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Influence of Heat Input And Post-Weld Heat

Treatment on Boiler Steel P91 (9Cr-1Mo-V-
Nb) Weld Joints, I. Microstructure

Article in International Heat Treatment & Surface Engineering · March 2013

DOI: 10.1179/1749514813Z.00000000050

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Influence of heat input and post-weld heat
treatment on boiler steel P91 (9Cr–1Mo–V–Nb)
weld joints
Part 1 – Microstructure

M. Abd El-Rahman Abd El-Salam, I. El-Mahallawi* and M. R. El-Koussy

Steel P91 is known for its excellent high temperature properties. The achievement of optimum
weld metal properties for steel P91 within the course of its extensive applications in power plants
has however often caused concern. In the present work, three thick pipes of P91 steel were
welded using three different levels of heat inputs within the range of 1?15–3?5 kJ mm21. A
circumferentially multipass butt welded P91 steel pipe, typically used for high temperature
applications in power plants was selected for this investigation. The achievements of optimum
weld metal properties, which are closely linked to microstructure, are known to cause concern in
such weldments. Two types of heat treatments were employed, subcritical post-weld heat
treatment and normalising/tempering treatment. The microstructure was evaluated by optical,
scanning electron microscope, X-ray diffraction and magnetic permeability. The results have
shown a great influence of heat input and heat treatment on the microstructure. Martensite and
ferrite were the main structures obtained. Bainite and d-ferrite have been observed in the weld
metal, heat affected zone and weld metal for all heat input/treatment conditions. The volume
fraction of bainite and d-ferrite increased with increase in heat input till a critical value slightly
lower than 1?15 kJ mm21; then decreased with the increase in heat input. The normalising/
tempering treatment resulted in a decrease in the volume fraction of d-ferrite and bainite
compared to the subcritical post-weld treatment which is conventionally used. This explains the
enhancement in the toughness and creep properties of the steel presented in the second paper.1
Keywords: Microstructures, d-ferrite, Modified 9Cr–1Mo steel, Welding, Heat treatments, Heat input

Introduction Modified 9Cr–1Mo steel tubes with high strength at

The need to reduce the fuel cost as well as environmental
pollution from fossil fuels by significantly decreasing
carbon dioxide emissions from power generation plants
has led to efforts to increase the thermal efficiency of
power plants.1 The increase in the thermal efficiency of
fossil fuel fired steam power plant that can be achieved
by increasing the steam temperature and pressure; has
provided the incentive for the development of heat
resistant steels with excellent creep properties as well as
superior oxidation and corrosion resistance properties.2
In the last two decades and to face up these require-
ments; several new Cr–Mo and 9–12% chromium steels
were developed ranging from P11 (1Cr–0?5Mo) to P122
(12Cr–1Mo).1,3
Department of Metallurgy, Cairo University/Faculty of Engineering,
University Street, University Square, El-Giza, Egypt
*Corresponding author, email saiman@eng.cu.edu.eg
elevated temperatures and oxidation resistance (ASME
SA213 T91, abbreviated SA335 P91 or super 9Cr steel)
are frequently used in high temperature boilers for high
efficiency power generation.4 Hence, the welding char-
acteristics of P91 constitute an important criterion for its
selection; it has been shown that P91 can be welded
satisfactorily by many processes including manual metal
arc, submerged arc, and gas tungsten arc welding.5 Post-
weld heat treatment (PWHT) is necessary for tempering
the martensite formed during welding, and many
investigations have highlighted the need for optimising
the PWHT temperature and time as well as filler
material composition.5,6 On the other hand, due to the
heat input during welding, not only different micro-
structures are obtained within the weld, but also,
microstructural changes take place in a small area
besides the fusion line. If the A1 temperature (the lower
transformation temperature at which ferrite is partly
transformed into austenite)is exceeded in an area, phase
transformations lead to changes in the microstructure of

