Controlled deposition welding (CDW) is a joining technique to refine grains and to temper underlying heat affected zone (HAZ) in the base metal. Applications and technical justifications of CDW for coke drum repairs are presented in this article. CDW procedures have been developed and field implemented both offline and online. Computer modeling to predict weld microstructure and mechanical properties is used to pre-select welding variables and minimize laboratory testing. Several field cases are summarized. Coupons obtained from post weld heat treatment repairs and CDW repairs were collected and fatigue tested. Also shown are examples of fitness for service assessments to define repair strategy.

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