASE HEAT RESISTANT ALLOYS, AND
WELD METAL AND WELDED JOINT OBTAINED BY USING THE SAME
MATERIAL
TECHNICAL FIELD
[0001]
The present invention relates to a welding material for Ni base heat
resistant alloys, and a weld metal and a welded joint obtained by using the
said welding material. More particularly, the present invention relates to a
welding material suitable for welding Ni base heat resistant alloys employed
for equipment used at high temperatures, such as power generation boilers,
and a weld metal and a welded joint obtained by using the said welding
material.
[0002]
BACKGROUND ART
In recent years, from the viewpoint of environmental loading reduction,
the power generation boilers and the like have increasingly been operated at
higher temperature and pressure on a worldwide scale, and accordingly the
material used for such equipment has been required to have a greater high
temperature strength.
[0003]
As a material that meets such a requirement, for example, the Ni base
heat resistant alloy specified in UNS06617 has been available. In addition,
the Patent Literatures 1 to 5 disclose various Ni base alloys. All of these alloys
have a wide variety of alloying elements specified to meet the essential
properties as a base metal.
[0004]
When these Ni base heat resistant alloys are used for a structure, the
assembly is generally carried out by welding.
[0005]
When the assembly is carried out by welding, if the said each Ni base
alloy for a base metal is used as a welding material as it is, the susceptibility to
hot cracking at the welding time in the weld metal sometimes becomes high.
The "hot cracking at the welding time" include the "solidification cracking" and
the "ductility'dip cracking".
[0006]
On the other hand, as a welding material for Ni base heat resistant
alloys used when the assembly is carried out by welding, AWS A5.14-2005 ER
NiCrCoMo'l has been known.
[0007]
Further, the Patent Literatures 6 to 8 propose various welding materials
for Ni base alloys.
[0008]
The Patent Literature 6 proposes a welding material for oxide dispersion'
strengthened alloys that is used for welding an oxide dispersion'strengthened
alloy having a high strength to a heat resistant alloy, and aimed at improving
the strength by positively containing solid solution strengthening elements
such as Mo and Nb. The Patent Literatures 7 and 8 propose welding materials
for Ni base alloys that are aimed at increasing the strength by making the most
of the solid solution strengthening effect due to Mo and Wand the precipitation
strengthening effect due to AI and Ti.
[0009]
A structure assembled by welding using the said Ni base heat resistant
alloys and welding materials for Ni base heat resistant alloys is used at high
temperatures, and therefore has a problem of occurrence of cracking in weld
zones when the structure is used at high temperatures for a long period.
[0010]
For example, in the Non-Patent Literature 1, in a weld heat affected
zone (hereinafter, referred to as a "HAZ") of a Ni base heat resistant alloy, a
fact that the intergranular cracking occurs during post weld heat treatment is
pointed out, and in addition to the precipitation of y' phase, the influence of
grain boundary segregation of S is suggested.
[0011]
Furthermore, in the Non-Patent Literature 2, a study has been carried
out on the preventive measures against intergranular cracking in the HAZ of
the weld zone of an 18Cr-8Ni-Nb type austenitic heat resistant steel at the
time of a long period of heating. The measures are proposed from the
viewpoint of welding process such that the decrease in welding residual
stresses caused by a proper application of post weld heat treatment is effective
in preventing intergranular cracking in the HAZ.
[0012]
Thus, from long ago, there has been known a phenomenon that cracking
occurs in the HAZ when a Ni base heat resistant alloy is used for a long period.
In recent years, however, as many kinds of alloying elements are contained in
order to increase the strength of material, there has been a tendency for
cracking occurrence at the time of a long period of heating to become
remarkable even in weld metal.
[0013]
However, the mechanism of cracking occurred in the weld zone during a
long period of use has not yet been elucidated, and further, the measures
against the said cracking, especially, the measures against cracking from the
viewpoint of the material of weld metal have not been established.
[0014]
Therefore, the weld metal obtained by using the welding material for Ni
base heat resistant alloys (AWS A5.14-2005 ER NiCrCoMo"1) has an unsolved
..
for Ni base heat resistant alloys having excellent resistance to hot cracking at
the welding time and to provide a weld metal obtained by using the said
welding material, which has resistance to hot cracking during welding,
resistance to stress relaxation cracking during a long period of use at high
temperatures, and an excellent creep strength. Furthermore, another
objective of the present invention is to provide a welded joint consisting of the
weld metal obtained by using the said welding material and a base metal of a
Ni base heat resistant alloy excellent in high temperature strength.
MEANAS FOR SOLVING THE PROBLEMS
[0018]
In order to achieve the above objectives, the present inventors first
carried out detailed investigation of stress relaxation cracking which occur in a
weld metal during a long period of use at high temperatures. As a result, the
following items (a) to (c) were clarified.
[0019]
(a) The stress relaxation cracking occurs at the boundaries of columnar
crystals of the weld metal.
[0020]
(b) The cracking fracture surface IS poor In ductility, and P and S
concentrate on the fracture surface.
[0021]
(c) In the microstructure in the vicinity of a cracking portion, fine
intermetallic compounds precipitate in large amounts within the grains.
[0022]
From the above"clarified items (a) to (c), the present inventors reached
the following conclusions (d) to (D.
[0023]
(d) The stress relaxation cracking is the cracking that is opened by the
application of welding residual stresses and external stresses at the grain
boundary that is weakened by the segregation of P and S during solidification
at the welding time and during the subsequent heating at high temperatures.
