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Production, Fabrication, and

Performance of Alloy 625 Clad Steel


for Aggressive Corrosive Environments
C . E . STEVENS and R. W. ROSS, Jr.

INCONEL* alloy 625 is a nickel-chromium-molybdenum-columbium alloy used in ag-


gressive corrosive applications where high strength, fabricability, and outstanding corro-
sion resistance are required. Because of these properties, the alloy is used by the power
and chemical industries in a variety of components in coal-fired, nuclear, and chemical
process plants. However, widespread use of lNCONEL alloy 625 is limited due to its cost.
There is a need, notably in utility flue gas desulfurization systems (scrubbers)for an
economical, highly corrosive-resistant material. To satisfy this need, INCONEL alloy 625
thin-gauge clad steel plate was developed by Lukens Steel Company. The corrosion
resistance of INCONEL alloy 625 in several aggressive corrosive environments will be
reviewed. Additionally, this paper will describe methods used to manufacture, fabricate,
and weld INCONEL alloy 625 clad plate. Field test evaluation programs conducted at six
power plant scrubber systems will also be reported.

INTRODUCTION outstanding resistance to localized corrosion (pitting and


crevice), corrosion fatigue, and stress corrosion cracking.
INCONEL alloy 625 is a Ni-Cr-Mo-Cb-Fe alloy used for its
Alloy 625 also has very good to excellent resistance in
high strength, outstanding corrosion resistance, and excel-
oxidizing and reducing acids, acid chlorides, and other
lent fabricability. Strength of alloy 625 is derived from the
severe chemical environments. Because of this excellent
stiffening effect of molybdenum and columbium on its
corrosion behavior, INCONEL alloy 625 has been used in a
nickel-chromium matrix. This combination of elements also
variety of applications in the marine, chemical processing,
is responsible for superior resistance to a wide variety of
power, and pollution control industries for nearly 20 years.
very corrosive aqueous environments as well as high-
INCONEL alloy 625 has been readily fabricated into heat
temperature (1800 ~ effects such as oxidation and carbu-
exchangers, reaction vessels, distillation columns, transfer
rization. The chemical composition of alloy 625 base metal
piping, and valves in the production of salt, super-
and welding electrodes is given in Table I. Typical mechani-
phosphoric acid, hydrofluoric acid, chemical fume incin-
cal properties are presented in Table II.
erator scrubbers, seawater, ore processing, and pulp and
The properties of INCONEL alloy 625 that make it an
paper bleaching equipment. In coal-fired boilers in energy
excellent choice for chloride containing environments are
related industries, INCONEL alloy 625 has been success-
*INCONELis a trademarkof the Inco familyof companies. fully used in ash pit seals, bellows, SO2 scrubbers,
reheaters, dampers, ducting, fans and fan housings, and
C.E. STEVENS is with Lukens Steel Company, Coatesville, stack liners. In nuclear power plants, radwaste evaporators
PA 19320. R. W. ROSS, Jr. is with Inco Alloys International, Inc., and reactor components have been readily fabricated from
Huntington, WV 25720. INCONEL alloy 625.
This paper was presented at the ASM Conference on Coatings
and Bimetallics for Energy and Power Systems and Chemical All of the above applications may require very large quan-
Process Environments, 12-14 November 1984, Hilton Head, SC. tities of INCONEL alloy 625. As an alternate to expensive,

J. MATERIALSFOR ENERGYSYSTEMS 9 AMERICANSOCIETYFOR METALS VOL. 8, NO. 1, JUNE 1986 7


Table I. Nominal Chemical Composition (Pct Weight)

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

Tensile Yield Strength


Strength, (0.2 Pet Offset), Reduction Hardness
1000 psi 1000 psi Elongation, Pet of Area, Pet Brinell
120 to 150 55 to 95 60 to 30 60 to 40 145 to 220