ß 2013 IHTSE Partnership

Published by Maney on behalf of the Partnership
DOI 10.1179/1749514813Z.00000000050 International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1 23
Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

ferritic steels; this can clearly be seen using optical

microscope, and the area is called heat affected zone
(HAZ). Therefore, the HAZ does not represent the
optimal microstructure and precipitation characteristics
that can be found in the unaffected base material (BM)
for optimized creep resistance and different properties.
In the current work, welded joints were produced in
P91 using three different heat inputs, and two different
PWHTs (subcritical PWHT or normalizing/tempering)
were carried out for different heat input conditions.
Detailed metallographic characterisation enabled a
correlation among welding heat input/heat treatment
and resulted microstructure. Important conclusions
could thus be drawn regarding the choice of heat input
and heat treatment which yield a microstructure that
may lead to the best combination of different mechan-
ical properties.
Experimental
The P91 steel used in this research was supplied by K & I
Tubular Corporation as a pipe of 323?9 mm outside
diameter, 50?8 mm thickness and 6?5 m length. The P91
pipe steel was fabricated by hot forming followed by
normalising at 1050uC for 10 min, and tempering at
785uC for 45 min. Tables 1 and 2 show the chemical
analysis and the mechanical properties of the as received
P91 pipe. Three pipes were welded using different heat
inputs (1?15, 2?28 and 3?16 kJ mm21). These heat input
values were calculated based on arc efficiency of the
SMAW process equal to 0?8. In the actual girth welds of
the P91 pipes, GTAW rod ER90S-B9 were used for root
pass, and E9015-B9 SMAW electrode for first pass and
for filling. Table 3 summarises the chemical composition
of the used consumables. However, the root, first and
cap passes were discarded during sample preparation for
the different conducted tests.
Preheating and intermediate post-weld heat treatment
was conducted using a calibrated portable heat treat-
ment machine with ceramic blanket heaters. Figure 1
illustrates the process steps starting with preheating
(200–250uC), control of inter pass temperature at 300uC
and ending with the intermediate post-weld heat
treatment for 2 h at 350uC; this condition is considered
as the as welded condition. The weldment was inspected
1 Welding control and intermediate post-weld heat treat-
ment applied on each pipe after welding
by radiography to assure that the joint was free from
defects.
One half of each welded joint was hence subjected to
subcritical post weld heat treatment at 760uC for 3?5 h
with the same heating and cooling rates used during
intermediate PWHT. This heat treatment was suggested
based on preliminary results presented in EPRI report
1004702 which showed that the 760uC subcritical PWHT
temperature provides better tensile, Charpy, and rupture
strength results compared to heat treatment at 649 or
704uC.7 The other halves of the welded coupons were
subjected to a new heat treatment consisting of normal-
izing at 1050uC for 0?5 h followed by tempering at
760uC for 3?5 h.
Microstructure examinations were conducted for each
condition, on the cross-sections of weld samples
(25625 mm) selected from the centre of the welded
joints. The microstructure was revealed using Villella’s
Reagent (100 mL ethanol, 5 mL HCl and 1 gm Picric
acid). Each sample was examined by optical microscope
(OM), scanning electron microscope (SEM) and micro-
chemically analysed by using energy dispersion X-ray
(EDX). Some samples were selected from the as received
base and weld metals for all heat input/treatment
conditions for X-ray diffraction analysis to identify the
present phases. X-ray diffraction analysis was performed
using a diffractometer with a monochromatic source of
radiation (Cu Ka), (PaNalytical, X’pertpro), using
X’pertpro software and best fit compared to X-ray
diffraction data cards of the International Center of
Diffraction Data (ICDD) uploaded to the software. The

Table 1 Chemical composition of as received P91 steel/wt-%

Element C Si Mn P S Ni Cr Mo Al V Nb N

Standard 0.07–0.14 0.2–0.5 0.3–0.6 0.02 max. 0.01 max. 0.4 max. 8.0–9.5 0.85–1.05 0.04 max. 0.18–0.25 0.06–0.1 0.03–0.07
Actual 0.11 0.26 0.44 0.012 0.002 0.17 8.5 0.88 0.002 0.215 0.077 0.04

