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Development of the matching filler metal for MARBN—new advanced creep resisting alloys for thermal power plant

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Abstract

MARBN alloys, which are anticipated an estimated 25 °C increase in advanced ultra-super critical (A-USC) power plant operating temperature, are expected to be commercially available soon and will partially displace some older materials and lead the market. Two examples are the Japanese alloy, 9Cr-3W-3Co-Nd-B material, which is considered a strong contender in wrought pipework, and the UK’s IBN-1 alloy which currently leads the development in cast steels. Through the courses of two consecutive UK collaborative projects IMPEL and IMPULSE, a matching composition filler metal for welding MARBN alloys in the form of shielded metal arc SMAW electrode has been developed. The design of this filler metal was aimed to optimize the deposit chemical composition hence to provide creep resistance properties matching the base alloys. The weld metal was specifically intended for high integrity structural service at expected temperatures. Accordingly, the minor alloy additions responsible for its creep properties were kept at the middle of the base alloys or at least above the minimum considered necessary to ensure a satisfactory performance. This paper introduces the design, investigation and test results of the matching filler metal. Findings relevant to the microstructure, mechanical properties at ambient and elevated temperatures, including creep properties of the all-weld metal and weld joint made with IBN-1 base alloy, are presented.

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Abbreviations

MARBN:

MARtensitic 9Cr steel strengthened by Boron and Nitrides; the creep properties are enhanced by addition of nominal 3%Co, 3%W and 100ppmB. More details could be found from relevant references cited in this paper

SAVE12DA:

A MARBN type alloy with 9Cr-3 W-3Co-Nd-B; details can be found in ASME Code case 2839; reference [6] of this paper

CB2:

A 9%Cr-Mo creep resistance alloy developed through the European COST projects. The creep properties are enhanced by additions of nominal Co and B

P92:

A widely used 9%CrMo type creep resisting steels. Different forms of grade 92 steels are listed in various specifications. For example, in EN 10216-2, they are classified as X10CrWMoVNb9-2; in ASTM standards, they have forms of tube T91 in A213, pipe P92 in A335, grade 92 plates in A387, and forgings F92 in A369

IMPACT Project:

“Innovative Materials, Design and Monitoring of Power Plant to Accommodate Carbon Capture”, A UK Technology Strategy Board (TSB) funded collaborative R&D project, December 2009–December 2013

IMPEL Project:

A UK collaborative project for feasibility studies of MARBN base alloy and filler metal, 2014–2019

IMPULSE Project:

“Advanced Industrial Manufacture of Next-Generation MARBN Steel for Cleaner Fossil Plant”, Innovate UK File Ref. 102468, May 2016–April 2019

IMPLANT Project:

“Advanced Materials and Manufacturing for Improved Power and Process Plant Performance”, Innovate UK File Ref. 105769, January 2020–December 2022

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Acknowledgements

The authors gratefully acknowledge the funding from Innovate UK, under Project IMPULSE: “Advanced Industrial Manufacture of Next-Generation MARBN Steel for Cleaner Fossil Plant”, Innovate UK File Ref. 102468 and their project partners within IMPULSE Project and IMPEL Project: Doosan Babcock Ltd, Goodwin Steel Castings Ltd, Alstom Power (now GE Energy), Uniper Technologies Ltd, IMPACT PowerTech Ltd, Wyman-Gordon Ltd, Loughborough University, University of Nottingham, University of Birmingham, NUI Galway and University of Limerick.

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  1. Lincoln Electric Europe, Sheffield, UK

    Zhuyao Zhang & Vincent van der Mee

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  1. Zhuyao Zhang
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  2. Vincent van der Mee
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Correspondence to Zhuyao Zhang.

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Zhang, Z., van der Mee, V. Development of the matching filler metal for MARBN—new advanced creep resisting alloys for thermal power plant. Weld World 65, 1599–1608 (2021). https://doi.org/10.1007/s40194-021-01104-4

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