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June 2023
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Thermocalc cracked5/29/2023 The strain-to-fracture test was modified to replicate the bending procedure, and an optimal parameter window consisting of bending temperature, total strain, and strain rate was identified based on test results. Serial sectioning shows that ductility-dip cracks form between the pre-existing weld metal liquation cracks and microcracks forming in the embrittled planar growth region, ultimately leading to through-thickness cracks of the overlay during induction bending. Analysis consisting of optical and scanning electron microscopy along with hardness traverses and mapping revealed weld metal heat-affected zone liquation cracks in the second overlay after welding, as well as a region of high hardness in the planar growth region of the weld metal directly adjacent to the dissimilar metal weld interface. A detailed metallurgical investigation was carried out to understand the root cause of the cracking phenomenon. ![]() Cracking in corrosion resistant clad overlays on low alloy carbon steel pipes made with Alloy 825 has been experienced in the industry in an effort to reduce production costs by changing the cladding material from the more costly Alloy 625.
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