[0024]
(e) In the case where large amounts of intermetallic compounds
precipitate finely within the grains, since the deformability within the grains
decreases, stress concentration on the grain boundary surface occurs.
Therefore, cracking is liable to occur on account of the superimposing action of
the stress concentration and weakened grain boundary.
[0025]
(f) The above-described mechanism is suggested concermng similar
cracking in HAZ in the Non-Patent Literature 1. The Non-Patent Literature
1 states that, to reduce S that weakens the grain boundary or to fix S, the
containing of Ca and Mg is effective in preventing the cracking. However, the
weld metal is generally used in a state of an as-solidified microstructure, and
it is presumed that the phenomenon is different from that ofHAZ that is based
on the base metal being thermally refined by a heat treatment or the like.
Therefore, the possibility that the measures against cracking in HAZ proposed
in the Non-Patent Literature 1 can be also taken against stress relaxation
cracking is little. Specifically, Ca and Mg that are proposed in the NonPatent
Literature 1 have very strong affinity for oxygen, and are liable to form
oxides during welding. Therefore, the amounts of Ca and Mg acting
effectively on the fixation of S in the weld metal are affected by the welding
conditions. For this reason, it is difficult to stably achieve the effect of fixing
S by using Ca and Mg. Furthermore, an extreme reduction in impurity
elements, especially a reduction in P, leads to a marked increase in production
cost, so that it is difficult to apply this mechanism to mass·produced industrial
products.
[0026]
Accordingly, the present inventors carried out further detailed studies to
prevent stress relaxation cracking. As a result, it was revealed that the
susceptibility to stress relaxation cracking can be decreased by the following
measures of items (g) and (h).
[0027]
(g) The contents of Sand P in the weld metal, which segregate at grain
boundaries and weaken the grain boundaries, are regulated so as to be within
specific ranges.
[0028]
(h) The content of element that precipitates as intermetallic compound
and causes an increase in resistance to deformation within the grains,
specifically AI, is regulated so as to be within a specific range.
[0029]
However, although the measures of the items (g) and (h) were taken,
stress relaxation cracking could not be prevented completely. In addition, it
was revealed that since the precipitation strengthening effect cannot be
achieved sufficiently, the desired high creep strength cannot be attained.
[0030]
Accordingly, the present inventors advances studies, and resultantly
found that by containing high·concentration Mo, both of prevention of stress
relaxation cracking and the securement of desired high creep strength can be
attained. The reasons for this are thought to be as described in the following
items (i) and G).
[0031]
.;r8
(i) At high temperatures, Mo combines with P which segregates at grain
boundaries; and thus it reduces grain boundary embrittlement caused by P.
[0032]
G) Mo contributes to the improvement in creep strength as a solidsolution
strengthening element. The decrease in deformability within the
grains in this case is less than that in the case where fine intermetallic
compounds precipitate.
[0033]
However, it was clarified that in the case where high-concentration Mo
is contained, although the stress relaxation cracking that occurs in the weld
metal during a long period of use at high temperatures can be prevented, the
susceptibility to solidification cracking during welding increases inversely.
[0034]
Accordingly, the present inventors further carried out studies to prevent
solidification cracking during welding. As a result, a finding of the following
item (k) was obtained.
[0035]
(k) By controlling the contents of Cr and C so as to be within specific
ranges, specifically by making, by mass percent, the C content 0.06 to 0.18% in
the case where 20 to 25% of Cr is contained, solidification cracking during
welding can be prevented.
[0036]
From the microstructure observation result of weld metal, the reason for
this is thought to be the following item (l).
[0037]
(l) In the case where the contents of C and Cr are controlled so as to be
within specific ranges, C mainly combines with Cr in the solidification process
of weld metal, and eutectic solidification of (Cr,Mh3Cs and austenite occurs.
..~q
As a result, the disappearance of liquid phase at the solidification time
quickens, so that the solidification cracking during welding can be prevented.
[0038]
In addition, it could be confirmed that the control for making the
contents of C and Cr within proper ranges is also effective in preventing
ductility-dip cracking during welding.
[0039]
From the above-described findings, the present inventors obtained a
finding that by using a welding material for Ni base heat resistant alloys in
which, by mass percent, C: 0.06 to 0.18%, Mo: exceeding 10.0% and not more
than 14%, and AI: 0.1 to 1.0% are contained with an alloy containing Cr: 20 to
25% and Ni: 46 to 56% being a base, the resistance to hot cracking during
welding, the resistance to stress relaxation cracking during a long period of use
at high temperatures, and the desired high creep strength can be ensured.
[0040]
By using this welding material for Ni base heat resistant alloys, there can
be obtained a weld metal having resistance to hot cracking during welding,
resistance to stress relaxation cracking during a long period of use at high
temperatures, and an excellent creep strength and a welded joint consisting of a
base metal of a Ni base heat resistant alloy excellent in high temperature
strength.
[0041]
When a welded joint is obtained by using this welding material, the use of
a Ni base heat resistant alloy excellent in high temperature strength, which
contains, by mass percent, Ni: 46 to 56%, Cr: 20 to 25% and Mo: 7.0 to 10.0%, as
a base metal is preferable because, for the base metal as well, an excellent creep
strength can be ensured. The Ni base heat resistant alloy excellent in high
temperature strength, which is used as the base metal, may be a Ni base heat
-y
\0
resistant alloy having the same or different chemical composition as or from
that of the welding material in accordance with the present invention.
