What does this research mean for the field?

Pulsed-GTAW welding of dissimilar SA335 P91 and SA218 P22 pipes using ER-307 filler produces joints with adequate mechanical strength, high toughness, and superior hot corrosion resistance due to the formation of a protective spinel oxide layer. Novelty: ClaimNovelty.INCREMENTAL. Consensus alignment: ConsensusAlignment.NEUTRAL.

What question did this study set out to answer?

To evaluate the mechanical integrity, microstructural evolution, and molten salt hot corrosion resistance of dissimilar SA335 P91 and SA218 P22 pipe joints fabricated via pulsed-GTAW using an ER-307 filler.

August 30, 2026Next MaterialsOpen Access

Dissimilar welding of SA335 P91 and SA218 P22 pipes fabricated through pulsed-GTAW: Metallographic, structural integrity, and molten salt hot corrosion behaviour

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Authors

SPS. Senthur Prabu JSJulia Sebastian GAG. Anirudh

Discussion

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Overview

Experimental study demonstrates robust mechanical integrity and hot corrosion resistance in dissimilar P91-P22 pipe welds, highlighting their viability for thermal heat exchangers.

Key Points

To evaluate the mechanical integrity, microstructural evolution, and molten salt hot corrosion resistance of dissimilar SA335 P91 and SA218 P22 pipe joints fabricated via pulsed-GTAW using an ER-307 filler.
Welded dissimilar SA335 P91 alloy steel and SA218 P22 low-carbon steel pipe joints using pulsed-current gas tungsten arc welding (PC-GTAW) with an ER-307 stainless steel filler.
Evaluated mechanical properties using standard tensile, notch tensile, and Charpy V-notch impact tests, alongside FESEM-EDS and XRD characterization.
Conducted Type-1 accelerated hot corrosion testing in a molten salt environment of K2SO4 with 60% NaCl.
Tensile failure occurred in the SA218 P22 base metal with an ultimate tensile strength of 520 ± 1 MPa and yield strength of 338 ± 2 MPa, whereas notch tensile strength was 588 ± 4 MPa and Charpy impact toughness was 71 ± 2 J.
FESEM-EDS identified Mo-rich phases and M23C6 carbide precipitates that enhanced the hardness of the weld zone.
The weldment exhibited lower parabolic hot corrosion rate constants (0.6314 × 10⁻⁵ g² cm⁻⁴ s⁻¹) than P91 (1.003 × 10⁻⁵ g² cm⁻⁴ s⁻¹) and P22 (1.248 × 10⁻⁵ g² cm⁻⁴ s⁻¹) due to a protective NiFe2O4/NiCr2O4 spinel oxide layer.

Cite This Study

Prabu et al. (2026) studied this question.

synapsesocial.com/papers/6a93f00a6c1a8fb52e79c045 https://doi.org/10.1016/j.nxmate.2026.103280

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August 30, 2026Next MaterialsOpen Access

Dissimilar welding of SA335 P91 and SA218 P22 pipes fabricated through pulsed-GTAW: Metallographic, structural integrity, and molten salt hot corrosion behaviour

View Full Paper

Ask AI

Bookmark

Authors

SPS. Senthur Prabu JSJulia Sebastian GAG. Anirudh

Discussion

Member takes

Overview

Experimental study demonstrates robust mechanical integrity and hot corrosion resistance in dissimilar P91-P22 pipe welds, highlighting their viability for thermal heat exchangers.

Key Points

To evaluate the mechanical integrity, microstructural evolution, and molten salt hot corrosion resistance of dissimilar SA335 P91 and SA218 P22 pipe joints fabricated via pulsed-GTAW using an ER-307 filler.
Welded dissimilar SA335 P91 alloy steel and SA218 P22 low-carbon steel pipe joints using pulsed-current gas tungsten arc welding (PC-GTAW) with an ER-307 stainless steel filler.
Evaluated mechanical properties using standard tensile, notch tensile, and Charpy V-notch impact tests, alongside FESEM-EDS and XRD characterization.
Conducted Type-1 accelerated hot corrosion testing in a molten salt environment of K2SO4 with 60% NaCl.
Tensile failure occurred in the SA218 P22 base metal with an ultimate tensile strength of 520 ± 1 MPa and yield strength of 338 ± 2 MPa, whereas notch tensile strength was 588 ± 4 MPa and Charpy impact toughness was 71 ± 2 J.
FESEM-EDS identified Mo-rich phases and M23C6 carbide precipitates that enhanced the hardness of the weld zone.
The weldment exhibited lower parabolic hot corrosion rate constants (0.6314 × 10⁻⁵ g² cm⁻⁴ s⁻¹) than P91 (1.003 × 10⁻⁵ g² cm⁻⁴ s⁻¹) and P22 (1.248 × 10⁻⁵ g² cm⁻⁴ s⁻¹) due to a protective NiFe2O4/NiCr2O4 spinel oxide layer.

Cite This Study

Prabu et al. (2026) studied this question.

synapsesocial.com/papers/6a93f00a6c1a8fb52e79c045 https://doi.org/10.1016/j.nxmate.2026.103280

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