DUPLEX

Material for Winning Ideas

Outokumpu Duplex Stainless Steels

Contents
Find out how the right material choices can save enormous costs and accelerate your business in the long run. See inspiring case studies from around the world.
BUsINEss & TRENds

Winning the future Duplex revolution Case studies When to go with Outokumpu Duplex

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What makes Outokumpu Duplex such a strong material? How to weld and form duplex? See in-depth technical information and enjoy our tips for best results.
CoMPosITIoN ANd bENEFITs

Chemical composition Mechanical properties Physical properties Corrosion resistance in various environments Advice for fabrication Product assortment

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Activating your ideas

Pre-fabrication according
to your needs

Whats your winning idea?

Case highlights Outokumpu is fast becoming the undisputed number one in stainless. What makes us special is total customer focus all the way, from R&D to delivery. You have the idea. We offer you world-class stainless steel, technical know-how and support.
Benets in mass production Duplex is the material used for the water heaters of Kingspan Hot Water Systems Ltd. making them both easier to handle and cheaper to produce. See page 10. Reinforcing the present Brisbanes six-lane Gateway Bridge is reinforced with Outokumpu Duplex on its most critical parts, ensuring a design life of 300 years. See page 11. Building the future The Marina Bay Pedestrian Bridge in Singapore is stunning in architectural design, taking advantage of the possibilities of Outokumpu Duplex. See page 12.

Suggestions for material

replacements

Computer simulations
and calculations to ease design work

On-site testing options

and administrative help

Trend-setting duplex tank farm See how Relisa S.A. managed to reduce construction material by up to 50%. See page 9.

Outokumpu Duplex more strength, less material Outokumpu Duplex allows you to realise your most demanding projects: thanks to its superior strength, you can sometimes manage with even 50% less material, which means considerable cost savings. Outokumpu Duplex is a highly environmentally

sustainable material with signicantly longer service life in corrosive environments when the proper material selection is made. See interesting case studies and read all about material properties as well as fabrication hints for Outokumpu Duplex. Together, lets turn your winning ideas into a successful project.

Montanstahls head ofce with sculptures by Helidon Xhixha on the left. Courtesy of Montanstahl.

Winning the future useful answers for future challenges

The use of stainless steel is increasing fast due to the material's durability, corrosion resistance and aesthetics. If the right grades are selected, stainless steel lasts even hundred years. In the long run, stainless steel is also often the least expensive material, thanks to low maintenance costs.
TREND 1:

Global economics and striving for stability When it comes to economics, all parties seek stability. In large-scale construction projects, right material choices can multiply savings. Outokumpu Duplex stainless steel has excellent strength, which can often mean the same structure can be built with less material: for example, tank walls can be considerably thinner. Compared to other grades with comparable corrosion resistance, also the nickel content of Outokumpu Duplex is very low. This means more price stability, less surprises and easier budgeting.
TREND 2:

for the environment is simply not accepted anymore. Environmental responsibility and legislation have an increasing impact on companies operations in every industry. Proof of responsibility is demanded for the whole life cycle of the product. Those who can oer action instead of words in social and environmental responsibility will be the winners of tomorrow. Outokumpu Duplex is an environmentally sound choice from many dierent viewpoints: It uses recycled steel as main raw material and it is 100% recyclable. Very low level of metal ion is released in to the environment. Less need for hazardous coatings. Thanks to high strength, it is possible to reduce the weight of the structures and therefore lower energy consumption in transport, construction and usage.

TREND 3:

Ensuring safety, pleasing to the eye In addition to corrosion-resistance and durability, constructors face increasing demands for a human approach: it is not enough anymore that the tanks, vessels and buildings do their job. They need to be safe for both the builders and the employees and be aesthetically pleasing. Outokumpu Duplex makes it possible to fabricate strong, fascinating structures while reducing the total weight.

Rising environmental awareness In previous years, temporary structures built for world fairs and events for example, could be demolished after the event. Such a waste of labour and disrespect
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Positioning of Duplex grades

More strength, less material

Put simply, the benet of Outokumpu Duplex lies in weight reduction. You gain more strength with less material. Below, you can see an example of what happens when standard austenitic steel is substituted with Outokumpu Duplex.
Rp0,2[MPa]

600 550 500 450 400 350 300 250 LDX 2101

Hot coil LDX 2404 2507 2205

Great combination of both high strength and adequate corrosion resistance.

