ABSTRACT In order to define a disbonding test procedure representative of actual service conditions, an industry join research program has

been performed at a European level. A numerical approach has been used to calculate the hydrogen profiles both for laboratory test specimens and for actual reactors. It has been possible to establish relationships between the maximum amount of hydrogen at the interface and geometrical and exposure or service parameters. Laboratory test conditions representative of actual situation in a reactor wall can be defined. An experimental testing program has been conducted for one overlay condition. The results show a good correlation between the maximum hydrogen content at the interface and the disbonding test results. From both the numerical approach and experimental results, it is possible to define a critical amount of hydrogen at the interface for disbonding occurrence. Proposition are made for standardization of disbonding test conditions. Finally it is shown that the approach used can be helpful for qualification of disbonding resistance of welded or cladded overlays.

INTRODUCTION Disbonding behavior of welded or cladded overlays have become a problem of great concern in the refinery industry. More and more specifications for hydro treating reactors are asking for disbonding test qualification. Before 1996 there was not a standardized disbonding test, so that different procedures have been developed. It is difficult to compare results from different laboratories and there is no definition of what can be considered as an acceptable test result. Even the recent ASTM standard (ASTM G146-96) which indicates how to run a test (specimen preparation, test procedure...) doesn't give indications on what has to be considered acceptable .It becomes necessary to know more about the meaning of a disbonding test in order to define reasonable test conditions.

An Industry join research program has then been conducted at a European scale with the following objectives: 1) Numerical simulation of hydrogen profiles in test specimens and reactors; 2) Experimental study of the influence of test parameters on disbonding test results and 3) Definition of representative test conditions.

BACKROUND Disbonding is due to the conjunction of both hydrogen over saturation and the presence of sensitive microstructure at the interface between a stainless steel welded or cladded overlay and the base material. Typical hydrogen profiles through the wall of a reactor in steady state conditions or after cool down are shown on figure 1. At steady state, there is a linear gradient of hydrogen content in the stainless steel overlay and in the base material. The maximum hydrogen content is obtained on the internal side, were it is in equilibrium with the hydrogen partial pressure. The hydrogen content in the overlay and in the base material is in equilibrium at the interface. The lower hydrogen content in the base material comes from the lower hydrogen solubility in the Cr-Mo steel when compared with the austenitic stainless steel. Hydrogen over saturation in the overlay at the interface, after cooling down is the consequence of the higher hydrogen solubility and lower hydrogen diffusivity in the stainless steel. High hydrogen concentrations can be found in the stainless steel just near the interface [ 1 ].

In the case of welded overlays, parameters acting on the phenomena have already been studied. It has been shown that disbonding depends on [2,3]: (1) Materials parameters (Base Metal Chemistry, Stainless Steel overlay chemistry). For example it has been shown that Carbon content in the bse material is an important parameter since it can influence interface recarburation.