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Welding Solutions for Thermal Power Generation

The development and production of heat and creep resistant welding consumables for power plant applications are a focus of voestalpine Böhler Welding. Additionally, we support the manufacturers with our far-reaching experience in the welding of creep resistant steels. Fontargen Brazing provides filler metals and fluxes for the brazing in the generators and transformers. voestalpine Böhler Welding produces TUV-approved welding consumables for the base metals most used in thermal power plants. 

The matching filler metals for the creep resistant steels and alloys are tested under creep conditions at elevated temperature. The creep tests have been performed on both all weld metal specimens and weld joints.  

Welding of Steam Generators and Boilers

A: Superheaters / Reheaters

Superheater and reheater tubes are necessary to convert wet, saturated steam into dry steam. These tube bundles are located within the combustion chamber of the boiler. voestalpine Böhler Welding offers top quality high alloyed welding consumables that, depending on the operating conditions, are required to guarantee resistance against heat and corrosion.

B: Headers

Headers are thick-walled extruded pipes in which the fluids carried by the tubes are mixed and homogenized. These heavy-section components have to meet creep strength requirements. voestalpine Böhler Welding offers welding consumables for the high-quality welding of these critical components.

C: Main steam / Hot reheat piping

Main steam and hot reheat piping are thick-walled seamless pipes which transport the dry steam from the headers to the turbine. The wall thickness of these pipes is up to 100 mm. voestalpine Böhler Welding offers the proven welding consumables necessary for this application, which is highly demanding due to the high temperature (up to 620°C) and pressure (up to 350 bar).

D: Water walls (or membrane walls)

Many kilometers of tubes and fins are welded together and form the outside wall of the boiler. Different tube and fin material is used depending on the design of the boiler, the capacity, the temperature and the pressure (e.g. T1, T12, T23, T24...). voestalpine Böhler Welding offers welding consumables for the mechanized welding of these components in SAW or GMAW/FCAW processes as well as for the tube-to-tube welds that are necessary as performed in GTAW process (manual or auto).

Welding of Steam Turbines

Special steels and special welding consumables are required for highly stressed components such as valves, turbine housing and rotors.. Heavy steel castings and rotor forgings, made of creep resistant steels, play a key role in fossil fuel fired power plants for highly loaded components in the high and intermediate pressure sections of a turbine casting. Turbine and generator rotors withstand high stresses and are the most significant components of a turbine generator system from a safety point of view.

Combinations of different steels are used for the welded rotors. Depending on the operating temperatures, the shafts can be fabricated out of creep resistance material or of highly toughened material.

The welding of low-pressure shafts require matching filler metals. Combined intermediate-low pressure shafts and combined high-low pressure shafts are welded using different steels. These dissimilar welded joints are designed to be located in low stress shaft areas. For this reason, the strength requirements for these welded joints are lower than for the base material. On the other hand, impact energy values of the weldments are even higher than minimum base material values. Creep is not a problem for the low-pressure end of the rotor, but high yield strength, high ductility and low Fracture Appearance Transition Temperature (FATT) behavior is required.

voestalpine Böhler Welding offers tailor-made solutions for the specific customer requirements regarding different steel combinations.

Welding of Flue Gas Desulphurization Units

Depending on the application, FGD units require high corrosion resistant steels and Ni-alloys, for tanks, piping, absorbers, etc. The materials selection criteria depend on the chloride and pH concentration. In general, the flue of lignite coal fired power plants is more aggressive than that of hard coal fired power plants. Therefore, the FGDs of a lignite coal fired power plant generally needs high corrosion-resistant Ni-base alloys with increased CPT values.

Depending on the requirements, voestalpine Böhler Welding offers welding consumables higher alloyed than the base material, in order to match the base material corrosion resistance properties compensating the effect of the dilution.

