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In this work, macroscopic and microscopic examinations on the failure specimen were conducted on T91/HR3C dissimilar steel welded joints for the high temperature reheater in a 3033t/h USC boiler. The cracking is along the circumferential direction of tube, initiated in the CGHAZ (course grain HAZ) and terminated at the FGHAZ (fine grain HAZ) of the outer wall. The high hardness and unstability microstructure in the HAZ are responsible for the cracking failure. Post welding heat treatment (PWHT) is suggested for improving the ductility and reducing the residual stress for the welded joints. The delta ferrite with lower hardness was observed near the fusion line of T91 side. However, it was not related to the failure

Failure Analysis of Dissimilar Steel Welded Joints in a 3033t/h USC Boiler