[0042]
As the base metal, there is preferably used a Ni base heat resistant alloy
excellent in high temperature strength, comprising, by mass percent, C: 0.04 to
0.12%, Si: 1.0% or less, Mn: 1.5% or less, p: 0.03% or less, S: 0.01% or less, Ni:
46 to 56%, Co: 10 to 15%, Cr: 20 to 25%, Mo: 7.0 to 10.0%, W: 0.5% or less, Ti:
0.1 to 0.5%, N: 0.01% or less, B: 0.005% or less, AI: 0.8 to 1.8%, and Nd: 0.005 to
0.1%, with the balance being Fe and impurities.
[0043]
The term "impurities" so referred to in the phrase "the balance being Fe
and impurities" indicates those impurities which are mixed on account of
various factors in the production process including raw materials such as ore
or scrap when the welding material or the Ni base heat resistant alloy is
produced on an industrial scale.
[0044]
The present invention has been accomplished on the basis of the abovedescribed
findings. The main points of the present invention are the welding
materials of the following items (1) and (2), the weld metal of the following
item (3), and the welded joints of the following items (4) to (6).
[0045]
(1) A welding material for Ni base heat resistant alloys, having a
chemical composition comprising, by mass percent, C: 0.06 to 0.18%, Si: 0.5%
or less, Mn: 1.5% or less, Ni: 46 to 56%, Co: 10 to 15%, Cr: 20 to 25%, Mo:
exceeding 10.0% and not more than 14.0%, Ti: 0.01 to 0.5%, AI: 0.1 to 1.0%,
and N: 0.006% or less, with the balance being Fe and impurities, in which the
contents of 0, P and S as the impurities are, 0: 0.02% or less, p: 0.008% or less,
and S: 0.005% or less.
[0046]
(2) The welding material for Ni base heat resistant alloys according to the
above (1), which has a chemical composition containing, by mass %, Nd: 0.1% or
less in lieu of a part of Fe.
[0047]
(3) A weld metal obtained by using the welding material for Ni base heat
resistant alloys according to the above (1) or (2).
[0048]
(4) A welded joint consisting of the weld metal according to the above (3)
and a base metal of a Ni base heat resistant alloy excellent in high temperature
strength.
[0049]
(5) The welded joint according to the above (4), wherein the said base
metal of a Ni base heat resistant alloy excellent in high temperature strength
contains, by mass percent, Mo: 7.0 to 10.0%, Ni: 46 to 56%, and Cr: 20 to 25%.
[0050]
(6) The welded joint according to the above (4), wherein the said base
metal of a Ni base heat resistant alloy excellent in high temperature strength
comprises, by mass percent, C: 0.04 to 0.12%, Si: 1.0% or less, Mn: 1.5% or less,
p: 0.03% or less, S: 0.01% or less, Ni: 46 to 56%, Co: 10 to 15%, Cr: 20 to 25%,
Mo: 7.0 to 10.0%, Ti: 0.1 to 0.5%, N: 0.01% or less, B: 0.005% or less, AI: 0.8 to
1.8%, and Nd: 0.005 to 0.1%, with the balance being Fe and impurities.
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0051]
According to the present invention, a welding material for Ni base heat
resistant alloys having excellent resistance to hot cracking at the welding time
can be provided, and also a weld metal having resistance to hot cracking
during welding, resistance to stress relaxation cracking during a long period of
'.Jr'
lLuse
at high temperatures, and an excellent creep strength can be provided by
using the said welding material. Further, a welded joint consisting of the
weld metal having resistance to hot cracking during welding, resistance to
stress relaxation cracking during a long period of use at high temperatures,
and an excellent creep strength and a base metal of a Ni base heat resistant
alloy excellent in high temperature strength can be provided by using the said
welding material.
MODE FOR CARRYING OUT THE INVENTION
[0052]
The reason why the chemical composition of the welding material for Ni
base heat resistant alloys is restricted in the present invention is as described
below. In the following description, the symbol "%" for the content of each
element means "% by mass".
[0053]
C: 0.06 to 0.18%
Carbon (C) is an austenite-forming element, and is also an element
effective in enhancing the stability of austenitic structure at the time of use at
high temperatures. Moreover, in the present invention, C is an important
element for preventing hot cracking at the welding time. That is to say, C
combines mainly with Cr in the solidification process to produce eutectic
carbides, to quicken the disappearance of liquid phase, and to make the
microstructure of final solidification portion a lamellar structure of (Cr, MhaC6
and austenite. As a result, the remaining mode of liquid phase changes from
a plane shape to dot shape, and also the stress concentration on a specific
surface is restrained, so that solidification cracking can be prevented.
Furthermore, since C increases the final solidification boundary area, which
serves as a segregation site of impurities, C also contributes to the prevention
of ductility·dip cracking during welding and the decrease in susceptibility to
stress relaxation cracking during the use at high temperatures. In order to
sufficiently achieve the above-described effects within the Cr content range of
the present invention, to be described later, it is necessary that 0.06% or more
of C be contained. However, in the case where C is contained excessively,
excessive q, which does not turn to carbides during solidification, precipitates
finely as carbides during the use at high temperatures, so that the
susceptibility to stress relaxation cracking is rather increased. Therefore, the
content of C is set to 0.06 to 0.18%. The preferable lower limit of the C
content is 0.07%, and the preferable upper limit thereof is 0.15%.