Table 2 Mechanical properties of as received P91 pipe

Tensile test Average hardness Average charpy V-notch impact

YS/MPa UTS/MPa Elongation/% HB J

501.3 669.5 49.5 207 224

Table 3 Chemical composition of GTAW rod ER90S-B9 and SMAW electrode E9015-B9 used during welding/wt-%

Electrode/
Rod C Si Mn P S Ni Cr Mo Cu Al V Nb N

ER90S-B9 0.09 0.2 0.49 0.004 0.003 0.66 8.7 0.9 0.03 0.006 0.19 0.08 0.05
E9015-B9 0.1 0.19– 0.66– 0.01 0.005– 0.27– 8.9– 0.9– ,0.1 0.001– 0.21– 0.04– 0.03–
0.38 0.69 0.009 0.75 9.3 0.98 0.002 0.26 0.06 0.04

24 International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1

 Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

2 a image (OM) and b image (SEM) of as received base material

a along martensite lathes; b along ferrite grains

3 Location of precipitates subjected to EDX in as received base metal

ferrite content was measured in the weld zone, HAZ and Results and discussion
base metal for each condition using Fisher ferrite scope
FMP-30. The ferrite scope measurement is based on the Base metal
difference in magnetic permeability between the mar- In the as received (normalised and tempered condition),
tensite and ferrite phases, and was used to evaluate the the microstructure of the P91 base metal consists of fully
changes that occur in the microstructure as a function of tempered martensite (Fig. 2a). Small precipitate parti-
the heat input and heat treatment. cles could be identified on the prior austenite grain
For the sake of traceability of the various samples of boundaries and within the grains (Fig. 2a). SEM
different heat input/heat treatment conditions a coding investigation of the base metal (Fig. 2b) shows the lath
system described in Table 4 will be used throughout the martensitic structure, as well as the precipitate particles
following text. embedded along the lath boundaries, which are possibly
of the M23C6 type as identified in earlier studies.8,9,10
EDX analysis (Fig. 3 and Table 5) confirm the presence
of M23C6 (M5Cr, Fe, Mo) precipitates across different
areas within the tempered martensite. However, much
Table 4 Coding system for different sample conditions finer precipitate particles of niobium rich or vanadium
(heat input/heat treatment) rich compounds were also observed both along the
boundaries and within the laths.11 Carbides of type MC,
Sample Code Condition M2C have been identified in Grade 91 steels.11
L 350 Low heat input condition followed by
intermediate PWHT at 350uC for 2 h Weld metal and HAZ
(as welded condition) Figure 4, illustrates the expected microstructure of the
L 760 Low heat input condition followed weld metal and HAZ as a function of the peak
by PWHT at 760uC for 3.5 h temperature gradient along the P91 weldment.12 The
L1050 Low heat input condition followed by N&T
M 350 Medium heat input condition followed
optical micrographs of the three welding heat inputs of
by intermediate PWHT at 350uC for 2 h as welded conditions are shown in Fig. 5 which show
(as welded condition) a typical untempered martensite structure with a
M 760 Medium heat input condition followed by
PWHT at 760uC for 3.5 h Table 5 Results of EDX analysis related to precipitates
M1050 Medium heat input condition followed indicated through Fig. 3/wt-%
by N&T
H 350 High heat input condition followed by Element C Si V Cr Mn Fe Ni Nb Mo
intermediate PWHT at 350uC for 2 h
(as welded condition) Spec.1a 42.98 … 0.2 6.13 0.39 49.23 0.29 … 0.79
H 760 High heat input condition followed by Spec.2a 39.02 0.73 0.26 5.43 0.77 52.37 0.25 0.23 0.95
PWHT at 760uC for 3.5 h Spec.1b 40.30 0.17 0.15 7.72 … 50.56 … 0.05 1.05
H1050 High heat input condition followed by N&T Spec.3b 42.10 0.21 0.16 5.17 0.23 51.83 … … 0.28

