Engineering and Technology Journal Vol. 35, Part A, No.

1, 2017

A.H. Fadhil Welding procedures of Turbine Blades by

Materials Engineering
Department- University
Using ER 309L Austenitic Filler Wire
of Technology, Iraq
hashembsb@yahoo.com Abstract-In the present work it has been investigated the repair of LP-
blades steam turbine made of AISI 410 martensitic stainless steels (MSS)
by GTAW welding, the repair welding carried out by using ER 309L as
S. A. Emad consumable filler wire. PWHT was carried out at 1100C for 1h. The
Materials Engineering structure-property relationships of the weldments were established based
Department- University on the current modes employed by utilizing combined techniques of
of Technology, Iraq optical microscopy, line/point and EDS analysis. Results showed that
Micro-hardness along the base and HAZ regions increased after PWHT
K.H. Abbas as compared to in state of as-welded. After welding process,
Materials Engineering microstructure photographs of weld-metal region revealed two phase the
Department- University vermicular -Ferrite and -austenite matrix. HAZ region consisted of
of Technology, Iraq tempered lath martensite with carbides. Line/Point analysis revealed the
direction of segregation, whereas chromium was increased in core and
H. A. Olaa depleted in boundary, while nickel was depleted in core and increased in
boundary, this support the ferrite was primarily solidified.
Materials Engineering
Department- University Keywords- Steam Turbine, LP- blades, GTRW, Repair welding, PWHT,
of Technology, Iraq martensitic stainless steels (MSS).

Received on: 28/09/2016

Accepted on: 29/12/2016

A.H. Fadhil, S.A. Emad, K. H. Abbas and H.A. Olaa, Welding procedures of Turbine Blades by Using ER
309L Austenitic Filler Wire, Engineering and Technology Journal, Vol. 35, Part A, No. 1, pp. 68-75, 2017.

1. Introduction
Gas and steam power plants in Iraq appeared to consumable filler wire as ER 410 MSS and ER
be off important options of the electrical energy. 316L austenitic filler wires. Results showed that
These plants contain of several number of units employing ER 410 filler wire with preheating and
and components that must be work together in PWHT processes is appropriate to weld MSS blades
proper way to achieve the best efficiency and turbine. Divya [3] investigated the details in-situ
performance. In worldwide, Steam turbines weld repair of cracked shrouds of turbine and
considered mainstay production of electricity characterization the weld joint. Crack shrouds of the
worldwide, since nearly 80% of the whole 3rd stage of a Low Pressure turbine was in-situ
generated electricity by the use of steam turbines. repaired by removing the cracked pieces of the
Todays the competition in the market of shroud that made of AISI 414 martensitic stainless
electricity generation market has been increased steel (SS) and welding using gas tungsten arc
the pressure to keep planet generation of power welding with ER 410NiMo consumable wire.
on line whenever required maintenance of steam Micro-hardness result showed weld-metal region in
turbine is of quite importance to insurance the state as welded and after heat treated was reduced
high steam turbines efficiency and to keep safety from 400-260 VHN with applied load 500g. Sara
standards in order to avoid any unexpected [4], studied the metallurgical transformations
dangers. The steam turbines operate under high accruing through SMAW welding of AISI 316L
steam pressure, and have parts that require austenitic stainless steel with AISI 430 ferritic
extremely high velocities. Turbine nozzles and stainless steel. AWS E309L austenitic and AWS
blades are designed via accurate analysis and E2209-16 duplex stainless steels were using as filler
manufactured with high degree of finishing and wires to perform this study. Microstructural results
accuracy Patil [1]. Bhaduri [2] investigated the of a dissimilar austenite-ferrite stainless steel
developed of welding repair procedure on welding using two different filler metals was
cracked blades steam turbine was made from showed, the morphology and amount of delta ferrite
MSS (martensitic stainless steel) by using TIG is a function of the chemical composition of the
(Tungsten Inert Gas) welding process with filler metal. Arivarasu [5]