[0054]
Si: 0.5% or less
Silicon (SO is contained as a deoxidizer; however, it segregates at
columnar grain boundaries at the time of solidification of weld metal, lowers
the melting point of liquid phase, and increases the susceptibility to
solidification cracking. Therefore, the content of Si must be set to 0.5% or less.
The content of Si is preferably 0.3% or less. However, in the case where the
content of Si is decreased excessively, the deoxidizing effect is not achieved
sufficiently. Consequently, the cleanliness of the alloy decreases, and
moreover the production cost increases. Therefore, the lower limit of the Si
content is not particularly restricted; however the preferable lower limit
thereof is 0.01%. If at least 0.01% of Si is contained, the deoxidizing effect
can be achieved. The lower limit of the Si content is more preferably 0.02%.
[0055]
Mn: 1.5% or less
Like Si, manganese (Mn) is contained as a deoxidizer. However, an
excessive content of Mn causes embrittlement. Therefore, the content of Mn
must be set to 1.5% or less. The content of Mn is preferably 1.2% or less.
The lower limit of the Mn content is not particularly restricted; however, the
- 13"IY
preferable lower limit thereof is 0.01%. If at least 0.01% of Mn is contained,
the above"described effect can be achieved. The lower limit of the Mn content
is more preferably 0.02%.
[0056]
Ni: 46 to 56%
Nickel (NO is an element effective in obtaining an austenitic structure,
and is also an essential element for ensuring the structural stability during a
long period of use and thus attaining the sufficient creep strength. In order to
achieve the above"described effects, it is necessary that 46% or more of Ni be
contained. However, since Ni is an expensive element, a high content of Ni
exceeding 56% leads to an increase in cost. Therefore, the content of Ni is set
to 46 to 56%. The preferable lower limit of the Ni content is 46.5%, and the
preferable upper limit thereof is 55.5%. The further preferable lower limit of
Ni content is 47%, and the further preferable upper limit thereof is 55%.
[0057]
Co: 10 to 15%
Like Ni, cobalt (Co) is an element effective in obtaining an austenitic
structure; it increases the phase stability and makes a contribution to the
enhancement of creep strength. In order to sufficiently achieve these effects,
it is necessary that 10% or more of Co be contained. However, since Co is an
extremely expensive element, a high content of Co exceeding 15% leads to an
increase in cost. Therefore, the content of Co is set to 10 to 15%. The
preferable lower limit of the Co content is 10.5%, and the preferable upper
limit thereof is 14.5%.
[0058]
Cr: 20 to 25%
Chromium (cd is an essential element for ensuring oxidation resistance
and corrosion resistance at high temperatures. Cr combines with C in the
solidification process to produce eutectic carbides and to prevent solidification
cracking and ductility-dip cracking during welding, and also has an effect for
reducing the susceptibility to stress relaxation cracking during the use at high
temperatures. In order to achieve the above-described effects, it is necessary
that 20% or more of Cr be contained. However, if the content of Cr becomes
excessive and exceeds 25%, the structural stability at high temperatures
deteriorates, and the creep strength decreases. Therefore, the content of Cr is
set to 20 to 25%. The preferable lower limit of the Cr content is 20.5%, and
the preferable upper limit thereof is 24.5%. The more preferable lower limit
of the Cr content is 21%, and the more preferable upper limit thereof is 24%.
[0059]
Mo: exceeding 10.0% and not more than 14.0%
Molybdenum (Mo) is an element that dissolves in matrix and contributes
enormously to the improvement in creep strength at high temperatures
exceeding 700°C. In addition, Mo has strong affinity for P; and thus by
combining with P, it reduces grain boundary embrittlement due to P during
post weld heat treatment and the use at high temperatures, and contributes to
the prevention of stress relaxation cracking. In order to ensure these effects
sufficiently and to attain both of resistance to stress relaxation cracking and the
creep strength during the use at high temperatures, it is necessary in terms of
the relationship with other elements constituting the present invention that Mo
exceeding 10.0% be contained. However, even if Mo is contained excessively,
the said effects are saturated; hence the toughness and creep strength are
rather decreased. Further, since Mo is an expensive element, a high content of
Mo exceeding 14.0% leads to an increase in cost. Moreover, a high content of
Mo exceeding 14.0% enhances the susceptibility to solidification cracking.
Therefore, the content of Mo is set in the range of exceeding 10.0% and not
more than 14.0%. The preferable lower limit of the Mo content is 10.5%, and
.,
the preferable upper limit thereof is 13.8%. The more preferable lower limit of
the Mo content is 11.0%, and the more preferable upper limit thereof is 13.5%.
[0060]
Ti: 0.01 to 0.5%
Titanium (Ti) precipitates finely within the grams as intermetallic
compounds by combining with Ni, and contributes to the improvement in creep
strength at high temperatures. In order to achieve this effect, it is necessary
in terms of the relationship with other elements constituting the present
invention that 0.01% or more of Ti be contained. However, if the content of Ti
becomes excessive and exceeds 0.5%, intermetallic compounds precipitate
excessively, and the deformation resistance within the grains is enhanced
remarkably, so that the susceptibility to stress relaxation cracking during the
use at high temperatures is increased. Therefore, the content of Ti is set to
0.01 to 0.5%. The preferable lower limit of the Ti content is 0.1%, and the
preferable upper limit thereof is 0.4%.
