Effects of HFRW Variables on Weldded Joint Quality of the Ferritic Stainless Steel to Cr-Mo Low Alloy Steel in Heat Recovery Steam Generator

Document Type : Original Article


1 Department of Materials Engineering, Karaj Branch, Islamic Azad University, Karaj, Iran

2 School of Metallurgy and Materials Engineering, Iran University of Science and Technology, Tehran, Iran


Heat recovery steam generator (HRSG) is obviously a very desirable and environmental friendly energy source, increasing thermal efficiency while reducing energy costs is possible through the use of industrial boilers. In this study, the effect of high frequency resistance welding (HFRW) variable factors on joints between AISI 409 stainless steel finned to 2 ¼ Cr-1Mo alloy steel tube as helical finned tube was investigated. So HFRW was implemented on actual samples by changing multiple factors including travel speed, electric potential, current of welding and fin pitch. Meanwhile metallography of weld joint, tensile strength and hardness tests were carried out several sections of the samples according to international standard fin tube.  The diffusion zone indicating metallurgical joining more than 90% was measured at the weld interface, with applying optimum welding parameters, fin-tipand tube-tipposition and hydraulic pressure jack setting on squeeze rollers. Furthermore as the lower pitch and fin thickness are selected, the higher quality of fin tube welding joint is achieved. On the other hand as the pitch and fin thickness are reduced, the output transfer surface treatment in final process diminished. However, this paper presents emphasis on finned tube manufacturing processes and the best weld parameters conditions have been reached a sound joint.


[1]  Z. Dziemidowicz, P. Szyszka and I. Krupa : Power units on the horizon. The technical requirements of new generation units at PGE Power Plant Opole S.A. Electric Heat and Vocational Education, 11, (2011).
[2] V. Eriksen, Heat Recovery Steam Generator Technolo. , Woodhead Publishing, (2017).
[3] J. Mitrovic, Heat Exchanger and Condenser Tubes, Tube Types Materials Attributes Machining. Publico Publications, (2004).
[4] P. Breeze, Raising steam plant efficiency – Pushing the steam cycle boundaries. PEI Magazine 20, (2012).     
[5] E. Pis’mennyi, P. Georgiy, C. Ignacio, S. Florencio and I. Pioro, Handbook for Transversely Finned  Tube  Heat Exchanger Design Academic Press ,(2016).
[6] R. Kocurek and J. Adamiec, Adv. Mater. Sci., 13, 3 (37), (2013), 26.
[7] J. Adamiec and M. Więcek,Biuletyn Institute Spawalnictwa ,5, (2014), 41.
[8] N. Erling, Appl. Therm. Eng. 30, 1531e1537, (2010).
[9] S. R. Mcilwain, A Comparison of Heat Transfer around a Single Serrated, IJRRAS 2 (2), (2010), 88.
[10] J. Noordermeer, P. Eng, IAGT Symposium, Training Sessions, Banff Alberta, (2013).
[11] R. Huseman : Advanced (700°C) PF Power Plant. A Clean Coal European Technology. Advanced Material for AD700 Boilers, Cesi Auditorium, Milano, (2010).  
[12] H. Kushima, T. Watanabe, M. Murata, K. Kamihira, H. Tanaka and K. Kimura, Metallographic Atlas for 2.25Cr-1Mo Steels and Degradation due to Long-term Service at the Elevated Temperatures , ECCC Creep Conference, )2005(, 223.
[13] B. King, Welding and Post Weld Heat Treatment of 2.25%Cr-1%Mo Steel, M.Eng thesis, Faculty of Engineering, University of Wollongong Australia, (2005), 13.
[14] L. Wagner Ferreira, R. Glaucio, C. Heloisa,  M. Furtadoa, L. Barreto and A. Luiz Henrique de, , Mater. Res., 10, 1590, (2017), 0596.
[15] S. Zuback, T. Mukherjee, T. A. Palmer and T. DebRoy, Novel Dissimilar Joints between 2.25Cr-1Mo Steel and Alloy 800H through Additive Manufacturing, Pennsylvania State University, AWS FABTECH Conference, Las Vegas, NV (2016).
[16] C. Ornek, Performance Characterisation of  Duplex Stainless Steel in Nuclear Waste Storage Environment, PhD thesis, University of Manchester, (2015), 25.
[17] ASTM A 240 Standard Specification for heat resisting chromium and chromium-nickel stainless steel strip for pressure vessels, (2020).
[18] ASTM A213 Standard Specification for Seamless Ferritic and Austenitic Alloy-Steel Boiler, Superheater, and Heat-Exchanger Tubes, (2020).