Product Overview

Welding Consumables for Thermal Power

Product Name Industry Application Base Material / Consumable Alloy type AWS EN/ISO Process
BÖHLER FOX EV 50 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.1 / SFA-5.1, E7018-1H4R 2560-A, E 42 5 B 4 2 H5 SMAW
BÖHLER EMK 6 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.18 / SFA-5.18, ER70S-6 636-A, W 3Si1 GTAW
BÖHLER EMK 6 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.18 / SFA-5.18, ER70S-6 14341-A, G 42 4 M21 3Si1 / G 42 4 C1 3Si1 GMAW
diamondspark 52 RC Boiler Tubes and Pipes P265GH, SA106A,B,C A5.20 / SFA-5.20 E71T-1M/T-9M/T-12M JDH4 E71T-1C/T-9C/T-12C DH4 17632-A T 46 4 P M21 1 H5 T 46 2 P C1 1 H5 FCAW
Union S 2 Si - UV 418 TT Boiler Tubes and Pipes P265GH, SA106A,B,C A5.17 : F7A8-EM12K / F6P8-EM12K 14171-A, S 42 5 FB S2Si H5 SAW
BÖHLER FOX EV 50 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.1 / SFA-5.1, E7018-1H4R 2560-A, E 42 5 B 4 2 H5 SMAW
BÖHLER EMK 6 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.18 / SFA-5.18, ER70S-6 636-A, W 3Si1 GTAW
BÖHLER EMK 6 Boiler Tubes and Pipes P265GH, SA106A,B,C A5.18 / SFA-5.18, ER70S-6 14341-A, G 42 4 M21 3Si1 / G 42 4 C1 3Si1 GMAW
diamondspark 52 RC Boiler Tubes and Pipes P265GH, SA106A,B,C A5.20 / SFA-5.20 E71T-1M/T-9M/T-12M JDH4 E71T-1C/T-9C/T-12C DH4 17632-A T 46 4 P M21 1 H5 T 46 2 P C1 1 H5 FCAW
Union S 2 Si - UV 418 TT Boiler Tubes and Pipes P265GH, SA106A,B,C A5.17 : F7A8-EM12K / F6P8-EM12K 14171-A, S 42 5 FB S2Si H5 SAW
Union S 2 - UV 305 Water Walls P265GH, SA106A,B,C A5.17 : F7AZ-EM12 14171-A, S 38 0 AR S2 H5 SAW
BÖHLER FOX DMO Kb Boiler Tubes and Pipes 16Mo3, Grade 1 A5.5 / SFA-5.5, E7018-A1 H4 R 3580-A, E Mo B 4 2 H5 SMAW
BÖHLER DMO-IG Boiler Tubes and Pipes 16Mo3, Grade 1 A5.28 / SFA-5.28, ER70S-A1 (ER80S-G) 21952-A, W MoSi GTAW
BÖHLER DMO-IG Boiler Tubes and Pipes 16Mo3, Grade 1 A5.28 / SFA-5.28, ER80S-G (ER70S-A1) 21952-A, G MoSi GMAW
Union S 2 Mo - UV 420 TT-LH Boiler Tubes and Pipes 16Mo3, Grade 1 A5.23 : F8A4-EA2-A2-H8 / F8P4-EA2-A2-H8 14171-A, S 46 4 FB S2Mo H5 SAW
Union S 2 Mo - UV 305 Water Walls 16Mo3, Grade 1 A5.23 : F8A0-EA2-A2 14171-A, S 46 0 AR S2Mo H5 SAW
FOXcore DMO RC Boiler Tubes and Pipes 16Mo3, Grade 1 A5.29 / SFA-5.29, E81T1-A1M-H8 17634-A, T MoL P M21 1 H10 FCAW
BÖHLER FOX EV 64 Boiler Tubes and Pipes 15NiCuMoNb5, WB 36 A5.5 / SFA-5.5, E9018-G 2560-A, E 50 4 Z1NiMo B 4 2 H5 SMAW
Böhler DMO-IG Boiler Tubes and Pipes 15NiCuMoNb5, WB 36 A5.28 / SFA-5.28, ER70S-A1 (ER80S-G) 21952-A, W MoSi GTAW
Union S 3 NiMo 1 - UV 420 TTR-W Boiler Tubes and Pipes 15NiCuMoNb5, WB 36 A5.23 : F9A8-EF3-F3-N / F9P8-EF3-F3-N 26304-A, S 55 4 FB S3Ni1Mo SAW
BÖHLER FOX DCMV Castings G17CrMoV5-10 A5.5 / SFA-5.5, E9018-G 3580-A, E Z CrMoV1 B 4 2 H5 SMAW
diamondspark DCMV RC Castings G17CrMoV5-10 17634-A, T Z P M21 1 H5
