voestalpine Grobblech GmbHwww.voestalpine.com/grobblech

voestalpine Grobblechand

Boehler Welding Group

Seminar

Tehran, May 25th 2010

voestalpine Grobblech GmbHwww.voestalpine.com/grobblech

Roll-bonded clad platesOur answer to corrosion

Heavy Wall CrMoV-steel gradesWe face high temperatures

3 May 2010 Iran| |voestalpine Grobblech GmbH

Voestalpine Grobblech GmbH

voestalpine produces clad platesby hot-roll-bonding

production of clad plates byvacuum technology since 1965

our own steel mill produces ultra clean steel by continous casting

voestalpine is the biggest supplierof roll-bonded clad plates in Europe

4 May 2010 Iran| |voestalpine Grobblech GmbH

Typical combination is a thin corrosion resistant alloy (CRA)as cladding and carbon steel or low-alloyed steel as backing

Metallurgically bonded composite

Definition roll-bonded clad plate

Base materialfor static demands

Clad materialfor corrosion protection

The bond is created by hot rolling (pressure+temperature)

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Typical fields of application

Clad plates for pipes

Chemical industry

Fittings

Flue-gas desulphurisation

Oil and gas production

Desalination plants

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Mainly heavy wall thickness (typical above 50mm total thickness)

Clad plates for pressure vessel

Typical clad materials used:A 240 Type 410SA 240 Type 304 LA 240 Type 321/347A 240 Type 316L, 317LAlloy 625, Alloy 825

Typical base materials:Carbon steel (A 516, 533, 537,…) Cr-Mo steel (A 387,…)Cr-Mo-V steel (A 542)

7 May 2010 Iran| |voestalpine Grobblech GmbH

Roll-bonded clad plates for clad pipes

Linepipes can be layed by reeling

Delivery conditions: TMCP (for high strength and excellent toughness),quenched and tempered, normalised

Usable for highest technical demands (catenary risers, high-strength linepipesfor deep sea applications, bends, fittings)

Wide dimensions (pipe diameter, wall thickness) possible

8 May 2010 Iran| |voestalpine Grobblech GmbH

Comparison of two process routes: TMCP and QTCharpy transition curves: The TMCP material has a lower transition temperatureBattelle properties: QT resulted in unacceptable BDWTT valuesCorrosion properties:Clad material in TMCP-condition shows better corrosion resistance

Typical CRA materials:Riser pipes / Fittings: 316L, Alloy 825, Alloy 625Linepipe: 316L, Alloy 825

Roll-bonded clad plates for clad pipes

Streichertest in acc. with ASTM A262 Pr. B:Corrosion rate [g/(m2h)]: 0.215 +/- 0.01

Hueytest in acc. with ASTM A262 Pr. C:Corrosion rate [g/(m2h)]: 0.074 +/- 0.005

CPT - Test in acc. with ASTM G48, A: Critical Pitting Temperature CPT [°C]: 37.2 +/- 1.0

Hardness HV10: 235 +/- 6

Alloy 825, hardness and corrosion data for TMCP-condition

9 May 2010 Iran| |voestalpine Grobblech GmbH

Important industrial cladding methods

roll bondingSuperior surface finishNo dilution from the base materialReduction of weld length due to larger sizesUse of thinner clad material is possibleBest shear strengthFlatness consistencyNo areas of non-bonds

explosion bonding

overlay welding

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Risksdilution, local hard spots and porosities

at wave crests

sensible to hydrogen attacksside bending leads to delaminationcaused by wavy interface

rollbonded explosion bonded

Cladding process – Explosion bonding

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large area ++ - -thin wall ++ - - -heavy wall + ++ ++Zirconium, … + ++ - -

roll bonding

weld overlay

explosion bonding

Comparison of the different cladding methods -suitability and costs

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Advantages of roll-bonded clad platesversus solid CRA plates

reduced wall thickness due to higher strength of base material less weight reduced material costs

versus explosion bondinghigher bonding quality (no bond waves)smaller weld length due to larger dimensionsreduced welding costs, lower cost of filler metalsmaller thickness of claddings possible (< 3 mm)

versus weld overlayimproved surface conditionno dilution from the base materialhomogeneous chemical composition

13 May 2010 Iran| |voestalpine Grobblech GmbH

Cladding process (1)

1 Acceptance of base material (heat analysis) acc. standard and specification (customerrequirements)

2 Order of cladding material – purchasedmaterial acc. standard and specification(customer requirements)

3 Hot rolling of base and clad material

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Cladding process (2)

5 Package assembly

4 Internal UT – internal examination of pre-material

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Base material: shotblastedtop side ground

CRA: bottom side ground

Separating medium

CRA: top side ground

Base material: shotblastedbottom side ground

Weld frame and proper welding makes the pack airtight

Cladding process (3)Assembly of a sandwich clad pack

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6 Evacuation

Cladding process (4)

7 Reheating of clad pack

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8 Hot rolling of clad pack

Cladding process (5)

9 Heat treatment

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Cladding process (6)

10 Plasma torch cut

11 Levelling

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13 Grinding of clad surface

Cladding process (7)

12 Ultrasonic testing

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Innovative investments (1)Heavy plate rolling mill state-of-the-art

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Shot blasting for clean surfaceFinishing of clad plates

Innovative investments (2)Most advanced finishing lines for roll-bonded clad plates

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Innovative investments (3)Most advanced finishing lines for roll-bonded clad plates

Belt grinding on clad surface

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Clad plate properties (1)Bond strength (shear test)

Mean value = 357 MPa

Min. 140 MPa acc. standard

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Clad plates perform as well as solid material concerning corrosionresistance.

Clad plate properties (2)Corrosion resistance

0,00 0,05 0,10 0,15 0,20 0,25 0,300

5

10

15

20

25 clad alloy 59solid alloy 59

frequ

ency

Corrosion rate [mm/year]

25 May 2010 Iran| |voestalpine Grobblech GmbH

Based on the chemical composition themechanical-technological properties of the basematerial as well as the corrosion properties of the clad material are adjusted by productionroute and proper heat treatment:

as rolled with simulated testing

normalizing rolled (N)

normalized in furnace (N)

normalized and tempered (N+T)

quenched and tempered (Q+T)

thermomechanically rolled and acceleratedcooled (TM+ACC)

Clad plate properties (3)Heat treatment / production route

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MaterialsProduction range

Dimensions:cladding thickness: 1 – 15 mmtotal plate thickness: 6 – 150 mmlength: up to 18 m

Q+T up to 12 mwidth: up to 3.8 msingle plate weight: 2 – 22 mt

Surface finish:base material: as rolled or shot blastedclad material: normally ground with a grainsize of 80

We can provide technicalsupport concerningprocessing (cutting, forming) and welding (processes, fillermetals, weld shapes,..)

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Disbonding test (1)

autoclave

Bended specimen

Specimen, ready for testing

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Disbonding test (2)

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300200

220

240

260

280

300

320

340

360

380

400

420

440

460

480

500

UT-Ranking "A" UT-Ranking "B" UT-Ranking "C" UT-Ranking "D" UT-Ranking "E"

Tem

pera

ture

[°C

]

H2-pressure [bar]

387 Gr.22Cl.2 + Type 347

387 Gr.11Cl.2 + Type 317L

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CrMoV-steel grades (1)

Heavy wall CrMoV-steel grades

We face high temperatures

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CrMoV-steel grades (2)

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CrMoV-steel grades (3)

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CrMoV-steel grades (4)

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