Copyright 2017 by UOT, IRAQ 68

Engineering and Technology Journal Vol. 35, Part A, No. 1, 2017

investigated dissimilar welding joint between AISI (25mm*100mm). Followed by, it is achieved
304L (ASS) and low alloyed AISI 4340 aeronautical standard V-Butt configurations (single V-groove
steel that welded joint by CC (continuous current) having a root face of 2 mm, size land of 1 mm and
and PC (pulsed current) GTAW techniques, using included angle of 70) was worked on these pairs.
two types of consumables filler metal as ER309L Multi-pass welding was performed through TIG
and ERNiCr- welding machine (type/ ESAB LRT 160, Materials
3. optical microstructure results of the weldments Engineering, University of technology)and V-butt
joined by CCGTAW with 2 consumable filler metals welding joint process was depended on the skill of
was showed weld-metal was revealed coarser welder; Figure 1, illustrated specimens after
microstructure contained columnar dendrites with welding. No preheating was made before welding to
appearances of secondary phase (s) at the interface a void hydrogen induced cracks. The parameters of
of AISI 4340 side. The aim of the present research welding joint were fixed: - Main Supply 70-80
is investigation the developed repair welding V/Hz, Current Range 130 A and Gas Flow Rate 6
procedure to repair turbine blades with using ER L/min-1. When welding process was completed, the
309L austenitic filler wire. Also, the effects of post- samples were cute by Wire Electrical Discharge
weld treatments were studied on the Machining (WEM) or Wire-Cut EDM (type/ Smart
microstructural, hardness and chemical DEM), to small specimens with dimension (50 * 10
composition of the welded joints of AISI * 10) mm, as shown in Figure
410MSS/ER309L. 2. After welding and cutting process, each
sectioned specimen was subjected to PWHT (Post
2- Materials and Experimental Procedure Weld Heat Treatment) in order to obtained best
LP blades of a steam turbine made from AISI 410 mechanical properties and some stress relief.
martensitic stainless steel used as a base metal. PWHT method was conducted at 1100 C. PWHT
ER 309L austenitic filler metal is candidate and was carried out by using furnace (type/Carbolite
employed, chemical composition for 410MSS 1200). The holding time for PWHT was 1hr and
and ER309L is represented in Table 1. cooling rate 30 C/min. The furnace was switched
The blades were sectioned by the spark discharge off and cross-section specimens were placed in to
machine (EDM) to the pairs symmetry (each slowly cool to room temperature in order to
piece of pairs has dimensioned approximately prevent high-temperature oxidation of the joint.

Table 1:- Chemical Composition of Base Metal and Filler Alloys

Base/Filler Chemical Composition (% by Weight)
metal
C% Cr% Ni% Mo% Mn% Si% Fe% Creq Nieq req/Nieq
AISI 410 0.127 11.94 0.2 0.0109 0.755 0.38 B -- --- ---
ER 309L 3.79 21.24 14.24 1.04 1.87 0.73 57.1 23.3 15.2 1.53

Cr eq & Ni eq estimated from Shaeffler-Delong diagram assuming N=0.03wt%.

Figure 2: Specimen after cutting

Figure 1: Specimen after welding

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I. Microstructure and Micro-hardness Testes to the moderate cooling rate used in the TIG welded
After grinding, polishing and etching melt pool. HAZ affected zone heated during
(metallography procedure), microstructure and welding to various temperatures ranging from
micro hardness along weldments studied. Optical ambient temperature to the melting range of the
microscope with 5 mega pixel CCD camera into alloy. The grain growth occurs in the HAZ AISI 410
image pro software with the magnification of 5, MSS appeared tampered lath marten site with
10, and 20X used to examine samples after carbides as shown in Figure 4. Whereas, with high
grinding and polishing processes. carbon content, carbon may precipitated at HAZ
The Vickers micro hardness test (HVS-1000) with region ( matrix (FCC)) in the form of carbides as
diamond indenter was conducted on the polished M23C6 and M7C3 or M6C, due to carbon solubility
mounted weld cross section, with load of 1Kg and at ambient temperature became very low about
duration time 15 seconds. Samples were prepared in 0.006% in austenitic steels and even lower in ferritic
accordance with to ASTM E3-11 standard [6]. steels, as reported by Erich Folkhard [7].