International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1 25

Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

4 Schematic representations of microstructures developed in weld metal and HAZ as function of peak temperature dur-
ing welding12

a L350, 75% ferrite (F); b M350, 77?5%F; c H350, 82%F

5 Microstructure of weld metals of as welded condition for different heat inputs showing fine untempered martensite and
acicular ferrite

considerable amount of acicular ferrite. A reheating
effect results from multilayer welding leading to the
formation of a microstructure similar to that expected
for the HAZ (Fig. 6). An increase in the ferrite volume
fraction was found to occur with the increase in heat
input, where the ferrite content measured by the ferrite
scope was from 75 to 77?5 and up to 82% respectively in
the weld zone. On the other hand, ferrite content after
subcritical PWHT shows a significant increase in the
measured ferrite volume fraction for all heat input
conditions, where the ferrite content became 95, 92 and
93% respectively. This significant increase in the ferrite
volume fraction came as a result of the decomposition of
the untempered martensite during the subcritical PWHT
(Fig. 7). The obtained results mean a significant
enhancement in the homogeneity of the resulted micro-
structure of the weld metals as the volume fraction of the
measured ferrite and martensite within the microstruc-
ture are nearly the same irrelevant of the heat input.
Similarly, a higher degree of microstructure homo-
geneity (homogenous microstructure of tempered mar-
tensite) was obtained for all heat input conditions after
normalising and tempering treatment as a result of
recrystallisation effect of the normalisation treatment

a fine grains structure; b intercritical grains structure; c coarse grains structure

6 Martensite/ferrite microstructure at different areas between weld passes as result of reheat effect during multiple layers
welding

26 International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1

 Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

a L760, 95% ferrite (F); b M760, 92%F; c H760, 93%F

7 Microstructure of weld metals after subcritical PWHT conditions

a L1050; b M1050; c H1050

8 Image (SEM) of weld metals of normalised/tempered conditions

(Fig. 8). Figure 8c reflects also the slightly finer grain A particularly important feature of interest in the P91
size resulting from the high heat input condition weld metal is the occurrence of patches of d-ferrite.
compared to that obtained for both low and medium Figure 9 show different shapes of formed d-ferrite
heat input conditions (Fig. 8a and b). within the weld metal for different heat inputs of the

a, b L350; c, d M350; e, f H350

9 Different types of formed d-ferrite within weld metals of as welded conditions

International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1 27

Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1
a L760; b M760; c H760
10 d-ferrite within weld metal after subcritical PWHT
as welded condition. It was observed that the volume
fraction of d-ferrite decreased with the increase in heat
input. The volume fraction of the d-ferrite in the weld
metal of the low, medium and high heat input of the as
welded conditions were found to be about 0?013, 0?0088
and 0?0033% respectively. The resulted volume fractions
presented the ratio of the total area of d-ferrite indicated
along the weld cross section to the total area of the weld
cross section. Arivazhagan observed that the volume
fraction of d-ferrite increased with the increase of heat
input in a low heat input ranging from 0?52 to
0?88 rev min21.13 Combination of this published results
with that from our research leads to the conclusion that
volume fraction of d-ferrite increases with the increase in
heat input till a critical value of heat input and then
decreases with the increase of heat input. This critical
heat input value is still within the low heat input range.
On the other hand, d-ferrite is still present in the
a L760; b M350; c H350; d SEM image, fusion line, H760
11 d-ferrite at fusion line and CGHAZ of different heat inputs of as welded and subcritical PWHT conditions: optical
micrographs
28 International Heat Treatment and Surface Engineering
microstructure after subcritical PWHT as it formed
during welding as a result of the high peak temperature
at the welding pool and was retained after cooling
(Fig. 10). Decarburisation like effect was also observed
at the boundary area between d-ferrite and martensite
(lighter martensite around ferrite as in Fig. 10), and this
may be due to the retarded diffusion of carbon atoms
and other alloying elements during rapid solidification
after welding solidification. This may also be the reason
of considerable increase in the precipitation of carbides
observed within d-ferrite grains after subcritical PWHT.
d-ferrite is also formed after solidification at the fusion
line area (solid–liquid transition area) and may be
formed at the course grain region in the heat affected
zone CGHAZ located just beside the fusion line
(Fig. 11). On the other hand, smaller traces of d-ferrite
grains within the weld metal are present only after
normalising and tempering treatment with a significant
2013 VOL 7 NO 1
 Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

