Metrode P91 Profile How To

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© Metrode Products Ltd

Welding consumables for P91 steels
for the power generation industry
CONTENTS
Page
1 Introduction 1
2 Background 2
3 Weld metal compositions 6
4 Consumable specifications 7
5 Welding Processes 9
6 Metrode range of welding consumables 10
7 Mechanical Properties 17
8 Preheat, Interpass, Post Heat & PWHT 28
9 Welding P91 to dissimilar materials 31
10 Future developments 34
11 Further Reading 35
Appendix 1 Data sheet
Appendix 2 Welding Procedure Specifications

Welding consumables for P91 steels
for the power generation industry
Figure 1
1 Introduction
The major challenge facing the power generation industry, Figure 1, in the 21st Century will be to
achieve the targets for increased efficiencies demanded by both mature economies and developing
nations. Environmental regulations requiring reduced CO2 emissions coupled with inevitable
pressures on reliability, availability and maintainability will all be major driving forces. Materials
developments, and in particular advanced creep resisting steels for high temperature pressure
components, will continue to play a significant role in improvements for existing plants and will
increasingly do so in new projects. Modified 9%CrMo steels (P/T91) are already well established
and variants such as P92 and E911 are likely to take a share of the market in the coming years.
The advantages of such steels are clearly illustrated in Figure 2 which shows a comparison of the
required design wall thicknesses for a given set of service conditions for P91, P22 and X20 CrMo
steels. These benefits can be exploited by reductions in wall thickness and weight for a given
operating condition or by increasing design/operating temperature with consequent improvements
in thermal efficiency. Of course, such advantages can only be fully exploited provided these steels
can be welded with appropriate welding consumables to give weldments which will not compromise
the integrity and operating lifetime of the completed structure.
This technical profile presents the range of Metrode welding consumables designed specifically for
the welding of P91 steels, together with information on specifications, welding processes and
properties.
© Metrode Products Ltd Page 1 of 35 Issue 6 July 2006

P22,
t=115mm (4.5in)
P91, t=49mm (2in)
ID=300mm
(12in)
X20, t=77mm (3in)
Figure 2: Comparison of required wall thicknesses for equivalent service. Temperature

600°C (1100°F), pressure 30MPa (4.4ksi), 100 000 hour life.
2 Background
“Super 9 chrome” alloys were initially evaluated for power boiler use in the late 1950’s, however the
present generation of P91 steels, 9%Cr-1%Mo with controlled additions of Nb(Cb), V and N arose
from a USA development programme. In 1974, a task force was initiated by the US Department of
Energy to select materials for a Fast Breeder Reactor programme. The Oak Ridge National
Laboratory (ORNL) in conjunction with Combustion Engineering initiated a project to develop a
9%Cr-1%Mo steel that combined the advantages of earlier 9%Cr and 12%Cr steels with improved
weldability.
Creep resistance, weldability, toughness and commercial production were all primary requirements
and by 1980 over 100 base metal compositions had been produced and tested. The resultant
composition of the modified 9%Cr-1%Mo is given in Table 1, and the various product forms,
properties and heat treatments are given in Table 2. The commonly used descriptors are:
T91 - Alloy 91 Tube P91 - Alloy 91 Pipe F91 - Alloy 91 Forging
but for simplicity in the remainder of this document the material will be referred to as P91, meaning
modified 9%Cr-1%Mo, not specifically pipe.
Table 1: Specified composition for P91 steel

C Mn Si S P Cr Ni Mo Nb (Cb) V N
min 0.08 0.30 0.20 - - 8.00 - 0.85 0.06 0.18 0.03
max 0.12 0.60 0.50 0.010 0.020 9.50 0.40 1.05 0.10 0.25 0.07

Table 2: Summary of product forms, heat treatment and mechanical property requirements for modified 9%Cr-1%Mo steels
Product form Forged Seamless Castings Wrought Seamless Forging Forged & Plate Forgings Forgings
fittings tubing piping fittings pipe bored pipe
SA213 SA335
ASME Section II-A / BS SA182 SA217 SA234 SA336 SA369 SA387 BS 1503 BS EN
T91 P91
specification F91
(SA199)
C12A WP91
(SA200)
F91 FP91 Gr. 91 Gr 91 10222-2
tensile strength, ≥585 ≥585 585–760 ≥585 ≥585 585 – 760 ≥585 585 – 760 630 – 780 630-730
MPa (ksi) (≥85) (≥85) (85-110) (≥85) (≥85) (85-110) (≥85) (85-110) (90-115) (90-105)
0.2% proof stress, ≥415 ≥415 ≥415 ≥415 ≥415 ≥415 ≥415 ≥415 ≥450 ≥450
MPa (ksi) (≥60) (≥60) (≥60) (≥60) (≥60) (≥60) (≥60) (≥60) (≥60) (≥60)
Page 3 of 35
longitudinal elongation,
≥20 ≥20 ≥20 ≥20 ≥20 ≥20 ≥20 ≥20 ≥18 ≥19
%
reduction of area, % ≥40 NR ≥45 NR NR NR NR NR ≥41 NR
hardness, HB 248 250 NR 248 NR NR NR NR NR NR
normalising temp, 1040–1095 1040 1040-1080 1040–1095 1040 1040–1095 1040–1095 1040–1095 1040–1090 1040–1090
°C (°F) (1900–2000) (1900) (1900-1975) (1900–2000) (1900) (1900–2000) (1900–2000) (1900–2000) (1900–1995) (1900–1995)
tempering temp, ≥730 ≥730 730-800 ≥730 ≥730 ≥730 ≥730 ≥730 730–790 730–780
°C (°F) (≥1345) (≥1345) (1345-1470) (≥1345) (≥1345) (≥1345) (≥1345) (≥1345) (1345-1455) (1345-1435)
NR – Not required by specification

Issue 6 July 2006
The first set of 9%Cr-1%Mo (modified) test tubes was installed in superheater sections in May 1980
– replacing type 321 tubing. By 1983 the steel was recognised for tubing by ASTM as A213, Grade
T91 and by ASTM and ASME as A/SA-335, Grade P91 in 1984.
By the mid 1980’s, UK interest in the material was developing and the former CEGB established a
programme leading to the installation of replacement headers in P91 at West Burton Power Station
during 1989.
Development of suitable welding consumables and a test programme started in 1986 and Metrode
was already supplying prototype batches for evaluation by 1987. Commercial production
commenced in 1988 and welding consumables to a variety of specifications have been in continuous
production and use up to the present time.
In the last twenty years many hundreds of tonnes of P91 consumables have been supplied
worldwide for both repair and upgrading of existing power stations, and for the construction of new
units both in the UK and overseas. Research work continues to introduce new products (eg root
welding SMAW electrodes, Chromet 91VNR), to generate data and to increase our understanding of
the welding of P91.
An outline of a typical modern fossil fuelled power station is shown in Figure 3 with the major
components shown, many of which can be manufactured in, or replaced by, P91.
Figure 3: Schematic diagram of modern coal fired power station.

Modern Combined Cycle Units (CCU’s) which aim to produce electricity at very high thermal
efficiencies are increasingly using P91 for the high temperature and superheated steam lines. The
basic principle of CCU’s is that natural gas fired gas turbines generate power in their own right but
the high temperature exhaust gases are used to produce steam in a recuperation boiler which then
powers a steam turbine for additional electricity generation. Depending on the detailed design, the
units may be single or multiple shaft types – the single shaft types have a common shaft for both
steam and gas turbines. The pipes for the line and reheated steam range in size from 350mm (14
inch) Schedule 120 (28mm/1.1inch wall thickness) up to 500mm (20 inch) Schedule 30 (13mm/1
inch wall thickness). A typical general arrangement is shown in Figure 4.
Figure 4: Schematic Diagram of combined cycle power plant based on single shaft
design – note P91 steels could be used for various steam lines

3 Weld metal compositions
The P91 parent material composition is essentially 0.1% carbon, 9% chromium, 1% molybdenum
modified with controlled additions of vanadium, niobium (columbium) and nitrogen to give long
term, high temperature creep strength. The composition is balanced with the aim of producing a
fully martensitic microstructure with little or no retained delta ferrite.
Figure 5: Typical P91 weld metal microstructure

The weld deposit composition is designed to be as close as possible to the parent P91 steel
consistent with achieving optimum properties, weldability and microstructure, see Figure 5. Early
work on matching compositions showed that the toughness of the weld metal was rather low,
particularly at typically economic time and temperature post weld heat treatment (PWHT) cycles, eg
2-3h at 750-760°C (1380-1400°F). In order to achieve the optimum balance of creep properties
and toughness, the weld metal compositions differ from the parent alloy as follows:
Niobium Early work in the USA showed that reducing the niobium below that of the parent
steel (0.06-0.10%) improved weld metal toughness. In order not to compromise
creep resistance, a range of 0.04%-0.07% is considered optimum; although some
specifications allow as little as 0.02%, and others require Nb to match the parent
material range (0.06% minimum).
Nickel Is beneficial in improving toughness for two reasons: it lowers the Ac1 temperature
and this improves the response to tempering, and it reduces the tendency for the
formation of undesirable δ ferrite. Excessive nickel (>1%) is detrimental in that it
can reduce the Ac1 below the PWHT temperature and so result in the formation of
fresh untempered martensite. Excessive nickel may also contribute to the
degradation of creep properties. Nickel is therefore usually controlled in the range
0.4–1.0%, although some authorities require <0.4% as in the parent material.
Manganese Is generally controlled at a higher level than the parent material to promote
deoxidation and ensure a sound weld deposit. However, some authorities limit
Mn+Ni to 1.5%, or even 1.0% maximum, to avoid austenite reformation at the
highest PWHT temperatures.

Silicon Is an essential deoxidant and in conjunction with chromium it contributes, in a small
way, to the alloy’s oxidation resistance. A low level of Si benefits weld toughness
and as a consequence of early work in the USA a limit of 0.30% Si (which is below
the parent material range of 0.20 – 0.50%) has been adopted in some USA
specifications.
Vanadium All have a minor influence on toughness, unless incorrect balance leads to ferrite
Carbon formation, and weld metal ranges and values are essentially the same as the parent
Nitrogen alloy to maintain good creep performance.
4 Consumable specifications
There are national standards covering consumables for all of the major arc welding processes
(electrodes for MMA and solid wires for TIG/MIG/sub-arc) except flux cored wires. There is a
proposed specification for flux cored wires which should be issued when the relevant AWS standard
(A5.29) is next revised.
The specification composition ranges from a number of sources are given in Table 3, together with
the mechanical property requirements after PWHT in Table 4. The European and USA weld metal
specifications are similar to the parent material specifications. The manganese and silicon levels,
particularly in the European EN specifications have been broadened to accommodate a number of
different manufacturers’ design philosophies. The nickel limits recognise the beneficial effects on
toughness with a maximum of 0.8 or up to 1.0% in all specifications and minimum of 0.4% in the
BS EN specifications. The minimum levels for the strengthening elements niobium (columbium),
vanadium and in some cases nitrogen are lowered compared with the parent material specification,
this recognises the beneficial effects on toughness and the fact that high levels are not considered
to be essential to provide suitably overmatching weld metal strength. The mechanical property
requirements of the weld metals are all generally in line with the parent steel except that slightly
lower minimum elongations are permitted and minimum toughness values are mandatory in the BS
EN specifications whereas values are by agreement in AWS.
There is some divergence in specified preheat and interpass temperatures for test plates to
determine mechanical properties. The lower range of 205 ± 55°C (400 ± 100°F) in AWS A5.28 for
filler wire, compared with 260 ± 28°C (500 ± 50°F) in AWS A5.5 for covered electrodes, can be
justified with respect to the process-dependent levels of potential hydrogen. However, this logic
has been reversed in the EN specifications for no apparent reason; 250°C ± 50°C (480°C ± 90°F) in
EN 1599 for covered electrodes and 300°C ± 50°C (575°C ± 90°C) in EN 12070 for solid wires.
Fabrication welds typically employ a preheat-interpass range of 200–300°C (400–575°F). PWHT
requirements vary with respect to time at temperature; the AWS requirement is one hour and the
EN requirement is three hours for solid wires and 2-3 hours for covered electrodes. In practice the
one hour PWHT applied in AWS is too short but the times used in the EN standards are more
representative of fabrication practice, as will be discussed in Section 8.