[0061]
AI: 0.1 to 1.0%
Like Ti, aluminum (AI) precipitates finely within the grains as
intermetallic compounds by combining with Ni, and contributes to the
improvement in creep strength at high temperatures. In order to achieve this
effect, it is necessary in terms of the relationship with other elements
constituting the present invention that 0.1% or more of AI be contained.
However, if the content of Al becomes excessive and exceeds 1.0%, intermetallic
compounds precipitate excessively, and the deformation resistance within the
grains is enhanced remarkably, so that the susceptibility to stress relaxation
cracking during the use at high temperatures is increased. Therefore, the
content of AI is set to 0.1 to 1.0%. The preferable lower limit of the AI content
is 0.2%, and the preferable upper limit thereof is 0.9%. The more preferable
lower limit of the AI content is 0.3%, and the more preferable upper limit
thereof is 0.8%.
[0062]
N: 0.006% or less
Nitrogen (N) is an element effective in stabilizing the austenitic phase.
However, in the Cr content range of the present invention, if the content of N
becomes excessive and exceeds 0.006%, large amounts of fine nitrides
precipitate within the grains during the use at high temperatures, which leads
to a decrease in creep ductility and toughness. Therefore, the content of N is
set to 0.006% or less. The preferable upper limit of the N content is 0.005%.
The lower limit of the N content is not particularly restricted; however, the
extreme decrease thereof leads to an increase in production cost. Therefore,
the preferable lower limit of the N content is 0.0005%.
[0063]
One welding material for Ni base heat resistant alloys of the present
invention has a chemical composition comprising elements ranging from C to
N described above with the balance being Fe and impurities, in which the
contents of 0, P and S as the impurities being restricted to the ranges
described below.
[0064]
0: 0.02% or less
Oxygen (0) exists as an impurity. In the case where 0 is contained in
large amounts, it deteriorates the workability of welding material and the
ductility of weld metal. Therefore, the content of 0 must be set to 0.02% or
less. The content of 0 is preferably set to 0.015% or less.
[0065]
p: 0.008% or less
x.. "
Phosphorous (P) is an element contained as an impurity. P lowers the
melting point of final solidification portion at the time of solidification of weld
metal, increases the susceptibility to solidification cracking remarkably, and
brings about grain boundary embrittlement during the use at high
temperatures, thereby decreasing the resistance to stress relaxation cracking.
Therefore, the content of P must be set to 0.008% or less. The content of P is
preferably set to 0.006% or less.
[0066]
S: 0.005% or less
Like P, sulfur (S) is an element contained as an impurity. S lowers the
melting point of final solidification portion at the time of solidification of weld
metal, and increases the susceptibility to solidification cracking. Further, Sis
an element that precipitates and concentrates at the grain boundaries during
the use at high temperatures, and remarkably enhances the susceptibility to
stress relaxation cracking. Therefore, the content of S must be set to 0.005%
or less. The content of S is preferably set to 0.003% or less.
[0067]
Another welding material for Ni base heat resistant alloys of the present
invention has a chemical composition containing 0.1% or less of Nd in lieu of a
part of Fe in the "balance being Fe and impurities".
[0068]
Hereunder, the effects of containing Nd and the reasons for the
restriction of content of Nd, which is an optional element is explained.
[0069]
Nd: 0.1% or less
Neodymium (Nd) has strong affinity for P, and forms compounds with P,
and moreover it combines with Sand 0 to form compounds; thus Nd is an
element that restrains grain boundary embrittlement due to P and Sand
contributes to the improvement in resistance to stress relaxation cracking.
For this reason, according to need, Nd can be contained. However, if the
content of Nd becomes excessive and exceeds 0.1%, the above-described effects
are saturated, and additionally Nd precipitates within the grains in large
amounts as carbides, so that the susceptibility to stress relaxation cracking is
rather enhanced. Therefore, if Nd is contained, the content of Nd is set to
0.1% or less. When Nd is contained, the content of Nd is preferably set to
0.08% or less.
[0070]
On the other hand, in the case where Nd is contained, in order to stably
achieve the above-described effect of Nd, it is preferable that the content of Nd
be set to 0.005% or more, further preferably 0.01% or more.
[0071]
The above is a detailed description of the chemical composition of the
welding materials for Ni base heat resistant alloys in accordance with the
present invention. These welding materials have excellent resistance to hot
cracking at the welding time, respectively. By using these welding materials,
a weld metal having resistance to hot cracking during welding, resistance to
stress relaxation cracking during a long period of use at high temperatures,
and an excellent creep strength can be obtained. Further, by using these
welding materials, a welded joint consisting of the weld metal having
resistance to hot cracking during welding, resistance to stress relaxation
cracking during a long period of use at high temperatures, and an excellent
creep strength and a base metal of a Ni base heat resistant alloy excellent in
high temperature strength can be obtained.
[0072]
When a welded joint is obtained by using the welding materials for Ni
base heat resistant alloy in accordance with the present invention, the use of a
Ni base heat resistant alloy excellent in high temperature strength, which
contains Mo: 7.0 to 10.0%, Ni: 46 to 56%, and Cr: 20 to 25%, as a base metal is
preferable because the base metal as well has excellent ductility and creep
strength in the high temperature zone of 700°C or higher. The Ni base heat
resistant alloy excellent in high temperature strength, which is used as the
base metal, may be a Ni base heat resistant alloy having the same or different
chemical composition as or from that of the welding materials for Ni base heat
resistant alloys in accordance with the present invention.
