# Patent

## Title
Welded component

## Abstract

A welded component includes at least one high temperature segment of a high alloy Cr steel with high creep strength and a low temperature segment of a low alloy steel with high toughness and/or a high yield strength which are connected materially to one another via a weld joint. In one such component a gradual transition of chemical, physical and mechanical properties in the joining area is achieved in that between the weld joint and the high temperature segment there are at least two successive clad layers of at least two lower alloy weld metals with a total content of elements which increase the creep strength, such as for example Cr, Mo, W and V, which total content decreases toward the weld joint, and/or an increasing total content of elements which increase the toughness and/or yield strength, such as for example Ni and Mn, which total content increases toward the weld joint.

## Background
This disclosure is based upon German Application No. 10 2004 024 299.2, filed May 15, 2004, the contents of which are incorporated herein by reference.
TECHNICAL DOMAIN
This invention relates to the area of turbomachinery. For example, it relates to a welded component and a process for producing such a component.
PRIOR ART
Rotors of turbomachinery, for example of steam or gas turbines, generally have a high temperature segment and a low temperature segment which are exposed to high and low temperatures respectively (from steam or hot gas) during operation. In the high temperature segment a high creep strength is necessary which can be best achieved by high alloy steels with a high proportion of Cr. Other alloying elements such as for example Mo, W and V additionally increase the creep strength. In the low temperature segment conversely a high yield strength and toughness are necessary; they can be best achieved with a low alloy steel with a proportion of Ni of 3.5%, for example.
The best approach in this respect is a welded rotor. The different steels of the segments can be directly welded to one another along the rotor axis when a weld metal of a composition between the two steels is used (see in this respect U.S. No. 6,499,946) and if the welded rotor is subjected to following heat treatment (post weld heat treatment, abbreviated PWHT) before it is started up. But this approach has two disadvantages:

    
    
        Transversely to the weld joint there is an abrupt change in the chemical, physical and mechanical properties; this leads to nonuniform loading and reduced service life of the component.
        The temperature for post weld heat treatment PWHT is a compromise between the ideal temperatures for the two steels, i.e it is too high for the low allow steel (softening) and too low for the high alloy steel (low toughness and high residual welding stresses).
    
    


Alternatively to the above described approach, the high alloy steel can first be provided with a weld layer of a steel with a somewhat lower proportion of Cr and a lower creep strength and then can be subjected to heat treatment PWHT typically at a temperature which is roughly 20° C. below the tempering temperature of the base material of the high temperature segment, i.e. at the temperature at which the residual welding stresses are largely reduced without a noteworthy decrease of strength values. Then it is welded by means of a weld metal of somewhat lower creep strength (and lower Cr content) to the low alloy segment. Finally, the welded component is subjected to heat treatment PWHT at a temperature which is suitable for a low alloy steel (U.S. Pat. No. 4,962,586), i.e. in turn roughly 20° C. below the tempering temperature of the base material of the low temperature segment. The disadvantage of this approach is that as before there is an abrupt, step-by-step transition in the chemical, physical and mechanical properties.
DESCRIPTION OF THE INVENTION
Therefore the object of the invention is to form a welded component of the initially mentioned type which is characterized by a gradual transition in the chemical, physical and mechanical properties from one segment to another segment, and to devise a process for its production.
The object is achieved by a welded component formed according to the present invention. The heart of the invention is to provide, between the weld joint and the high temperature segment, at least two successively clad layers of at least two lower alloy weld metal deposits with a total content of elements which impart high creep strength to the steel, such as for example Cr, Mo, W, and V, which total content decreases toward the weld joint, and/or an increasing total content of elements which increase the toughness and/or yield strength, such as for example Ni or Mn. In this way the desired gradual transition between the welded segments in chemical, physical and mechanical properties is easily achieved.
In order to achieve a uniform structure of the clad layers even for greater layer thicknesses, it is advantageous if the clad layers each consist of several successively applied welding beads with low thickness. According to one preferred development the clad layers each have a thickness of several millimeters, especially 8 to 15 mm, especially preferably roughly 10 mm.
It has proven especially suitable in practice for rotors that the high temperature segment consists of a 8.5 to 13% Cr steel, that the first clad layer consists of a 4 to 6% CrMo steel and the second clad layer consists of 1.8 to 2.5% CrMo steel, that the low temperature segment consists of a 0.8 to 3.7% Ni, 0.8 to 2.5% Cr steel, and that the weld joint is built up with a weld metal of 0.8 to 2.7% Ni, 0.5 to 1.3% Cr steel. The weld joint has a thickness of several millimeters, especially up to 30 mm.
One preferred configuration of the process as claimed in the invention is characterized in that to apply the clad layers in succession individual weld beads of low thickness are applied.
If the high temperature segment consists of 8.5 to 13% Cr steel, to produce the first clad layer preferably weld beads of 4 to 6% CrMo steel and to produce the second clad layer weld beads of a 1.8 to 2.5% CrMo steel are applied, and in the second step the high temperature segment with the clad layers is stress-relieved for 10 hours at 670±10° C.
If the low temperature segment consists of a 0.8 to 3.7% Ni, 0.8 to 2.5 Cr steel, the weld joint is produced preferably using a weld metal of 0.8 to 2.7% Ni, 0.5 to 1.3% Cr steel, and the component is stress-relieved in the fourth step for 10 hours at 590±10° C.



