Wo 03 PDF

Dissimilar Metal Welds (DMW) in German LWRs Design Types, Disbonding, NDT
W. Mayinger, K.J. Metzner E.ON Kernkraft, Hannover, Germany
Scope
Scope Flaws/Cracks in Dissimilar Metal Welds (DMW)

1. Interfacial Flaws/Cracks in DMWs (Disbonding) - DMW-types / Influence Factors on Disbonding / Appropriate NDT-methods - Results and Conclusions of Recent German Investigations and NDT-Examinations 2. Transverse Cracks in NPP - Virgil C. Summer) 3. Control Rod Drive Mechanism (CRDM) Incidents (e.g. Oconee Nuclear Station)
KK-TTF-Dr.Mayinger-Metzner/Falkenstern/smirt16dmw128s/Juli 2001 2 SMIRT-Conference 2001 - Dissimilar Welds
1. Disbonding at Interface Buttering / Ferritic Steel ! Location of cracks in a German NPP detected by ISI
Hot cracks detected by Penetration Testing (PT) after grinding

Buttering: austenitic 22 NiMoCr 37
~ASTM 508 Cl.2 40 mm (~1.5 in.)
SS (1.4550)
Disbonding: crack detected by Ultrasonic testing (UT) during ISI Crack depth : 16 mm (~ 0.6 in.) Crack length: 200 mm (~ 8 in.)
Disbonding at Interface ...
Welding Process Inspections Performed

Inspection of interface bonding o.k. (UT*or RT*) after buttering:
RT UT
Crack follows from joint welding Final fabrication inspection of DMW - disbonding not detected PT *: overwelding of the interface PT RT RT: interface not in the focus of NDT
* PT: Penetration Testing
RT: Radiographic Testing UT: Ultrasonic Testing
ferritic
KK-TTF-Dr.Mayinger-Metzner/Falkenstern/smirt16dmw128s/Juli 2001 4
austenitic
SMIRT-Conference 2001 - Dissimilar Welds
Influences on Potential Disbonding Occurrence

Austenitic filler metal: disbonding possible
Hardness increase due to chromium carbide precipitation intense carbon diffusion from ferritic to austenitic side during Past Weld Heat Treatment of buttering reduced toughness at interface High residual stresses during the welding process Inconel filler metal: o.k., no disbonding
Disbonding not to be expected due to negligible chrome-carbide precipitation at the interface; very low carbon diffusion due to high nickel content
Austenitic buttering: Increased hardness at interface due to carbide precipitation and carbon diffusion after welding and heat treatment
Buttering: austenitic (1.4550) 1. Layer : high alloyed electrode
Cladding type 1.4550

Buttering: austenitic (1.4550)
Martensitic and carbide zone

Fusion line
Austenitic buttering: residual stresses
Disbonding of buttering due to residual tensile stresses (shrinkage) during manufacturing of joint weld
ferritic
Increasing shrinkage stresses
austenitic
KK-TTF-Dr.Mayinger-Metzner/Falkenstern/smirt16dmw128s/Juli 2001
Conclusion:
Root cause of crack singular fabrication defect (not generic), no crack growth during plant operation
Required Remedial Actions in German NPPs:

Review weld fabrication-NDT and ISI-NDT results (UT and/or RT) of DMW with buttering:
extent/sensitivity of UT/RT records cover - weld-inside/-outside /-volume sufficiently - weld-inside/-outside/(no volume) sufficiently " No action req.
" Actions in later outages no sufficient extent/sensitivity of UT/RT records " Immediate action RT: Radiographic Testing; UT: Ultrasonic Testing in next outage
DMW with buttering in German NPPs: Location in Reactor Coolant Pressure Boundary (RCPB)
German BWR: - joints of stainless steel SS-lines to ferritic RPV - safe ends of austenitic valves German PWR: - joints of the ferritic MCL to connected lines
Dimensions:
pipe diameter wall thickness 100 OD 450 mm (~ 4 - 16 in.) 15 t 55 mm (~ 1/2 - 2 in.)
9 SMIRT-Conference 2001 - Dissimilar Welds
Different Design of Dissimilar Welds with Buttering in German NPPs

10 10
stainless steel ferritic steel
buttering: aust. or inconel weld mat.: aust. or inconel weld root: aust. (filler: inconel)
15 mm t 55 mm
aust. cladding
Dissimilar Welds with Buttering - Welding Materials

German BWR: root: filler: German PWR: root*: filler*: Old Design austenitic austenitic Old Design austenitic austenitic New Design austenitic inconel 82 New Design inconel 82 or 182 inconel 82 or inconel 182
in some cases root: filler:
austenitic inconel 82
Most DMW are shop welded good fabrication conditions

Dissimilar Welds without Buttering: Location in Pressure Retaining Boundary of German NPPs
# German PWR: RPV closure head 1. control rod drive mechanism 2. pressure housing
Dimensions
pipe diameter wall thickness 65 OD 140 mm (~2.5 - 5.5 in.) 5.4 t 23.5 mm (~1/4 - 1 in.)
12
Dissimilar Metal Welds without Buttering: Different Design Types in German NPPs
Pressure housing
t
: ferritic steel : stainless steel : inconel 82 or 182
5.4 mm t 13.5 mm CRDM-flange

t
: austenitic root : aust. cladding
t 23.5 mm
Dissimilar welds without Buttering - Welding Materials

German PWR: closure head
1. Control rod drive mechanism (CRDM)-flange & 2. Pressure housing root: filler metal: austenitic inconel 182
DMW are shop welded good fabrication conditions
14
NDT of Dissimilar Metal Welds (DMW)
NDT of DMW using Ultrasonic Testing (UT)