Table 3: Chemical specifications for welding consumables and parent steel of type 91 material
Type Specifications C Mn Si S P Cr Ni Mo Nb Cu Al V N
Parent steel Type 91 0.08-0.12 0.30-0.60 0.20-0.50 0.010 0.020 8.00-9.50 0.40 0.85-1.05 0.06-0.10 - 0.04 0.18-0.25 0.030-0.070
BS EN 1599:1997;
Covered electrode 0.06-0.12 0.40-1.50 0.60 0.025 0.025 8.0-10.5 0.40-1.00 0.80-1.20 0.03-0.10 - - 0.15-0.30 0.02-0.07
ECrMo91B b
BS EN 12070: 2000;
Solid wire c 0.07-0.15 0.4-1.5 0.60 0.020 0.020 8.0-10.5 0.4-1.0 0.80-1.20 0.03-0.10 0.25 - 0.15-0.30 0.02-0.07
CrMo91 d
Covered electrodes and
Client example b 0.08-0.12 0.50-1.20 e
0.50 0.012 0.020 8.0-9.5 0.80 e
0.85-1.10 0.040-0.080 - - 0.18-0.25 0.030-0.070
solid wire
AWS A5.5-96
Covered electrode 0.08-0.13 1.25 0.30 0.01 0.01 8.0-10.5 1.0 0.85-1.20 0.02-0.10 0.25 0.04 0.15-0.30 0.02-0.07
E9015-B9 b
AWS A5.23-97
Wire/flux for SAW EB9 d 0.07-0.13 1.25 0.30 0.010 0.010 8.0-10.0 1.00 0.80-1.10 0.02-0.10 0.10 0.04 0.15-0.25 0.03-0.07
B9 b 0.07-0.13 1.25 0.15-0.30 0.010 0.010 8.0-9.5 1.00 0.80-1.20 0.03-0.10 0.10 0.04 0.15-0.25 0.03-0.07
AWS A5.28-05 8.00-
Solid wire 0.07-0.13 1.20 e 0.15-0.50 0.010 0.010 0.80 e
0.85-1.20 0.02-0.10 0.20 0.04 0.15-0.30 0.03-0.07
ER90S-B9 d 10.50
e e
Flux cored wire AWS A5.29 E91T1-B9 0.08-0.13 1.20 0.50 0.015 0.020 8.0-10.5 0.80 0.85-1.20 0.02-0.10 0.25 0.04 0.15-0.30 0.02-0.07
a: Single values shown in the table are maximum values; c: Prefix W = TIG, S = Sub-arc, G = MIG e: Mn + Ni = 1.50% maximum
b: Composition requirements for undiluted weld metal; d: Composition requirements for wire;
Table 4: Mechanical property requirements for weld metals of various specifications for type 91 material
Page 8 of 35
Type Specifications Shielding gas Tensile strength, Yield strength at Elongation, Impact requirement Preheat and interpass PWHT procedure
MPa (ksi) 0.2% offset, % @ +20°C (68F) temperature,
MPa (ksi) Avg/min, J (ft-lbs) C° (°F)
585-780 415 If specified 730-780°C
Parent steel Type 91 NA 20 NA
(85-115) (60) >41 (>30) (1345-1435°F)
BS EN 1599:1997; 585 415 47/38
a
200 to 300 750-770°C / 2-3h
Covered electrode NA 17
ECrMo91B b (85) (60) (35/28)
a
(400 to 575) (1380-1420°F/ 2-3h)
BS EN 12070: 2000; 585 415 47/38 250 to 350 750-760°C / 3 hrs
a
Solid wire c Not specified 17
CrMo91 d (85) (60) (35/28)
a
(480 to 660) (1380-1400°F/ 3hrs)
AWS A5.5-96 620 530 232 to 288 730 to 760°C / 1hr
Covered electrode NA 17 Not specified
b
E9015-B9 b (90) (77) (450 to 550) (1345-1400°F / 1h)
AWS A5.23-97
620–760 c 540 205 ± 15 730 to 760°C / 1hr
c
Wire/flux for SAW EB9 d Flux 17
c
Not specified
d
(90-110) c (78) (400 ± 25) (1345-1400°F / 1h)
c
B9 b
AWS A5.28-96 620 410 150 to 260 730 to 760°C / 1hr
Solid wire 16 Not specified
e b
Argon/5% O2
ER90S-B9 d (90) (60) (300 to 500) (1345-1400°F / 1h)
AWS A5.9 620-830 540 210-310 745 to 775°C / 1hr
Flux cored wire
Issue 6 July 2006
Argon/CO2 16 Not specified

b
E91T1-9 (90-120) (78) (400-600) (1375-1425°F / 1h)
a: Minimum average from three test specimens and only one single value lower than minimum average is permitted. d: Impact properties achieved from a specific wire-flux combination can be classified by
b: AWS does not specify impact requirements for E9015-B9 or ER90S-B9, but the non-mandatory appendices to A5.5-96 replacing the Z with a code number, which indicates the temperature at which 27J
and A5.28-96 propose that a test criterion can be agreed by the purchaser and supplier if required. (20ft-lbs) is achieved; eg 0 = 0°C, 2 = -20°C etc.
c: The strength requirements are not specified for EB9. The specification is used to classify the strength achieved (the e: Other gas mixtures can be used as agreed between the purchaser and supplier.
values given are representative of P91).
5 Welding processes
The choice of welding process depends on a number of factors, including:
− size and thickness of the component to be welded

− shop fabrication or site repair
− availability of suitable equipment
− necessary skilled staff
− availability of suitable consumables
− mechanical properties required, particularly toughness
Table 5 shows the arc welding process options for high temperature power plant. The various
components are shown on the power station schematic in Figure 3.
Table 5: Welding process options for power plant

Component Joint Type Possible Arc Welding Process
Boiler panel Site welding/ Manual TIG and MMA
(small bore tubing) Repair Manual/orbital TIG and MMA
Superheater/ Tube to tube Fixed/orbital TIG, manual TIG and MMA

reheater/ Spacers, attachments Manual TIG and MMA
economiser (small bore tubing) Site welding Manual TIG and MMA, orbital TIG
Steam pipework and headers Butt Welds TIG, MMA, FCW, Sub Arc
Stub to header Manual TIG/MMA
Butt welds Mechanical TIG/MIG
Site welding Manual TIG and MMA, orbital TIG, FCW
Pressure vessels, Butt welds TIG, MMA, FCW, Sub Arc

eg steam drums
Valve Chests Butt welds Mainly TIG, MMA, FCW, possibly Sub Arc
Loop pipework Butt welds Mainly TIG, MMA, FCW, possibly Sub Arc
Site welding TIG, MMA, FCW

6 Metrode range of welding consumables
Table 6 gives a summary of the Metrode consumables available for P91. A brief description of each
of the consumables is given in this section along with typical welding parameters; mechanical
properties are covered in Section 7. Data sheets for all products are given in Appendix 1, and
guideline weld procedure specifications (WPS) in Appendix 2.
Table 6: Metrode range of consumables for P91

Process Specifications
AWS A5.5/ASME SFA 5.5
E9015-B9
Chromet 9MV-N MMA (SMAW)
BS EN 1599
E CrMo91 B
Chromet 9-B9 MMA (SMAW)
E9015-B9
E9016-B9
Chromet 91VNR MMA (SMAW)
BS EN 1599
E CrMo91 R 3 2
E9015-B9
Chromet 91VNB MMA (SMAW)
BS EN 1599
E CrMo91 B 3 2
TIG (GTAW) ER90S-B9
9CrMoV-N
BS EN 12070
W CrMo91
AWS A5.23
EB9
SAW
BS EN 12070
(S CrMo 91)

Cormet M91 MCW for MIG (GMAW)
ER90C-G (B9)
Supercore F91 FCW
E91T1-B9
BS EN 760
LA491 Sub arc flux
SA FB 2 55 AC
BS EN 760
L2N Sub arc flux
SF CS 2 DC
9CrMoV-N + AWS A5.23
Wire + flux combination
LA491 (F62 PZ-EB9-B9)
9CrMoV-N + AWS A5.23
Wire + flux combination
L2N (F62 PZ-EB9-B9)

6.1 MMA (SMAW)
MMA welding is still the most adaptable of the arc welding processes and hence for
construction/fabrication work, especially on-site or repair work, is still very widely used. Typical
areas of application are shown in Section 5.
As already discussed, P91 materials are fully martensitic under virtually all cooling conditions, and
hence as-welded hardnesses are high (~450HV). This means that measures to avoid hydrogen
cracking are particularly important. Preheat etc is covered in Section 8, but in relation to MMA
electrodes, coating moisture and hence hydrogen potential are critical. To ensure low coating
moisture content, the MMA electrodes all have specially designed flux binder systems.
The consumables are packed in hermetically sealed metal tins as defined in AWS A5.5 paragraph
22.2. The as-packed moisture content of the electrode coatings is <0.15%, and the exposed
coating moisture (27°C/81°F, 85%RH) as per AWS A5.5 is <0.40%, which means that in AWS
terminology the electrodes can be classified with the H4R suffix. All the electrodes can also be
supplied in vacuum sealed site packs to special order if required. These vacuum sealed site packs
contain a convenient 1-2kg (2-4.5lb) of electrodes, depending on diameter, and produce a
guaranteed hydrogen of <5ml/100g of weld metal.
All of Metrode’s P91 MMA consumables are basic, low hydrogen types with moisture resistant
coatings to produce low weld metal hydrogen levels. The consumables all operate DC+ and AC (70
OCV), although DC+ is preferred. The electrodes are all-positional and are suitable for welding
fixed pipework in the ASME 5G/6G positions.
There are three variant Metrode MMA consumables for P91, each with a different typical analysis,
see Table 7. The reasons for this are briefly explained.
6.1.1 Chromet 9MV-N
This is the standard consumable available and conforms to the BS EN specification, E CrMo 91 B,
and AWS specification, E9018-B9, Table 3. This product, which contains ~0.7%Ni, would be
specified for most standard applications but still meets Ni + Mn of 1.5% maximum. ASME IX QW-
432 F-Number 4 and QW-442 A-Number 5. The Chromet 9MV-N electrode has also taken the place
of Metrode’s first P91 electrode, Chromet 9MV.
6.1.2 Chromet 9-B9
This electrode is a derivative of Chromet 9MV-N, originally manufactured for the US market. It is
made to conform to the AWS specification, E9015-B9 Table 3, (but with additional restrictions on
Mn and Ni) and hence has been favoured for ASME specified projects. ASME IX QW-432 F-Number
4 and QW-442 A-Number 5.
6.1.3 Chromet 91VNR and Chromet 91VNB
These electrodes are specifically designed for depositing root runs in single sided open butt joints
without gas purging. Chromet 91VNR conforms to both AWS E9016-B9 and BS EN E CrMo91 R and
Chromet 91VNB conforms to AWS E9015-B9 and BS EN E CrMo91 B. To achieve the best root
welds joints should be set-up with a root gap of 2.5-4mm (0.10-0.15inch) and root face of 1.5-
2.5mm (0.05-0.10inch) and then welded on DC+ at ~75A with a 2.5mm (3/32inch) diameter
electrode. For positional joints vertical-up welding is recommended.

Table 7: Typical MMA weld metal compositions
C Mn Si Cr Ni Mo Nb V N
Chromet 9MV-N 0.1 0.6 0.25 9 0.7 1 0.05 0.2 0.05
Chromet 9-B9 0.1 0.5 0.25 9 0.3 1 0.04 0.2 0.05
Chromet 91VNR 0.1 0.6 0.25 8.5 0.5 1 0.04 0.2 0.05
Chromet 91VNB 0.1 0.8 0.25 8.5 0.5 1 0.04 0.2 0.05
The three variants each have a different typical analysis (Table 7) in order to conform to the
different specifications, see data sheets in Appendix 1 for full analysis ranges. These different
analyses, given the same PWHT, may produce slightly different average mechanical properties. The
role of the different alloying elements has already been discussed and the mechanical properties
are discussed in Section 7. The diameters that each product is manufactured in are given on the
data sheet in Appendix 1, and guideline procedures/parameters are given in Appendix 2.
6.2 TIG (GTAW)
There is a need for solid wire consumables for the TIG process for various applications, notably for
small diameter pipework and root welding, see Section 5.
6.2.1 Wire analysis of 9CrMoV-N
Metrode’s solid P91 TIG wire is 9CrMoV-N and the typical wire and deposit analysis is:
C Mn Si S P Cr Ni Mo Nb (Cb) V N O
Wire 0.10 0.6 0.3 0.005 0.005 9 0.7 1 0.05 0.20 0.04 0.003
Deposit 0.08 0.6 0.3 0.005 0.005 8.5 0.7 1 0.04 0.18 0.04 0.005
In national standards solid wire classification is based on wire analysis, as can be seen from the
above the deposit analysis will be slightly different from the certified wire composition. Owing to
the nature of the TIG process, very little loss of the alloying elements is seen, the most noticeable
loss being C which tends to be up to about 0.01–0.02% lower in the deposit than the wire.
The analysis of 9CrMoV-N is aimed at conforming to the AWS ER90S-B9 specification. The 9CrMoV-
N wire also conforms to the BS EN WCrMo91 analysis range.
6.2.2 Procedural aspects
TIG welding of P91 using 9CrMoV-N is carried out using pure argon shielding gas on DC- polarity.
As many applications of the TIG process are for depositing root runs, it is also important to consider
gas purging. For single side root runs, Ar should also be used as the purge gas; which if practical
should be maintained for at least the first three runs. The most commonly used size for manual
TIG welding is 2.4mm (3/32in) diameter, although other sizes can be supplied: 1.6mm (1/16in) and
3.2mm (1/8in) for manual TIG, and 0.8mm/1.2mm (0.035in/0.045in) spooled wire for auto-TIG.
For depositing root runs, a 2.4mm (3/32in) diameter 2% thoriated tungsten would typically be
used. The current should be DC- and typical parameters would be about 90A, 12V; with a gas flow
rate of about 10 l/min (0.3ft3/min).

