Info - Butter Welds

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APPENDIX A

WELDING PROCEDURE DETAILS

A.1 F22-IN 625 butter weld

Figure A.1 Hub materials are butter welded to build up IN 625 material in a horizontal layering

fashion and then machined with a bevel in preparation for a closure weld.

Preheat Parameters

Minimum Preheat 177°C

Maximum Preheat 288°C

Preheat Method Propane

Preheat control Contact Pyrometer

Post Weld Bake Out 260°C for 1 hr

Weld Processing Set-Up Parameters

GTAW WFS 100 IPM

GTAW Heat Angle 0° with trailing wire feed

Gas Flow 40 CFH w/ #10 cup / gas lens

Tungsten 2% Thoriated, 1/8" diameter

Post Weld Heat Treatment

PWHT 649°C for 5, 10, 15 hr

Heating rate 204°C per hr

Cooling rate 204°C per hr

Start/Finish Temperature 427°C

PWHT prior to Bevel Yes

Material and Weld Parameters

Material ASTM 182

Grade F22

Pipe Diameter 10.75"

Thickness 1.2"

Type of Welding Hot wire -GTAW-Machine

Position 2G

Electrode AWS ERNiCrMo-3

Electrode Alloy Inconel 625

Electrode Size 0.045"

Current Polarity DC

Pass Multiple

Arc Single

Hot Wire Set-Up Parameters

AC Amperage 110 A

AC Volts 3.3 V

Step Increment 50% of bead width

Wire Stick Out 0.625" to 0.750"

*AC measurements taken while welding

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Pulse Set-Up Parameters

Peak Current 240 A

Background Current 120 A

Pulse Duration 0.300 s

Heat Input

Pass #

Bead Number Amps Volts

Travel Speed (in/min) Heat Input (KJ/in) Interpass Preheat (°C)

1 1 to 7 182 11.2 8 15.2 NA

2 8 to 13 182 11.4 8 15.5 343

3 14 to 22 178 11 8 14.6 343

4 23 to 31 182 10.7 8 14.6 343

5 32 to 37 182 10.9 8 14.8 343

6 38 to 45 182 10.9 8 14.8 343

7 46 to 53 182 10.8 8 14.7 343

8 54 to 60 182 11 8 15 343

9 61 to 68 182 10.9 8 14.8 343

10 69 to 79 182 11.1 8 15.1 343

11 80-87 182 10.9 8 14.8 343

12 88-95 182 10.7 8 14.6 343

13 Buildup 183 10.7 8 14.6 343

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A.2 AISI 8630-IN 625 butter weld

Figure A.2 Hub materials are butter welded to build up IN 625 material in a horizontal layering

fashion.

Preheat Parameters



Preheat Method Oxyacetylene torch




GTAW WFS 75 IPM





PWHT 691°C for 5, 10, 15 hr





Material AISI 8630

Grade 8630

Pipe Diameter 10" OD

Thickness 3.5"

Type of Welding Pulse-Hot Wire -GTAW-Machine

Position 1G

Electrode AWS ERNiCrMo-3

Electrode Alloy Inconel 625


Current Polarity DCEN

Pass Multiple

Arc Single

Gas Argon


AC Amperage 110 A

AC Volts 3.3 V




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Peak Current 270 A


Voltage 11.4

Peak Time (sec) 0.2

Background Time (sec) 0.2

Heat input

Pass # Bead Number Amps Volts

Travel Speed (in/min) Heat Input (KJ/in)

Interpass Preheat (°C)

1 1 to 6 209 10.4 7 21.2 209-244

2 7 to 12 209 10.2 7 20.7 217-277

3 13 to 18 209 11 7 22.2 208-266

4 19 to 23 209 10.9 7 22.1 43-260

5 24 to 29 209 10.6 7 21.4 209-263

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A.3 F22-LAS butter weld

Figure A.3 Hub materials are butter welded to build up LAS material in a horizontal layering

fashion and then machined with a bevel in preparation for a closure weld.

