How to Optimize the Welding Process for Incoloy 800 Tube: Best Practices

Incoloy 800 is an alloy with high nickel, chromium, and iron levels, offering excellent corrosion resistance in high-temperature and high-pressure environments. Welding incoloy 800 tubes requires careful consideration of various factors to achieve optimal results. This blog will discuss the best practices that can help you optimize the welding process for incoloy 800 tubes.

Proper Preparation of the Tube Surface

Proper preparation of the surface is crucial to optimize the welding process for the Incoloy 800 tube. This includes cleaning off any oil, grease, dirt or other contaminants that could weaken the weld and lead to failure. Before welding, it is also important to use a grinding wheel or file to remove all rust and mill scale from the surface of the tube. After grinding/filing, degrease with a solvent such as acetone or alcohol and finish with an abrasive cloth dampened in warm soapy water. The final step is passivation which involves immersing the tube in an acidic solution, such as nitric acid, that removes any residual oxidation on its surface and helps ensure optimal weld strength. Following these steps will help guarantee high-quality welds with improved durability when welding Incoloy 800 tubes.

Choosing the Right Welding Consumables

Optimizing the welding process for Incoloy 800 tube includes selecting the right welding consumables. The selection of consumables depends on the type and size of the weld joint, location and environment. It is important to use AWS-approved filler metals compatible with Incoloy 800 Tube grade material for maximum performance. An E309T1 or E310 electrode is recommended in combination with a matching 308H wire or electrodes for root pass applications. Also, when using GTAW (Gas Tungsten Arc Welding), one should always use ERNi99 filler metal to ensure good corrosion resistance against harsh environments such as an H2S-containing atmosphere. In addition, proper preheat and post-heat treatments should be followed strictly to reduce thermal shock and maintain uniform temperatures during the welding procedure.

Controlling the Heat Input

Optimizing the welding process for Incoloy 800 tube is a key step in ensuring high-quality welds. To do this, controlling the heat input and avoiding defects due to excessive softening in the base metal is important. The way to control heat input is by properly selecting welding parameters such as amperage, voltage, arc length, travel speed and wire feed rate. Combining these variables will ensure a steady flow of energy to produce good-quality welds without causing excessive softening in the base metal (Incoloy 800). Additionally, preheating can be used for better fusion between metals and to reduce residual stress. Regularly monitoring the temperature during welding helps achieve consistent results that last longer with minimum distortion or discolouration at the edges.

Preheating and Post-weld Heat Treatment

Preheating and post-weld heat treatment are essential processes when welding Incoloy 800 Tube. Preheating temperatures should be between 250°C and 450°C, depending on the material thickness. It’s important to use caution when preheating, as too much temperature can cause more stress on the tube joints. To ensure a successful weld, it is recommended that post-weld heat treatment be done in a controlled environment with specific temperature rates for each hour of heating time. It’s critical to properly cool down the tube after this process by either air or furnace cooling so that you don’t compromise your workpiece integrity through metallurgical changes due to rapid cooling methods like water quenching. Proper optimization of these two steps will create stronger bonds within your Incoloy 800 Tube joint, so you can have confidence in results that last!

Weld Inspection

After welding the incoloy 800 tubes, it is essential to inspect the weld for any defects or imperfections that can affect the quality or performance of the joint. Inspection techniques such as visual inspection, ultrasonic testing, or radiography can be employed to detect any flaws in the welded joint. It is crucial to correct any defects that are found before the material is put into service.


In summary, optimizing the welding process for incoloy 800 tubes requires proper preparation of the tube surface, choosing the right welding consumables, controlling the heat input, preheating and post-weld heat treatment, and weld inspection. By following these best practices, you can achieve excellent results that offer superior mechanical strength and corrosion resistance, ensuring that your incoloy 800 tubes are fit for purpose and long-lasting.