6.3 MIG (GMAW)
As a process of potentially high productivity, interest in MIG welding of P91 material is increasing.
Of the wires available for MIG welding, the metal cored wire (MCW) is proving to be the most
attractive owing to its compositional flexibility and lower cost. Metrode’s Cormet M91 MCW, which
is available in 1.2mm (0.047in) or 1.6mm (1/16in) diameter, has already found use in a number of
applications, including surfacing and casting repair. The use of solid MIG wire is not considered
here because experience indicates that the operability of currently available wire is unsatisfactory,
owing to typical Mn + Si deoxidant levels which are incompatible with active gas welding.
6.3.1 Shielding gases and weld metal composition for Cormet M91
The most important factor with the MIG process is the choice of shielding gas, which plays a
significant part in both operability and deposit analysis. In general terms a suitably high content of
CO2 in the shielding gas is beneficial to operability. The influence of shielding gas composition on
weld metal analysis is shown in Table 8.
Table 8: Chemical composition of Cormet M91 metal cored wire deposits

Shielding C Mn Si S P Cr Ni Mo Nb V N O
gas (Cb)
M12 (2) 0.074 1.16 0.40 0.011 0.008 8.4 0.34 1.0 0.04 0.21 0.044 0.041
M12 0.083 1.10 0.38 0.011 0.008 8.7 0.36 1.1 0.04 0.20 0.041 0.051
M24 0.079 0.90 0.25 0.010 0.008 8.7 0.35 1.1 0.03 0.21 0.053 0.100
* M12(2) = Ar-38%He-2%CO2
M12 = Ar-2½%CO2
M24 = Ar-20%CO2
Table 8 indicates that the levels of the more active elements, such as Si, Mn and Nb are influenced
by the shielding gas. The general trend is that the recovery rate of these elements decreases as
the oxidising potential of the shielding gas increases. The oxygen content however significantly
increases as the oxidising potential increases; this is important for weld metal toughness, which is
discussed later (Section 7.2). The other alloying elements exhibit stable transfer, irrespective of
shielding gas composition.
The best balance of operability and weld metal toughness is found when using M12 shielding gas.
The M12(2) mixture was capable of producing better weld metal toughness but with an
unacceptable degradation in operability. For optimum operating performance, a higher CO2
content, M24, could be used for applications where weld appearance and soundness is the main
priority, whilst maximum toughness is not required. The effect of shielding gases on weld metal
toughness is discussed in Section 7.2.
Cormet M91 meets the AWS analysis requirement for solid wire although the silicon content in the
metal cored wire is higher than the typical silicon content of the solid wire. The higher Si content,
~0.35%, is required to optimise operability, particularly when using less oxidising (active) shielding
gases. The Si content is still in conformance with the BS EN solid wire requirement, and within the
base material range.

6.3.2 Welding parameters
Cormet M91 is designed for downhand welding although the 1.2mm (0.047in) diameter wire may
be suitable for limited positional use with appropriate pulsed parameters. Using Ar-2.5% CO2, at a
flow rate of 15-20 l/min (0.5-0.7ft3/min), the optimum welding parameters are as follows:
Stickout, mm (in) Current, A Voltage, V WFS, m/min (in/min)

1.2mm (0.047in) 10 – 20 (0.4-0.8) 260 28 ~10 (~400)
1.6mm (1/16in) 15 – 25 (0.6-1.0) 330 29 ~7 (~280)
The use of Ar-20% CO2 requires similar parameters, although the voltage will need to be increased
by approximately 1 volt. These welding parameters produce a stable spray type transfer and are
usable for downhand butt and HV fillet welds.
6.3.3 Flux cored wires (FCW)
The interest in FCW is growing because of the potential productivity benefits that can be achieved
and improved operability compared to solid MIG wires. These benefits would show in both shop and
site welding applications, but the main interest is in the potential advantage for positional welding.
Supercore F91 flux cored wire has been developed to address these applications.
There are presently no national specifications for relevant flux cored wires but it is proposed to
include a classification in the next revision of AWS A5.29, the classification would be E91T1-B9, the
analysis is essentially the same as the solid wire specifications but the Si is typically 0.3% to ensure
sufficient deoxidation and optimum operability. The typical deposit analysis of Supercore F91 is as
follows:
C Mn Si S P Cr Ni Mo Nb V N
0.08 8.0 0.85 0.02 0.15 0.02
AWS range - 1.20 0.50 0.015 0.020 - 0.80 - - - -
0.13 10.5 1.20 0.10 0.30 0.07
Deposit 80/20 0.11 0.8 0.35 0.010 0.015 9 0.6 1.1 0.03 0.20 0.04
Deposit 100% CO2 0.09 0.7 0.25 0.010 0.015 9 0.6 1.1 0.03 0.20 0.04
Ar-20%CO2 is the recommended shielding gas for Supercore F91 although good results can also be
achieved with 100%CO2. For improved toughness but slightly inferior arc characteristics Ar-5%CO2
shielding gas can be used. Typical welding parameters for Supercore F91 using Ar-20%CO2
shielding gas are:
Current, A Voltage, V ESO, mm (in)

Range 140 – 280 24 – 30 10 – 25 (0.4 – 1.0)
For 6G Pipe 150 25 15 (0.6)
If 100%CO2 is used, the voltage will need to be increased by ~2Volts.

6. 4 Submerged Arc Welding (SAW)
For welding positions and components where mechanised welding is practical, SAW is undoubtedly
the preferred and most productive process. To date 2.4mm (3/32in) diameter 9CrMoV-N solid wire
is preferred for SAW, although 3.2mm (1/8in) diameter has been used for selected applications.
6.4.1 9CrMoV-N sub-arc wire
The wire analysis is the same as the TIG wire, but the deposit analysis is inevitably different owing
to the influence of the flux. The preferred flux for use with 9CrMoV-N consumables is Metrode
LA491, although L2N has also been used successfully. Typical deposit analyses are:
C Mn Si S P Cr Ni Mo Nb V N O
Wire 0.10 0.6 0.3 0.005 0.005 9 0.7 1 0.05 0.20 0.04 0.005
Deposit
0.08 0.6 0.35 0.005 0.007 8.5 0.7 1 0.04 0.16 0.04 0.040
LA491
Deposit
0.09 0.5 0.6 0.005 0.007 8.3 0.6 1 0.04 0.16 0.05 0.060
L2N
The 9CrMoV-N sub-arc wire analysis generally conforms to both the AWS A5.23 EB9 and BS EN
SCrMo91 specifications.
In the AWS A5.23 specification, a wire-flux combination can also be classified and this includes a
weld deposit analysis. The combination of 9CrMoV-N and LA491 generally conforms to the deposit
analysis requirements of AWS A5.23, but the deposit Si will be above the specification limit. If
LA491 + 9CrMoV-N were to be classified, F62 PZ-EB9-B9 is the nearest relevant classification in
AWS A5.23. The same comments apply to the use of L2N with the 9CrMoV-N wire. The BS EN
specification also has mechanical property requirements, the minimum tensile requirements are met
but the minimum impact requirement of 47J (35ft-lb) at 20°C (68°F) may be difficult to achieve
after the specified PWHT.
6.4.2 Practical aspects
The 9CrMoV-N wire is supplied as standard in 2.4mm (3/32in) diameter although other diameters,
eg 3.2mm (1/8in), are available to order; typical parameters are:
Dia, Electrode extension, Current, Voltage, Travel Speed,

Flux
mm (in) mm (in) A V mm/min (in/min)
LA491 + 2.4 (3/32) 20 (0.8) 350 – 500 (DC+) 28 – 32 400 – 500 (16 - 20)
L2N
3.2 (1/8) 20 (0.8) 400 – 600 (DC+) 28 – 32 400 – 600 (16 - 24)
The preferred flux, LA491, produces good slag release and an excellent cosmetic bead appearance.
The flux is a fluoride basic agglomerated flux with a Basicity Index of approximately 2.7. As with
the submerged arc welding of any low alloy steel, hydrogen control is important (see Section 6.1 on
MMA) which means that correct housekeeping for the flux is imperative. A flow chart outlining
general flux handling procedures is shown in Figure 6. If flux is recycled, the machine hopper
should be periodically topped-up with new flux to prevent the build-up of fines. Flux that has got
damp or has been exposed to the atmosphere for 10 hours, or more, should be re-baked at 350-
400°C (650-750°F) for 2 hours.

The L2N flux produces excellent slag release and bead appearance. The flux is a neutral calcium
silicate fused flux with a Basicity Index of approximately 1.3. Being a fused flux, it is very resistant
to moisture absorption but if required the flux should be redried at 150-250°C (300-500°F) for 1-2
hours.
Store in a Heated
At end of shift all
Hopper >100°C (200°F)
New Flux Flux to be returned
50 – 150kg
to Heated Hopper
(100 – 300lb)
Sub-Arc Machine
A Flux Hopper B
~10kg (~20lb)
Sieving
Welding
A or B
Vacuum Unused Flux
Recycling Unit
Figure 6: Control and storage of sub-arc flux LA491

7 Mechanical properties
7.1 Room temperature tensile properties
A high resistance to softening by PWHT (temper-resistance) is an intrinsic feature of P91 weld

metals and is also noticeable in the high temperature (supercritical) HAZ of weldments. Therefore
all-weld metal tensile tests will always overmatch P91 parent material and cross-weld tests typically
fail in parent material beyond the hardened HAZ (in the low temperature HAZ). The tempering
response of weld metals, base material and HAZ is shown in Figure 7. This graph clearly
demonstrates the higher hardnesses found in the weld metal and high temperature HAZ, and also
the low hardness in the low temperature HAZ. Typical tensile properties of Metrode consumables
are given in Table 9. The tensile properties of the Metrode consumables meet the requirements of
the appropriate specifications as listed in Table 6.
Table 9 Typical all weld metal tensile properties

PWHT, UTS, 0.2% proof Elongation, % RoA Mid-weld
Process Product °C/h MPa stress, MPa % hardness,
(°F/h) (ksi) (ksi) 4d 5d HV
755/3 765 625
MMA Chromet 9MV-N 20 19 55 250
(1390/3) (111) (91)
755/8 735 610

25 21 65 250
(1390/8) (107) (88)
755/1 830 710

Chromet 9-B9 18 16 50 270
(1390/1) (120) (103)
760/2 710 580

23 20 60 240
(1400/2) (103) (84)
760/2 750 600

Chromet 91VNR 20 18 55 250
(1400/2) (109) (87)
760/2 750 600

Chromet 91VNB 20 18 55 250
(1400/2) (109) (87)
755/3 800 705

TIG 9CrMoV-N 22 19 70 265
(1390/3) (116) (102)
755/3 755 615

MIG Cormet M91 21 19 65 245
(1390/3) (109) (89)
Supercore F91 760/2 775 660

FCW 21 18 55 270
(80/20) (1400/2) (112) (96)
760/4 755 625

22 19 55 265
(1400/4) (110) (91)
755/3 745 630

Sub arc 9CrMoV-N + LA491 25 23 70 250
(1390/3) (108) (91)
755/3 740 620

9CrMoV-N + LA2N 24 22 65 245
(1390/3) (107) (90)

375
TIG 9CrMoV-N
MMA Chromet 9-B9
MMA Chromet 9MV-N
FCW Supercore F91
SAW 9CrMoV-N + LA491
325 Low Temperature HAZ
Hardness, HV(10kg)
Base Material
High Temperature HAZ
275
225
175
19.5 20 20.5 21 21.5
Tempering Parameter, P
P = oK(log t + 20) 10-3
Figure 7: Effect of tempering on weld metal, base material and HAZ hardness
7.2 High temperature properties
For an alloy that is designed to be used at 500–600°C (900–1100°F), the high temperature
properties of P91 weld metals are of considerable importance.
7.2.1 Hot tensile properties
Hot tensile tests are not representative of service conditions for P91 weld metals owing to the short
term nature of the test but they provide a convenient method for comparison of weld metals with
base material data in a short term test. Figure 8 shows how weld metal data in the temperature
range 500-650°C (900-1200°F), compares to base material requirements. For example, a
requirement of >250MPa (36ksi) 0.2% proof stress at 550°C (1020°F) is always satisfied.
Hot tensile data has been reported from cross-weld joints completed using MMA and sub-arc, which
shows failure in the base material HAZ. When tested at 550°C (1020°F) the cross-weld tensile tests
consistently failed in the P91 base material at a UTS of ~390MPa (~55ksi). The UTS of all-weld
tensile specimens tested at +550°C (1020°F) for all processes is >450MPa (62KSi).

600
500
0.2% Proof Stress, MPa

400
300
Base Material Minimum (BS EN 10222-2)
TIG 9CrMoV-N
200 MMA Chromet 9MV-N
MMA Chromet 9-B9
MMA Chromet 9MV
100 MCW Cormet M91
FCW Supercore F91
SAW 9CrMoV-N+LA491/L2N
0
400 450 500 550 600 650 700
Temperature, °C
Figure 8: Hot tensile data
7.2.2 Creep properties
Stress rupture tests on all-weld metal specimens show that properties are within the parent
material envelope and generally at or above the parent material average. However, it is known
that lower rupture stress values may be obtained in non-optimised weld metal, particularly if very
low C+Nb+N is combined with excessive Mn+Ni (>2%).
1000
565oC/105hr
P=29.33
+20%
600oC/105hr
Rupture Stress, MPa
P=30.56
-20%
100
GTAW (9CrMoV-N)
SMAW (Chromet 9MV-N)*
SAW (9CrMoV-N)
FCAW (Supercore F91)
P/T91 base material
10
25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0
-3
P = K(30+Logt)x10
Figure 9a: All-weld metal stress-rupture test results at 550–660°C (1020–1220°F) for
all processes. (* Includes Chromet 9-B9 data).

