ASME SA-542/SA-542M

SA542 Type E Category 2 Pressure Vessel Steel Plate Product-Performance

Technical Datasheet

Chromium-molybdenum-vanadium (Cr-Mo-V) quenched and tempered pressure vessel steel plate, with very high strength and excellent toughness. Suitable for the most demanding pressure vessel applications in petrochemical and power generation industries.

1. SA542 Type E Category 2 Material Identification & ASTM ASME Standards

Standards

  • ASTM A542 / ASME SA542
  • ASTM A20/A20M (General Requirements)
  • ASME BPVC Section II Part A

Alloy Type

2.75Cr-1Mo-V

Grade Classification

  • SA542 Type E (2.75Cr-1Mo-V, standard strength)
  • SA542 Type E Class 4 (2.75Cr-1Mo-V, lower strength)
  • SA542 Type E Class 4a (2.75Cr-1Mo-V, intermediate strength)
  • SA542 Type E Category 2 (2.75Cr-1Mo-V, very high strength) ← This Spec

2. SA542 Type E Category 2 Chemical Composition & Ladle Analysis Requirements

2.1 SA542 Type E Category 2 Chemical Composition Limits

Table 2.1: SA542 Type E Category 2 Chemical Composition Requirements (ASTM A542/ASME SA542 Mass Percent)
Element Smelting Analysis Finished Product Analysis
C 0.10-0.15 0.06-0.18
Mn 0.30-0.60 0.25-0.66
Si, ≤ 0.15 0.15
S, ≤ 0.010 0.010
P, ≤ 0.025 0.025
Cr 2.75-3.25 2.63-3.37
Mo 0.90-1.10 0.85-1.15
Ni, ≤ 0.25 0.28
V 0.20-0.30 0.18-0.33
B 0.0005-0.0150 NA
Ti ...
Cu, ≤ 0.25 0.28
Nb 0.015-0.070 0.010-0.075
Ca ...
Zr ...
Others ...

Carbon Equivalent (CE)

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15

Typical value: 0.65-0.85 (depending on actual composition)

Note: Cr-Mo-V steel requires controlled welding procedures due to high hardenability; low hydrogen practice is mandatory. Boron is added for hardenability but is not applicable to finished product analysis.

3. SA542 Type E Category 2 Mechanical Properties & Tensile Strength Specification

3.1 SA542 Type E Category 2 Tensile Properties

Property Standard Value Test Method Remarks
Tensile Strength Rm 795-930 MPa ASTM A370 Transverse specimen
Yield Strength ReH >=690 MPa ASTM A370 Upper yield strength
Elongation A (2in./50mm) >=13% ASTM A370 Per A20/A20M
Charpy Impact KV₂ ... — By agreement

3.2 Charpy Impact Test Requirements for SA542 Type E Category 2

Standard Grade

Impact testing not required by standard

Very High Strength Service

Low Temperature Service

  • Impact testing by agreement
  • Cr-Mo-V provides good toughness
  • Typical test temperature: 0°C to -20°C
By Agreement

3.3 SA542 Type E Category 2 Hardness & Brinell Hardness Limits

  • As-supplied condition (quenched + tempered): Typically ≤280 HBW
  • NACE service environment: Weld & HAZ ≤250 HV10

4. SA542 Type E Category 2 Quenched + Tempered: Heat Treatment Guide

1

As-Rolled (AR)

Not applicable for SA542

High hardenability requires Q+T

→
2

Quenched + Tempered (Q+T)

Austenitizing: 900-960°C

Quench: Water or Oil

Tempering: 620-700°C

→
3

Simulated PWHT (SPWHT)

620-700°C × 2-4h

For property verification

Critical Control Points:
  • SA542 must be supplied in quenched + tempered condition
  • Austenitizing temperature: 900-960°C, quench in water or oil
  • Tempering temperature: 620-700°C, air cool
  • Tempering temperature must be carefully controlled to achieve required strength and toughness balance

5. SA542 Type E Category 2 Welding Procedure Specification (WPS/PQR)

5.1 SA542 Type E Category 2 Welding Procedure Specification WPS

SMAW (Shielded Metal Arc) SAW (Submerged Arc) GTAW (Gas Tungsten Arc) FCAW (Flux Cored)

5.2 SA542 Type E Category 2 Preheat & Interpass Temperature Chart

Thickness Range Min Preheat Temp Recommended Preheat Max Interpass Temp
<=13mm 150°C 150-200°C 250-300°C
>13-38mm 150°C 150-250°C
>38mm 150°C 200-250°C

5.3 Recommended Welding Consumables for SA542 Type E Category 2

Process AWS Classification Strength Match Hydrogen Control
SMAW E11018-M, E11018-M-H4 110 ksi Low Hydrogen (H4)
GTAW ER110S-G 110 ksi Shielding: Ar
FCAW E110T5-K4 110 ksi Self/ Gas Shielded
SAW F11A4-EG, F11P4-EG 110 ksi Flux bake 300°C*2h

5.4 SA542 Type E Category 2 PWHT Requirements & Post Weld Heat Treatment

Temperature Range 620-700°C
Holding Time 1h/25mm thickness (min 30min)
Heating Rate <=150°C/h
Cooling Rate <=150°C/h (to 300°C)
PWHT Notes:
  • PWHT is mandatory for SA542 steel to achieve required mechanical properties
  • Tempering temperature must be carefully controlled to avoid over-tempering
  • Cooling rate should be controlled to prevent residual stresses

6. SA542 Type E Category 2 High Temperature Service & Creep Resistance

6.1 SA542 Type E Category 2 High Temperature Properties

High Temperature Capability

  • Very high strength at elevated temperatures
  • Good hydrogen resistance at elevated temperatures
  • Good oxidation resistance (2.75% Cr)
  • High thermal conductivity