diamondspark DCMV BC Castings G17CrMoV5-10 A5.29 / SFA-5.29, E90T5-GM-H4 17634-A, T Z B M21 3 H5 FCAW
BÖHLER FOX DMV 83 Kb Boiler Tubes and Pipes 14MoV6-3 A5.5 / SFA-5.5, E8018-G 3580-A, E MoV B 4 2 H5 SMAW
BÖHLER DMV 83-IG Boiler Tubes and Pipes 14MoV6-3 A5.28 / SFA-5.28, ER90S-G 21952-A, W MoVSi GTAW
BÖHLER DMV 83-IG Boiler Tubes and Pipes 14MoV6-3 A5.28 / SFA-5.28, ER90S-G 21952-A, G MoVSi GMAW
BÖHLER FOX DCMS Kb Boiler Tubes and Pipes 13CrMo4-5, Grade 11 A5.5 / SFA-5.5, E8018-B2 H4 3580-A, E CrMo1 B 4 2 H5 SMAW
BÖHLER DCMS-IG Boiler Tubes and Pipes 13CrMo4-5, Grade 11 A5.28 / SFA-5.28, ER80S-G 21952-A, W CrMo1Si GTAW
BÖHLER DCMS-IG Boiler Tubes and Pipes 13CrMo4-5, Grade 11 A5.28 / SFA-5.28, ER80S-G 21952-A, G CrMo1Si GMAW
Union S 2 CrMo - UV 420 TTR Boiler Tubes and Pipes 13CrMo4-5, Grade 11 A5.23 : F8P4-EB2R-B2R-H4 24598-A, S S CrMo1 FB SAW
Union S 2 CrMo - UV 305 Water Wall 13CrMo4-5, Grade 11 A5.23 : F10AZ-EB2R-B2 24598-A, S S CrMo1 AR SAW
FOXcore DCMS RC Boiler Tubes and Pipes 13CrMo4-5, Grade 11 A5.29 / SFA-5.29, E81T1-B2M-H8 17634-A, T CrMo1 P M21 1 H10 FCAW
BÖHLER FOX CM 2 Kb Boiler Tubes and Pipes 10CrMo9-10, Grade 22 A5.5 / SFA-5.5, E9018-B3 H4 R 3580-A, E CrMo2 B 4 2 H5 SMAW
BÖHLER CM 2-IG Boiler Tubes and Pipes 10CrMo9-10, Grade 22 A5.28 / SFA-5.28, ER90S-G 21952-A, W CrMo2Si GTAW
BÖHLER CM 2-IG Boiler Tubes and Pipes 10CrMo9-10, Grade 22 A5.28 / SFA-5.28, ER90S-G 21952-A, G CrMo2Si GMAW
Union S 1 CrMo 2 - UV 420 TTR Boiler Tubes and Pipes 10CrMo9-10, Grade 22 A5.23 : F9P2-EB3R-B3R-H4 24598-A, S S CrMo2 FB SAW
Union S 1 CrMo 2 - UV 305 Water Wall 10CrMo9-10, Grade 22 A5.23 : F11AZ-EB3R-B3 24598-A, S S CrMo2 AR SAW
FOXcore CM 2 RC Boiler Tubes and Pipes 10CrMo9-10, Grade 22 A5.29 / SFA-5.29, E91T1-B3M-H8 17634-A, T CrMo2 P M21 1 H10 FCAW
Thermanit Chromo 9 V Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.5 / SFA-5.5, E9015-B91 H4 3580-A, E CrMo91 B 4 2 H5 SMAW
Thermanit Chromo 9 V Mod. Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.5 / SFA-5.5, E9015-B91 H4 3580-A, E CrMo91 B 4 2 H5 SMAW
BÖHLER FOX C 9 MV Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.5 / SFA-5.5, E9015-B91 H4 E CrMo91 B 4 2 H5 SMAW
BÖHLER FOX C 9 MV LNi Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.5 / SFA-5.5, E9015-B91 H4 3580-A, E Z CrMo91 B 4 2 H5 SMAW
Thermanit MTS 3 Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.28 / SFA-5.28, ER90S-B9 21952-A, W CrMo 9 1 GTAW
Thermanit MTS 3 LNi Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.28 / SFA-5.28, ER90S-B9 21952-A, W CrMo 9 1 GTAW
Thermanit MTS 3 Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.28 / SFA-5.28, ER90S-B9 21952-A, G CrMo 9 1 GMAW
Thermanit MTS 3 - Marathon 543 Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.23 : F9PZ-EB91-B91-H4 24598-A, S S CrMo91 FB SAW