Figure 9a presents a Larson-Miller plot comparing representative GTAW, SMAW, FCW and SAW
weld metal with parent material. The tests were conducted at 550 – 660°C (1020 – 1220°F) with
durations up to almost 3000 hours.
Numerous tests, by many investigators, have shown that long term creep failure of welded joints in
P91 steel welded with matching or near-matching weld metal occurs in the parent material. The
consequent reduction in transverse creep strength of weldments is about 20% at 600°C (1100°F).
300
Modified 9CrMo
200
Applied stress, MPa
600°C
100
90
80
70
60 CHROMET 9MVN (weld joints)
Weld Joints (Bendick et al) 650°C
50 GTAW weld joint (Nippon)
SAW weld joints (Nippon)
40
Base metal, average (ORNL)
30
Weld joints, average (ORNL)
Weld joints, minimum (ORNL)
20
10 100 1000 10000 100000
Time to rupture, h
Figure 9b: Stress rupture properties for welded joints

Figure 9b shows a plot of stress-rupture properties at 600°C (1100°F) and 650°C (1200°F) for P91,
and some representative weldments have been added to the original. A number of observations
can be made:
1. With the possible exception of very short duration tests, all the weldments lie below the
average claimed by ORNL for P91 steel.
2. In longer duration tests, weldment properties show increasing divergence from the parent
material average. For a given duration it is common to find a larger divergence at higher test
temperatures.
3. All the weldments, made with a range of consumables and processes, show similar behaviour.
The failure location in cross-weld tests is at the outer boundary of the visible HAZ. This region is
partially re-austenitised by re-heating within the intercritical temperature range during the welding
thermal cycle and most of the carbon and nitrogen is precipitated from solution. Further
recrystallisation and over-ageing of the transformed microstructure during PWHT produces a
relatively soft martensite which lacks the carbo-nitride strengthening essential for creep resistance.
This weakened zone, where “type IV” creep failure occurs, is characteristic of all creep resisting
CrMo steels. Figure 10 shows a typical hardness survey with hardness, in the critical region, almost
40HV below the base material average.

Figure 10: Hardness survey across a P91 joint
Since type IV failure is typical for cross-weld creep tests (except possibly for very high stress/short
duration tests), the role of the weld metal creep performance could be considered as having little
practical significance, except that it should perform at least as well as the outer HAZ region - the
type IV zone. Some authorities accept this view; however, there are two other contrasting opinions
concerning the influence of weld metal creep properties on the overall behaviour of weldments or
the possibility that weld metal behaviour might be optimised in an attempt to delay the onset of
type IV failure. One proposal is that the weld metal should actually be weaker than the parent
material and comparable with the type IV zone creep strength. The alternative proposition is that
the relatively wide weld zone should have strength comparable to the base material so that less
strain will be transferred to the narrow type IV zone and failure will therefore be delayed.
There is general agreement that the failure mode of weldments is ultimately controlled by HAZ
behaviour, but currently there is no consensus as to whether there is an optimum choice of weld
metal composition and strength to delay such failure and so prolong component life.
7.2.3 Effects of weld metal composition on creep properties
The compositions of four different MMA electrodes are given in Table 10, together with cross-weld
creep properties after PWHT at 760°C (1400°F) for 2 hours in Table 11. Three electrodes A, B and
C were compared with a sample batch of Chromet 9MV-N. Chromet 9MV-N gave the longest
rupture times and only composition C failed in the weld metal rather than the HAZ type IV zone.
Electrode C had the lowest level of those elements considered critical for creep resistance, Nb, C
and N.
Similarly the other compositions A and B can be interpreted (along with differences in hardness
after PWHT) as intermediate in creep strength between compositions C and Chromet 9MV-N. These
results lend some support to the view that it is preferable for weld metal to match the parent metal
and to overmatch the type IV zone and this optimum condition was achieved with Chromet 9MV-N.
The performance of weldments in actual service is likely to be significantly better than that obtained
in cross-weld creep tests, except for unusual situations where material thickness and loading
conditions are directly simulated by laboratory creep tests. In most actual weldments, this is not
the case and the weld metal and narrow type IV zone are constrained by surrounding material,
especially in radially loaded pressure pipe where this constraint increases with thickness and the
transverse stress across the weldment is only half of the circumferential (hoop) stress
predominantly borne by the pipe.

Table 10: Weld metal compositions evaluated in creep tests
Electrode A B C Chromet 9MV-N
C 0.09 0.08 0.08 0.10
Mn 1.0 1.0 1.1 1.1
Si 0.4 0.4 0.2 0.4
Cr 8.7 9.3 8.9 8.9
Ni < 0.1 < 0.1 0.7 0.7
Mo 1.0 1.0 0.9 1.0
V 0.17 0.21 0.19 0.18
Nb 0.06 0.09 0.03 0.05
N 0.05 0.05 0.02 0.05
Hardness (HV) after PWHT 225 235 225 253
Table 11: Cross-weld creep properties (PWHT 760°C/2h)

Electrode A B C Chromet 9MV-N
600 600 600 650 600 650
temp. °C (°F)
(1110) (1110) (1110) (1200) (1110) (1200)
110 130 110 130 130 110 110 130 110
stress, MPa (ksi)
(16) (19) (16) (19) (19) (16) (16) (19) (16)
rupture time, h 1780 515 2271 607 367 29 3429 1730 51
elongation, % 3.8 5.2 3.9 8.0 8.7 11.7 3.0 5.3 7.7
red. of area, % 41 58 39 57 57 76 31 37 70
failure zone HAZ: type IV Weld HAZ: type IV
7.3 Weld metal toughness
High temper-resistance is also one factor which increases the difficulty of obtaining high toughness
in MMA deposits within realistically short PWHT regimes or at lower temperatures within the
accepted tempering range. The composition modifications already discussed for weld metals
(Section 3) primarily gain toughness by promoting a more rapid tempering response.
It can be argued that weld metal toughness is an irrelevant consideration in fabrications which are
designed to operate at temperatures in the range 500-600°C (900-1100°F); far above the range at
which any possible risk of fast brittle fracture could occur. However, there are situations where
components might be pressurised or loaded structurally at ambient temperatures during testing or
construction.
One example of testing is during hydrotesting which, depending on code requirements, may be
undertaken at any temperature between 0-30°C (32-86°F), although most will be above 20°C
(68°F). ASME guidelines recommend that the minimum temperature for hydrotesting is 20°C
(68°F).

Table 12: Average all-weld metal toughness with Metrode consumables
PWHT Average toughness **
Process Product Gas or Flux *
°C/h (°F/h) J at +20°C (ft-lb at 68°F)
MMA Chromet 9MV-N NA 755 / 3 (1390 / 3) 65 (50)
755 / 8 (1390 / 8) 95 (70)
Chromet 9-B9 NA 746 / 1 (1375 / 1) 20 (15)
760 / 2 (1400 / 2) 85 (60)
774 / 2 (1425 / 2) 85 (60)
Chromet 91VNR NA 760 / 2 (1400 / 2) 55 (40)
Chromet 91VNB NA 760 / 2 (1400 / 2) 65 (50)
TIG 9CrMoV-N Argon 755 / 3 (1390 / 3) 220 (160)
MIG Cormet M91 M12 (2) gas 755 / 3 (1390 / 3) 35 (25)
M12 gas 755 / 3 (1390 / 3) 30 (20)
M24 gas 755 / 3 (1390 / 3) 25 (20)
M24 gas 755 / 6 (1390 / 6) 30 (20)
FCW Supercore F91 M24 gas 755 / 3 (1390 / 3) 20 (15)
760 / 2-4 (1400 / 2-4) 30 (20)
775 / 2 (1425 / 2) 30 (20)
M14 gas 760 / 4 (1400 / 4) 35 (25)
100%CO2 775 / 2 (1425 / 2) 30 (20)
SAW 9CrMoV-N LA491 flux 755 / 3 (1390 / 3) 40 (30)
L2N flux 755 / 3 (1390 / 3) 30 (20)
* M14 = Ar-5%CO2. See Table 8 for other gas compositions.
** There will inevitably be a certain degree of batch-to-batch variation in impact properties, but
these represent average values from a number of tests.
To cater for these situations, it is considered by some authorities that the weld metal should have a
minimum toughness at +20°C (68°F). The AWS specification does not specify impact
requirements, but the non-mandatory appendix to A5.5-96 proposes that a suitable test criterion
can be agreed by the purchaser and supplier if required. On the other hand, the European
specification BS EN 1599: 1997 requires a minimum average of 47J (35ft-lbs) and a minimum single
value of 38J (28ft-lbs) at +20°C (68°F). These values are in line with those authorities who have
decided to impose their own toughness requirements and specified values of 27-50J (20-37ft-lbs) at
+20°C (68°F) (after a prescribed PWHT) are typical. However, it is difficult to justify the need for
significantly higher toughness than that specified for X20 (12CrMoV), a well-established weld metal
with a minimum requirement of 34J (25ft-lbs) average and 22J (16ft-lbs) single value at +20°C
(68°F).

Although 20°C (68°F) is the test temperature normally specified for impact testing, minor variations
in this test temperature can result in significant changes in the impact results. This arises because
the transition temperature for P91 MMA weld metals occurs at about 20°C (68°F). Figure 11 shows
the transition behaviour of Chromet 9MV-N. As can be seen, the transition takes place in the
temperature range 0-40°C (32-105°F).
Temperature, o F
-13 12 37 62 87 112 137 162 187 212
125 90
100 75
Absorbed Energy, ft-lb

Absorbed Energy, J
60
75
45
50
30
25
15
0 0
-25 0 25 50 75 100
Temperature, oC
Figure 11: Impact transition curve for Chromet 9MV-N after a PWHT of 755°C/3 hours
The typical impact properties achieved from Metrode’s P91 consumables are shown in Table 12. It
can be seen that the MMA consumables and TIG process are capable of achieving 47J (35ft-lbs)
average at +20°C (68°F). The MIG and sub-arc processes, though, generally fall short of the 47J
(35ft-lbs) requirement in the BS EN specifications.
There are four factors which have a major influence on weld metal toughness: composition, PWHT,
welding process and microstructural refinement; these are discussed in the following sections.
7.3.1 Composition
In general terms, those elements that are beneficial in improving creep performance are
detrimental in terms of toughness, ie Nb, V and to a lesser extent N and Si. A composition
balanced to restrict delta ferrite and to give a fully martensitic microstructure helps to contribute
both optimum toughness and creep performance.
7.3.2 Post weld heat treatment
Effective tempering of the martensitic microstructure is essential to obtain a reasonable level of

toughness. In practice this involves selecting both an appropriate temperature and time. The AWS
specification for consumable classification requires PWHT of 730-760°C (1345-1400°F) for 1 hour.
This is considered insufficiently long for normal fabrication procedures and a minimum of 2-3 hours
at a temperature in the range 750-760°C (1380-1400°F) is usual, or longer for thicker sections.
This temperature-time aspect is recognised by BS EN 1599, which specifies a PWHT requirement of
750-770°C (1380-1420°F) for 2-3 hours for consumable classification. It is important not to set
PWHT at too high a temperature because of the risk of austenite reformation, and the
transformation to fresh untempered martensite, particularly in nickel bearing weld metals. The
effects of PWHT temperature and time (expressed as a tempering parameter, P) on weld metal
toughness are summarised in Figure 12. In practice, for the weld metals described here, a PWHT
regime of 755°C (1390°F) for 2-3 hours (at P above about 21) gives satisfactory results and also
ensures hardness is well below 300HV throughout the weldment (typically 240-280HV in the weld
metal).

125
100 75
Impact Energy, ft-lb

Impact Energy, J
75
50
50
25
25
760oC/2
AWS PWHT range h
0 0
20 20.5 21 21.5 22
Tempering Parameter, P
o -3
P= K(log t + 20) 10
Figure 12: Effect of PWHT on weld metal toughness demonstrated with Chromet 9-B9
7.3.3 Welding process
The choice of welding process can have a dramatic effect on weld metal toughness because of the
effects of fluxes and shielding gases. Typical impact properties for Metrode’s P91 consumables are
given in Table 12. The highest toughness values are achieved using the TIG process with pure
argon. The TIG process gives low oxygen contents typically less than 100-200ppm whereas the flux
shielded processes such as MMA and SAW give values of 400-800ppm, which significantly reduces
toughness. The situation with MIG welding is more complex, but the influence of shielding gas on
the oxygen content of the weld deposit shows a definite trend with toughness. Figure 13 shows
the general trend of toughness with oxygen content, this is a simplified picture because it does not
take into account variations in PWHT or analysis, but it does give a guideline as to what oxygen
content will need to be achieved in order to get high toughness using the MIG and sub-arc
processes.
300
GTAW-Solid wire
200 GTAW-MCW
GTAW-MCW(91W)a
SAW-MCW
SAW-Solid wire
Average absorbed energy @20°C (J)
GMAW-solid wire
100 FCAW-FCW*
90 FCAW-MCW
80
70
60
50
40
30
20
10
9
8
0 0.02 0.04 0.06 0.08 0.1
Oxygen content in weld (wt%)
Figure 13: Effect of oxygen on toughness

7.3.4 Microstructural refinement
Although not reviewed here microstructural refinement which is influenced by heat input, bead size
and bead sequence can also vary the toughness; as is the case generally for weld metals which
undergo austenite transformations during cooling and reheating in multipass welding.
It has been reported that thin weld beads result in superior weld metal refinement and hence
produce better impact properties. For MMA deposits, this was reported as resulting in
improvements of up to 50% in impact properties at 20°C (68°F). Tests carried out using Chromet
9-B9 (9MV-N) MMA electrodes did not manage to show such distinct improvement and impact
properties were actually found to be unaffected by bead size/placement.
7.4 Toughness in perspective
An alternative measure of toughness is the CTOD test which allows fracture toughness assessments
to be carried out. CTOD tests are rarely carried out so Figure 14 shows the correlation between
CTOD and Charpy energy for P91 weld metals carried out over the temperature range -40 to +80°C
(-40 to 175°F).
0.4
0.35
0.3
0.25
CTOD, mm
0.2
0.15
0.1
0.05
0
0 20 40 60 80 100 120 140
Charpy Energy, J
Figure 14: CTOD-Charpy energy correlation for P91 weld metal

The benefit of having CTOD data is that it allows the maximum tolerable flaw size to be
determined. In order to carry out a worse-case-scenario assessment of the tolerable flaw size, the
lowest ambient temperature (20°C / 68°F) CTOD value of 0.018mm was used to carry out an
analysis. The calculation of the maximum tolerable flaw size was carried out using TWI’s
Crackwise® software, which automates the engineering critical assessment procedures set out in
BS 7910. The model selected was a fabricated header of 450mm outside diameter and 50mm wall
thickness, as shown in Figure 15, welded using Supercore F91 flux cored wire. The design
conditions were taken to be 176bar at 580°C (1075°F) and hydrotest conditions of 1.25 times
design pressure at ambient temperature. The tensile properties of the weld metal used for the
assessment were 809MPa (117ksi) tensile strength and 690MPa (100ksi) 0.2% proof stress. The
result showed that the maximum tolerable flaw size was 125mm long and 12.5mm deep for a
longitudinal seam weld, Figure 15. The result indicates that despite the relatively low fracture
toughness there is good defect tolerance because PWHT is applied, and in the above example the
primary membrane stress is low. For the above conditions Figure 16 shows the effect of primary
membrane stress on the maximum tolerable flaw depth.