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

8 VOL.8, NO. 1, JUNE 1986 J. MATERIALSFOR ENERGYSYSTEMS


higher or lower as determined by the type of cladding alloy
plates in the pack. Once a uniform elevated temperature has Table IlL Typical Shear Strength
been achieved during the heating cycle, the pack is removed for Various Alloys Clad to Steel
from the soaking pit and placed on the rolling mill tables.
The table rolls are powered so that clad packs, ingots, or Shear Strength,
slabs can be automatically moved to a 140 inch four high Clad Type Plate Thickness Pct Clad psi
reversing plate mill. T304L 1/2 inch 20 45,300
A small hole has been drilled through the center of one T316L 3/4 inch 20 46,000
spacer bar to allow expanded gases to escape from the pack T410 1/2 inch 10 41,100
Nickel 3/4 inch 10 46,300
during the heating cycle. When the pack enters the rolling INCONEL alloy 600 1//2 inch 20 48,700
mill, the end with the "vented" spacer bar is the trailing INCONEL alloy 625 1/4 inch 25 41,000
edge. Hot gases inside the pack are expelled through the
vent, while the pressure from the work rolls bond the dis-
similar metals together. If the work rolls reduce the thick- steel. A low velocity oxygen stream is essential for flame
ness of each of the four components during the first pass, a cutting clad steel. Frequently, the cause of trouble when
bond will occur at that point. cutting clad steel plate can be traced to excessive oxygen
Usually, because of thickness variations within the pack, pressure. The desired oxygen pressure is usually too low
two or three passes are required to complete the bond. Roll- to provide adequate oxygen to the preheat flames when a
ing continues until the desired pack thickness, width, and two-hose cutting torch assembly is used. It is advisable,
length have been obtained. The parting compound prevents therefore, that a three-hose cutting torch arrangement be
the two cladding alloy plates from bonding to each other. employed so that the preheat oxygen and the cutting oxygen
Subsequent processing involves separating the two clad can be controlled from the separate regulators.
plates, heat treating to impart corrosion resistance to the The correct tip size is of the utmost importance in main-
alloy 625 and, in some cases, heat treating to obtain a taining a high quality cut edge. Oversized tips tend to pro-
desired strength range in the steel backer plates. Cleaning of duce nonuniform edge widths through the cut and also
the alloy 625 plate consists of pickling and grinding a spe- produce excessive slag adherence to the underside of
cial finish on the clad (process) side prior to cutting to size, the plate.
flattening, and wrapping for shipment. Alloy 625 clad steel plates are readily weldable. It is
The cladding thickness is normally specified as a per- important, however, that the corrosion or abrasion resistant
centage of the total plate thickness. Thicknesses from 5 pct properties of the alloy 625 are retained during fabrication.
to 50 pct are available; however, there are further limitations Proper weld joint design and welding procedures must be
based on cladding material and overall plate size. The most incorporated to assure success.
common thickness of alloy 625 cladding are 25 pct of the The usual procedure for butt welding clad plates is to
total composite thickness. weld the carbon steel side first with carbon electrodes and
The ASME Boiler Code j and ASTM Specification 2 re- then the cladding side with high alloy electrodes. In the
quire a minimum bond shear strength of 20,000 psi for clad fabrication of thin clad steel plates, however, a full alloy
steels. ASME has standardized the test procedure for deter- weld procedure is preferred. The technique employed for
mining shear strength. Table III shows several production this type of weld is almost identical to that used for welding
test results of typical shear strength for various clad types. high alloy plates.
One procedure (Figure 1) for making manual butt welded
joints is to prepare a 45 deg bevel on the base metal to make
FABRICATION AND W E L D I N G C L A D PLATE a single V-joint. Retain a small amount of base metal adja-
Alloy 625 clad steel plates may be either hot formed or cold cent to the clad metal to prevent welding onto the alloy 625.
formed into shells, heads, and fittings. Forming is accom- Fill the steel side groove with carbon steel electrode without
plished in a manner similar to forming carbon and alloy penetrating to the clad. Grind or arc-air gauge the seam
plates. All working surfaces of the plate and forming ma- on the clad side down to the carbon steel weld deposit.
chine must be cleaned to eliminate loose scale, free steel Weld the clad side of the joint using INCONEL Welding
particles, and shop dirt in order to prevent impressions and Electrode 112. Weld metal dilution by the backing steel can
imbedded foreign material from contaminating the clad be compensated by using electrodes richer in molybdenum,
surface. Special attention should be paid to the condition such as INCONEL Welding Electrode l12Mo (12 pct Mo)
of the plate edges before bending. Corners in tension or INCO Welding Electrode C-276 (16 pct Mo) as identified
should be rounded to remove sharp edges and notches. in Table I.
The alloy 625 clad plate can be flame cut using proce- Another method (Figure 2) is to deposit the first bead on
dures that are only slightly different from cutting carbon the clad side without fully penetrating the clad thickness.
j. MATERIALSFOR ENERGYSYSTEMS VOL. 8, NO. l, JUNE 1986 9
y
1. Beveled Joint Design to Minimize Grinding
O