Duplex

2304

4565

4439

254 SMO 904L

Austentic

4307

4404 4436

4438

High strength

200 150 0

10

20

30

40

50

60

70

80

90

Low nickel content for price stability

Wide range of applications

Corrosion Resistance, CPT typical

Potential savings with Duplex compared to austenitic grades

Savings in costs 40% 30% 20% 10%

Thinner material and therefore possible lower cost

Good corrosion resistance

Duplex saving potential compared to austenitic grades. The curve will shift depending on grades compared and actual price level.

Calculate your weight savings on the Internet Steel professional tool at www.outokumpu.com oers interactive tools for materials selection, rough estimation on wall thickness calculations etc. Visit our website and learn more!

Less material means benets in every step of the project With Outokumpu Duplex, you can purchase, transport, weld and assemble less material. When thinking of the cost of labour, savings can be tremendous.

0% 10% -10% Weight saving 20% 30% 40%

TANK cOSt ExAmPLE 1:

TANK cOSt ExAmPLE 2:

Pipes: reductions in wall thickness and weight between grades 1.4307 and LDX 2101
Grade 1.4307 WT = 6.0 mm Weight = 90 tons Design data Pressure = 16 bar Temperature = 50C OD = 610 mm Required Pipe length = 1000 m Min WT acc to EN 13480-3: Weld factor z = 0.7 1.4307 = 5.8 mm LDX 2101 = 2.9 mm Grade LDX 2101 WT = 3.0 mm Weight = 45 tons

Case: Duplex as a substitute for austenitic in storage tank

4301 61.5 ton LDX 2101 43.5 ton

Austenitic steel versus Outokumpu Duplex When the same tank is manufactured from Outokumpu Duplex instead of conventional austenitic steel, the biggest savings are made in manufacturing phase, thanks to less amount of material needed. The tank walls can be signicantly thinner, yet safe in use.
4301 Plate thickness Material cost*
Welding cost** Labour cost** (Welding and tank assembly)

Carbon steel versus Outokumpu Duplex When the same tank is manufactured from Outokumpu Duplex instead of carbon steel, the biggest savings come in the maintenance phase: carbon steel needs to be properly protected in the manufacturing phase and again after certain periods of usage. All this means extra labour, which can be avoided using Outokumpu Duplex.
Carbon steel Total initial cost* Surface protection cost Elapsed time between maintenance events Life cycle duration Operating cost Total LCC 192 kEUR 100 Euro/m2 x 1000 m2 15 years 30 years 64 kEUR 256 kEUR 30 years 0 kEUR 192 kEUR LDX 2101 192 kEUR No surface protection required!

[m] 18 16 14

LDX 2101 5-7 mm 108 kEUR

35 kEUR 49 kEUR

Required thickness Duplex Required thickness austenitic

12 10 8 6 4 2

5-12 mm 144 kEUR

55 kEUR 89 kEUR

Total manufacturing cost Total initial cost

144 kEUR 288 kEUR

84 kEUR 192 kEUR

[mm] 12 11 10 9 8 7 6 5 4 3 2 1

Potential cost saving ~33% Tank size: diameter 18.5 m, height 18 m. *Based on Outokumpu price list per 19 Oct 2009. **Based on actual costs provided by a Swedish Contractor 2008.

Potential cost saving ~25% Tank size: diameter 18.5 m, height 18 m. *Assume equal intitial cost level: lower material cost for carbon steel equals the measures for protecting the plate surfaces for a tank designed for aggresive environment.

Tank farm Oostwouder, the Netherlands

Stainless racing motorcycle Highland Group, Sweden

Biofuel plant expansion Agroetanol, Sweden

Trend-setting duplex tank farm up to 50% weight savings

Celtic Gateway footbridge United Kingdom

Storage tank farm Gold Bridge, China

Road tankers Indox, Spain

Worlds largest digester Jinhall Mill, China

Bilbao Bridge Spain

Natural gas owline Sosta, Oman

Storage tanks Emypro, Spain

Desalination plant SIDEM

Trend-setting tank farm Relisa, Spain

Clean coal technology Enel, Italy

Bioethanol fermentation tanks Cital, Italy

Courtesy of Emypro

Duplex revolution examples of ideas in action

Avesta Jernverk AB of Sweden, today part of Outokumpu, produced its rst commercial duplex alloy in 1930. Avesta 453S, contained 26% Cr, 5% Ni and 1,5% Mo, and was in the beginning used as so called acid proof material in the production of sulphite pulp. However, its higher strength was immediately noticed and then tested with certain components that were subjected to wear, such as spindles, pumps and shafts. When industries developed further, the possibilities of duplex truly opened up. To date, Outokumpu Duplex has proven its worth around the world. We are proud of the masterpieces realised by our customers.

