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Product Form C Fe Ni Cr Mo Cb + Ta W
INCONEL alloy 625 plate 0.05 2.5 61.0 21.5 9.0 3.6 --
INCONEL Welding Electrode 112 weld deposit 0.05 4.0 61.0 21.5 9.0 3.6 --
INCONELWelding Electrode l12Mo weld deposit 0.05 4.0 58.0 21.5 12.0 3.6 --
INCONEL Welding Electrode I I2HMo weld deposit 0.05 4.0 54.0 21.5 16.0 3.6 --
INCO WeldingElectrodeC-276 weld deposit 0.01 5.3 56.3 15.5 15.9 -- 3.4
Table II. Nominal Room-Temperature Mechanical Properties for INCONEL Alloy 625 (Annealed) Plate
solid alloy 625 construction, a 0.250 inch plate product is hand. The alloy 625 plates are nickel plated on one surface
now available offering considerable cost savings with essen- prior to pack assembly. Additional cleaning is necessary to
tially the same corrosion protection. It is a composite plate effect a good nickel plate. The purpose of the nickel plating
of INCONEL alloy 625 and carbon steel which have been is to facilitate a metallurgical bond between the clad and
mill rolled under heat and pressure until they are integrally base metal layers. This is accomplished by preventing the
bonded over their entire interface. This new product, alloy formation of refractory oxides on the alloy 625 surfaces
625 thin-gauge clad steel plate, can result in an approximate which would interfere with bonding.
savings of 50 pet of the solid alloy 625 installed cost. The After nickel plating one surface of the alloy 625 plate, the
economy of this product has produced much interest, no- opposite surface is painted with a compound that prevents
tably in utility scrubber applications where massive quan- the two alloy 625 plates from bonding to each other. This
tities (2 to 4 million pounds) of corrosion resistant materials compound, which is a proprietary formula, allows applica-
are needed. tion as a paint. The coating dries without later flaking off.
Flakes could find their way to areas between the cladding
alloy and the base metal, thus preventing a bond.
PRODUCTION AND PROPERTIES
The base metal slabs are also produced to restrictive di-
OF C L A D PLATE
mensional tolerances. Their lengths and widths are some-
Most of the clad plates produced at Lukens Steel Company what greater than the corresponding cladding alloy plates.
are manufactured by the four-ply process. This is the most This permits space around the perimeter to place a carbon
economical method. The four-ply term refers to a steel fab- steel bar. An operator hand welds the joints between the bars
rication consisting of four plates welded around the periph- and the base metal slabs.
ery to make a pack. The components of the pack are two As discussed above with the cladding alloy plates, the
alloy 625 plates that will become the clad layers sandwiched base metal slabs are also cleaned to remove all traces of
in between two slabs that will become the steel layers. Two scale and mill oxide. The four-ply pack that has been fabri-
clad plates are produced simultaneously by the four- cated by hand welding is now moved to an automatic welding
ply method. station where high heat input welds are deposited around the
Prior to assembly of the pack the alloy 625 plates are periphery. Each submerged-arc bead joins the base metal
carefully produced to restrictive dimensional tolerances. slab to the spacer bar. When this operation is completed, the
Heat treatment is not required at this stage because the pack four-ply pack has sufficient structural integrity to withstand
will subsequently be heated for rolling to temperatures that the stresses imposed during heating and rolling. This method
exceed the standard annealing cycles for these materials. of clad plate manufacture is referred to as the hot roll bond
The alloy 625 plate surfaces are thoroughly cleaned to re- process. Other processes available are explosion bond and
move scale, oxide, and other visible imperfections. Clean- weld overlay methods.
ing is accomplished by high velocity steel grit blasting, acid The four-ply pack is heated in a refractory lined, gas fired
pickling, water rinsing, air drying, and touch-up grinding by soaking pit at about 2200 ~ This temperature could be
3. Back-Chip by Grinding
3. Deposit 2nd Bead to Achieve
Full Penetration of 1st Bead
Specimen Exposure Corrosion Rate, Localized Attack, Temp., Period, Weight Corrosion Max. Depth, mils
Type Period, Years mpy mils
F Months pH Loss, gm Rate, mpy Pitting Crevice
Plain 0.5 nil 0
85 4 3.6 0.001 nil nil nil
Crevice 0.5 nil 0
135 4 7.6 0.001 nil nil nil
Plain 1.0 nil 0 165 4 7.6 0.001 nil nil nil
Crevice 1.0 nil 0 225 4 7.6 0.001 nil nil nil
Welded 1.0 nil 0
Crevice 7.0 nil 0
Welded 7.0 nil 0
300
Plain 10.0 nil 0
Crevice 10.0 nil etch 280
Welded 10.0 nil 0
260
240
Concentration, %
PHOSPHORIC ACID Fig. 3--Corrosion resistance of INCONEL alloy 625 in boiling phos-
phoric acid solutions.