1. Deposit First Bead on Clad side

2. Deposit First Two Beads


2. Back-Chip Joint by Grinding

3. Back-Chip by Grinding
3. Deposit 2nd Bead to Achieve
Full Penetration of 1st Bead

4. Deposit 3rd Bead to Fully Penetrate the 1st


Bead, Deposit the 4th Bead to Complete in
Weldment.
4. Deposit 3rd Bead to Fill Joint
Fig. 1 - Welding sequence for welding from both sides--steel side first
(after Shoemakera). Fig. 2--Welding sequence for welding from both sides--clad side first
(after Shoemaker3).

This procedure results in minimal weld dilution. The joint is


then back chipped (ground) from the steel side down to the by Paul and Ross, 5 both laboratory and field testing showed
alloy 625 cladding and then filled with INCONEL Welding that welded alloy 625 clad steel plate was as corrosion
Electrode 112 or 112Mo. A detailed study of various weld- resistant as solid welded alloy 625 relative to scrubber envi-
ing procedures had been developed by Shoemaker. 3 Many ronments. It, therefore, follows that alloy 625 clad steel
of these same procedures were also evaluated by Hibner4 plate should be equivalent in corrosion resistance to other
for effects of welding dilution on corrosion in a severe, commercially important aggressive media found in the
simulated flue gas desulfurization environment. These chemical process industry. The resistance of INCONEL
results showed that alloy 625 clad steel plate can be welded alloy 625 in some of these corrosives is presented below.
using INCONEL Welding Electrode 112 (9 pet Mo) without
deleterious effects of weld metal dilution on corrosion
SEAWATER
resistance.
INCONEL alloy 625 has displayed excellent corrosion re-
sistance to a wide variety of marine environments. Stagnant
CORROSION RESISTANCE OF or low-velocity seawater (19,000 ppm chlorides) is one of
INCONEL ALLOY 625
the most severe marine environments because crevice condi-
Much of the emphasis of this paper will be concerned with tions are generally produced by attachment of marine
the corrosion resistance of alloy 625 clad steel for aggressive organisms or deposits of other debris on the metal surface.
corrosive environments found in the electric energy indus- INCONEL alloy 625 has shown no measurable corrosion in
try, notably SO2 scrubbers. In corrosion research reported low-velocity, natural seawater exposures after ten years of

10 VOL. 8, NO. 1, JUNE 1986 J. MATERIALS FOR ENERGY SYSTEMS


Table IV. Corrosion Resistance of INCONEL Table Vl. Corrosion Resistance of INCONEL Alloy 625
Alloy 625 In Flowing (2 fps), Ambient Seawater in Hot, Deaerated (100 ppb) Seawater Flowing 8 fps