Relisa S.A. of Spain stores liquid foods and chemicals in a new tank farm at the Port of Barcelona: Spanish storage-tank fabricator Emypro S.A. has built the entire farm, consisting of 22 units, using Outokumpu Duplex LDX 2101 plate. When engineering the rst phase of the farm, Emypro could see the advantages of the duplex grade and partnered with Outokumpu to convince Relisa. As Emypro was putting the nishing touches to the tanks, Relisa ordered 9 more using the same grade. The grade selection has oered the fabricator and tank owner major competitive advantages thanks to the qualities of LDX 2101. The grades strength is almost twice that of standard austenitic grades. This has allowed Emypro to achieve major reductions in material quantities compared to the austenitic alternatives 1.4301/1.4307 (304/304L). The total weight saving is more than 20%, in some sections of tanks, even up to 50%. Technical highlights Outokumpu Duplex has good weldability, and the material supports most known welding techniques. See welding tips on page 20. Interesting facts Emypros and Outokumpus pioneering development continues a history of milestones achieved together, including the worlds largest duplex storage tank (22 m in diameter and 25 m in height) fabricated using Outokumpu Duplex grade 2304.

Built to last for 300 years

Brisbanes six-lane Gateway Bridge will be duplicated as part of the Gateway Upgrade Project. This is the largest road and bridge project in Queenslands history, delivered by Queensland Motorways with design and construction by the Leighton Abigroup Joint Venture. Looking to the future, the new bridge will have a design life of 300 years. To ensure such a long lifespan, the bridge will have stainless steel reinforcement bars (rebar) in the most critical bridge structures; the pilecaps located in the splash zone of the Brisbane river. Leighton Abigroup Joint Venture approached Outokumpu as they were searching for a stainless rebar supplier. We are one of the leading producers of stainless steel long products in the world. Based on their thorough expertise and due to stainless steel prices at the time, the bridge engineers set out to nd a low nickel content stainless steel, such as Outokumpu LDX 2101 . The next task was, with the help of Outokumpu, to convince the customer that LDX 2101 had the required characteristics for the environment. Based on concrete mix properties and the corrosion resistance of LDX 2101 , the result was a concrete cover of 75 mm, more than enough to match the demanding durability requirements. The result was a cost ecient and durable solution for the customer. Technical highlights Outokumpu Duplex has excellent resistance to atmospheric corrosion, which is caused by harsh conditions that can be found, for example, in industrial sites, near the sea and in big cities. Read more on page 19. Interesting facts In the United States, corrosion is estimated to cost close to US$ 300 billion per year, eating away 3-4 % of GDP. As much as 40 % of this could be prevented. Corrosion of the carbon steel reinforcement is the main reason why structures show premature failure today. The annual direct cost of corrosion to bridges alone in the USA, is estimated to be US$ 5.9 billion to US$ 9.7 billion1. If indirect costs were to be included, i.e. loss of economic revenue, the report forecasts that this could be as much as ten times higher. In Western Europe, the gures are not much better, an estimation in a Nordic report stated that 5 billion is spent yearly for repair of corroding concrete infrastructures2.
References: 1 B. Elsener, L. Bertolini, R.B Polder, P. Pedeferri, Corrosion Of Steel In Concrete Prevention, Diagnosis, Repair, John Wiley and Sons Ltd., Weinheim, 2004. 2 D.B. McDonald, D.W. Pfeifer, Y.P. Virmani, Corrosion-resistant reinforcing bars Findings of a 5-year FHWA Study. Int. Conf. Corrosion and Rehabilitation of Reinforced Concrete Structures. FHW, Orlando 711 December 1998.

Courtesy of Kingspan Hot Water Systems Ltd.

Multiplying benets in mass production

When your household needs a water heater, its a question of reliability, right? Manufacturers often want to give their products warranties for longer periods even up to 30 years, so it is understandable that they seek undisputed quality in their materials. Kingspan Hot Water Systems Ltd, a long-term customer of Outokumpu, is a market leader in high performance hot water storage solutions throughout the United Kingdom and Ireland. Kingspan wanted to nd a more cost ecient alternative to mild carbon steel and copper, which have been the industry standards for 50 years. The answer was Outokumpu Duplex: it gives pioneering manufacturers such as Kingspan a clear competitive edge. The strength of the material allows at least a 30% wall thickness reduction, making the boiler both easier to handle and cheaper to produce. The benets multiply in mass production. Warm water in thousands of households is ensured for years to come. Technical highlights Outokumpu Duplex oers excellent resistance to stress corrosion cracking. Read more on page 18. Interesting facts Water quality diers around Europe, and Outokumpu can oer grades to match Kingspans needs. LDX 2101 or 2304 are perfect for European water quality. For more demanding environments, 2205 is recommended.