Corrosion tests of INCONEL alloy 625 in boiling phos-
phoric acid solution are given in Figure 3. Alloy 625
showed excellent corrosion resistance in concentrations up to 50 pet. Above 50 pet H3PO4, the corrosion rate of
alloy 625 is shown to increase sharply with increasing
acid concentration.
Table V. Crevice Corrosion Resistance of
INCONEL Alloy 625 in Heated, Natural Seawater
HYDROCHLORIC ACID
Period, Number of Pet Corroding Max. Depth
Temp., F Days Crevices Crevices Attack, mils INCONEL alloy 625 corrosion tests in hydrochloric acid at
55 30 120 0 0
150 ~ are given in Table VII. Alloy 625 showed fair to
55 365 120 0 0 good corrosion resistance throughout the acid concentration
55 730 120 0 0 range studied. At higher temperature, however, the alloy is
55 1095 120 0 0
not expected to be very resistant. Because of its high nickel
122 30 120 0 0
122 90 120 0 0 content, alloy 625 is very resistant to stress corrosion
cracking in acid chloride environments.
5
10
71
81 104
~176////
15 65
20 50
25 38
Chloride Field Tests / / / / /
30 34 Content 10 3
Cone. 15 (ppm)
Temp.
"C
"Ioo Boiling Point Cu
~ ='0.w mm/y(20l /
l 2so Temp.
"F
Environmental Chloride
and Fluoride Content, Corrosion Rate, Maximum Crevice
ppm by Weight mpy Attack, mils
150 90,000 a CI- + No F- 1 0
so / 0.13 mm/y (w ~ , . ~ lOO 89,500 CI + 500 F- I 0
89,000 CI + 1,000 F- 1 0
l I I I 1 I I I I I 150 88,500 CI- + 1,500 F- 1 3
0 ao 20 30 40 so 60 70 eo ~0 ~00
Sulfudc Acid, Wt.%
Fig. 4--Corrosion resistance of INCONEL alloy 625 in sulfuric acid aMaximum chloride content for crevice corrosion resistance.
(after Crumg).
Fig. 6--Overall view of alloy 625 clad stack liner access door showing Fig. 7 - - Overall view showing back chipping of steel side of the alloy 625
first weld pass on clad side with INCONEL Welding Electrode 112 clad steel test plate during field welding in the vertical-up position before
(one-third of weld length). Balance of weld (not shown) will be l12Mo installing in the quencher inlet floor at Pennsylvania Power Company's
(12 pct Mo) and II2HMo (16 pct Mo). Bruce Mansfield Unit #3 Scrubber.
Table X. Field Testing of Alloy 625 Clad Steel Plate (after ROSSTM)
Sprinngfield (IL) City Water, Light & Power Co.--Dallman wet/dry zone 4/81 to 10/81
quencher 4/81 to 10/81
absorber 4/81 to 10/81
outlet duct 4/81 to 10/81
Pennsylvania Power C o . - Mansfield wet/dry zone 11/82
fan housing 10/82
stack liner 10/82
Louisville Gas & Electric--Cane Run outlet duct 1/83
Duquesne Light C o . - Phillips scrubber venturi 3/83
Southern Indiana Gas & Electric--Brown stack liner 6/83
Potomac Electric Power Co.--Dickerson stack liner 11/83
South Mississippi Electric Power Assn.--Morrow breeching duct 12/83
East Kentucky Power Cooperative--Spurlock outlet duct 9/84
T
Sample #2 Location at 80 Ft. _ _ _
Clad #a f Scrubber outlet duct (120"1=)
Fig. 12--Overall view of overhead welding of alloy 625 clad steel plates
in the outlet ducting at LouisvilleGas and Electric Company'sCane Run
Unit #5 scrubber.
ass Duct (290"F)
Fig. 13--Similar area as Fig. 12, but after cleaning. No corrosion was
observed after almost one year testing.