Nickel-base weldments such as Alloy 82/182 dissimilar metal (DM) butt welds used in Pressurized Water Reactor (PWR) nuclear power plant components have experienced Primary Water Stress Corrosion Cracking (PWSCC), resulting in the need to repair/replace these weldments. The nuclear industry has been actively engaged in inspecting and mitigating these susceptible DM butt welds for the past several years. Full and Optimized Structural Weld Overlay as well as Mechanical Stress Improvement Process (MSIP®) are some of the mitigation/repair processes that have been implemented successfully by the nuclear industry to mitigate PWSCC. Three conditions must exist simultaneously for PWSCC to occur: high tensile stresses, susceptible material and an environment that is conducive to stress corrosion cracking. These mitigation/repair processes are effective in minimizing the potential for future initiation and crack propagation resulting from PWSCC by generating compressive residual stress at the inner surface of the susceptible DM weld. Weld inlay is an alternative mitigation/repair process especially for large bore nozzles such as reactor vessel nozzles. The weld inlay process consists of excavating a small portion of the susceptible weld material at the inside surface of the component and then applying a PWSCC resistant Alloy 52/52M repair weld layer on the inside surface of the component to isolate the susceptible DM weld material from the primary water environment. The design and analysis requirements of the weld inlay are provided in ASME Code Case N-766. This paper provides the structural integrity evaluation results for a typical reactor vessel outlet nozzle weld inlay performed in accordance with the ASME Code Case N-766 design and analysis requirements. The evaluation results demonstrate that weld inlay is also a viable PWSCC mitigation and repair process especially for large bore reactor vessel nozzles.

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