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Water-wall tubes are important components in power plants and are used to absorb the heat from the boilers, and they often fail prematurely due to corrosion, erosion, and fatigue during service. To repair the defects, weld overlay repair is often adopted by forming a compressive stress area around the susceptible area to prevent the cracks from propagating. In order to obtain reasonable process parameters of weld overlay repair, a study combining experiments and numerical simulations was performed to investigate the welding residual stress distribution on the repaired area with different welding repair methods. The results reveal that a compressive stress area is generated on the repaired area after the repair, and a center-to-outside welding sequence is better than either a right-to-left welding sequence or an outside-to-center welding sequence when overlaying a one-layer weld; with an increase in the number of weld layers, the compressive stress area of the repaired area is expanded, and the stress level is increased, which results from the upward movement of the compressive stress area of the subsequent-overlaying layer and the superposition of the compression areas of the subsequent-overlaying layer and previous-overlaying layer, respectively. In addition, the number of the weld passes of each layer should be not less than four with the center-to-outside welding sequence.

metals

Effect of Welding Sequence and the Transverse Geometry of the Weld Overlay on the Distribution of Residual Stress in the Weld Overlay Repair of T23 Tubes