Discussion and conclusions

Therefore, beyond the ~100 μm distance and due to lower Fe content, the

(Mo, Cr)-rich (μ) phase becomes stable and formation of this phase decreases

the chemical potential of Cr and Mo and prevents carbide formation in this

area. However, this phase formed very close to the Nb-rich (δ) in the

interdendritic regions and so it is difficult to distinguish these phases from

each other. It can be said that both these phases are co-exist in these regions.

In the D128 sample some acicular bright precipitates become visible in the

microstructure very close to carbides which are suggested to be the (δ) phase.

In this region, the Cr and Mo atoms formed carbides and as such, the Nb

atoms are free to form the Ni3Nb phase. The (δ) phase was also seen in the

WD128 sample along the grain boundaries close to interface because (μ)

phase is not stable at this region due to high Fe content.

7-4- Summary

The precipitation behaviour following thermal exposure, in various regions of

the weld overlaid tube, are different due to variation of as-welded

microstructure and composition. Moreover carbon migration causes further

changes in the interfacial region due to wide differences in its chemical

potential in the 2.25Cr1Mo steel and the nickel alloy.

The main process in the early stages of thermal exposure is dissolution of

metastable carbides in the steel region and formation of carbides at the

interface and along the grain boundaries of the interfacial region. However,

different microstructures in the steel region cause different rates of dissolution

and precipitation sequences which are considered in a new model to explain

microstructural evolution in the different regions of steel. It is clear that the

Microstructural stability of a nickel-based alloy on a 2.25Cr1Mo steel substrate...250

Discussion and conclusions

width of the HAZ zone is related to heat input during welding. Therefore

choosing a welding process with a narrower HAZ could be useful in changing

the width of the soft zone during service.

Formation of a carbide network at the interface interrupts carbon supply

across the interface. However, there is carbon redistribution in the steel region

which causes further changes in the microstructure of the near-HAZ region.

The re-hardening of this region and the formation of fine ferrite grains is

explained by formation of fine Cr-rich carbides and Mo replenishment in the

coexisting ferrite. Due to the above observations, carbon migration cannot

continue indefinitely and it is observed that the mechanical properties and

microstructure of the central and the far-HAZ zones remain almost unchanged

at 650˚C. Therefore, it is suggested that increasing the steam temperature to

above 450˚C in the power plants is possible. However, the technical issues in

this regard should be considered.

The Fe/Mo ratio is the major parameter in formation of different phases in the

microstructure of weld overlay region. Increasing distance from the interface

with lower Fe/Mo ratio results in formation of the (μ) intermetallic phase at

the expense of carbide precipitates which are stable at higher ratio along the

grain boundaries. This fact indicates that the steel substrate has some effect on

the first 100 μm of the weld overlay material. Therefore, it is suggested that by

consideration of corrosion rate and it relation to the thickness, the weld

overlay thickness can be reduced which means reduction of costs for

manufacturing of the bimetallic tube.

Microstructural stability of a nickel-based alloy on a 2.25Cr1Mo steel substrate...251

Discussion and conclusions

Based on the results of this research, it is clear that formation of the hard band

is not related to the carbide formation as it also formed in the WD128 sample.

Although formation of this hard band layer has not a significant effect on the

hook stress, due to the temperature fluctuation and 3 dimensional forces in the

tube, the presence of a hard band adjacent to the soft zone could degrade

mechanical properties of the tube during its service life.

7-5- Future work

The first important issue is to determine the realistic temperature profile in the

wall thickness of a super heater tube in the service condition. This thermal

analysis helps to understand the effect of increasing service temperature on the

different regions of this tube especially at interface.

The second issue is that the aim of applying a weld overlay on ferritic steel is

to increase the corrosion resistance in the severe operating conditions such as

WtE boilers. The corrosion resistance is related to the microstructure and it is

necessary to analyse this property of the weld overlay. It is clear that the weld

overlay material contains about 9 wt% Fe which may cause different corrosion

behaviour compared to that of the standard wrought Inconel 625 with less than

5 wt% Fe content.

The third issue is to understand the affects of the hard band and the soft zone

on the mechanical properties under service conditions. Therefore mechanical

tests need to be done on different samples.

Microstructural stability of a nickel-based alloy on a 2.25Cr1Mo steel substrate...252