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

exposure (Table IV). Even test specimens with an artificial,


220
plastic crevice produced no detectable corrosion.
The corrosivity of seawater can be made more aggressive 20O

by increasing the temperature, especially for crevice corro- 180


sion resistance of passive stainless or nickel alloys. 6 E
d 160
The effect of temperature on crevice corrosion resistance of Samples Lying on
INCONEL alloy 625 is given in Table V. Clearly, alloy 625 Bottom of Beaker
g 140
showed no evidence of attack up to 122 ~ For temperatures
120
higher than 140 ~ the seawater must be decarbonated to O

prevent scaling. 7 In corrosion tests where temperature was 100


increased up to 225 ~ no corrosion was detected on alloy
80
625 after 4 months of exposure (Table VI). However, an Suspended Samples , , ~
INCONEL alloy 625 heat exchanger used to heat the sea- 60
water during this test program showed crevice corrosion in
40
some areas of the waterbox under a tight fitting gasket where
the metal temperatures were 165 to 225 ~ In previous hot 20

seawater tests, Fink reported that titanium and alloy C also


0
showed crevice corrosion under similar conditions. 8 0 10 20 30 40 50 60 70 80 90

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.

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 11


INCONEL alloy 625 Saturated
Chloride
Table VII. Corrosion Resistance of INCONEL
Alloy 625 in Hydrochloric Acid at 150 *F 105 __ i__..--

Acid Concentration, Pet Corrosion Rate, mpy

5
10
71
81 104
~176////
15 65
20 50
25 38
Chloride Field Tests / / / / /
30 34 Content 10 3
Cone. 15 (ppm)

SULFURIC ACID 102

INCONEL alloy 625 shows good corrosion resistance to


sulfuric acid at temperatures up to 180 ~ and concentrations 9 Corrosion
O No Corrosion
to 30 pet. At lower temperatures, alloy 625 showed de- 10 I I I I I I I
creasing corrosion resistance as sulfuric acid concentration 2 3 4 5 6 7 8
increased. Poor corrosion resistance was noted with in- pH
creasing temperatures and acid concentrations above 180 ~ Fig. 5--Laboratory corrosion test results for INCONEL alloy 625 in
simulated 135F SO.~ scrubber environments v s field tests (after HibnerH).
and 30 pet respectively. These observations are determined
by using an iso-corrosion chart as shown in Figure 4.

SIMULATED SCRUBBER CORROSION TESTS


Table VIII. Effect of Exposure Time on Crevice Corrosion of
Welded INCONEL Alloy 625 Plate in a Simulated SO2
INCONEL alloy 625 has displayed excellent corrosion re-
Scrubber Environment at pH 5, 135 ~ and
sistance in a wide variety of laboratory corrosion tests 110,000 ppm* Chlorides (after Hibner')
simulating SO2 scrubber environments. ~~ Field cor-
rosion test data have indicated less correlation with labora- Exposure Corrosion Rate,** Maximum Crevice
Time, Days mpy Attack,** mils
tory data, especially under low pH (acidic) slurry conditions
(Figure 5). Under simulated absorber conditions (pH 5 to 30 <1 0
60 <1 4
6, 135 ~ alloy 625 has displayed no corrosion up to
90 <1 4
110,000 ppm chlorides (Table VIII), even after extended 180 <1 5
test periods (360 days). Fluoride ion has been identified as 270 <1 2
a very detrimental species of scrubber condensates, which 360 <1 5

greatly reduces alloy corrosion resistance. ~2 As shown in


*By weight
Table IX, INCONEL alloy 625 is very resistant to effects of **Duplicate specimens, most of attack in weld metal
fluoride ion. In the simulated, severe scrubber test envi-
ronment, 1500 ppm fluoride ion addition was required to
initiate localized corrosion on alloy 625 test samples.

Table IX. Effect of Fluorides on Crevice Corrosion of


200 - ' ~ ' ~ ~ ' ~ I 1 40o
INCONEL Alloy 625 after 30 Days in Simulated Scrubber
"

Corrosion rates In parentheses


erein mils per year /
I I
13so Environments Containing Chlorides and Fluorides as NaCI
and NaF, at pH 5.0 with H=SO3 (after Hibner TM)
- 31111

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).