Courtesy of Leighton Abigroup Joint Venture ABN.

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Courtesy of Urban Redevelopment Authority, Singapore.

Building the Future

The Marina Bay Pedestrian Bridge in Singapore, stunning in architectural and engineering design, will both link key sites of development and be an attraction in itself, symbolising Singapores aspirations as a biomedical hub. Nearly 300 metres long, the bridge is unique in many ways. It is composed of two spiraling tubular stainless steel members, resembling the structure of DNA. According to the designers, the DNA-like structure symbolises life and continuity, renewal and growth . The stainless double-helix structure takes bridge architecture and engineering to entirely new directions. The inner spiral of the double helix is used to support fritted-glass and stainless-steel mesh canopies to provide shading to pedestrians. The bridge engineers selected Outokumpu Duplex 2205 (EN 1.4462) as the appropriate stainless grade for the
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Project checklist when to go with Duplex?

double-helix and support structures. In the hot and humid, maritime climate of Singapore, this highly corrosion resistant grade ensures low maintenance costs and good appearance during a service life of at least 100 years. The high strength of duplex 2205 also enables the development of a cost-ecient design. This duplex contract follows a series of demanding bridge projects worldwide for which Outokumpu has supplied duplex stainless products in several dierent grades. Technical highlights With the right tools and parameters for equipment, duplex grades can be shaped in to exciting and functional forms. Read more about forming of Outokumpu Duplex on page 22. Interesting facts The stainless steel surfaces will provide spectacular night-time illumination by reecting a series of lights programmed to enhance the design. Are some of the characteristics listed below relevant for your application? Then Outokumpu Duplex might be your material of choice. Demands for material resistance to uniform corrosion resistance to pitting and crevice corrosion resistance to stress corrosion cracking and corrosion fatigue high mechanical strength good abrasion and erosion resistance good fatigue resistance high energy absorption low thermal expansion good weldability within temperature range -40 C to + 250-325C* pressure vessel, beams No need for sharp bend radius demanding forming techniques

*max temperature = 250C in EN10028-7 , max temperature = 325C in ASME II-D 2007 .

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The recipe for success: ingredients according to your needs

What makes Outokumpu Duplex such a strong material? The secret lies in connecting the best of both microstructures: mixing austenite and ferrite. The result is two crystallographic phases, each with a composition sufcient to make it corrosion resistant. The phases in duplex grades are a body centered cubic phase (ferrite), and a face centered cubic phase (austenite). Favorable properties of both phases can be utilised in one alloy.

Mechanical properties: superior strength

The mechanical and physical properties are benecial characteristics of Outokumpu Duplex. The mechanical strength is superior compared to austenitic or ferritic stainless steels, and the physical properties oer new possibilities. This is a clear advantage for structural applications, such as pressure vessels and beam constructions. Pressure vessel approvals All Outokumpu duplex grades, except for LDX 2101 and LDX 2404 , are listed in EN 10028-7. Work is in progress to get a European material approval for LDX 2101 . (LDX 2101 . is partly listed in EN 10088). Work in progress for ASTM/ ASME approval of LDX 2404 .

The chemical composition of duplex grades gives good corrosion resistance and desired mechanical and physical properties. Outokumpu can supply you with stainless grades especially designed to meet your needs. Alloying elements and their purpose Chromium makes it stainless At least about 11% chromium has to be added to a steel to form the passive layer that makes it stainless. These contents improve the corrosion and oxidation resistance. Outokumpu Duplex steels have a high chromium level, between 21.5 and 25%. Nickel adds toughness Nickel obtains the desired phase balance and provides toughness. Duplex steels contain a relatively small amount of nickel, between 1.5 and 7%. If corrosion initiates, a higher Ni level is benecial for repassivation.
Table 1. Chemical composition

Nitrogen adds strength and corrosion resistance Nitrogen is a very important addition as it gives a substantial increase in strength and pitting corrosion resistance. At the same time it strongly stabilises the austenite phase. Furthermore, nitrogen improves welding properties. Molybdenum improves corrosion resistance Molybdenum improves corrosion resistance in most environments, particularly in chloride-containing environments.
Duplex microstructure. Longitudinal cross section of hot rolled plate, light phase austenite, darker (blue) phase ferrite.

ASME: In ASME II-D 2007 (Metric) edition grades S31803 (2205), S32304 (2304) and S32750 (2507) are listed for general use between -30C to +325C. Data for LDX 2101 can be found in ASME code case 2418.

Table 2. Mechanical properties for at products at room temperature.