BRIEF EXPLANATION OF FIGURES
The invention will be explained below using embodiments in conjunction with the drawings.
FIG. 1 shows in a schematic a section through the weld preparation of the high temperature segment for the junction weld to the low temperature segment according to one preferred embodiment of the invention;
FIG. 2 shows the characteristic of the measured proportions of Cr, Mo, and Ni in the first component area of the weld joint which is comparable to FIG. 1, as shown in FIG. 5;
FIG. 3 shows the characteristic of the measured proportions of Cr, Mo, and Ni in the second component area of the weld joint which is comparable to FIG. 1, as shown in FIG. 5;
FIG. 4 shows the measured characteristic of the microhardness over the weld joint as shown in FIG. 5; and
FIG. 5 shows the macrosection through a weld joint which has been implemented as shown in FIG. 1.



EMBODIMENTS OF THE INVENTION
FIG. 1 shows in a schematic a section through the weld preparation of the high temperature segment for the junction weld to the low temperature segment according to one preferred embodiment of the invention. FIG. 5 shows a macrosection through the weld joint which has been implemented as shown in FIG. 1. The two figures should be examined at the same time.
The component 10, for example the rotor of a steam turbine or gas turbine, of which FIGS. 1 and 5 show only a small extract, comprises a high temperature segment 11 and a low temperature segment 12 which consist of different steels which are adapted to the respective temperature of use. As shown in FIG. 5, they are joined to another materially along the direction of the rotor axis via a weld joint 15. FIG. 1 shows the state immediately before the junction welding of the two segments 11, 12. The point at which the weld 15 with a thickness c is located is identified with a broken reference line and positions 15 and c are placed in parentheses.
Between the weld joint 15 and the joining surface 16 of the high temperature segment 11 there are two clad layers 13 and 14 directly in succession; they cause a gradual transition between the two segments 11 and 12 in chemical, physical and mechanical properties. This is achieved by a matched choice of materials for the clad layers 13, 14 and the weld joint 15 for which likewise alloy steels are used.
For a component 10 in the form of a rotor for a turbomachine, in practice the following alloy steels for segments 11, 12 and the layers 13, 14, and 15 have proven themselves (proportions of the alloying elements in % by weight).

















11
13
14
15
12























C
0.12
0.09
0.08
0.06
0.21



Si
0.10
0.27
0.2
0.15
0.05



Mn
0.45
0.88
0.8
1.2
0.20



Cr
10.4
6.5*)
3.4*)
0.76
2.27



Ni
0.74
0.67
0.25
2.0
2.18



Mo
1.06
0.80
0.8
0.52
0.73



P
0.008
0.006
0.013
0.018
0.004



S
0.002
0.001
0.006
0.007
0.003



W
0.81
—
—
—
—



V
0.18
0.33
—
—
0.07







*)for the clad layers 13 and 14 a 5% CrMo steel or a 2.25% CrMo steel is used; the locally measured Cr proportions in the examined weld beads result from dilution with the preceding bead.