Preheat Parameters







GTAW WFS 100 IPM





PWHT 649°C for 5, 10, 15 hr




PWHT prior to Bevel Yes


Material ASTM 182

Grade F22

Pipe Diameter 10.75"

Thickness 1.2"

Type of Welding Hot Wire -GTAW-Machine

Position 2G

Electrode AWS ER80S-D2


Current Polarity DC

Pass Multiple

Arc Single


AC Amperage 110 A

AC Volts 3.3 V




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Peak Current 280 A


Pulse Duration 0.300 s

Heat Input

Pass # Bead Number Amps Volts Travel Speed (in/min) Heat Input (KJ/in)

Interpass Preheat (°C)

1 1 to 5 214 10.2 8 16.3 NA

2 6 to 10 210 10.8 8 17 288

3 11 to 16 215 10.4 8 16.7 288

4 17 to 19 216 10.4 8 16.8 288

5 20 to 24 215 10.4 8 16.7 288

6 25 to 29 325 10.4 8 16.7 288

7 30 to 34 218 9.9 8 16.1 288

8 35 to 39 215 10.6 8 17 288

9 46 to 48 210 10.4 8 16.3 288

10 49 to 52 211 10.4 8 16.4 288

11 53 to 56 216 10.9 8 17.6 288

12 57 to 61 211 10.4 8 16.4 288

13 Buildup 215 10.7 8 17.1 288

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A.4 F22-IN 625 closure weld

Figure A.4 A closure weld is completed between the butter material and the pipeline steel.

Preheat Parameters








General Material and Weld Parameters

Buttered Material ASTM 182

Buttered Material Grade F22

Pipe Material API5L

Pipe Material Grade X70

Pipe Diameter 10.75”

Pipe Thickness 1.2”

Position 5G

Pass Direction Up

Land 0.050”

Gap 0.125”

Primary Electrode GTAW-Manual

Primary Electrode AWS ERNiCrMo-3

Primary Electrode TN Inconel 625

Primary Current Polarity DCEN

Secondary Electrode SMAW-Manual

Secondary Electrode AWS ENiCrMo-3

Secondary Electrode TN Inconel 112

Secondary Current Polarity DCEP

Shielding gas Argon

Purge gas Argon

Pass Multiple

Arc Single

PWHT None

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Heat Input

Pass

Electrode

Amps Volts

Travel Speed

(in/min)

Heat Input (KJ/in)

Preheat Or Interpass

Temperature (°C)

Weld Type AWS Class

Size (in)

Root ERNiCrMo-3 0.125 101 14 2 42.4 154 Manual GTAW

Hot ERNiCrMo-3 0.125 164 14.6 2.4 59.8 149 Manual GTAW

Fill 1 ERNiCrMo-3 0.094 65 23.4 2.7 33.8 202 SMAW






Fill 7 ERNiCrMo-3 0.125 83 25 3 41.5 232 SMAW






Fill 13 ERNiCrMo-3 0.125 91 25.6 3.1 45 232 SMAW

Fill 14 ERNiCrMo-3 0.125 87 25.9 3 45 232 SMAW


Fill 16 ERNiCrMo-3 0.125 90 25.4 4 34.2 232 SMAW

Fill 17 ERNiCrMo-3 0.125 88 24 4.1 30.9 218 SMAW


Cap 19 ERNiCrMo-3 0.125 80 25.4 4 30.4 232 SMAW

Cap 20 ERNiCrMo-3 0.125 85 24.4 3.7 33.6 232 SMAW


Cap 22 ERNiCrMo-3 0.125 82 25 2.2 55.9 232 SMAW

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A.5 F22-LAS closure weld

Figure A.5 A closure weld is completed between the butter material and the pipeline steel.

Preheat Parameters








General Material and Weld Parameters

Buttered Material ASTM 182

Buttered Material Grade F22

Pipe Material API5L

Pipe Material Grade X70

Pipe Diameter 10.75”

Pipe Thickness 1.2”

Position 5G

Pass Direction Up

Land 0.050”

Gap 0.125”

Primary Electrode GTAW-Manual

Primary Electrode AWS ERNiCrMo-3

Primary Electrode TN Inconel 625

Primary Current Polarity DCEN

Secondary Electrode SMAW-Manual

Secondary Electrode AWS ENiCrMo-3

Secondary Electrode TN Inconel 112

Secondary Current Polarity DCEP

Shielding gas Argon

Purge gas Argon

Pass Multiple

Arc Single

PWHT None

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Heat Input

Pass

Electrode

Amps Volts

Travel Speed

(in/min)