Minimum values, according to EN 10088 P LDX 2101

Outokumpu typical values P(15mm) 480 700 38 220 H (4mm) 570 770 38 230 520 685 35 220 620 800 32 C (1mm) 600 800 35 230 545 745 35 225 640 850 30

H *480 *680 *30

C *530 *700 *30

Proof strength Tensile strength Elongation Hardness 2304 Proof strength Tensile strength Elongation

Rp0.2 Rm A5 HB R p0.2 Rm A5 HB Rp0.2 Rm A5 HB R p0.2 Rm A5 HB R p0.2 Rm A5 HB

MPa MPa %

*450 *650 *30

MPa MPa %

400 630 25

400 650 20

450 650 20

450 670 40 210

Outokumpu steel name

International steel No EN ASTM S32101 S32304 S82441 S32205* S32750 304L 316L N08904 S31254 C 0.03 0.02 0.02 0.02 0.02 0.02 0.02 0.01 0.01 N

Chemical composition, % by weight Typical values Cr 21.5 23 24 22 25 18.1 17 .2 20 20 Ni 1.5 4.8 3.6 5.7 7 .0 8.1 10.1 25 18 Mo 0.3 0.3 1.6 3.1 4.0 2.1 4.3 6.1 Others 5Mn 3Mn 1.5Cu Cu

Hardness LDX 2404 Proof strength Tensile strength Elongation Hardness 2205 Proof strength Tensile strength Elongation Hardness 2507 Proof strength Tensile strength Elongation Hardness

MPa MPa % max MPa MPa %

**480 **680 **25 290 460 640 25

**550 **750 **25 290 460 700 25

**550 **750 **25/30 1) 290 500 700 20

540 750 33 230 510 750 35 250

LDX 2101 2304 Duplex LDX 2404 2205 2507 4307 Austenitic 4404 904L 254 SMO

1.4162 1.4362 1.4662 1.4462 1.4410 1.4307 1.4404 1.4539 1.4547

0.22 0.10 0.27 0.17 0.27 0.20

620 820 35 250 590 900 30 265

635 835 35 250 665 895 33 255

MPa MPa %

530 730 20

530 750 20

550 750 20

550 820 35 250

*Also available as S31803

Table 2 summarises mechanical properties for at rolled products, (data according to EN 10088). The allowed design values may vary between product forms. The appropriate values are given in the relevant specications/design standards. Grade 4501 is only produced as hot rolled plate by Outokumpu. 1) Refrs to A80 for gauges less than 3,0 mm

P = hot rolled plate and bar H = hot rolled strip C = cold rolled coil and strip, cold drawn bar * Mechanical properties according to ASTM A240 ** Mechanical properties according to internal standard AM 641.

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Temperature and embrittlement Duplex steels are more prone to precipitation of sigma phase, nitrides and carbides than corresponding austenitic steels, causing embrittlement and reduced corrosion resistance. The formation of intermetallic phases such as sigma phase occurs in the temperature range 600-950C and decomposition of ferrite occurs in the range 350-525C (475C embrittlement). Exposures at these temperatures should therefore be avoided. In proper welding and heat treatment the risk of embrittlement is low. However, certain risks exist, for example at heat treatment of thick sections, especially if the cooling rate is low. Due to the risk of embrittlement, the duplex steels should not be used at temperatures above 250-325C (See gure 1). The maximum temperature and strength value depends on grade and the design rules being used. High energy absorption The combination of high strength and ductility gives Outokumpu Duplex a very good ability to absorb energy. This makes it a perfect material for

applications like blast walls at oil rigs and car body components. Good fatigue strength in base material The high tensile strength of Outokumpu Duplex also implies high fatigue strength in the base material. The fatigue strength of the duplex steels follows the proof strength of the material. Our research personnel can provide you with more detailed information, if needed. What comes to welds, the benet of the high fatigue strength of the parent or base material is limited. The fatigue strength is reduced by unfavorable weld geometry, residual stresses, distortions and weld defects.

Physical properties: new opportunities

Easy to weld to carbon steel Outokumpu Duplex grades have a lower thermal expansion ratio (approximately 13 10-6/C) and higher thermal conductivity than austenitic steels. This means that there are less problems with temperature expansions caused by connecting Outokumpu Duplex with carbon steels. Duplex is a good alternative for lining mild steel vessels that are running with large cyclic temperature variations. Magnetic properties Duplex stainless steels are more magnetic than austenitic grades due to higher ferrite content. For safety reasons magnets must not be used to lift duplex sheets.
Table 4. Physical properties of duplex stainless steels, according to EN 10088.