[0073]
Hereunder, the reason why, in the case where the Ni base heat resistant
alloy excellent in high temperature strength is used as the base metal, the
base metal preferably contains M: 7.0 to 10.0%, Ni: 40 to 50%, and Cr: 20 to
25% is explained in detail.
[0074]
Mo: 7.0 to 10.0%
Molybdenum (Mo) is an element that dissolves in matrix and contributes
enormously to the improvement in creep strength at high temperatures
exceeding 700°C as in the weld metal. Unlike the weld metal that is used as'
solidified condition, the base metal is homogenized by heat treatment, so that
the effect ofMo is achieved more easily. Therefore, the base metal preferably
contains Mo, and the content of Mo may be 7.0% or more. However, Mo is an
expensive element and the containing thereof leads to an increase in cost.
Therefore, if Mo is contained, the content of Mo is preferably 10.0% or less.
The more preferable lower limit of the Mo content in the base metal is 7.5%,
and the more preferable upper limit thereof is 9.8%. The still more preferable
lower limit of the Mo content in the base metal is 8.0%, and the still more
preferable upper limit thereof is 9.5%.
[0075]
· ..26'"
'2.Ni: 46 to 56%
Nickel (Ni) is an element effective in obtaining an austenitic structure,
and is also an effective element for ensuring the structural stability during a
long period of use and thus attaining the sufficient creep strength as in the
weld metal. In order to achieve these effects, the base metal preferably
contains Ni, and the content of Ni is preferably set to 46% or more as in the
weld metal. On the other hand, Ni is an expensive element and the
containing thereof leads to an increase in cost. Therefore, if Ni is contained,
the content of Ni is preferably set to 56% or less. The more preferable lower
limit of the Ni content in the base metal is 46.5%, and the more preferable
upper limit thereof is 55.5%. The still more preferable lower limit of the Ni
content in the base metal is 47%, and the still more preferable upper limit
thereof is 55%.
[0076]
Cr: 20 to 25%
Chromium (Cr) is an element effective in ensuring oxidation resistance
and corrosion resistance of the base metal at high temperatures as in the weld
metal. In order to achieve the effects equivalent to those of the weld metal,
the base metal preferably contains Cr, and the content of Cr is preferably set
to 20% or more. However, if the content of Cr becomes excessive, the
structural stability at high temperatures deteriorates, and the creep strength
decreases. Therefore, if Cr is contained, the content of Cr is preferably set to
25% or less. The more preferable lower limit of the Cr content in the base
metal is 20.5%, and the more preferable upper limit thereof is 24.5%. The
still more preferable lower limit of the Cr content in the base metal is 21%,
and the still more preferable upper limit thereof is 24%.
[0077]
-p.t'2-
1-
The base metal of Ni base heat resistant alloy excellent in high
temperature strength preferably contains elements each having the content
described below in addition to Mo, Ni and Cr of the above"described content
range, with the balance being Fe and impurities.
[0078]
C: 0.04 to 0.12%
Carbon (C) is an austenite"forming element, and is also an element
effective in enhancing the stability of austenitic structure at the time of use at
high temperatures as in the weld metal. Unlike the weld metal that is used
as"solidified condition, the base metal is homogenized by heat treatment, so
that the effect of C is achieved more easily, and also the measures against weld
cracking need not be taken. Therefore, the base metal preferably contains C,
and the content of C may be 0.04% or more. However, if the content of C
becomes excessive, coarse carbides are produced during the use at high
temperatures, and the creep strength rather decreases. Therefore, if C is
contained, the content of C is preferably set to 0.12% or less. The more
preferable lower limit of the C content in the base metal is 0.05%, and the
more preferable upper limit thereof is 0.10%.
[0079]
Si: 1.0% or less
Silicon (Si) has a deoxidizing effect. As described above, the base metal
does not require measures against weld cracking. However, if the content of
Si becomes excessive and exceeds 1.0%, the toughness deteriorates. Therefore,
in the case where the base metal contains Si, the content of Si is preferably set
to 1.0% or less. The content of Si in the base metal is more preferably 0.8% or
less. However, if the content of Si is decreased excessively, the deoxidizing
effect is not achieved sufficiently. Consequently, the cleanliness of the alloy
decreases, and moreover the production cost increases. Therefore, the lower
- .2-2' "
2-3
limit of the Si content in the base metal is not particularly restricted; however
the preferable lower limit thereof is 0.01%. If at least 0.01% of Si is contained,
the deoxidizing effect can be achieved. The lower limit of the Si content is
more preferably 0.02%.
[0080]
Mn: 1.5% or less
Like Si, manganese (Mn) has a deoxidizing effect. However, an
excessive content of Mn leads to embrittlement. Therefore, in the case where
the base metal contains Mn, the content ofMn is preferably set to 1.5% or less,
and more preferably 1.2% or less. The lower limit of the Mn content in the
base metal is not particularly restricted; however, the lower limit thereof is
preferably 0.01%. If at least 0.01% of Mn is contained, the deoxidizing effect
can be achieved. The lower limit of the Mn content is more preferably 0.02%.
[0081]
p: 0.03% or less
Phosphorous (P) is an element contained as an impurity. If the content
of P becomes excessive, the creep ductility decreases. Unlike the weld metal,
the base metal does not require the measures against weld cracking, and an
extreme decrease in the P content leads to a marked increase in production
cost. Therefore, the P content in the base metal is preferably set to 0.03% or
less, and more preferably 0.02% or less.