12 VOL. 8, NO. 1, JUNE 1986 J. MATERIALS FOR ENERGY SYSTEMS


FIELD SCRUBBER CORROSION plate, three different welding products are also being evalu-
TESTS OF CLAD PLATE ated: (1)INCONEL Welding Electrode 112 (9 pet Mo),
(2) INCONEL Welding Electrode l12Mo (12 pct Mo), and
The first field corrosion evaluation of alloy 625 clad steel
(3) INCONEL Welding Electrode 112HMo (16 pct Mo). As
plate was reported by Paul and Ross. 5Welded alloy 625 clad
indicated, three different levels of molybdenum in the weld-
specimens were exposed in various areas of the Springfield
ing products (Table I) are being tested to study effects of
City Water, Light & Power Company's Dallman scrubber.
dilution of iron into the weld metal and effects on corrosion
Based upon these favorable test results, several more field
resistance.
tests were initiated by the utilities identified in Table X.
In tests evaluating field fabrication, a large plate section
Subsequently, detailed shop and field welding procedures
was plasma arc cut into seven sections and field welded in
were developed for installing alloy 625 clad steel plate. Two
the fiat, vertical up (Figure 7), and vertical down positions.
examples were presented above in Figures 1 and 2.
One shop weld was also performed for comparative pur-
The corrosion tests at Pennsylvania Power Company's
poses. Welding sequences were the same as described
Bruce Mansfield Power Plant Air Quality Control Systems
above. Similarly, all three welding products were utilized.
are of special interest. In this evaluation program, both shop
Clad plates were welded on the quencher floor and wall of
and field welding procedures are being studied. Figure 6
the Mansfield Unit #3 scrubber (Figure 8).
shows an alloy 625 clad steel access door being welded
Both test areas were located in the wet/dry zone of the
prior to installation in the Unit # 1 stack liner. In this test
quencher. This area is the most corrosive zone of the scrub-
ber system. The reason is that hot (225 ~ unscrubbed inlet

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)

Power Plant Location Date Installed

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

J. MATERIALS FOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 13


Fig. 8--Alloy 625 clad test plates installed in the quench floor and Fig. 10--Overall view of the alloy 625 clad steel test plate exposed for
wall areaof the PennsylvaniaPower Company'sBruce Mansfield Unit # 3 about 1.5 years in Pennsylvania Power Company's Bruce Mansfield
scrubber system, Unit #3 quencher inlet wall.

flue gas is quenched to 125 ~ As a result, the metal sur-


faces are exposed to pH 1 to 6.5 and severe build-up of
slurry deposits. Chemical analysis of slurry deposits re-
vealed 8000 ppm chlorides and 7000 ppm fluorides for a
total halide content of 15,000 ppm. It is well known that
hot, acid chloride deposits will severely corrode most
stainless and nickel alloys containing less than 9 pct
molybdenum, s
Figure 9 shows the appearance of the alloy 625 clad steel
access door after about one year of testing in the Mansfield
Unit #1 stack liner at 377 feet of elevation. There was no
evidence of corrosion in any of the test plate. Figure 10
shows the appearance of the alloy 625 clad steel test plate
after about 1.5 years on the Mansfield Unit # 3 quencher
wall. There was no evidence of corrosion, except a small
area (less than 2 pct of the test plate area) shown in Fig-
ure 11. Here, localized corrosion was found with a depth of
attack of 0.001 inch to 0.018 inch. There was no attack in
any weld metal. Similar observations were noted during the Fig. 11- - Sameas Fig. 10, but showinglocalizedcorrosionin the quencher
inspection of the clad plate installed on the floor. However, inlet wall wet/dry zone. Depth of attack was 0.001 inch to 0.018 inch.