Physical property Density [g/cm3] Modulus of Elasticity [GPa] Poissons ratio [Dimensionless] Linear expansion from 20C to 200C (x10-6/C) Thermal conductivity [W/mC] Thermal capacity [J/kgC] Electric resistivity [/m]

20C 7 .8 200 0.3 15 500 0.8

200C 186 13.5 17 560 0.9

Table 3. Impact toughness. Minimum values according to EN 10028-7 transverse direction.

LDX 2101* 2304 20C -40C 60 27 60 40

LDX 2404* 60 40

2205 2507 60 40 60 40

*according to internal specication

Fig. 1. Curves for reduction of impact toughness to 50% compared to solution annealed condition.

Palm oil tank farm, photo courtesy of Loders Croklaan

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Corrosion resistance in a wide range of environments

The corrosion resistance of Outokumpu Duplex is generally very good. The resistance is especially good in environments like halide-containing media, oxidising acids, and hot alkaline solutions. This means that for example, heat exchangers, water heaters, offshore equipment, storage tanks, evaporators and ue gas cleaning equipment greatly benet from the material properties of duplex steels.

Corrosion fatigue and intergranular corrosion The combination of high mechanical strength and very good resistance to corrosion gives duplex steels superior corrosion fatigue strength. Due to the duplex microstructure and low carbon content, the duplex grades have a good resistance to intergranular (intercrystalline) corrosion. Erosion corrosion Stainless steel in general oers good resistance to erosion corrosion. Duplex grades are especially good due to their combination of high surface hardness and good corrosion resistance. Galvanic corrosion Galvanic corrosion may occur when two dissimilar metals are electrically connected (as by welding) in an electrolyte. Stainless steel is in most cases nobler than other metallic materials. The most noble metal is protected while the less noble metal is more severely attacked. Stainless steel in contact with carbon steel

rebars in concrete does not cause galvanic corrosion of the carbon steel due to the high pH in concrete. Galvanic corrosion does not occur between dierent grades of stainless steels as long as both grades are passive. Atmospheric corrosion Atmospheric corrosion is not a unique form of corrosion, but a collective term to denote the corrosion of surfaces in the atmosphere. When stainless steel is exposed to an aggressive atmosphere it is primarily stained, this is sometimes referred to as tea staining, but it can also be attacked by localised corrosion with time, particularly at high chloride levels as in marine atmospheres. Today there is a duplex grade available for all types of atmospheres. The Outokumpu Corrosion Handbook For more information on corrosion and corrosion resistance in dierent media is plural of medium, please see the Outokumpu Corrosion Handbook. You can obtain your own copy from your local sales oce.
Table 5. shows PRE values for different grades. LDX 2101 has a higher pitting and crevice corrosion resistance than 4307 . Grade 2304 is on the same level as the conventional molybdenum alloyed steel 4404, while 2205 is on a level with 904L. The duplex grade 2507 has a similar resistance as 254 SMO.

Uniform corrosion The uniform corrosion resistance is generally considered good if the corrosion rate is less than 0.1 mm/year Due to their high chromium content, duplexes oer excellent corrosion resistance in many media, especially in alkaline solutions. Pitting and crevice corrosion: heat exchangers, water heaters, offshore equipment, storage tanks etc. In chloride solutions LDX 2101 has, in most cases, a better resistance than 4307 and in some cases as good as 4404. Grade 2304 is in most cases equivalent to 4404, while the other more highly alloyed duplex steels show even better resistance. The resistance to pitting and crevice corrosion is often illustrated by the pitting resistance equivalent (PRE) for the material. The most commonly used formula for PRE is: PRE = %Cr + 3,3x%Mo + 16x%N The PRE value can be used for a comparison of dierent stainless steels. A more in-depth way to rank steels is measuring the Critical Pitting corrosion Temperature (CPT). Outokumpu uses an electrochemical method, ASTM G150, involving our own developed Avesta Cell, see Fig. 2., and we can provide you with necessary data when requested. Chloride and sulphide induced stress cracking: boreholes and gas wells etc. All duplex grades are much more resistant than the standard austenitic grades to chloride induced stress corrosion cracking (SCC). They can thus tolerate higher chloride contents at elevated temperatures. In the presence of hydrogen sulphide and chlorides (e.g. sour conditions in bore holes and gas wells) the risk of stress cracking, at low temperatures, increases.. Such environments can exist, for example, in boreholes for oil and gas wells. Duplex grades, especially 2205 and 2507, have demonstrated good resistance.

