Selection of Optimal Filler Metal for Dissimilar Welding of SA335 Gr. P11 and Incoloy 800 in Primary Reformer Tube Catalyst Repairs
A Mechanical Property Analysis
Corresponding author: Akhyar Akhyar
Abstract
This investigation explores the effect of various filler metals on the mechanical performance of dissimilar weld joints between SA335 Gr. P11 and Incoloy 800, with particular relevance to repair operations in primary reformer tube catalysts used in petrochemical plants. The joining technique employed was Gas Tungsten Arc Welding (GTAW). Three different filler metals: ER-NiCr-3, ER-NiCrMo-3, and ER-NiCrCoMo-1, were evaluated, and their performance was assessed using tensile strength and hardness testing across the weld metal, the Heat-Affected Zone (HAZ), and the base materials. The findings demonstrate that ER-NiCrMo-3 achieved the highest tensile strength, reaching approximately 60 kgf/mm², which was superior to the values recorded for ER-NiCr-3 and ER-NiCrCoMo-1. With respect to hardness, the Vickers hardness of the base material (BM-1, SA335 Gr. P11) was found to be 234.7 HV when welded with ER-NiCr-3, 217.6 HV with ER-NiCrMo-3, and 223.8 HV with ER-NiCrCoMo-1. However, in the HAZ-1 region, ER-NiCrMo-3 again displayed the greatest hardness value, reaching 299.4 HV, thereby outperforming the alternative fillers. The study contributes to the optimization of filler metal selection for dissimilar welding in repair applications within the petrochemical sector. By demonstrating that the use of ER-NiCrMo-3 not only enhances mechanical performance but also has the potential to reduce repair time from 252 days to 90 days, the study highlights significant opportunities to improve plant reliability and achieve cost savings in large-scale industrial operations.
Keywords:
dissimilar welding, SA335 Gr. P11, Incoloy 800, filler metal selection, mechanical propertiesDownloads
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