II. Line/Point with EDS analysis 2. Weldment AISI 410/ER 309L after 1100C/1h
Electron probe micro-analyzer (EPMA), Houses a Figure 5, showed the presence of fully austenite
JEOL 8200 Super probe EPMA device at (light etching) of ER 309 weld-metal zone after heat
Microprobe Laboratory in the Department of treated 1100C/1h, this may belong to the
Earth Sciences at the University of Dalhousie in dissolution of all phases residual -ferrite phase and
Canada Country was used to complete these tests. carbides at 1100C and homogenous weld-metal
Specimens were prepared by grinding and zone structure formed. According to Erich Folkhard
polishing with dimension (50 * 10 * 10) mm and [7], austenitic steels always preferred subjected to a
then making set of points along weldments across solution annealing treatment between 1050-1100C
base, HAZ and weld-metal regions, each of these at which phases including carbide M23C6, sigma
points have been analyzed. phase and delta ferrite were completely dissolved
and the annealing process produces a homogenous
3. Results and discussion I. fully austenitic structure.
Figure 6, illustrated liquid-solid interface and HAZ
Microstructure Test Results
regions. Liquid-solid interface appeared as sharp
1. Weldment AISI 410/ER 309L before PWHT Profile line between weld-metal zone and HAZ. Also, HAZ
concentration of ER 309 stainless steel consisted of region has tempered lath marten site structure which
57.1% Fe, 21.24% Cr and 14.24% Ni by weight as was consisted of -Ferrite (BCC) and carbides.
mention in Table 1. Depending on Cr-Ni content
21.24/14.24, weld-metal zone consist of two phases -
III. Line/Point and EDS Analysis Results
ferrite in the vermicular or skeletal form (dark etching)
1. Weldment AISI 410/ER 309L before PWHT:-
and austenite matrix (light etching), as shown in
Line/point analysis and EDS results showed the
Figure 3. - Ferrite crystals firstly formed from the
chemical composition of weld-metal region, as
melt. With higher nickel content, crystals are also
shown in Figure 7. These results showed presence
precipitated from the melt apart from crystals in the
of Mo in weld-metal zone center. Average Mo was
three phase (L + + ) sector. After solidification found equal 1.48% along weld-metal zone center,
completed, transformation of a ferrite into austenite ( Mo element was constricted area of phase, while its
- transformation starts almost simultaneously, the supported ferrite formation. Also it observed from
structure being completely transformed into austenite Figures 7 (A and B), that the line/point analysis was
with residual - ferrite. When Cr:Ni ratio is equal to austenite at center of weld metal zone at point (Pt1)
1.53%, the solidification mode found to be ferritic- enricher by nickel, at which Cr and Ni content were
austenitic (FA) with moderate cooling rate and the found 19.19% and 11.90% respectively. While at point
final microstructure of weld-metal zone presents (Pt2) the analysis appeared residual delta ferrite and
vermicular -Ferrite as a primary phase within the the content of Cr and Ni elements were 20.22% and
dendritic arms enveloped by the austenite. Liquid-solid 9.67% respectively. In electric arc welding, -
interface, also called solidification front, represents the transformation is normally passed through rather
boundary between melt and precipitated crystal. Weld- quickly and an impeded equalization of alloy
metal zone (fusion zone) is predominantly of columnar concentration is to be expected. Impediment is greater
dendrites, which nucleated at the fusion boundary, and on the side of precipitated austenite crystals than on
grown towards the center of the molten pool (opposite the ferrite. Moreover, it can be noted from Figure (7)
to the direction of heat flow). The existence of and (8), line/point analysis of weld-metal zone and
columnar dendrites structure is predominantly due initial weld boundary that at point (Pt1) in Figure 8 (A
and B)

