A Review of Challenges to Hastelloy – C Series Weld Overlay
169
Table 10 Selection of consumable for Hastelloy – C series [11, 45]
UNS number (alloy)
Filler wire (GTAW)
Electrodes (SMAW)
N10276 (Alloy C-276)
ERNiCrMo-4
ENiCrMo-4
N06455 (Alloy C-4)
ERNiCrMo-7
ENiCrMo-7
N06022 (Alloy C-22)
ERNiCrMo-10
ENiCrMo-10
N06200 (Alloy C-2000)
ERNiCrMo-17
ENiCrMo-17
E-Coated Electrode used in SMAW process
ER-Bare Wires
Welding process selection for weld overlay is an important factor, and selection
of process depends on lots of factors, but the major factor is the higher deposition
rate, lower dilution, and good finishing of the weld overlay.
Conventional welding process is used for filling of strip back weld overlay and
grinding/chipping bottom side area of weld overlay using submerge arc welding
process (SAW), GTAW, shielded metal arc welding (SMAW) process and metal
active or inert gas welding process (MIG/MAG). Among these, the most traditional
process used in small-scale and medium-scale industries is SMAW process.
Every process has its pros and cons such as the low deposition rate in SMAW
and manual GTAW process, more spatter, less quality finish, and higher dilution in
MIG/MAG, high heat input, and depth of penetration in SAW. Control over dilution,
adequate deposition rate and good weld overlay finish can be achieved using advanced
welding processes such as CMT, HWT, laser cladding, and PTAW process, but they
involved high machine cost and skilled man power [42–44].
Selection of correct welding consumables for the Hastelloy – C series weld overlay
is quite important due to their elements’ effect on mechanical properties and corrosion
behavior. Suggested welding consumables for the Hastelloy – C series weld overlay
application are as shown in Table 10.
For the quality of the weld overlay and easiness in the deposition, the selection
of proper joint geometry is essential. Among the four possible construction method,
butt joint methods are used whenever possible [3, 11]. Construction method details
are as per Fig. 4.
For quality weld overlay of Hastelloy – C series, bead placement sequences are
important. Start the bead placement from both the ends than last bead placement at
the center [11].
4 Summary
Hastelloy – C series alloys are an important class of material for industries like
chemical processing, pressure vessel, and heat exchanger manufacturers due to
their excellent corrosion resistance in numerous chemical atmospheres. Corrosionresistant weld overlay offers an economical alternative to solid alloy manufacturing.
169
Table 10 Selection of consumable for Hastelloy – C series [11, 45]
UNS number (alloy)
Filler wire (GTAW)
Electrodes (SMAW)
N10276 (Alloy C-276)
ERNiCrMo-4
ENiCrMo-4
N06455 (Alloy C-4)
ERNiCrMo-7
ENiCrMo-7
N06022 (Alloy C-22)
ERNiCrMo-10
ENiCrMo-10
N06200 (Alloy C-2000)
ERNiCrMo-17
ENiCrMo-17
E-Coated Electrode used in SMAW process
ER-Bare Wires
Welding process selection for weld overlay is an important factor, and selection
of process depends on lots of factors, but the major factor is the higher deposition
rate, lower dilution, and good finishing of the weld overlay.
Conventional welding process is used for filling of strip back weld overlay and
grinding/chipping bottom side area of weld overlay using submerge arc welding
process (SAW), GTAW, shielded metal arc welding (SMAW) process and metal
active or inert gas welding process (MIG/MAG). Among these, the most traditional
process used in small-scale and medium-scale industries is SMAW process.
Every process has its pros and cons such as the low deposition rate in SMAW
and manual GTAW process, more spatter, less quality finish, and higher dilution in
MIG/MAG, high heat input, and depth of penetration in SAW. Control over dilution,
adequate deposition rate and good weld overlay finish can be achieved using advanced
welding processes such as CMT, HWT, laser cladding, and PTAW process, but they
involved high machine cost and skilled man power [42–44].
Selection of correct welding consumables for the Hastelloy – C series weld overlay
is quite important due to their elements’ effect on mechanical properties and corrosion
behavior. Suggested welding consumables for the Hastelloy – C series weld overlay
application are as shown in Table 10.
For the quality of the weld overlay and easiness in the deposition, the selection
of proper joint geometry is essential. Among the four possible construction method,
butt joint methods are used whenever possible [3, 11]. Construction method details
are as per Fig. 4.
For quality weld overlay of Hastelloy – C series, bead placement sequences are
important. Start the bead placement from both the ends than last bead placement at
the center [11].
4 Summary
Hastelloy – C series alloys are an important class of material for industries like
chemical processing, pressure vessel, and heat exchanger manufacturers due to
their excellent corrosion resistance in numerous chemical atmospheres. Corrosionresistant weld overlay offers an economical alternative to solid alloy manufacturing.