Thermanit MTS 3 LNi - Marathon 543 Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.23 : F9PZ-EB91-B91-H4 24598-A, S S ZCrMo91 FB SAW
FOXcore C 9 MV RC Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.29 / SFA-5.29, E91T1-B9M-H4 17634-A, T ZCrMo9VNb P M21 1 H5 FCAW
FOXcore C 9 MV MC Boiler Tubes and Pipes X10CrMoVNb9-1, Grade 91 A5.28 / SFA-5.28, E90C-B9-H4 17634-A, T69T15-1G-9C1MV MCAW
Thermanit MTS 616 Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.5 / SFA-5.5, E9015-B92 H4 / E9015-G 3580-A, E Z CrMoWVNb9 0.5 2 B 4 2 H5 SMAW
Thermanit MTS 616 LNi Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.5 / SFA-5.5, E9015-B92 H4 / E9015-G 3580-A, E Z CrMoWVNb9 0.5 2 B 4 2 H5 SMAW
Thermanit MTS 616 Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.28, ER90S-G [ER90S-B9(mod.)] 21952-A, W Z CrMoWVNb 9 0.5 1.5 GTAW
Thermanit MTS 616 Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.28, ER90S-G [ER90S-B9(mod.)] 21952-A, G Z CrMoWVNb 9 0.5 1.5 GMAW
Thermanit MTS 616 - Marathon 543 Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.23 : F9PZ-EG-G-H4 24598-A, S S ZCrMoWVNb9 0.5 1.5 FB SAW
Thermanit MTS 616 LNi - Marathon 543 Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.23 : F9PZ-EG-G-H4 24598-A, S S ZCrMoWVNb9 0.5 1.5 FB SAW
FOXcore P92 RC Boiler Tubes and Pipes X10CrWMoVNb9-2, Grade 92 A5.29 / SFA-5.29, E91T1-GM 17634-B, T Z CrWMo9VNb P M21 1 FCAW
BÖHLER FOX 20 MVW Boiler Tubes and Pipes X20CrMoWV12-1 3580-A, E CrMoWV12 B 4 2 H5 SMAW
Thermanit MTS 4 Si Boiler Tubes and Pipes X20CrMoWV12-1 A5.28 / SFA-5.28, ER90S-G 21952-A, W CrMoWV 12 Si GTAW
Thermanit MTS 4 Si Boiler Tubes and Pipes X20CrMoWV12-1 A5.28 / SFA-5.28, ER90S-G 21952-A, G CrMoWV 12 Si GMAW
Thermanit MTS 4 - Marathon 543 Boiler Tubes and Pipes X20CrMoWV12-1 A5.23 : F9PZ-EG-G-H4 24598-A, S S CrMoWV12 FB SAW
BÖHLER FOX C 9 MVW Boiler Tubes and Pipes X10CrMoWNb9-1-1, E911 A5.5 / SFA-5.5, E9015-B92 H4 (mod.) 3580-A, E ZCrMoWVNb 9 1 1 B 4 2 H5 SMAW
Thermanit MTS 911 Boiler Tubes and Pipes X10CrMoWNb9-1-1, E911 A5.28 / SFA-5.28, ER90S-G [ER90S-B9(mod.)] 21952-A, GZ CrMoWVNb 9 1 1 GMAW
Thermanit MTS 911 - Marathon 543 Boiler Tubes and Pipes X10CrMoWNb9-1-1, E911 A5.23 : F9PZ-EG-G-H4 24598-A, S S ZCrMoWVNb9 1 1 FB SAW
Thermanit MTS 5 Co 1 Castings GX13CrMoCoVNb9-2-1, CB2 A5.28 / SFA-5.28, ER90S-G 21952-A, W Z CrCoMoV 10 1 1 GTAW
Thermanit MTS 5 Co 1 Castings GX13CrMoCoVNb9-2-1, CB2 A5.5 / SFA-5.5, E9015-G 3580-A, E Z CrCoMoV 10 1 1 B 4 2 H5 SMAW
FOXcore CB 2 RC Castings GX13CrMoCoVNb9-2-1, CB2 A5.29 / SFA-5.29, E91T1-GM 17634-A, T ZCrMoCo9VNbNB P M21 1 FCAW
Thermanit MTS 5 CoT Super- / Reheater Tubing X12CrCoWVNb11-2-2, VM12-SHC A5.28 / SFA-5.28, ER110S-G 21952-A, W Z CrCoW 11 2 2 GTAW
Thermanit ATS 4 Super- / Reheater Tubing X6CrNi18-10, 304H A5.4 / SFA-5.4, E308H-15 3581-A, E 19 9 B 4 2 H5 SMAW