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Chromium and Nickel contents were 20.04% and 4.63% respectively. While in Figure 7 (A and B) at
point (Pt1) at weld-metal zone, chromium and Nickel contents were 19.19% and 11.90% respectively.
This was agreed with Erich Folkhard [7], the author has reported when solidification is mainly -
ferrite, the segregation of chromium was increased in core and depleted in boundary, while nickel was
depleted in core and increased in boundary, this means ferrite was primarily solidified.
Line/point analysis at HAZ showed; the presence of Fe, Cr and C elements richly along HAZ, as shown
in Figure 9. Average C content along HAZ was 2.5%. Excess carbon may precipitate in the form of
chromium-iron carbides, mainly as M23C6, and in rarely as M7C3 or M6C. M23C6 were agglomerated
at liquid-solid interface and precipitated as coarse or finer particles at the grain boundaries and within
the grain areas.
2. Weldment AISI 410/ER 309L after 1100C/1h:-
Line/point analysis and EDS analysis results showed the chemical composition of weld-metal zone after
heat treated, as shown in Figure 10. As can be noticed from Figure 10 (A and B) the presence of Cr and
Ni content along weld-metal zone center at which Cr content were18.26%, 19.69%, 19.33%, 17.84%,
18.29% and 19.34%. Also, Ni content were equal to12.83%, 8.76%, 10.58%, 11.81%, 10.87% and
9.73%, this supported the existence of austenite phase in all weld-metal rejoin. In addition, the analysis
appeared presence of C and Mn in average 1.3% and 1.3% respectively along weld zone, because during
heat treatment carbon has more activity to diffuse from carbides at HAZ regions and then cross interface
toward weld-metal zone as compared weld-metal zone in state as-welded.
These elements C, Ni and Mn act as stabilizer to austenite phase. Also, the presence of molybdenum was
of importance for this heat treatment, since C and Mo elements shift the boundary of the range to
higher temperatures. Microstructure photographs of weld-metal shown in Figure 5 revealed the
presences of carbides in weld-metal zone. Also, X-Ray analysis with magnification 250m shown in
Figure 10 approved the presence of these carbides as black points, because as the temperature drops
down to ambient temperature the solubility of carbon reduced and tend to precipitate as carbides.
Figure 11, illustrated Line/point analysis with EDS analysis along HAZ region. This analysis resulted the
presences of Fe, Cr, C, Si, Mn, Al, V and Ni along HAZ region. And the average content of C was 2.47
% along HAZ rejoin, which was precipitated as carbides with Cr or Fe or mixed carbides as former
(FeCr)23C6. Chemical composition of HAZ after 1100C/1h was similar to chemical composition for
HAZ in state as-welded.

Figure 7: A) Line Analysis B) Point Analysis C) EDS Analysis at Weld-Metal Zone for Weldment AISI
410MSS/ ER 309L (As-Welded)

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Engineering and Technology Journal Vol. 35, Part A, No. 1, 2017

Figure 8:- A) Line Analysis B) Point Analysis C) EDS Analysis at Interface for Weldment AISI 410MSS/ ER
309L (As-Welded)

Figure 9: A) Line Analysis B) Point Analysis C) EDS Analysis at HAZ Region for Weldment AISI 410MSS/
ER 309L (As-Welded)

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Figure 10: A) Line Analysis B) Point Analysis C) EDS Analysis at Weld-Metal Regionfor AISI 410MSS/ ER
309L after PWHT 1100C/1h

Figure 11: A) Line Analysis B) Point Analysis C) EDS Analysis at HAZ Regions Weldment AISI 410MSS/
ER 309L after PWHT 1100C/1h

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Engineering and Technology Journal Vol. 35, Part A, No. 1, 2017