PWR + BWR: DMW are scanned from pipe outside OD
Examination of Disbonding Recording limit inner and outer surface: 2 mm deep notch (~ 0.1 in.), volume (wall thickness > 20 mm): CRR* 5 Inspection technique phased array probe, Long/Long/Trans (LLT-) probe, 70 degree dual longitudinal transducer (70 SEL)
* (circular reference reflector)
Phased Array-technique (45 SET 1.5)

Examination from austenitic and ferritic side Different angles of incidence used to scan the ID, OD and volume Different focus path lengths are possible
Phased array probe: wide range of the angle of incidence
16
Compact Long-Long-Trans (LLT)-Technique

(substitute for tandem technique) Examination from ferritic side Depending on wall thickness different angles of incidence are necessary to detect disbonding in weld volume
X 10 Cr Ni Nb 18 9 (1.4550)
17
NDT of DMW using Radiographic Testing (RT)

X-ray to be used; double wall radiographic required max. wall thickness 25 mm Required angle at fusion line < 5- 6 to detect small cracks
X-ray
max 5-6
ferritic
SS
18
Performed Extent of DMW-NDE in German NPPs

PWR
disbonding-NDT performed in 10 of 13 German PWRs approximately 10 - 15 DMWs with buttering (austenitic or inconel) per plant inspected (RCPB)
BWR
disbonding-NDT performed in 5 out of 6 German BWRs approximately 6 DMWs with buttering inspected (RCPB)
Result:
No disbonding detected at any DMW with buttering! Dose rate: costs: ~ 30-40 mSv per plant ~ 450.000 DEM (~ 225 000 US $) per NPP Total costs (estim.): 4 million US $
Transverse Cracks ...
2. Transverse Crack in the Buttering (V. C. Summer)
Design of the DMW
Repair of the weld
Crack location
Transverse Cracks ...
2. Examination of Transverse Defects: Extent and Results of NDE in E.ON NPPs

According to German KTA code requirements examination of DMWs for transverse defects not requested at present $GRS-Bulletin " actions required in next outages UT-examination of 8 DMWs (inconel filler) performed this year
Result: No crack indications in all examined DMWs
21
3. Control Rod Drive Mechanism (CRDM) Incident (Oconee Nuclear Station)

Design NDT
German design different to Examination of seal welds: visual French or US design testing (video inspection) CRDM are not directly welded Examination of DMW at CRDM to the RPV closure head, flange and pressure housing screwed connection with seal $ eddy current testing weld
NDE-Results in German NPP " o. k.
22
Design of the CDRM


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Dissimilar Metal Welds (DMW) in German LWRs Design Types, Disbonding, NDT

W. Mayinger, K.J. Metzner E.ON Kernkraft, Hannover, Germany

Scope Flaws/Cracks in Dissimilar Metal Welds (DMW)

Hot cracks detected by Penetration Testing (PT) after grinding

Disbonding at Interface ...

Welding Process Inspections Performed

SMIRT-Conference 2001 - Dissimilar Welds

Disbonding at Interface ...

Influences on Potential Disbonding Occurrence

Disbonding at Interface ...

Cladding type 1.4550

Martensitic and carbide zone

Disbonding at Interface ...

Austenitic buttering: residual stresses

Increasing shrinkage stresses

SMIRT-Conference 2001 - Dissimilar Welds

Required Remedial Actions in German NPPs:

Disbonding at Interface ...

Disbonding at Interface ...

Different Design of Dissimilar Welds with Buttering in German NPPs

stainless steel ferritic steel

Disbonding at Interface ...

Dissimilar Welds with Buttering - Welding Materials

in some cases root: filler:

Most DMW are shop welded good fabrication conditions

Disbonding at Interface ...

SMIRT-Conference 2001 - Dissimilar Welds

Disbonding at Interface ...

: ferritic steel : stainless steel : inconel 82 or 182

5.4 mm t 13.5 mm CRDM-flange

: austenitic root : aust. cladding

Disbonding at Interface ...

Dissimilar welds without Buttering - Welding Materials

DMW are shop welded good fabrication conditions

SMIRT-Conference 2001 - Dissimilar Welds

NDT of Dissimilar Metal Welds (DMW)

NDT of DMW using Ultrasonic Testing (UT)

NDT of Dissimilar Metal Welds (DMW)

Phased Array-technique (45 SET 1.5)

Phased array probe: wide range of the angle of incidence

SMIRT-Conference 2001 - Dissimilar Welds

NDT of Dissimilar Metal Welds (DMW)

Compact Long-Long-Trans (LLT)-Technique

SMIRT-Conference 2001 - Dissimilar Welds

NDT of Dissimilar Metal Welds (DMW)

NDT of DMW using Radiographic Testing (RT)

SMIRT-Conference 2001 - Dissimilar Welds

Performed Extent of DMW-NDE in German NPPs

Transverse Cracks ...

2. Transverse Crack in the Buttering (V. C. Summer)

Design of the DMW

Repair of the weld

Transverse Cracks ...

2. Examination of Transverse Defects: Extent and Results of NDE in E.ON NPPs

Result: No crack indications in all examined DMWs

SMIRT-Conference 2001 - Dissimilar Welds

3. Control Rod Drive Mechanism (CRDM) Incident (Oconee Nuclear Station)

NDE-Results in German NPP " o. k.

SMIRT-Conference 2001 - Dissimilar Welds

Design of the CDRM

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