Outokumpu steel name 4307 LDX 2101 4404 2304 LDX 2404 904L 2205 254 SMO 2507

PRE 18 26 24 26 33 34 35 43 43

CPT, C 100 90 80 70 60 50 40 30 20 10 0 4307 LDX 2101 4404 2304 4436 LDX 2404 2205 904L 2507 254 SMO

Fig. 2. Typical critical pitting corrosion temperatures (CPT) in 1M NaCl measured according to ASTM G150 using the Avesta Cell. Test surfaces wet ground to 320 mesh. CPT varies with product form and surface nish.

span CPT min. - CPT max.

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Fabrication strong opportunities

Outokumpu Duplex offers excellent opportunities to constructing challenging and durable structures. However, due to the high strength of the material, the working process is in some points different than with austenitic or ferritic steels. Outokumpu is here to help you with every possible technical detail. We can provide you with necessary training, computer simulations and further instructions.
Table 6. Characteristic heat treatment temperatures, C, for duplex stainless steels.

LDX 2101 Hot forming Quench annealing Stress relief annealing 1100 - 900 1020 - 1080 1020 - 1080

2304 1100 - 900 950 - 1050 950 - 1050

LDX 2404 1120 - 900 1000 - 1120 1000 - 1120

2205 1150 - 950 1020 - 1100 1020 - 1100

2507 1200 - 1025 1040 - 1120 1040 - 1120

Welding Outokumpu Duplex can be welded with most of the methods used for austenitic stainless steel: Shielded metal arc welding (SMAW) Gas tungsten arc welding TIG (GTAW) Gas metal arc welding MIG (GMAW) Flux-cored arc welding (FCAW) Plasma arc welding (PAW) Submerged arc welding (SAW) Others: Laser, resistance and high frequency (HF) welding
In general, the biggest issue with welding Outokumpu Duplex is to maintain the phase balance in the heat aected zone without precipitations. The chemical composition balances the microstructure, and it is important to have the right welding consumable and the right procedure. Dierent welding procedure: basic rules 1. weld without preheating 2. allow the material to cool between passes, preferably to below 150C. For 2507 100C 3. duplex ller material is needed and recommended with the exception for LDX 2101 which may be welded without ller material in some cases 4. the arc energy recommended by Outokumpu should be kept 5. the heat input should be adapted to the steel grade and adjusted to the thickness of the welded material 6. edge preparation angle should be about 10 greater and the land should be somewhat smaller compared to welding standard austenitics 7. if welded with ller, post-weld annealing is not necessary. In cases where heat treatment is considered, e.g. for stress relieving, it should be car-

Table 7. Welding consumables.

Steel grade

Consumable ISO designation C

Typical composition, % by wt. Cr Ni Mo N

LDX 2101 23 7 NL 22 9 3 NL 2304 23 7 NL 22 9 3 NL LDX 2404 22 9 3 NL 2205 22 9 3 NL 2507 25 9 4 NL 0.02 25 9.5 3.5 0.25 0.02 22.5 8.5 3.0 0.15 0.02 22.5 8.5 3.0 0.15 0.02 0.02 23.5 22.5 8.0 8.5 0.3 3.0 0.14 0.15 0.02 0.02 23.5 22.5 8.0 8.5 0.3 3.0 0.14 0.15

ried out in accordance with the temperatures stated in Table 6, but with the minimum temperature increased with 30-50C, to secure full dissolution of intermetallic phase in the weld metal. 8. GTAW and PAW methods: addition of nitrogen (1-2%) in the shielding/purging gas is recommended

Welding to other steels including carbon steels Outokumpu Duplex can be easily welded to other steels including carbon steels. The ller type can be of duplex. When duplex steels are welded to carbon steels an alternative is to use a ller of 23Cr13Ni2Mo type. The risk of galvanic corrosion can be avoided by shielding the joints from moistening. In most cases duplex ller oers more strength and better corrosion resistance. When joining duplex to super austenitic steels, please contact Outokumpu for assistance. Filler metals for joining similar duplex steels, see table 7.

Post fabrication treatment In order to restore the stainless steel surface and achieve good corrosion resistance, it is often necessary to perform a post fabrication treatment. Outokumpu Duplex supports all dierent methods available, such as brushing, blasting, grinding and pickling. Which method to apply depends on what type of imperfections shall be removed, but also on needs to corrosion resistance, hygiene and aesthetics. The Outokumpu Welding Handbook For more information on welding and post fabrication treatment, please see the Outokumpu Welding Handbook. You can obtain your own copy from your local sales oce.

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Forming Outokumpu Duplex is suitable for all forming techniques. The higher strength and the lower elongation compared to austenitic stainless steel will however impose some dierences in forming behaviour: generally higher force is needed. On the other hand, since duplex design often implies downgauging, the force level can be similar to austenitics. If the forming technique is not already decided, we recommend to choose the most appropriate one for duplex stainless steels. Machining The high strength will of course eect the machinability, but not as much as expected. Some information, good to have in mind when machining duplex, is given below: Stable setup Due to the higher strength the cutting forces will be higher. That will increase the risk of vibrations. The trick is to have a stable setup. Use the shortest possible tool extension good and rigid clamping.
Table 8.