[0082]
S: 0.01% or less
Like P, sulfur (S) is contained as an impurity. If the content of S
becomes excessive, the creep ductility decreases. Unlike the weld metal, the
base metal does not require the measures against weld cracking, and an
extreme decrease in the S content leads to a marked increase in production
cost. Therefore, the S content in the base metal is preferably set to 0.01% or
less, and more preferably 0.008% or less.
[0083]
Co: 10 to 15%
Similarly in the weld metal, cobalt (Co) is an element effective in
obtaining an austenitic structure, and is also an element that ensures the
structural stability during a long period of use and contributes to the
improvement in creep strength. Consequently, the base metal preferably
contains Co, and the content of Co may be 10% or more. However, since Co is
an extremely expensive element, a high content of Co exceeding 15% leads to
an increase in cost. Therefore, if Co is contained, the content of Co is
preferably set to 15% or less. The more preferable lower limit of the Co
content in the base metal is 10.5%, and the more preferable upper limit thereof
is 14.5%.
[0084]
Ti: 0.1 to 0.5%
Titanium (Ti) is an element that precipitates within the grains as fine
intermetallic compounds and carbo"nitrides, and contributes to the
improvement in creep strength at high temperatures. In the base metal that
is less susceptible to stress relaxation cracking during the use at high
temperatures than the weld metal, Ti can be contained positively to increase
the strength. For this reason, the base metal preferably contains Ti, and the
content of Ti is preferably set to 0.1% or more. However, if the content of Ti
becomes excessive, large amounts of carbo"nitrides are produced, thereby
decreasing the toughness. Therefore, if Ti is contained, the content of Ti is
preferably set to 0.5% or less. The more preferable lower limit of the Ti
content in the base metal is 0.15%, and the more preferable upper limit thereof
is 0.45%.
[0085]
N: 0.01% or less
Nitrogen (N) is an element effective in stabilizing the austenitic phase.
On the other hand, if the content of N becomes high, large amounts of carbo·
nitrides precipitate during the use; and thus the ductility and toughness
deteriorate. However, the base metal consists of fine grains and has a low
degree of influence as compared with the weld metal that is used as·welded
condition. Consequently, the N content in the base metal is preferably set to
0.01% or less. The more preferable upper limit of the N content in the base
metal is 0.008%.
[0086]
B: 0.005% or less
Boron (B) is an element that segregates at grain boundaries during the
use at high temperatures to strengthen the grain boundaries, and is also
effective in improving the creep strength by finely dispersing grain boundary
carbides. For this reason, the base metal preferably contains B. However, if
the content of B becomes excessive, the susceptibility to liquation cracking in
the HAZ enhances. Therefore, if B is contained, the content of B is preferably
set to 0.005% or less. The preferable lower limit of the B content in the base
metal is 0.0002%.
[0087]
Al: 0.8 to 1.8%
Aluminum (Al) is an element that precipitates finely within the grains as
fine intermetallic compounds by combining with Ni, and contributes to the
improvement in creep strength at high temperatures. In the base metal, the
susceptibility to stress relaxation cracking during the use at high temperatures
is less than in the weld metal; thus in the base metal, Al can be contained
positively to increase the strength. For this reason, the base metal preferably
contains AI, and the content of AI is preferably set to 0.8% or more. However,
if the content of AI becomes excessive, intermetallic compounds precipitate
excessively, thereby decreasing the toughness. Therefore, if AI is contained,
the content of AI is preferably set to 1.8% or less. The more preferable lower
limit of the AI content in the base metal is 0.9%, and the more preferable upper
limit thereof is 1.6%.
[0088]
Nd: 0.005 to 0.1%
Neodymium (Nd) is an element that has strong affinity for P, Sand 0,
and therefore, Nd is effective in improving the productivity of base metal, and
moreover it is effective in reducing the susceptibility to liquation cracking in
the HAZ. For this reason, the base metal preferably contains Nd, and the
content of Nd is preferably set to 0.005% or more. However, if the content of
Nd becomes excessive, the above-described effects are saturated, and
additionally Nd precipitates within the grains in large amounts as carbides, so
that the toughness is decreased. Therefore, if Nd is contained, the content of
Nd is preferably set to 0.1% or less. The more preferable lower limit of the Nd
content in the base metal is 0.01%, and the more preferable upper limit thereof
is 0.08%.
[0089]
The following examples illustrate the present invention more
specifically. These examples are, however, by no means limited to the scope
of the present invention.
EXAMPLES
[0090]
From an ingot obtained by melting and casting a material having the
chemical composition shown in Table 1 on an experimental basis, plates for
base metals to be welded with 12 mm in thickness, 50 mm in width and 100
mm in length were manufactured by hot forging, hot rolling, heat treatment
and machining.
[0091]
Furthermore, from ingots obtained by melting and casting materials of
marks 1 to 6 having the chemical compositions shown in Table 2 on an
experimental basis, welding materials (welding wires) having an outside
diameter of 1.2 mm and a length of 1000 mm were manufactured by hot
forging, hot rolling and machining.
[0092]
[Table 1]
Table 1
Chemical composition (% by mass) Balance: Fe and impurities
C Si Mn P S Ni Co Cr Mo Ti AI B Nd N
0.06 0.13 0.06 0.004 0.001 54.8 12.0 21.6 8.9 0.4 1.1 0.004 0.007 0.004
[0093]
[Table 2]
'0 .......