Applications

  • Ultra-high-strength hydroprocessing reactors
  • Hydrocracking equipment
  • High-temperature heat exchangers
  • Petrochemical pressure vessels

6.2 SA542 Type E Category 2 Creep Rupture Properties

Grade SA542 Type E Category 2 provides excellent creep rupture strength at elevated temperatures:

  • At 450°C: 100,000 hour creep rupture strength ~200 MPa
  • At 500°C: 100,000 hour creep rupture strength ~150 MPa
  • At 550°C: 100,000 hour creep rupture strength ~90 MPa
  • At 600°C: 100,000 hour creep rupture strength ~50 MPa

7. SA542 Type E Category 2 Inspection & NDT Testing Methods

7.1 Non-Destructive Testing

UT ASTM A578/A578M Level C (Most Strict)
MT ASTM A275/A275M Surface Crack Detection
PT ASTM A165 Surface Open Defects
RT ASME V Article 2 Weld Internal Quality

7.2 Specimen Orientation & Location

Transverse (T)

Preferred for tensile & impact

Reflects transverse properties

Longitudinal (L)

Only when width insufficient

Higher strength, lower toughness

Thickness Position

1/4T or 1/2T

Represents worst location

7.3 Retest Procedures

  • Tensile failure: Double retest from same plate; plate acceptable if both pass
  • Impact failure: Additional 3 sets (9 specimens) from same plate; average must meet requirement with individual values >=70% of specified
  • UT failure: Defect removal and re-inspection or rejection

8. SA542 Type E Category 2 Physical Properties & Thermal Conductivity

Density

7.80

g/cm3 (20°C)

Melting Point

~1510

°C

Thermal Conductivity

35-40

W/(m*K) (20-100°C)

Linear Expansion

11.5

*10-6/°C (20-300°C)

Specific Heat

460-500

J/(kg*K) (20°C)

Elastic Modulus

200-210

GPa (20°C)

9. SA542 Type E Category 2 Dimensions & Thickness Tolerance ASTM A20

9.1 Available Dimensions

Thickness 6-200 mm (Standard 6-100mm)
Width 1500-4350 mm
Length 3000-27000 mm
Unit Weight Max 60 MT

9.2 Thickness Tolerances (ASTM A20)

Nominal Thickness Class A (Unrestricted) Class B (Restricted)
6-25mm +1.20mm, -0.30mm +/-0.60mm
>25-50mm +1.50mm, -0.30mm +/-0.80mm
>50-100mm +2.40mm, -0.30mm +/-1.20mm

10. SA542 Type E Category 2 Mill Test Certificate & EN 10204 3.2 Documentation

EN 10204 3.1

Manufacturer Test Certificate

Based on non-specific inspection

EN 10204 3.2

Third Party Inspection Certificate

Witnessed by customer or third party

ASME Data Report

Form CM-1

For ASME stamped equipment

Mill Test Certificate must include:

  • ✓Heat number, plate number, batch traceability
  • ✓Chemical composition (ladle + product analysis)
  • ✓Mechanical properties (tensile, impact)
  • ✓Heat treatment records (temperature-time curves)
  • ✓NDT reports (UT/MT etc.)
  • ✓Dimensional inspection records

11. SA542 Type E Category 2 Equivalent Grades: Cr-Mo-V Steel Comparison

Grade Standard Country Yield
MPa		 Tensile
MPa		 Cr Content
%		 Key Differences
SA542 Type E Category 2 ASME USA >=690 795-930 2.75-3.25 ASME BPVC, very high strength Cr-Mo-V steel
SA542 Type E ASME USA >=515 655-795 2.75-3.25 Lower strength, same composition
SA542 Type D ASME USA >=415 585-760 2.75-3.25 Lower strength, 3Cr-1Mo-V
SA387 Gr.22 ASME USA >=310 515-690 2.00-2.50 Lower Cr, no V, much lower strength
High Temperature Service Notes:
  • SA542 Type E Category 2: Very high strength, yield ≥690 MPa
  • SA542 Type E: High strength, yield ≥515 MPa
  • SA542 Type D: Lower strength, similar composition, 3Cr-1Mo-V
  • SA387 Gr.22: Lower Cr content, no V, much lower strength
  • Cr-Mo-V steel requires controlled heat treatment and welding procedures

Warning: Equivalent grades are approximate. Project-specific Gap Analysis and PQR qualification required. Yield strength and creep rupture strength are critical for high-temperature pressure vessel design.

12. SA542 Type E Category 2 Design Considerations & Fabrication Guidelines

Design Considerations

  • Very high strength: SA542 Type E Category 2 suitable for the most demanding pressure vessel applications
  • Hydrogen service: Good resistance to hydrogen attack at elevated temperatures
  • Thickness effect: As plate thickness increases, strength and toughness decrease; allowable design stress must be interpolated per ASME II-D Table 1A

Fabrication Considerations

  • Cold forming: Limited formability due to very high strength; bend radius recommended >=5t (t=plate thickness)
  • Hot forming: Forming temperature 900-960°C, re-quenching and tempering required after forming
  • Grinding: Defect removal depth not to exceed 7% of plate thickness, PT/MT verification required

Common Failure Mode Prevention

  • Type IV cracking: Avoid prolonged PWHT in 750-850°C range
  • Hydrogen-induced cold cracking: Strict low-hydrogen practice, control diffusible hydrogen <=5 mL/100g
  • Creep damage: Regular inspection for creep damage in high-temperature service
  • Temper embrittlement: Avoid prolonged exposure to 350-550°C range

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