Flaw
450mm
125mm
Plan view
12.5mm
50mm
Transverse view
125mm
12.5mm
50mm
Longitudinal view
Figure 15: Schematic showing header with maximum tolerable surface breaking flaw in
a longitudinal seam weld
20
Flaw depth (constraint), mm
Based on CT OD = 0.018mm,
the lowest single value found
in tests at 0°C and 20°C
15
Supercore F91 weld metal
Unsafe area
PWHT : 760°Cx2hrs+FC
10 Rp0.2 = 690MPa
Rm = 809MPa
5 Safe area
0
0 100 200 300 400 500
Primary membrane stress, MPa
Figure 16: Effect of primary membrane stress on maximum tolerable flaw depth of
Supercore F91 weld metal

8 Preheat, interpass, post heat & PWHT
Reference has been made already to both PWHT and preheat in several sections of this profile; with
regard to specifications, Table 4; the effect on mechanical properties, section 7.2; and hydrogen
control. To clarify the position this section summarises the practical considerations with respect to
preheat, post heat and PWHT.
8.1 Preheat and interpass
Preheat needs to be applied to ensure freedom from hydrogen cracking. Although P91 has higher
hardenability than P22, the preheat required to eliminate hydrogen cracking in the Y-groove test is
lower, see Figure 17. This may be explained partly by its lower transformation temperature, with
the beneficial influence of a little austenite retained within a practical preheat-interpass range.
(200°F) (400°F) (575°F)
Figure 17: Y-groove weld cracking ratio/preheat temperature relationship

A preheat of 200°C (400°F) is standard irrespective of material thickness except when TIG welding.
For TIG welding, owing to the very low hydrogen potential, this can be relaxed to about 100-150°C
(200-300°F). Maximum interpass temperature is usually restricted to about 300°C (575°F) to
ensure that each bead substantially transforms to martensite which will be partially tempered by
subsequent beads; see Figure 18 Ms-Mf martensite transformation range.

8.2 Post heat
Post heat is a term used to describe the practice of maintaining the preheat temperature, ~200°C
(400°F) for 2-4 hours or more after completing the joint, essentially to remove hydrogen by
diffusion and allow safe cooling of thick weldments to ambient. To be effective in P91, partial cool
out below the preheat temperature would be necessary to eliminate untransformed austenite
before reheating for post-heat, because hydrogen is trapped in the austenite and diffuses from it
more slowly than from martensite. Fortunately, unlike the earlier higher carbon alloy X20
(12CrMoV), post-heat is not reported to be necessary with P91 and in practice welds up to 80mm
thick are cooled slowly to ambient without problems; it is recommended that joints above 80mm
thick are only cooled to 80°C (175°F) before PWHT. Untempered joints are not reported to be
susceptible to stress corrosion cracking when exposed to a damp environment but it is advisable to
keeps welds dry until PWHT is carried out.
8.3 PWHT
Following welding it is important to cool down to ~100°C (200°F), or lower, before full PWHT. The
reason for this is to ensure the martensite transformation has been fully completed prior to PWHT,
(see Figure 18, Mf temperature). Residual untransformed austenite will not respond to PWHT,
leading to fresh martensite formation on cool out. Unfortunately there is some uncertainty
concerning the Mf temperature, some authorities assuming that it is closer to 200°C (400°F). It is
possible that the Mf temperature of reheated multipass weld metal will be different to the as-cooled
alloy data of Figure 18. Some fabricators are certainly satisfied with cooling to 120-160°C (250-
320°F) for a minimum of 2 hours before PWHT. Tests carried out on P91 weld metals have shown
the Mf temperature can be as low as 107°C (225°F).
Figure 18: Transformation diagram for P91

There are certain restraints on selecting the PWHT temperature. The temperature should be above
any code or specification minimum, ASME requires a temperature above 730°C (1345°F). In
practice for weld metal tempering to occur within a reasonable time the temperature needs to be
significantly above this minimum. The maximum temperature that can be used is specified in some
codes (780°C or 790°C) but may also be limited by the weld metal composition. The PWHT
temperature should not exceed the Ac1 temperature, which for the base material is at about 810°C
(1490°F), but high Ni and Mn levels in the weld metal (Ni + Mn > 1.5%) will lower the Ac1
temperature, Figure 19. If the PWHT temperature is too close to the Ac1 temperature then it could
result in some austenite formation, which will transform to untempered martensite on cooling. For
this reason it is recommended that PWHT temperature for Chromet 9MV-N and 9CrMoV-N wire
should not exceed about 765°C (1410°F), while for Chromet 9-B9 (Mn + Ni < 1%) PWHT at 774°C
(1425°F) has been used successfully.
840
Metrode consumables (measured)

Other P91 consumables (measured)
820
Base material (V+M CCT diagram)
Ac1 Temperature, C
o
800
780
760
740
720
0.5 1 1.5 2 2.5
Ni + Mn, wt%
Figure 19: Variation of P91 weld metal Ac1 temperature with Mn and Ni content
In practice weld metals show satisfactory tempering at a tempering parameter (P) of 21 or above;
where P = K (logt + 20) x 10-3. In terms of time-temperature combinations this equates to 755°C
(1390°F) for 3 hours or 760°C (1400°F) for 2 hours. If the temperature needs to be kept even
lower, as it sometimes is with castings, then 730°C (1345°F) for 8 hours is approximately
equivalent. At the upper extreme, 1 hour at 774°C (1425°F) should be satisfactory, but only for
consumables with Ni+Mn < 1.0% (eg Chromet 9-B9).

9 Welding P91 to dissimilar materials
The use of P91 is logically applied where its combination of properties are most appropriate, so it is
inevitable that joints with dissimilar creep-resisting steels are often necessary. These are usually of
lower alloy ferritic types such as P22 (2CrMo) or one of the lean CrMoV alloys. Occasionally joints
may be needed between P91 and one of the austenitic stainless heat resisting steels such as 316H.
The joining of P91 to ferritic and austenitic alloys requires consideration separately
9.1 P91 to P22 or other low alloy steels
Although P91 has been used over a significant period of time in construction involving welds to
dissimilar materials, it is surprising that in practice there is no universally accepted recommendation
for a particular weld metal composition and procedure. Two specifications, which offer relevant
guidance for welding dissimilar creep resisting steels, are AWS D10.8 and BS 2633. In AWS D10.8
the four possible options for weld metal composition are listed; these are (1) matching the lower
alloy, 2CrMo, (2) matching the higher alloy, P91, (3) an intermediate composition, possibly 5CrMo
or 9CrMo, (4) different to any of these, in practice a nickel base alloy. Preference is given to the
lower alloy option, on the grounds that it should be sufficient to match the weaker of the two
materials being joined. A similar approach is presented in BS 2633 except that the intermediate
type 9CrMo is suggested for dissimilar joints involving P91. Greater emphasis is also given, in BS
2633, to considering a nickel base weld metal, whereas in AWS D10.8 this approach is considered
unnecessary except where stainless steel or nickel alloy base materials are involved. The use of
nickel base also limits the scope for NDT methods.
It is also important to consider the most appropriate PWHT regime to reconcile the different
optimum ranges for P91 730-790°C (1345-1455°F); P22 usually 680-720°C (1255-1330°F) and the
weld metal. BS 2633 explains that the PWHT temperature is a compromise and in general is
applied at the lowest temperature for the higher alloy material, although for optimum creep
properties the highest temperature allowed for the lower alloy material should be used. Hence a
temperature around 720-730°C (1330-1345°F), for 1-3 hours, is frequently reported. This is
sufficient to temper the P91 HAZ without over-tempering the P22, and is also a satisfactory
temperature for welds using either 2CrMo or 9CrMo consumables. However, it is too low for
satisfactory tempering if the weld metal is a P91 type, for which 746°C (1375°F) has been reported
for dissimilar joints; >2 hours or ~½ hour for small bore pipe <10mm (<0.4in) wall thickness.
PWHT is of course necessary for stress relief and to give the weldment satisfactory ductility and
toughness. However, there is a tendency for PWHT (and long term service at operating
temperature) to promote carbon migration around fusion boundaries towards the higher chromium
alloy. Consequently a weakened carbon-depleted zone develops in the adjacent material with lower
chromium, which may be located in the weld metal or base material, depending on weld metal
composition. If this process is not too severe, ultimate failure is expected in the lower alloy base
material (eg P22 type IV zone). It seems that the weld metal composition preferred by different
authorities is influenced by their assessment of these issues.
In summary the results of some recently reported tests are given in Table 13. The evidence of
these tests indicates that 2CrMo consumables are capable of providing satisfactory performance,
which supports a number of authorities and the recommendation given in AWS D10.8.
The use of 2CrMo is also consistent with procedures used by some fabricators who firstly butter the
P91 with 2CrMo and PWHT at ~760°C (~1400°F). The joint is then made between the P22 and
buttered P91 using 2CrMo consumables followed by a 720°C (1330°F) PWHT. This procedure has
overcome the need for field joints between two dissimilar materials by allowing a joint between P22
and 2CrMo buttering to be carried out on site.

Table 13: Summary of results reported for dissimilar joints between P91 and P22
Buttering Joining
Failure location [1]
Consumable PWHT Consumable PWHT
720°C/1h
None None 2CrMo TIG + MMA P22 HAZ [2]
(1330°F/1h)
720°C/1h
None None 2CrMo TIG + MMA + SAW P22 HAZ [2]
(1330°F/1h)
765°C/1h [3] 720°C/1h In P22 at fusion

9CrMo MMA on P91 9CrMo TIG + MMA
(1410°F/1h) (1330°F/1h) boundary
720°C/1h In 5CrMo at P91

5CrMo MMA on P91 None 2CrMo TIG + MMA
(1330°F/1h) fusion boundary [4]
Weldments were in 25mm (1in) thick material, with preheat/interpass 200–250°C (400-480°F).
[1] In the longest running creep tests at 600° C (1110°F).
[2] This location was associated with the best overall performance of the 4 variants.
[3] Those who currently specify 9CrMo consumables have now discontinued the buttering
procedure and weld directly, followed by the lower PWHT of 720–730°C (1330-1345°F) / 2-
3h. However, some consider that service temperature should be limited to about 545°C
(1010°F), above which nickel base consumables are favoured.
[4] Failure in 5CrMo weld metal was considered to be a result of its lower Mo content of 0.5%.
9.2 P91 to P92
Joining P91 to P92 is not really a dissimilar joint because of the similarities between the two
materials. A joint between these two materials can be treated the same as a joint in P91 base
material and the use of P91 consumables is acceptable.
9.3 P91 to austenitic or higher alloys
There is no significant diversity of opinion with respect to these combinations. Based on many
years experience with dissimilar welds between ferritic and austenitic stainless steels, nickel base
consumables are used because they provide the required metallurgical compatibility, long term
creep strength and ductility.
Although there is a steep composition gradient at the P91 fusion boundary, carbon migration here
is much slower with nickel base alloys and PWHT can be carried out without problems. In joints
with austenitic stainless steels, the effect of PWHT on the stainless steel should be considered. If
this must be avoided, the P91 will need to be buttered and given a PWHT to temper the HAZ before
the joint is filled, unless elimination of PWHT itself is acceptable.
The use of 309 consumables with moderate ferrite content is indicated in AWS D10.8 for welding
ferritic/martensitic steels to austenitic stainless steels where the joint service temperature is below
315°C (600°F). Above this temperature, excessive carbon migration, microstructural instability and
the high expansion coefficient relative to the low alloy material leads to unsatisfactory performance.
The appropriate Metrode consumables, which correspond to the generic 2CrMo, 5CrMo, 9CrMo,
309, and nickel base descriptions used in this section, are listed in Table 14.