a L1050; b M1050; c H1050

12 d-ferrite within weld metal after normalising and tempering treatment

precipitation within the d-ferrites grains increasing with
the increase of heat input (Fig. 12a and b). However,
low heat input shows the highest volume fraction of d-
ferrites grains.
The following different microstructures were identi-
fied along the HAZ toward the base metal in both as
welded and subcritical PWHT conditions:
(i) coarse grain region (CGHAZ): area near the
fusion boundary that reaches a temperature well
above Ac3 during welding; where, Ac3 is the
temperature at which transformation of ferrite
into austenite is completed upon heating.
Carbides which constitute the main obstacle to
growth of the austenite grains dissolve resulting
in coarse grains of austenite. This austenite
transform into high carbon and hard martensite
on cooling (Fig. 13a)
(ii) fine grain region (FGHAZ): away from the
fusion boundary where the peak temperature
(Tp) is lower, but still above Ac3. Austenite
grain growth is limited by lower temperature
and by the incomplete dissolution of carbides.
Fine grained austenite is produced, which
subsequently transforms into low carbon slit
softer martensite (Fig. 13b)
(iii) inter critical region (ICHAZ): here the peak
temperature Tp is lower than Ac3 but higher
than Ac1; where Ac1 is the temperature at which
transformation of ferrite into austenite is started
on heating, and this results in partial reversion
to austenite on heating. The new austenite
nucleates at the prior austenite grain boundaries
and the martensite lath boundaries; whereas the
remainder of the microstructure is simply
tempered. The austenite transforms into untem-
pered martensite on cooling (Fig. 13c)
(iv) over tempered region: with Tp below Ac1 the
original microstructure of the plate material
undergoes further tempering (Fig. 13d–e).
In fact, the obtained microstructure within the weld and
HAZ depends strongly on the obtained peak tempera-
ture and the cooling rate. However, the maximum

a CGHAZ; b FGHAZ e; c ICHAZ; d over tempering zone (OT); e boundary between over tempered (OT) and unaffected
base metal (UA); f unaffected base metal
13 Different areas at HAZ of low heat input (L350)

International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1 29

Abd El-Salam et al. Influence of heat input and treatment on P91 weld joints: Part 1

a L1050; b M1050; c H1050

14 Optical micrograph of HAZ after N&T treatment

a HAZ area near base metal of high heat input condition H760; b base metal affected by double tempering at 760uC
15 Image (SEM) showing bainite like grains in subcritical PWHT condition

obtained peak temperature at welding pool, its gradient
effect, cooling rate and the width of formed HAZ are all
directly dependent on the heat input used during the
welding cycle, the higher the heat input, the higher the
peak temperature, the lower the cooling rate, and the
larger the temperature gradient effect and the wider the
HAZ.14
To sum up, the higher the heat input:
(i) the lower the cooling rate of weld pool leading to
the formation of higher volume fraction of ferrite
and lower volume fraction of martensite
(ii) the coarser the CGHAZ grains and the harder
the martensite formed after cooling as a result of
complete dissolution of carbides within the
austenite grains
(iii) the wider the CGHAZ, FGHAZ, ICHAZ and
over tempered HAZ.
However, normalising and tempering treatment mini-
mize the difference between the HAZ, weld and base
metal structures for the same heat input as a result of
recrystallisation effect during normalising treatment, but
the differences between the HAZ microstructures of
different heat inputs exist. Figure 14 shows the optical
micrograph obtained from the HAZ of the three heat
inputs after normalising and tempering treatment.
However, average ferrite content measurement conducted