localized attack was limited to about 0.2 pct of the test


area and depth of attack was 0.001 inch to 0.010 inch.
At Louisville Gas and Electric Company's Cane Run Unit
#5 scrubber system, another significant field test is under-
way for alloy 625 clad steel plate. Figure 12 shows the
overhead seal welding of the four clad test plates. The plates
were attached to the roof of an existing steel outlet duct
between the scrubber outlet and reheater section. The outlet
duct flue gas environment is normally 125 ~ but some
excursions were reported up to 250 ~ Condensate in the
ducting was pH 1 to 2. Halides were present, but no analysis
was available. Figure 13 shows the test area after one year
of exposure. No evidence of corrosion was observed.
Fig. 9--Overall view of the alloy 625 clad steel stack liner access door
after aboutone year of testing in the PennsylvaniaPowerCompany'sBruce Two other field tests have also displayed excellent
Mansfield Unit #1 at 337 feet of elevation. No corrosion was detected. corrosion behavior of alloy 625 in scrubber outlet flue gas

14 VOL.8, NO. 1, JUNE 1986 J. MATERIALSFOR ENERGYSYSTEMS


b~ :Sample #3 Location at 100 Ft.
Clod #C

T
Sample #2 Location at 80 Ft. _ _ _
Clad #a f Scrubber outlet duct (120"1=)

Sample #1 Location at 60 FI,


Clad #A

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. 14--Diagram showing SIGECO--A. B. BrownUnit # 1 test sample


locations of alloy 625 clad steel plates in the acid brick stack liner.

Fig. 13--Similar area as Fig. 12, but after cleaning. No corrosion was
observed after almost one year testing.

environments. In both cases, the alloy 625 clad steel was


exposed downstream of mixing zones, i.e., areas where hot
(220 to 290 ~ unscrubbed gas is mixed with cooler,
125 ~ scrubbed gas. This mixing chamber condition has
produced the most aggressive environment identified to
date in power plant scrubber systems. 14
Figure 14 shows a diagram of the Southern Indiana Gas Fig. 15--Same as Fig. 14, but showing Sample C plate after 335 days of
& Electric Company's A.B. Brown Unit #1 stack liner. exposure in the stack liner at elevation 100 feet.
Three test plates of alloy 625 clad steel were evaluated at 60,
80, and 100 feet of elevation. The test plates were evaluated showed severe pitting corrosion after only six months of
after 211 and 335 days of exposure. Localized corrosion service. 14
was found in the alloy 625 cladding and all welds, but
maximum attack was only 0.002 inch deep. Figure 15
shows the alloy 625 clad plate exposed at elevation 100 CONCLUSIONS
feet after 335 days. (1) INCONEL alloy 625 has displayed exceptional
In a similar, severe test environment downstream of the corrosion resistance in a wide variety of severe corrosive
flue gas mixing chamber, alloy 625 clad steel was tested at environments of importance to energy-related and chemical
the South Mississippi Electric Power Association's R.D. processing industries.
Morrow Power Plant in Unit # 2 breeching duct. After six (2) INCONEL alloy 625 has been successfully roll
months of exposure, no measurable corrosion was observed bonded to carbon steel plate and is now available commer-
(Figure 16). In this area of the scrubber, alloy G (6 pct Mo) cially in thin-gauge (0.250 inch).

J. MATERIALSFOR ENERGY SYSTEMS VOL. 8, NO. 1, JUNE 1986 15


REFERENCES
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have demonstrated that alloy 625 clad steel has good to of High-Nickel Alloys in Simulated SO2-ScrubberEnvironments,"
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The authors wish to express their appreciation to Miss W. L.
Closed-Loop LimestoneFGD System," Paper No. 203, presented at
Rogers for preparing this manuscript. the NACE Annual Meeting CORROSION/82, March 1982.

16 VOL.8, NO. 1, JUNE 1986 J. MATERIALSFOR ENERGY SYSTEMS

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