Heat Input (KJ/in)

Preheat Or Interpass

Temperature (°C)

Weld Type AWS Class

Size (in)

Root ERNiCrMo-3 0.125 100 11.9 1.5 47.6 157 Manual GTAW

Hot ERNiCrMo-3 0.125 155 14.5 2.3 58.6 152 Manual GTAW














Strip 14 ERNiCrMo-3 0.125 77 25 2.6 44.4 227 SMAW

Strip 15 ERNiCrMo-3 0.125 78 24.5 1.9 60.3 232 SMAW

Strip 16 ERNiCrMo-3 0.125 79 23.7 2.5 44.9 232 SMAW


Fill 18 ERNiCrMo-3 0.125 79 23.4 4 27.7 152 SMAW





Cap 23 ERNiCrMo-3 0.125 73 23.4 3.2 32 232 SMAW



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AUTHOR’S BIOGRAPHY

Jamey Fenske was born on April 4, 1984 in Aurora, Illinois to Karen and Ronald

Fenske Jr. After graduating with honors from West Aurora Senior High School, he

secured an internship at Packer Engineering in Naperville, Illinois where he began

working in the metallurgical failure analysis and testing lab. In between lab work, he

made molds and steel sand castings of engine parts needed for a Wright Flyer recreation

project in celebration of the 100 year anniversary of powered flight. In the fall of 2002,

Jamey entered the Materials Science and Engineering program at the University of

Illinois, Urbana- Champaign with a focus on metals. The following summer he began an

internship with Packer Technologies International. He was stationed at Michigan Steel in

Muskegon, Michigan to improve production quality and to research thin wall stainless

sand steel casting. During the summer and winter breaks between semesters of college,

Jamey continued to work at Packer Engineering in the metallurgical failure analysis and

testing lab in support of a large variety of industrial projects and professional testimony.

He also conducted research in conjunction with Packer Engineering including the

development of an engine condition monitoring system for piston aircraft engines.

During his senior year in college, Jamey began doing undergraduate research under the

direction of Professor Ian M. Robertson investigating hydrogen permeation and

preventative measures against hydrogen embrittlement of pipeline steels. In 2006 Jamey

graduated with honors with a Bachelor of Science in Materials Science and Engineering

from the University of Illinois, Urbana-Champaign. The summer following graduation,

he continued to do research under the direction of Professor Ian M. Robertson

investigating deformation mechanisms in irradiated materials and equal channel angular

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pressed aluminum using in situ TEM, SEM and a variety of other microscopic

techniques. In the fall of 2006 Jamey began his graduate career at the University of

Illinois, Urbana-Champaign and joined the research group of Professor Ian M. Robertson

in the Materials Science and Engineering department. During his graduate career he

undertook a variety of research projects including, but not limited to: in situ high

temperature dislocation-boundary interactions in austenitic stainless steels, in situ high

and room temperature effects of radiation damage on the dislocation motion and

dislocation-grain boundary interactions in austenitic stainless steels, in situ dislocation-

loop interactions in aluminum alloys, deformation mechanisms in equal channel angular

pressed aluminum, hydrogen permeation of pipeline steels, hydrogen enhanced fracture

mechanisms in steel, in situ heating and grain growth in nano-grain gold, TEM

investigation of effects of hydride formation on the defect density in palladium, and TEM

investigation defects in oxide dispersion strengthened steels. In the summer of 2007

Jamey took an internship at the ExxonMobil Development Company in Houston, Texas

where he oversaw failure analysis, mechanical testing and qualification programs. He

brought hydrogen susceptible dissimilar metal weld samples back to Champaign with

him for detailed microscopic investigation which he eventually adopted as his thesis

work. During the summer of 2008 he secured an internship at the ExxonMobil Corporate

Strategic Research Company in Clinton, New Jersey where he continued to investigate

the hydrogen susceptibility of dissimilar metal butter welds. His work was presented in

the 2010 Microscopy and Microanaylsis Conference, the 2010 Materials and Science and

Technology Conference, and published in Metallurgical Transitions A. Following the

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deposition of this document Jamey plans to move to Houston, Texas with his new wife to

join the technical staff of the ExxonMobil Development Company.

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