Table 14: Metrode consumables for dissimilar joints involving P91
Alloy Group Product Process AWS BS EN
2CrMo Chromet 2 MMA E9018-B3 E CrMo2 B
2CrMo TIG/MIG ER90S-G CrMo2Si
ER90S-B3 TIG/MIG ER90S-B3 CrMo2Si
SA2CrMo SAW (EB3) CrMo2
LA121 Sub arc flux - -
Cormet 2 [1] FCW E91T1-B3 -
5CrMo Chromet 5 MMA E8015-B6 E CrMo5 B
& 5CrMo TIG/MIG ER80S-B6 CrMo5
9CrMo Cormet 5 FCW E81T1-B6M -
Chromet 9 MMA E8015-B8 E CrMo9 B
9CrMo TIG/MIG ER80S-B8 CrMo9
Cormet 9 FCW E81T1-B8M -
309 [2] Thermet 309CF MMA E309-16 -
309S94 TIG/MIG/SAW ER309 309S94
SSB Sub arc flux - SA AF2 DC
Nickel base Nimrod 182KS [3] MMA ENiCrFe-3 -
Nimrod AKS [4] MMA ENiCrFe-2 -
20.70.Nb TIG/MIG/SAW ERNiCr-3 -
NiCr Sub arc flux - -
[1] This FCW has shown creep performance exceeding P22 parent material, owing to controlled
micro-alloying.
[2] These 309 types have controlled carbon and moderate ferrite, and are usually preferred to
309L types for elevated temperature service.
[3] This high Mn type is most frequently specified, particularly for welds to austenitic stainless
steels.
[4] The lower Mn level in this electrode, compared to Nimrod 182KS, produces a slightly lower
thermal expansion coefficient which may be preferred for welds between P91 and P22 or
nickel base alloys.

10 Future developments
The commercial application of P91 is now well established but the development of this alloy system
has continued with further improvements in performance. In the new modified steels, creep
strength is increased by adding tungsten to raise the Mo-equivalent (Mo + 0.5W) from 1% to about
1.5% in a matrix composition essentially similar to P91.
Two new advanced steels of this type are now commercially available. The first originated in Japan
as Nippon NF616 and following an EPRI project became the basis for ASME type P92, with
0.5%Mo-1.8%W. The second alloy, E911 (anticipated ASME type P911) has 1%Mo-1%W and was
developed within the European COST 501 collaborative project. Welding procedures for these
materials are essentially similar to those applied to P91. Welding consumables are close to
matching base material but generally require a small addition of nickel to optimise toughness. As
with P91, the creep performance of welded joints is controlled by type IV failure in the base
material HAZ, but with an overall enhancement in rupture stress. The P92 alloy is now being
specified and there is a Metrode Technical Profile available covering consumables for P92.
Further active developments are aimed at increasing the applicable service temperature of W-
modified steels by raising chromium to around 11% to improve hot corrosion resistance. The
prototype for this class of steel is the well-established German type 12%CrMoWV with 0.2%C,
commonly called X20. Like the modified 9%Cr steels, the new 11%Cr steels have improved
weldability with around 0.1%C, supported by a controlled addition of nitrogen and V+Nb to
optimise creep strength. An example of this type is Sumitomo HCM12A, which is the basis for the
proposed ASME type P122.
An intrinsic problem at 0.1%C-11%Cr is the greater tendency to form delta ferrite and in type P122
this is suppressed with the addition of about 1% copper. In other respects the composition is
similar to P92 and creep performance is claimed to be equivalent. Additions of up to 3% cobalt are
used to suppress ferrite in other modified 11%Cr alloys, which may offer considerably higher creep
resistance than the advanced 9%Cr types.
There are also a number of developments based on the P22 alloy system eg. P/T23 and P/T24.
These base materials show creep properties approaching those of P91 but there is still work
required on the development of suitable welding consumables.
As with the application of P91, the driving force for these developments is not only the advantage
of higher strength to allow thinner sections with improved heat transfer and thermal fatigue
performance, but also the environmental imperative which requires new and improved materials for
advanced power plants operating at higher temperatures with the maximum thermal efficiency.
For new base materials to be used in practice and find widespread application they have to be
readily weldable and welding consumables need to be developed. Metrode is involved in a number
of research programmes, in addition to in-house development, involving the advanced CrMo creep
resisting alloys. MMA consumables have already been manufactured for P92 and work continues in
this area; Metrode Technical Department should be contacted for information on the latest
developments.

11 Further reading
A182, A213, A217, A287 & A335; ASTM / ASME IIA Specifications for Base Materials.
AWS A5.5; ‘Specification for low alloy steel electrodes for SMAW’.
AWS A5.23; ‘Specification for low alloy steel electrodes and fluxes for SAW’.
AWS A5.28; ‘Specification for low alloy steel electrodes and rods for GSMAW’.
AWS D10.8; ‘Recommended practices for welding of Cr-Mo steel piping and tubing’.
BS 2633; ‘Specification for class I arc welding of ferritic steel pipework for carrying fluids’.
BS EN 1599; ‘Welding consumables - Covered electrodes for MMA welding of creep-resisting steels -
Classification’.
BS EN 12070; ‘Welding consumables – Wire electrodes, wires and rods for arc welding of creep
resisting steels - Classification.’
‘Advanced heat resistant steels for power generation’; IoM Conference Proceedings, San Sebastian,
Spain, 1998.
‘The manufacture and properties of steel 91 for the power plant and process industries’; ECSC
Conference Proceedings, Düsseldorf, 1992.
‘New steels for advanced plant up to 620°C’; EPRI/National Power Conference, London, 1995.
Strang & Gooch (ed), ‘Microstructural development and stability in high chromium ferritic power
plant steels’; IoM Conference Proceedings, London, 1997.
‘Microstructural stability of creep resistant alloys for high temperature plant applications’;
Conference Proceedings, Sheffield, 1997.
Zhang, Marshall & Farrar ‘Recent developments in welding consumables for P(T)91 creep resisting
steels’; Conference Proceedings: International conference on integrity of high temperature welds,
November 1998, Nottingham, UK.
Zhang, Marshall & Holloway ‘Flux cored arc welding: The high productivity process for P91 steels’;
Conference Proceedings, 3rd EPRI Conference on ‘Advances in materials technology for fossil power
plants’, April 2001, Swansea, Wales.
Zhang, Farrar & Barnes ‘Weld metals for P91 – Tough enough?’; Conference Proceedings: 4th EPRI
Conference on welding repair technology for power plants, June 2000, Florida, USA.

DATA SHEET A-17
METRODE PRODUCTS LTD
HANWORTH LANE, CHERTSEY
SURREY, KT16 9LL
Tel: +44(0)1932 566721
Fax: +44(0)1932 565168 Sales
Fax: +44(0)1932 569449 Technical
Fax: +44(0)1932 566199 Export
P91 - MODIFIED 9CrMo Email: info@metrode.com
Internet: http//www.metrode.com
Alloy type PWHT

Modified 9CrMo for high temperature creep resistance. Minimum preheat temperature 150°C with maximum
interpass temperature of 300°C; in practice a preheat-
Materials to be welded interpass range of 200 – 300°C is normal. To ensure full
martensite transformation, welds should be cooled to ~100°C
ASTM prior to PWHT.
A 213 T91 (seamless tubes)
ASME base material codes and AWS consumable
A 335 P91 (seamless pipes)
classifications allow PWHT down to 730°C, whilst BS EN
A 387 Gr 91 (plates)
consumable classifications specify 750°C. Optimum
A 182 / A336 F91 (forgings)
properties are obtained with a tempering parameter (P) of
A 217 C12A (castings)
around 21 or above, where P = °C+273 (log t + 20) x 10–3.
A 234 WP91
Maximum PWHT temperature varies, AWS consumable
A 369 FP91
specifications are 760°C, BS EN 770°C; BS 1503 allows up
DIN / BS EN
to 790°C for base material forgings.
1.4903 (X10CrMoVNb 9 1)
BS When compared with directly matching weld metal, the
1503 Gr91 addition of some nickel and reduction of niobium provides a
3059-2 Gr91 useful improvement in toughness after conveniently short
AFNOR PWHT at 750 – 760°C. PWHT above 765°C is not generally
NF A-49213/A-49219 Gr TU Z 10 CDVNb 09-01 recommended for Ni-containing consumables, because some
re-hardening could occur due to the proximity of Ac1. Some
Applications authorities specify weld metal Ni + Mn < 1.5% to keep Ac1
high enough to allow higher PWHT temperature if required.
These consumables are designed to weld equivalent ‘type 91’
9CrMo steels modified with small additions of niobium, Additional information
vanadium and nitrogen to give improved long term creep
properties. More detailed information on the products and properties of
P91 are available in the Technical Profile – "Welding
These consumables are specifically intended for high
Consumables for P91 Steels for the Power Generation
integrity structural service at elevated temperature so the
Industry" – available from the Technical Department.
minor alloy additions responsible for its creep strength are
kept above the minimum considered necessary to ensure
satisfactory performance. In this case, weldments will be Products available
weakest in the softened (intercritical) HAZ region of parent Process Product Specification
material, as indicated by so-called ‘type IV’ failure in
transverse weld creep tests. MMA Chromet 9MV-N AWS E9015-B9
Modified 9CrMo steels are now widely used for components Chromet 9-B9 AWS E9015-B9
such as headers, main steam piping and turbine casings, in Chromet 91VNR AWS E9016-B9
fossil fuelled power generating plants. They may also find
future use in oil refineries and coal liquefaction and Chromet 91VNB AWS E9015-B9
gasification plants. TIG 9CrMoV-N AWS ER90S-B9
MIG Cormet M91 (MCW) AWS E90C-G
Microstructure
SAW 9CrMoV-N (wire) AWS EB9
In the PWHT condition the microstructure consists of
tempered martensite with alloy carbides. LA491 (flux) BS EN SA FB 255AC
L2N (flux) BS EN SF CS 2 DC
FCW Supercore F91 AWS E91T1-B9
Rev 10 07/06 DS: A-17 (pg 1 of 7)

General Data for all Modified 9CrMo (P91) Electrodes
Description Basic metal powder types made on high purity steel core wire.
Recovery is approx 120% with respect to core wire, 65% with respect to whole electrode.
Moisture resistant coatings giving very low weld metal hydrogen levels.
Operating parameters DC +ve. AC (OCV 70V min)
ø mm 2.5 3.2 4.0 5.0

min A 70 80 100 140
max A 110 140 180 240
Storage 3 hermetically sealed ring-pull metal tins per carton, with unlimited shelf life. Direct use from tin will give
hydrogen <5ml/100g weld metal during 8h working shift.
For electrodes that have been exposed:
Redry 250 – 300°C/1-2h to ensure H2 < 10ml/100g, 300 – 350°C/1-2h to ensure H2 < 5ml/100g. Maximum
420°C, 3 cycles, 10h total.
Storage of redried electrodes at 100 – 200°C in holding oven, or 50 – 150°C in heated quivers: no limit, but
maximum 6 weeks recommended.
Fume data Fume composition (wt %)

3
Fe Mn Ni Cr Cu Pb F OES mg/m )
15 5 < 0.1 <3 < 0.1 < 0.1 18 1.7
Chromet 9MV-N MMA electrode to AWS/BS EN with high Ni to maximise toughness

Product description MMA electrode – with Ni addition and lower Nb for improved toughness, conforming to BS EN 1599
Specifications AWS A5.5 E9015-B9

BS EN 1599 E CrMo91 B 3 2
ASME IX Qualification QW422 P-No 5B group 2, QW432 F-No 4, QW442 A-No 5
Composition C Mn Si S* P* Cr Ni Mo Nb V N Cu Sn Ni+Mn
(weld metal wt %) min 0.08 0.50 -- -- -- 8.0 0.4 0.85 0.04 0.15 0.03 -- -- --
max 0.12 1.20 0.50 0.01 0.01 10.0 1.0 1.2 0.07 0.25 0.07 0.25 <0.008 1.5
typ 0.1 0.6 0.25 0.008 0.01 9 0.7 1 0.05 0.2 0.05 0.05 0.003 1.3
* Low Ni variant is available, Chromet 9-B9.
(1)
All-weld mechanical PWHT 755°C / 3h min typical 550°C 600°C 650°C
properties Tensile strength MPa 620 770 >450 >375 >285
0.2% Proof stress MPa 530 640 >360 >255 >175
Elongation on 4d % 17 22 -- -- --
Elongation on 5d % 15 19 >15 >17 >21
Reduction of area % -- 60 >68 >75 >80
Impact energy + 20°C J 47 65 -- -- --
Lateral expansion + 20°C mm -- 1.00 -- -- --
Hardness after PWHT HV -- 250 -- -- --
Hardness as-welded HV -- 450 -- -- --
(1)
Minimum strength for parent material is lower than AWS requirement shown.
Packaging data ø mm 2.5 3.2 4.0 5.0

length mm 350 380 450 450
kg/carton 12.9 15.0 17.4 16.5
pieces/carton 651 405 234 150
Chromet 9-B9 MMA electrode meeting AWS/ASME
Rev 10 07/06 DS: A-17 (pg 2 of 7)

Product description MMA electrode – manufactured to the requirements of AWS A5.5 E9015-B9

BS EN 1599 (E CrMo91 B 3 2)
Composition C Mn* Si S P Cr Ni* Mo Nb V N Cu Al

(weld metal wt %) min 0.08 0.40 -- -- -- 8.0 0.2 0.85 0.03 0.15 0.03 -- --
max 0.12 0.75 0.30 0.01 0.01 10.0 0.4 1.2 0.07 0.25 0.07 0.25 0.04
typ 0.1 0.55 0.25 0.008 0.008 9 0.3 1 0.04 0.2 0.05 0.05 <0.01
* Ni + Mn < 1. 0%. Nickel is below 0.4% (as parent material) although AWS allows up to 1.0%Ni. See
Chromet 9MV-N for variant with 0.4 – 1.0%Ni conforming to BS EN specification.
(1)
All-weld mechanical PWHT 760°C / 2h min typical 550°C 600°C 650°C
properties Tensile strength MPa 620 710 >450 >375 >285
0.2% Proof stress MPa 530 590 >360 >255 >175
Elongation on 4d % 17 22.5 -- -- --
Elongation on 5d % 15 19 >15 >17 >21
Reduction of area % -- 63 >68 >75 >80
Impact energy + 20°C J -- 75 -- -- --
Lateral expansion + 20°C mm -- 1.10 -- -- --
Hardness after PWHT HV -- 240 -- -- --
Hardness as-welded HV -- 450 -- -- --
(1)
Packaging data ø mm 2.5 3.2 4.0* 5.0

length mm 350 380 380/450 450
kg/carton 13.5 15 15/17.1 16.5
pieces/carton 657 378 264/249 150
* 450mm is standard length for 4.0mm, 380mm produced to order.
Chromet 91VNR MMA electrode for root welding

Product description MMA electrode for root welding applications.