With the material compositions cited in the table above, a weld joint between the high temperature segment 11 (of 10% Cr steel) and a low temperature segment 12 is produced; FIG. 5 shows a photomicrograph.
In the production of the weld joint, first the two clad layers 13 and 14 are applied to the joining surface 16 of the high temperature segment 11 in succession by build-up welding. Each of the 10 mm thick clad layers 13, 14 was formed by successively applied weld beads (individual layers) of low thickness.
After applying the clad layers 13, 14 to the high temperature segment 11, the high temperature segment 11 with the clad layers 13, 14 was tempered (stress-relieved) at 670±10° C. for 10 hours. Afterwards the weld preparation (groove shape for the junction weld between the high temperature segment 11 and the low temperature segment 12) was produced by mechanical working. This state is shown in FIG. 1.
Then the high temperature segment 11 with the clad layers 13, 14 and the low temperature segment 12 are welded to one another with the formation of a 20 mm thick weld joint 15 (see FIG. 5), a 2.5 NiCrMo alloy having been used as the weld metal. After welding, the component 10 is tempered (stress-relieved) at 590±10° C. for 10 hours.
On the component 10 with the finished weld joint, the concentrations in % by weight of the elements Cr, Mo and Ni were measured transversely to the joining surface as a function of the local coordinate (x). The results are shown in FIGS. 2 and 3, the curve (1) showing the Cr proportion, curve (2) showing the Mo proportion and curve (3) showing the Ni proportion. It is apparent that with a simple 2-layer structure of clad layers a very uniform transition especially of the Cr concentration in the joining area can be achieved.
FIG. 4 plots the characteristic of the measured microhardness profile HV 1 by way of the local coordinate x. The triangles shown in the diagram mark the melting lines between the individual layers and segments. Aside from a hardness minimum of 200 HV 1 for the second clad layer 14 the hardness characteristic is very uniform.
Of course, the invention is not limited to the above described embodiment. Thus for example, the thickness of the clad layers 13, 14 can each be in the range from roughly 8 to 15 mm and the composition of the materials for the clad layers 13, 14 and the segments 11, 12 can likewise fluctuate within certain limits. For the high temperature segment 11 a steel with 8.5 to 13% Cr, especially 10% Cr, can be used to advantage and for the low temperature segment 12 a steel with 0.8 to 3.7% Ni, preferably 3.5% Mo and 0.8 to 2.5% Cr can be used. The first clad layer 13 consists of a 4 to 6% CrMo steel, preferably 5% CrMo steel and the second clad layer 14 consists of a 1.8 to 2.5% CrMo steel, preferably 2% CrMo steel. For the weld connection 15 a 0.8 to 2.7% Ni, 0.5 to 1.3% Cr steel is advantageous.
Finally, it is shown by way of example how the analysis can be controlled by fusion of the individual layers in the build-up welding of the layers 13, 14. The proportion of the previous layer is labelled x1 and the proportion of the new layer is labelled x2, the following applying:

    x1=1⁄3 to 2⁄3
    x2=1−x1.

5% Cr dilution:



For a base metal with 11% Cr the following applies to the individual layers:

    
    
        x1·11% Cr+x2·5% Cr, therefore
    
    
    1st layer: 1⁄2·11% Cr+1⁄2·5% Cr=8%Cr
    2nd layer: 1⁄3·8% Cr+2⁄3·5% Cr=6% Cr
    3rd layer: 1⁄3·6% Cr+2⁄3·5% Cr=5.3% Cr
    4th layer: 1⁄3·5.3% Cr+2⁄3·5% Cr=5.1% Cr


Therefore 4 weld layers are necessary to move from the Cr content of the base metal 11%) to the roughly 5% Cr of the cladding.
2.25% Cr dilution:


    1st layer: 0.6·5.1% Cr+0.4·2.25% Cr=4% Cr
    2nd layer: 0.6·4% Cr+0.4·2.25% Cr=3.3% Cr
    3rd layer: 0.6·3.3% Cr+0.4·2.25% Cr=2.9% Cr


REFERENCE NUMBER LIST


    10 component (rotor)
    11 high temperature segment
    12 low temperature segment
    13,14 clad layer
    15 weldjoint
    16 joining surface (high temperature segment)
    a,b,c thickness

## Claims

1. A welded turbine rotor comprising:
at least one prefabricated high temperature segment of a high alloy Cr steel with high creep strength;
a prefabricated low temperature segment of a low alloy steel with high toughness and/or a high yield strength;
a weld joint connecting the high temperature segment with the low temperature segment; and
at least two different successive clad layers of at least two lower alloy weld metals disposed on said high temperature segment and arranged between the weld joint and the high temperature segment, each of the clad layers containing a predetermined concentration of Cr, the predetermined concentrations decreasing in the successive clad layers toward the weld joint.

2. The welded rotor as claimed in claim 1, wherein the clad layers comprise several successively applied weld beads of low thickness.

3. The welded rotor as claimed in claim 1, wherein the clad layers each have a thickness of about 8 to 15 mm.

4. The welded rotor of claim 1, wherein the weld joint connects the high temperature segment with the low temperature segment along a rotor axis.

5. A welded turbine rotor comprising:
at least one prefabricated high temperature segment of a high alloy Cr steel with high creep strength;
a prefabricated low temperature segment of a low alloy steel with high toughness and/or a high yield strength;
a weld joint connecting the high temperature segment with the low temperature segment;
at least two different successive layers of at least two alloy weld metals disposed on said high temperature segment and arranged between the weld joint and the high temperature segment, each of said layers containing a predetermined concentration of Cr, the predetermined concentrations decreasing in the successive clad layers toward the weld joint;
wherein the high temperature segment comprises a 8.5 to 13 wt % Cr steel, and wherein the first clad layer comprises a 4 to 6 wt % CrMo steel and the second clad layer comprises 1.8 to 2.5 wt % CrMo steel.

6. The welded rotor as claimed in claim 5, wherein the low temperature segment comprises a 0.8 to 3.7 wt % Ni, 0.8 to 2.5 wt % Cr steel, and wherein the weld joint is built up with a weld metal of 0.8 to 2.7 wt % Ni, 0.5 to 1.3 wt % Cr steel.

7. The welded rotor as claimed in claim 6, wherein the weld joint has a thickness of up to 30 mm.

8. A welded component comprising:
at least one high temperature segment of a high alloy Cr steel with high creep strength comprising 8.5-13.0 wt % Cr steel;
a low temperature segment of a low alloy steel with high toughness and/or a high yield strength;
a weld joint connecting the high temperature segment with the low temperature segment; and
at least first and second clad layers of at least two lower alloy weld metals disposed on said high temperature segment and arranged between the weld joint and the high temperature segment, each of the clad layers containing a predetermined concentration of Cr, the predetermined concentrations decreasing in the successive clad layers toward the weld joint, the first clad layer comprising 4-6 wt % CrMo steel and the second clad layer comprises 1.8 to 2.5 wt. % CrMo steel.

9. A welded component comprising:
at least one high temperature segment of a high alloy Cr steel with high creep strength;
a low temperature segment of a low alloy steel with high toughness and/or a high yield strength;
a weld joint connecting the high temperature segment with the low temperature segment; and
at least first and second clad layers of at least two alloy weld metals disposed on said high temperature segment and arranged between the weld joint and the high temperature segment, each of said clad layers containing a predetermined concentration of Cr, whereby said predetermined concentrations decrease in successive layers toward the weld joint, the first clad layer comprising of a 4-6 wt-% CrMo steel and the second clad layer comprising of 1.8 to 2.5 wt-% CrMo steel;
wherein the low temperature segment comprises 0.8-3.7 wt % Ni, 0.8-2.5 wt % Cr steel, and wherein the weld joint is built up with a weld metal of 0.8-2.7 wt % Ni, 0.5-1.3 wt % Cr steel.