Thermanit 19 10 H Super- / Reheater Tubing X6CrNi18-10, 304H A5.9 / SFA-5.9, ER19-10H 14343-A, W 19 9 H GTAW
FOXcore 308 H-T1 Super- / Reheater Tubing X6CrNi18-10, 304H A5.22 / SFA-5.22, E308HT1-4(1) 17633-A, T Z 19 9 H P M21 (C1) 1 FCAW
Thermanit ATS 4 Super- / Reheater Tubing X8CrNiNb18-10, TP347H A5.4 / SFA-5.4, E308H-15 3581-A, E 19 9 B 4 2 H5 SMAW
Thermanit 19 10 H Super- / Reheater Tubing X8CrNiNb18-10, TP347H A5.9 / SFA-5.9, ER19-10H 14343-A, W 19 9 H GTAW
Thermanit 617 D Super- / Reheater Tubing X8CrNi19-11, 347H FG A5.11 / SFA-5.11, ENiCrCoMo-1 (mod.) 14172, E Ni 6117 (NiCr22Co12Mo) SMAW
UTP A 6170 Co Super- / Reheater Tubing X8CrNi19-11, 347H FG A5.14 / SFA-5.14, ERNiCrCoMo-1 18274, S Ni 6617 (NiCr22Co12Mo9) GTAW
Thermanit 304 H Cu Super- / Reheater Tubing X10CrNiCuNb18-9-3, 304HCu A5.9, ER308H (mod.) 14343-A, W Z 18 16 1 Cu H GTAW
UTP A 6170 Co Super- / Reheater Tubing X6CrNiNbN25-20, 310N, HR3C A5.14 / SFA-5.14, ERNiCrCoMo-1 18274, S Ni 6617 (NiCr22Co12Mo9) GTAW
Thermanit 617 D Boiler Tubes and Pipes NiCr23CoMo12 B, Alloy 617 B A5.11 / SFA-5.11, ENiCrCoMo-1 (mod.) 14172, E Ni 6117 (NiCr22Co12Mo) SMAW
UTP A 6170 Co Boiler Tubes and Pipes NiCr23CoMo12 B, Alloy 617 B A5.14 / SFA-5.14, ERNiCrCoMo-1 18274, S Ni 6617 (NiCr22Co12Mo9) GTAW
Thermanit 263 Boiler Tubes and Pipes NiCo20Cr20MoTi, Alloy C 263 14172, E Z NiCo20Cr20MoTi SMAW
Thermanit 263 Boiler Tubes and Pipes Alloy 740H 14172, E Z NiCo20Cr20MoTi SMAW
Thermanit Nicro 82 Dissimilar Welds Austenitic to Ferritic A5.11 / SFA-5.11, ENiCrFe-3 (mod.) 14172, E Ni 6082 (NiCr20Mn3Nb) SMAW
Thermanit Nicro 82 Dissimilar Welds Austenitic to Ferritic A5.14 / SFA-5.14, ERNiCr-3 18274, S Ni 6082 (NiCr20Mn3Nb) GTAW
Thermanit 617 D Dissimilar Welds Austenitic to Ferritic A5.11 / SFA-5.11, ENiCrCoMo-1 (mod.) 14172, E Ni 6117 (NiCr22Co12Mo) SMAW
UTP A 6170 Co Dissimilar Welds Austenitic to Ferritic A5.14 / SFA-5.14, ERNiCrCoMo-1 18274, S Ni 6617 (NiCr22Co12Mo9) GTAW
A314 Generator, Motors, Transformer Copper and Copper alloys Ag 155 Brazing
A 311 Generator, Motors, Transformer Steel, Copper and Copper alloys Ag 244 Brazing
A 347 Generator, Motors, Transformer Steel, Copper and Copper alloys B Ag-7 Ag 156 Brazing
A 320 Generator, Motors, Transformer Steel, Copper and Copper alloys B Ag-36 Ag 145 Brazing
A 330 Generator, Motors, Transformer Steel, Copper and Copper alloys B Ag-20 Ag 230 Brazing
A 3005 Generator, Motors, Transformer Copper and Copper alloys B Cu-P7 CuP 281 Brazing
A 3015 Generator, Motors, Transformer Copper and Copper alloys B Cu-P5 CuP 284 Brazing
A 3018 Generator, Motors, Transformer Copper and Copper alloys B Cu-P8 CuP 285 Brazing
F 300 H Ultra NT (Brazing Flux) Generator, Motors, Transformer Copper and Copper alloys FH 10 Brazing
Welding Consumables

Equipment Selection

Welding Equipment