Sharp Tools Use cutting tools with a positive geometry. The duplex grades are very adaptive to work hardening. A dull geometry will generate a hard surface and decrease the tool life. Avoid build up edge Stainless steels have a tendency to stick to the tool. Problems occur when the cutting speed is too low. The biggest dierence between carbon steel and stainless steels when machining is that you face into problems if you are running too slow. The result will be bad surface nish and short tool life. The problem is solved by increasing the cutting speed. LDX 2101 The lean duplex grade LDX 2101 have superior machinability compared to other duplex grades. Even if you compare with the low alloyed standard austenitic grades LDX 2101 , is easier to machine.

Product assortment and services

Outokumpu Duplex is available in various shapes and sizes to suit your needs. HRP(P), Quarto Plate CPP(H), coil and plate CR (C), coil and sheet Billet, wire rod, bar and rebar Welded tube, pipe, ttings and threaded ttings Structural sections, DUPROFTM Fasteners and ttings

Our Added value services ease your project and oer ways to save expenses at critical points Edge preparation Cut to shape Bending Surface nishing: 2B, 2E, 1D Polishing Construction kits Prefabrication Modied chemical analysis Slitted coils Package solutions Welding advice Technical support/Project administration surface nish in duplex stainless steels, which most often fullls the industry surface requirements without any further surface treatment saving both time and money. See our product programme at www.outokumpu.com/prodprog

For more information on various topics, please contact us.

Things to consider Cutting, shearing Maximum thickness for shearing and punching is 80-85% of that of austenitic steel

Roll bending

More bending force will be needed compared to other stainless steels. Through the downgauging, this effect will however be smaller than anticipated. The springback due to the higher strength is large when roll bending. Avoid sharp bending radius. Minimum ratio between inner radius to sheet thickness should not be less than 2.

Break bending

Cane Creeks World Bicycle Relief Reserve Headset made out of LDX 2101.

Deep drawing

If drawing is dominant, formability is comparable to austenitic stainless steel. If stretching is dominant, formability is closer to ferritic steels. The high strength of the sheet has to be considered in the design of the rolls. If this is made properly there are no problems in roll forming Duplex. Strong, durable tools (hardness, HRC larger than 500, Ra-value preferably lower than 0.2 micrometers).

2B surface nish perfect for food & health sectors Surface nish characteristics are not merely a question of appearance. The quality aects to the corrosion resistance as well as cleansability of dirt and bacteria, which is paramount in the food industry and health sector. Outokumpu can additionally oer a 2B

Roll forming

Table 9.

Product 1D

Type of process route Hot rolled, heat treated, pickled. Rough and dull.

Surface nish Standard for the most steel types to ensure good corrosion resistance; also common nish for further processing. Rough and dull. Light cold rolling can be carried out for thin hot rolled strips. Smooth surface with low lustre.

Tooling use

2E Lubrication Because of the high strength of Outokumpu Duplex and extreme pressure additives are useful in complex forming operations. 2B

Cold rolled, heat treated, mechanically descaled followed by pickling. Cold rolled, heat treated, pickled, skin passed or by levelling (as in Avesta Works).

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This document is for information only and seeks to provide professionals with the best possible information to enable them to make appropriate choices. Although every eort has been made to ensure the accuracy of the information provided in this document, Outokumpu can not accept any responsibility for any loss, damage or other consequence resulting from the use of this publication. The information provided herein may be subject to alterations without notice. This document does not constitute a recommendation or a contractual commitment on the part of Outokumpu. Product selection is the responsibility of the speciers, designers and builders, who are solely responsible for rendering the nished unit suitable for the use for which it is intended. It is the customers sole responsibility to ensure that the product is suitable for the use for which it is intended. Outokumpu shall not provide any guarantee in this respect. Copyright Outokumpu Group. All rights reserved.

1434EN-GB:2. Lnnberg, Finland, September 2010.

Activating Your Ideas

Outokumpu is a global leader in stainless steel with the vision to be the undisputed number one. Customers in a wide range of industries use our stainless steel and services worldwide. Being fully recyclable, maintenance-free, as well as very strong and durable material, stainless steel is one of the key building blocks for sustainable future. What makes Outokumpu special is total customer focus all the way, from R&D to delivery. You have the idea. We oer world-class stainless steel, technical know-how and support. We activate your ideas.

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