1-'$ 0
0 0
.<.:.. CO .p..... H:>. t-3
........
t::1
(JQ g"
en
~ ~
(") 0'" ::r 0
0
<:
I'-t')
en
.... '0 ::r .....
en ~ a .... en
CJ) :a ~ ........ ::r 1-'$
~ 0'"
CJ)
~
CJ) ::r en
~
'0 a
~~
en en
0 ....
I'-t') ~
--:::
..... CJ)
~ ....
0
00
0'" e
Documents
Application Documents
| # |
Name |
Date |
| 1 |
10497-delnp-2012-Form-18-(06-12-2012).pdf |
2012-12-06 |
| 2 |
10497-delnp-2012-Correspondence Others-(06-12-2012).pdf |
2012-12-06 |
| 3 |
10497-DELNP-2012.pdf |
2012-12-10 |
| 4 |
10497-delnp-2012-Form-13-(21-01-2013).pdf |
2013-01-21 |
| 5 |
10497-delnp-2012-Correspondence Others-(21-01-2013).pdf |
2013-01-21 |
| 6 |
10497-delnp-2012-1-GPA-(21-01-2013).pdf |
2013-01-21 |
| 7 |
10497-delnp-2012-1-Correspondence Others-(21-01-2013).pdf |
2013-01-21 |
| 8 |
10497-delnp-2012-Correspondence-Others-(31-01-2013).pdf |
2013-01-31 |
| 9 |
10497-delnp-2012-Form-3-(20-05-2013).pdf |
2013-05-20 |
| 10 |
10497-delnp-2012-Correspondence Others-(20-05-2013).pdf |
2013-05-20 |
| 11 |
10497-delnp-2012-Form-5.pdf |
2014-04-01 |
| 12 |
10497-delnp-2012-Form-3.pdf |
2014-04-01 |
| 13 |
10497-delnp-2012-Form-2.pdf |
2014-04-01 |
| 14 |
10497-delnp-2012-Form-1.pdf |
2014-04-01 |
| 15 |
10497-delnp-2012-Description (Complete).pdf |
2014-04-01 |
| 16 |
10497-delnp-2012-Correspondence-others.pdf |
2014-04-01 |
| 17 |
10497-delnp-2012-Claims.pdf |
2014-04-01 |
| 18 |
10497-delnp-2012-Abstract.pdf |
2014-04-01 |
| 19 |
10497-DELNP-2012-FER.pdf |
2018-05-30 |
| 20 |
10497-DELNP-2012-certified copy of translation (MANDATORY) [30-08-2018(online)].pdf |
2018-08-30 |
| 21 |
10497-DELNP-2012-RELEVANT DOCUMENTS [29-11-2018(online)].pdf |
2018-11-29 |
| 22 |
10497-DELNP-2012-PETITION UNDER RULE 137 [29-11-2018(online)].pdf |
2018-11-29 |
| 23 |
10497-DELNP-2012-PETITION UNDER RULE 137 [29-11-2018(online)]-1.pdf |
2018-11-29 |
| 24 |
10497-DELNP-2012-Information under section 8(2) (MANDATORY) [29-11-2018(online)].pdf |
2018-11-29 |
| 25 |
10497-DELNP-2012-FORM 3 [29-11-2018(online)].pdf |
2018-11-29 |
| 26 |
10497-DELNP-2012-FORM 13 [29-11-2018(online)].pdf |
2018-11-29 |
| 27 |
10497-DELNP-2012-FER_SER_REPLY [29-11-2018(online)].pdf |
2018-11-29 |
| 28 |
10497-DELNP-2012-COMPLETE SPECIFICATION [29-11-2018(online)].pdf |
2018-11-29 |
| 29 |
10497-DELNP-2012-CLAIMS [29-11-2018(online)].pdf |
2018-11-29 |
| 30 |
10497-DELNP-2012-AMENDED DOCUMENTS [29-11-2018(online)].pdf |
2018-11-29 |
| 31 |
10497-DELNP-2012-ABSTRACT [29-11-2018(online)].pdf |
2018-11-29 |
| 32 |
10497-DELNP-2012-Power of Attorney-061218.pdf |
2018-12-11 |
| 33 |
10497-DELNP-2012-OTHERS-061218.pdf |
2018-12-11 |
| 34 |
10497-DELNP-2012-Correspondence-061218.pdf |
2018-12-11 |
| 35 |
10497-DELNP-2012-RELEVANT DOCUMENTS [24-06-2019(online)].pdf |
2019-06-24 |
| 36 |
10497-DELNP-2012-FORM 13 [24-06-2019(online)].pdf |
2019-06-24 |
| 37 |
10497-DELNP-2012-AMENDED DOCUMENTS [24-06-2019(online)].pdf |
2019-06-24 |
| 38 |
10497-DELNP-2012-Correspondence-250619.pdf |
2019-07-11 |
| 39 |
10497-DELNP-2012-OTHERS-250619.pdf |
2019-07-13 |
| 40 |
10497-DELNP-2012-US(14)-HearingNotice-(HearingDate-03-09-2020).pdf |
2020-08-11 |
| 41 |
10497-DELNP-2012-Correspondence to notify the Controller [28-08-2020(online)].pdf |
2020-08-28 |
Search Strategy
| 1 |
10497DELNP2012ss_06-10-2017.pdf |