BS EN 1599 E CrMo91 R 3 2
Composition C Mn* Si S P Cr Ni* Mo Nb V N Cu

(weld metal wt %) min 0.08 0.4 -- -- -- 8.0 0.4 0.85 0.03 0.15 0.03 --
max 0.12 1.0 0.3 0.01 0.01 9.5 0.8 1.2 0.07 0.25 0.07 0.25
typ 0.1 0.6 0.25 0.008 0.008 8.5 0.5 1 0.04 0.2 0.05 0.05
* Ni + Mn <1.50
(1)
All-weld mechanical PWHT 760°C / 2h min typical
properties Tensile strength MPa 620 750
0.2% Proof stress MPa 530 600
Elongation on 4d % 17 20
Impact energy + 20°C J -- 55
Hardness HV -- 250
(1)
Packaging data ø mm 2.5 3.2

length mm 350 380
kg/carton 14.1 13.5
pieces/carton 714 408
Rev 10 07/06 DS: A-17 (pg 3 of 7)

Chromet 91VNB MMA electrode for root welding
Product description Basic coated MMA electrode for root welding applications made on high purity steel core wire. Recovery is
approx 120% with respect to core wire, 65% with respect to whole electrode. Moisture resistant coatings giving
very low weld metal hydrogen levels.

BS EN 1599 E CrMo91 B 3 2
Composition C Mn Si S P Cr Ni Mo Nb V N Cu Al
(weld metal wt %) min 0.08 0.4 -- -- -- 8.0 0.4 0.85 0.03 0.15 0.03 -- --
max 0.12 1.2 0.3 0.01 0.01 9.5 1.0 1.2 0.07 0.25 0.07 0.25 0.04
typ 0.1 0.8 0.25 0.008 0.008 8.5 0.5 1 0.04 0.2 0.05 0.05 0.01
(1)
All-weld mechanical PWHT 760°C / 2h min typical
properties Tensile strength MPa 620 750
0.2% Proof stress MPa 530 600
Impact energy + 20°C J -- 55
(1)
Operating parameters DC +ve, DC –ve or AC (OCV 70V min)
ø mm 2.5
min A 60
max A 110

3
Fe Mn Ni Cr Cu Pb F OES mg/m )
15 5 < 0.1 <3 < 0.1 < 0.1 18 1.7
9CrMoV-N Solid wire for TIG and SAW
Product description Solid wire, non-copper coated, for TIG and SAW
Specifications TIG SAW

AWS A5.23 N/A EB9
AWS A5.28 ER90S-B9 N/A
BS EN 12070 WCrMo91 (SCrMo91)
Composition C Mn Si * S P Cr Ni Mo Nb V N Cu Al
(wire wt %) min 0.08 0.40 0.15 -- -- 8.0 0.40 0.85 0.03 0.15 0.03 -- --
max 0.13 0.80 0.30 0.010 0.010 9.5 0.80 1.10 0.08 0.25 0.07 0.10 0.04
typ 0.1 0.5 0.25 0.006 0.008 8.7 0.6 1 0.05 0.2 0.05 0.03 <0.01
* A5.28 ER90S-B9 allows up to 0.50% Si and BS EN 12070 allows up to 0.60% Si.
All-weld mechanical TIG SAW typical SAW typical

properties PWHT 750 – 760°C / 2 – 3h min typical LA491 flux L2N flux
Tensile strength MPa 620 800 750 750
0.2% Proof stress MPa 415 700 630 630
Elongation on 4d % 16 22 25 25
Reduction of area % -- 70 70 70
Impact energy + 20°C J -- * 220 45 35
Hardness HV (mid) -- 265 250 250
* Minimum impact required by BS EN is 47 J.
Rev 10 07/06 DS: A-17 (pg 4 of 7)

9CrMoV-N (continued)
Parameters TIG SAW MIG
Shielding Argon LA491 or L2N flux 9CrMoV-N not recommended
Current DC- DC+ for MIG, Cormet M91 or
Typical parameters 2.4mm ø 100A, 12V 450A, 30V, 450mm/min Supercore F91 should be used.
Packaging data ø mm TIG SAW MIG

0.9 Spool to order --
1.2 -- -- Not recommended - see
1.6 5kg tube -- Supercore F91 or Cormet
2.4 5kg tube 25kg coil M91.
3.2 5kg tube 25kg coil
Fume data Fume composition (wt %); TIG and SAW fume are negligible:
3 3
Fe Mn Ni Cr Mo Cu OES (mg/m )
50 4 < 0.4 6 0.5 < 0.5 5
Cormet M91 Metal cored wire for MIG welding
Product description Metal cored wire for MIG welding. High purity steel sheath with 96% metal recovery with respect to wire.
Specifications AWS A5.28 E90C-G (B9)
Composition C Mn Si S P Cr Ni Mo Nb V N Cu Al
(weld metal wt %) min 0.08 0.60 -- -- -- 8.0 -- 0.85 0.03 0.18 0.03 -- --
max 0.13 1.20 0.40 0.014 0.014 10.0 0.40 1.2 0.07 0.25 0.07 0.15 0.04
typ 0.1 1 0.3 0.01 0.01 9 0.3 1 0.05 0.2 0.05 0.05 0.03
All-weld mechanical ---------------- typical -----------------

properties PWHT 755°C / 3h min Ar-2½%CO2 80/20 Ar-He-CO2
Tensile strength MPa 620 780 780 780
0.2% Proof stress MPa 530 650 650 650
Impact energy + 20°C J -- 30 25 35
Lateral expansion + 20°C mm -- 0.30 0.28 0.45
Hardness HV -- 260 260 260
Parameters Operability is influenced by the type of shielding gas; higher CO2 levels, up to 20%, give
better arc characteristics but lower CO2 and O2 levels produce better impact properties. The
best compromise is considered to be obtained from Ar-2½%CO2 although if impact properties
are not a major concern, higher CO2 levels can be used to obtain optimum arc characteristics.
ø mm Gas flow Optimum Stickout
1.2 15 – 25 l/min DC+ 260A 28V 10 – 20mm
1.6 15 – 25 l/min DC+ 330A 29V 15 – 25mm
Packaging data Resistance to moisture absorption is high, but to maintain the high integrity of the wire surface and prevent any
possibility of porosity, it is advised that part-used spools are returned to polythene wrappers. 15kg spools.
Where possible, preferred storage conditions are 60% RH max, 18°C min.

3 3
Fe Mn Ni Cr Mo Cu OES (mg/m )
60 5 < 0.5 5 <0.1 <0.1 5
Rev 10 07/06 DS: A-17 (pg 5 of 7)

LA491 and L2N Sub-arc fluxes for use with 9CrMoV-N solid wire
Product description LA491 is an agglomerated fluoride-basic submerged arc welding flux. L2N is a fused calcium silicate flux for
submerged arc welding.
Specifications LA491 L2N

BS EN 760 (flux) SA FB 255 AC SF CS 2 DC
AWS A5.23 (flux wire combination) (F62PZ-EB9-B9) (F62PZ-EB9-B9)
Composition LA491 L2N

(flux wt %) SiO2 + Ti O2 15% 30%
CaO + Mg O 40% 35%
AlO3 + MnO 20% 5%
CaF2 25% 20%
Basicity index (Boniszewski) ~2.7 ~1.3
Analysis deposit C Mn Si S P Cr Ni Mo Nb V N
(typical) 9CrMoV-N Wire 0.10 0.8 0.30 0.005 0.005 9.0 0.6 1 0.06 0.20 0.05
Deposit with LA491 0.08 0.8 0.35 0.005 0.010 8.6 0.6 1 0.05 0.17 0.05
Deposit with L2N 0.09 0.5 0.6 0.005 0.012 8.3 0.6 1 0.04 0.16 0.05
All-weld mechanical SAW typical SAW typical

properties PWHT 750 – 760°C / 2 – 3h min LA491 flux L2N flux
Tensile strength MPa 620 750 750
0.2% Proof stress MPa 415 630 630
Elongation on 4d % 16 25 25
Elongation on 5d % 17 23 23
Reduction of area % -- 70 70
Impact energy + 20°C J --* 40 35
Hardness HV (mid) -- 250 250
* Minimum impact required by BS EN 12070: SCrMo91 is 47 J.
Parameters LA491 L2N

AC or DC+ 800A maximum AC or DC+ 900A maximum
Packaging data LA491 L2N

Packaging: 20kg sealed drums Packaging: 20kg sealed drums
Preferred storage <60%RH, > 18°C. Preferred storage <60%RH, > 18°C.
If flux becomes damp, rebake at 300–350°C/ 1–2hours If flux becomes damp, rebake at 150-250°C/1–2hours
to restore to as-packed condition. For critical work, it to restore to as-packed condition.
is recommended to redry to ensure <5ml H2/100g.
Rev 10 07/06 DS: A-17 (pg 6 of 7)

Supercore F91 All-positional flux cored wire
Product description All-positional flux cored wire designed to weld equivalent modified 9CrMo steels (P91). Rutile flux system
with an alloyed strip producing weld metal recovery of about 90%.
Specifications AWS A5.29 E91T1-B9M
ASME IX Qualification QW432 F-No -, QW442 A-No -
Composition Ni+
C Mn Si S P Cr Ni Mo Nb V N Cu Al
Mn
(weld metal wt %) min 0.08 0.60 -- -- -- 8.0 -- 0.85 0.03 0.18 0.03 -- -- --
max 0.13 1.20 0.40 0.015 0.020 10.0 0.80 1.2 0.07 0.25 0.07 0.15 0.04 1.5
typ 0.1 0.8 0.3 0.010 0.016 9 0.5 1 0.04 0.2 0.05 0.05 0.01 1.3
All-weld mechanical ------------ High Temperature ---------

properties PWHT 760°C / 2h min typical +566°C +600°C +650°C
Tensile strength MPa 620 790 450 420 396
0.2% Proof stress MPa 560 660 360 288 245
Elongation on 4d % 16 20 21 27 29
Elongation on 5d % -- 18 20 25 26
Reduction of area % -- 55 73 81 85
Impact energy + 20°C J -- 25 -- -- --
Hardness HV -- 260 -- -- --
Operating parameters Shielding gas: 80%Ar-20%CO2 (or 15 – 25%CO2) or 100% CO2 at 20-25l/min.
Current: DC+ve ranges as below:
ø welding position amp-volt range * typical stickout
1.2mm
(0.045in)
Positional 140-170A, 24-26V 160A, 25V 15-25mm
* Using 100%CO2 the voltage should be increased by 1-2V
Packaging data Spools vacuum-sealed in barrier foil with cardboard carton: 15kg (33 lbs)
The as-packed shelf life is virtually indefinite.
Resistance to moisture absorption is high, but to maintain the high integrity of the wire surface and prevent any
possibility of porosity, it is advised that part-used spools are returned to polythene wrappers.
Where possible, preferred storage conditions are 60% RH max, 18°C min.
Fume data Fume composition (wt %), shielding gas 80%Ar-20%CO2:

3 6 3
Fe Mn Ni Cr Cr Cu F OES (mg/m )
18 8 < 0.5 3 3 <1 8 1.7
Rev 10 07/06 DS: A-17 (pg 7 of 7)

Welding Procedure Specification (WPS)
Welding Procedure No: CH9MVN-01
Consumables Base Material

Welding process (root): TIG (GTAW) Parent Material: A335 P91
- Consumable: 9CrMoV-N ASME IX P-Number 5B
BS EN: W CrMo 91
- Specification:
AWS: ER90S-B9
Welding process (fill): MMA (SMAW)
- Consumable: Chromet 9MV-N Thickness: 15-60mm
- Specification: BS EN, E CrMo 91 B Outside Diameter: 16″ NB (406mm OD)
Joint Details Joint Position
Joint Type: Butt single sided Welding Position: ASME: 5G
Manual/Mechanised: Manual BS EN: PF
Joint Sketch
Joint for thickness < 20mm Joint for thickness > 20mm
α β
f g f g
f = 1-3mm; g = 2-4mm; α = 70° f = 1-3mm; g = 2-4mm; α = 70°; β = 20°
Welding Details
Diameter Current Voltage Type of current Wire Feed Heat