IV. Micro-hardness Test Results steam turbine performance predication, International

Typical micro-hardness profiles across weldment 410 Journal of Research in Aeronautical and Mechanical
MSS/ ER 309L before PWHT (as-welded) and after Engineering, Vol. 2, No. 2, 43-55, 2014.
PWHT 1100C/1h were showed in Figure 12. Results [2] A.K. Bhaduri, T.P.S. Gill, S.K. Albert, K.
showed variation in micro hardness profile before and Shanmugam and D.R. Iyer, Repair welding of cracked
after the heat treatment depending on dilution from the steam turbine blades using austenitic and martensitic
stainless-steel consumables, Nuclear Engineering and
base metal and weld-metal zone. Moreover, the
Design, Vol. 34, No. 23, 249-259, 2001.
average hardness of the HAZ and base regions was
increased from HV 416.9, 251.3 in state as-welded to [3] M. Divya, C.R. Das, S.K. Albert, V. Ramasubbu,
A.K. Bhaduri and P. Sivaraman., In-situ weld repair
HV 449, 426.3 after PWHT 1100C/1h respectively.
of cracked shrouds of turbine and characterization of
Finally, hardness results showed increment along HAZ the weld joint, Ommi, 1-11, 2011.
region in state as welded due to carbon aggregated at
[4] A. Sara, T. Ramn, S. Claudia,Microstructural
interface and increased again after heat treatment due
transformations of dissimilar austenite-ferrite stainless
to more carbides formed above 500C. steels welded joints, Journal of Materials Physics and
Chemistry, Vol. 1, Issue. 4, 65-68, 2013.
[5] M. Arivarasua, D.R. Kasinatha, A. Natarajan,
Effect of continuous and pulsed current on the
metallurgical and mechanical properties of gas
tungsten arc welded aisi 4340 aeronautical and aisi
304 l austenitic stainless steel dissimilar joints,
Materials Research, Vol. 18, 59-77, 2015.
[6] E3-11 Standard guide for preparation of
metallographic specimens, alloys, specimens, ASTM
International, West Conshohocken, PA, 2011.
Figure12: Micro-hardness Variation across the 410 MSS/ ER 309L [7] E. Folkhard, Welding metallurgy of stainless
before PWHT (as-welded) and after PWHT 1100C/1h steels,, Springer-Verlag/Wien, New York, ISBN-
13978-3-7091-8967-2, 1988.
4. Conclusions
The present study has investigated the repair of Authors biography
turbine blades by using ER309L as austenitic
filler metals and studied the effect PWHT on Assist. Prof. A.H. Fadhil is with metal engineering,
structure and properties of weldments: Department of Materials Engineering,
University of Technology, Iraq. He has
After welding process, weld-metal region been working on various aspects related to
consisted of two phases - ferrite in the skeletal welding of materials. His areas of interest
form and austenite matrix, while after heat treated include repair welding, dissimilar metal
weld-metal region consisted of homogenous joining, development of hard facing
austenite phase. technology.
C, Mn, Ti, V and Al elements moved toward Assist. Prof. S.A. Emad is with metal engineering, Materials
weld-metal region after heat treatment. Engineering Department, University of
Large amounts from carbon elements Technology, Iraq. He has been working
aggregated at HAZ region close to interface in on various aspects related to shape
state as-welded and after 1100C/1h. memory alloys and biomedical metals.
Average hardness at the weld-metal zone was Assist. Prof. Abbas K. Husain is with metal
increased from HV 172.2 to 176.1, also, the engineering, Materials Engineering Department,
University of Technology, Iraq. He has been working
hardness of the alloy increased after heat treated
on various aspects related to welding, corrosion and
along base and HAZ regions. coating of
Segregation of elements was reduced after materials.
1100C/1h.
5. Acknowledgement Dr. H.A. Ola is withmetal engineering,
This work didnt fund by any government institution. engineering, Materials Engineering Department-
University of Technology, Baghdad, Iraq. She has
References been working on welding of materials and
composite material
[1] H.G. Patil and V.G. Arajpure, Improvements to
opening and closing appraisal method of low pressure

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