16 X-ray diffraction pattern of base metal and weld metals of all heat/treatment conditions

30 International Heat Treatment and Surface Engineering 2013 VOL 7 NO 1

 Abd El-Salam et al.
by ferrite scope on the HAZ area of the three heat inputs
after normalising and tempering treatment shows slight
differences in measured ferrite content between low and
medium heat inputs compared to that of the high heat
input condition, 90, 90?5 and 92% respectively.
Another particularly important feature of interest is the
possibility of bainite formation as a result of martensite
decomposition during multiple tempering at 760uC. A
percentage of bainitic ferrite was detected at base
materials and HAZ/base boundaries in the subcritical
PWHT conditions (Fig. 15). The presence of bainitic
ferrite is more evident in the high heat input condition
which may indicate an increase in the probability of
bainite formation with the increase of heat input. In fact,
the continuous cooling transformation (CCT) diagram
published for P91 material did not indicate the prob-
ability of bainitic transformation.15,16 However, Mile
demonstrated that in P91 steel a microstructure which
appeared to be of bainitic character.17 This could be the
case if multiple heat treatments during a manufacturing
process (e.g. bending) took place.17 Milović reported the
formation of small amounts of bainite in P91 steels during
cooling from austenisation temperature as the martensite
formation was preceded by separation of a smaller
quantity of bainite.18 He reported also the formation of
bainite in addition to martensite in simulated HAZs using
simulation temperature up to 1150uC and with cooling
time t8/5 of 40 s followed by PWHT at 730uC.18
However, X-ray diffraction patterns of the weld
metals indicated similar patterns to that obtained from
the base material (martensite/ferrite phase) and no
retained austenite was indicated (Fig. 16).
Conclusions
1. Heat input and heat treatment were found to have
a great influence on the obtained microstructure of P91
weldments which may have direct effect on the obtained
mechanical properties and weldments serviceability.
2. Martensite and ferrite were the main observed
phases through different areas of P91 weldments, and
bainite and d-ferrite can be formed under certain
conditions.
3. In the as welded conditions; ferrite volume fraction
of the weld metal increases with the increase in heat
input.
4. Subcritical PWHT and normalising/tempering
treatments leads to a homogenous microstructure within
the weld metal with a near similar volume fraction of
ferrite in all heat input conditions.
5. d-ferrite was observed in the weld metal at all heat
input/treatment conditions, and its volume fraction
increased with increase in heat input till a critical value
lower than 1?15 kJ mm21, then decreased with the
increase in heat input.
6. d-ferrite was observed at the fusion boundary and
CGHAZ of all as welded and subcritical PWHT
conditions, but was not reported for normalised and
tempered conditions.
7. Normalising and tempering treatment reduces the
amount of retained d-ferrite within the weld metal, and
results the optimum degree of microstructure homo-
geneity along the weldments of all heat input conditions
as a result of recrystallisation effect during normalising
treatment.
International Heat Treatment and Surface Engineering
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Influence of heat input and treatment on P91 weld joints: Part 1
8. Bainite may appear in the microstructure of P91
steel in weld, HAZ and base metal as a result of double
reheating effects during multiple layers welding and
tempering treatments.
9. Retained Austenite was not detected by X-ray
diffraction analysis.
10. The formation of a soft zone is expected to be
formed in the HAZ portion subjected to over tempering
effect and may act as the source of earlier creep failure
during service.19
Acknowledgement
The authors wish to deeply thank the Project Services
Company (PSC) for offering the materials and facilities
available at their plant, without which this work would
have not been possible.
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