Run Process Consumable Speed Input
mm A V / Polarity
m/min kJ/mm
1 TIG 9CrMoV-N 2.4 70-110 ~12 DC- NA ~1.2
2-3 TIG 9CrMoV-N 2.4 80-140 ~12 DC- NA ~ 1.2
4-7 MMA Chromet 9MV-N 3.2 90-130 ~24 DC+ NA ~ 1.0
Rem MMA Chromet 9MV-N 4.0 120-170 ~25 DC+ NA ~ 1.2
o
Electrode Baking or Drying: 300-350 C/1-2h Notes:
Gas – root (TIG) shielding: Pure Ar
1. Maintain purge for runs 1-3.
purge: Pure Ar (note 1)
Gas Flow Rate (TIG) – Shielding: 8-15 l/min o
2. Preheat 150 C min for TIG.
Purge: 4-10 l/min
o
Tungsten Electrode Type/Size: 2% Th/2.4mm 3. Cool to ~100 C before PWHT.
o
Details of Back Gouging/Backing: NA 4. Heating & cooling rate <100 C/h (above 300°C).
o
Preheat Temperature: 200 C min (note 2) 5. Stringer beads, maximum weave 3 x ø.
o
Interpass Temperature: 300 C max
Post-Weld Heat Treatment: Note 3.

o o
Temperature: 760 C ± 10 C
Time: 1h/25mm (2 hours min)
Note 4.
c:\my documents\technical\welding procedure specifications\tr884 wps.doc

Welding Procedure No: CH9MVN-02

Welding process (root): NA Parent Material: A335 A217 C12A ((cast)
- Consumable: - ASME IX P-Number 5B
- Specification: -
- Consumable: Chromet 9MV-N Thickness: 15-60mm
- Specification: BS EN, E CrMo 91 B Outside Diameter: -

Joint Type: Butt/groove Welding Position: ASME, 1G
Manual/Mechanised: Manual BS EN, PA
Joint Sketch
R =8-12mm; α = 20-30°
Welding Details

mm A V / Polarity
m/min kJ/mm
MMA Chromet 9MV-N 3.2 90-135 ~23 DC+ NA ~ 1.2
o
Gas – root (TIG) shielding: NA o
1. Cool to ~100 C before PWHT.
purge: NA
Gas Flow Rate (TIG) – Shielding: NA o
2. Heating & cooling rate <100 C/h (above 300°C).
Purge: NA
Tungsten Electrode Type/Size: NA
Details of Back Gouging/Backing: NA
o
Preheat Temperature: 200 C min
o

o o
Time: 8 hours
Note 2.

Welding Procedure No: CH9B9-01

- Specification: AWS ER90S-B9 (note 1).
- Consumable: Chromet 9-B9 Thickness: 15-60mm
- Specification: AWS E9015-B9 (note 2). Outside Diameter: 16″ NB (406mm OD)
Joint Type: Butt single sided Welding Position: ASME, 5G
Manual/Mechanised: Manual BS EN, PF
Joint Sketch
α β
f g f g
Welding Details

mm A V / Polarity
m/min kJ/mm
1 TIG 9CrMoV-N 2.4 70-110 ~12 DC- NA ~ 1.2
2-3 TIG 9CrMoV-N 2.4 80-140 ~12 DC- NA ~ 1.2
4-7 MMA Chromet 9-B9 3.2 90-130 ~24 DC+ NA ~ 1.0
Rem MMA Chromet 9-B9 4.0 120-170 ~25 DC+ NA ~ 1.2
o
1. ASME IX, QW-432 F-number 4.
Gas Flow Rate (TIG) – Shielding: 8-15 l/min
2. ASME IX, QW-442 A-number 5.
Purge: 4-10 l/min
Tungsten Electrode Type/Size: 2% Th/2.4mm 3. Maintain purge for runs 1-3.
o
Details of Back Gouging/Backing: NA 4. Preheat 150 C min for TIG.
o o
Preheat Temperature: 200 C min (note 4) 5. Cool to ~100 C before PWHT.
o o
Interpass Temperature: 300 C max 6. Heating & cooling rate <100 C/h (above 300°C).

o o
Note 6.

Welding Procedure No: CMM91-01

- Specification: BS EN: W CrMo 91
Welding process (fill): MIG (GMAW)
- Consumable: Cormet M91 (MCW) Thickness: 15-60mm
- Specification: AWS: ER90C-G Outside Diameter: -

Joint Type: Butt single sided Welding Position: ASME, 1G
Manual/Mechanised: Manual BS EN, PA
Joint Sketch
α β
f g f g
Welding Details

mm A V / Polarity
m/min kJ/mm
1–5 TIG 9CrMoV-N 2.4 70-110 ~12 DC- NA ~1.2

- MCW Cormet M91 1.2 240-280 ~28 DC+ (note 1) ~10 ~ 1.6
- MCW Cormet M91 1.6 270-330 ~29 DC+ (note 2) ~7 ~ 2.0
Electrode Baking or Drying: NA Notes:

Gas – (Cormet M91) shielding: Ar-2.5%CO2
1. Electrode stickout 10-20mm.
purge: Ar
Gas Flow Rate – Shielding: 15-25 l/min
Purge: 4-10 l/min
o
Tungsten Electrode Type/Size: 2% Th/2.4mm 3. Preheat 150 C min for TIG.
o
Details of Back Gouging/Backing: NA 4. Cool to ~100 C before PWHT.
o o
Preheat Temperature: 200 C min (note 3) 5. Heating & cooling rate <100 C/h (above 300°C).
o

o o
Note 5.

Welding Procedure No: SCF91-01

- Specification: AWS: ER90S-B9 Thickness: 15-60mm
Welding process (fill): MMA Joint Details
- Consumable: Chromet 9MV-N Joint Type: Single side butt weld
- Specification: AWS: E9015-B9 Manual/Mechanised: Manual
Welding process (fill): FCAW Joint Position
- Consumable: Supercore F91 (Note 1) Welding Position: ASME: 6G
- Specification: _ BS EN: HL045
Joint Sketch Welding Sequences
f g
f = 1-2mm; g = 3-4mm; α = 75°; β = 10-20°
Welding Details
Diameter Current Voltage Type of Wire Feed Heat

Run Process Consumable current / Speed Input
mm A V
Polarity m/min kJ/mm
1 TIG 9CrMoV-N 2.4 80-120 ~12 DC- NA ~1.4

2-6 MMA Chromet 9MV-N 3.2 90-110 ~22 DC+ NA ~1.0
Fill FCW Supercore F91 1.2 160-190 25-27 DC+ (Note 2) ~6-8 ~1.2
Electrode Baking or Drying: 300-350°C/1-2h Notes:

Gas – root (TIG) shielding: Argon
1. Shielding gas Ar-20%CO2 at 15-25 l/min.
purge: Argon (Note 3)
Purge: 4-10 l/min
Tungsten Electrode Type/Size: 2% Th / 2.4mm 3. Maintain purge for at least first two runs.
Details of Back Gouging/Backing: NA 4. Preheat 150°C min for TIG.
Preheat Temperature: 200°C min (note 4) 5. Cool to ~100°C before PWHT.

Interpass Temperature: 300°C 6. Heating & cooling rate <100°C/h (above 300°C).

Temperature: 760°C ± 10°C
Time: 1 h/25mm (min 3 hours)
Note 6.

Welding Procedure No: SAW-P91-01

Welding process (root): TIG (GTAW) Parent Material: A335 P91 ASME IX P-No. 5B
- Consumable: 9CrMoV-N Thickness: 25-75mm
- Specification: BS EN, W CrMo 91 Outside diameter:
Welding process (hot pass): MMA (SMAW) Joint Details
- Consumable: Chromet 9MV-N Joint Type: Butt single sided
- Specification: BS EN E CrMo 91 B Manual/Mechanised: Manual & mechanised
Welding process (fill): SAW Joint Position
- Consumable: 9CrMoV-N + LA491 (flux) Welding Position: ASME, 1G (1GR; note 6).
- Specification: BS EN S CrMo 91 (wire). BS EN, PA (note 6).
Joint Sketch
f g
f = 1–3mm; g = 2-4mm; α = 70°; β = 20°
Welding Details
Diameter Current Voltage Type of Travel Heat

Run Process Consumable current / Speed Input
mm A V
Polarity mm/min kJ/mm
1 TIG 9CrMoV-N 2.4 70-110 ~12 DC- NA ~ 1.0
2-3 TIG 9CrMoV-N 2.4 80-140 ~12 DC- NA ~ 1.2
4-7 MMA Chromet 9MV-N 3.2 90-130 ~24 DC+ NA ~ 1.2
Rem SAW (note 1) 9CrMoV-N 2.4 350-450 ~30 DC+ 400-500 ~ 2.0
o
Electrode & Flux Drying: 300-350 C/1-2h Notes:
1. SAW flux LA491.
~20mm wire extension, ~30mm flux depth.
Purge: 4-10 l/min
Tungsten Electrode Type/Size: 2% Th/2.4mm 2. Maintain purge for runs 1-3.
o
Details of Back Gouging/Backing: NA 3. Preheat 150 C min for TIG.
o o
Preheat Temperature: 200 C min (note 3) 4. Cool to <100 C before PWHT.
o o
Interpass Temperature: 300 C max 5. Heating & cooling rate <100 C/h (above 300°C).
Post-Weld Heat Treatment: Note 4. 6. For rotated pipe, head to be 10° before TDC
o o
Temperature: 760 C ± 10 C perpendicular to pipe.
Note 5.

Metrode P91 Profile How To

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Metrode Products Limited

Metrode in France Telephone +33(0)237 647000

Metrode in China Telephone +86(0)27 8759 7196

© Metrode Products Ltd

3 Weld metal compositions 6

6 Metrode range of welding consumables 10

8 Preheat, Interpass, Post Heat & PWHT 28

9 Welding P91 to dissimilar materials 31

Appendix 1 Data sheet

Appendix 2 Welding Procedure Specifications

© Metrode Products Ltd

© Metrode Products Ltd Page 1 of 35 Issue 6 July 2006

P91, t=49mm (2in)

X20, t=77mm (3in)

Figure 2: Comparison of required wall thicknesses for equivalent service. Temperature

Table 1: Specified composition for P91 steel

© Metrode Products Ltd Page 2 of 35 Issue 6 July 2006

hardness, HB 248 250 NR 248 NR NR NR NR NR NR

NR – Not required by specification

Figure 3: Schematic diagram of modern coal fired power station.

© Metrode Products Ltd Page 4 of 35 Issue 6 July 2006

© Metrode Products Ltd Page 5 of 35 Issue 6 July 2006

Figure 5: Typical P91 weld metal microstructure

© Metrode Products Ltd Page 6 of 35 Issue 6 July 2006

© Metrode Products Ltd Page 7 of 35 Issue 6 July 2006

Argon/CO2 16 Not specified

The choice of welding process depends on a number of factors, including:

− size and thickness of the component to be welded

Table 5: Welding process options for power plant

Superheater/ Tube to tube Fixed/orbital TIG, manual TIG and MMA

Pressure vessels, Butt welds TIG, MMA, FCW, Sub Arc

© Metrode Products Ltd Page 9 of 35 Issue 6 July 2006

Table 6: Metrode range of consumables for P91

AWS A5.28/ASME SFA 5.28

© Metrode Products Ltd Page 10 of 35 Issue 6 July 2006

6.1.1 Chromet 9MV-N

6.1.2 Chromet 9-B9

6.1.3 Chromet 91VNR and Chromet 91VNB

© Metrode Products Ltd Page 11 of 35 Issue 6 July 2006

Chromet 9-B9 0.1 0.5 0.25 9 0.3 1 0.04 0.2 0.05

6.2 TIG (GTAW)

6.2.1 Wire analysis of 9CrMoV-N

6.2.2 Procedural aspects

© Metrode Products Ltd Page 12 of 35 Issue 6 July 2006

Table 8: Chemical composition of Cormet M91 metal cored wire deposits

© Metrode Products Ltd Page 13 of 35 Issue 6 July 2006

Stickout, mm (in) Current, A Voltage, V WFS, m/min (in/min)

1.6mm (1/16in) 15 – 25 (0.6-1.0) 330 29 ~7 (~280)

6.3.3 Flux cored wires (FCW)

Current, A Voltage, V ESO, mm (in)

For 6G Pipe 150 25 15 (0.6)

If 100%CO2 is used, the voltage will need to be increased by ~2Volts.

© Metrode Products Ltd Page 14 of 35 Issue 6 July 2006

6.4.1 9CrMoV-N sub-arc wire

6.4.2 Practical aspects

Dia, Electrode extension, Current, Voltage, Travel Speed,

© Metrode Products Ltd Page 15 of 35 Issue 6 July 2006

Figure 6: Control and storage of sub-arc flux LA491

© Metrode Products Ltd Page 16 of 35 Issue 6 July 2006

7.1 Room temperature tensile properties

A high resistance to softening by PWHT (temper-resistance) is an intrinsic feature of P91 weld

Table 9 Typical all weld metal tensile properties

755/8 735 610

755/1 830 710