Forming and Fabrication of Duplex Stainless Steels

Nicole Kinsman International Molybdenum Association Fabtech 2001, Chicago, Illinois

Chemical Tanker (2205)

Courtesy of Lincoln Smitweld bv

Presentation Overview
What is Stainless Steel? What is Duplex Stainless Steel?
Metallurgy Phase balance Sigma phase

Welding Forming Summary

What is Stainless Steel?

Chromium Increases Corrosion Resistance

Corrosion Rate, mm/y
0.200 0.175 0.150 0.125 0.100 0.075 0.050 0.025 0 2 4 6 8 10 12 14 16

Chromium, Wt. Pct.

How Stainless Steel Works

Iron +
< 11% Chromium
Rust

> 11% Chromium

Passive Film

Carbon Steel

Stainless Steel

Types of Stainless Steels

Austenitic Ferritic Duplex

Type 304 Type 409 2205

Crystal Structures
Ferrite
Add Nickel

Austenite

Body Centered Cubic

Face Centered Cubic

Ferritic Microstructure

Courtesy of AvestaPolarit

Austenitic Microstructure

Courtesy of AvestaPolarit

What is Duplex Stainless Steel?

Austenite Ferrite

Duplex Microstructure
Courtesy of AvestaPolarit

Influence of Nickel
Add Nickel Add Nickel

0% Nickel Ferrite

5% Nickel Duplex

> 8% Nickel Austenite

Duplex Stainless Steel Types

Lean Standard Super 2304 2205 2507

2304 stands for 23% Chromium and 4% Nickel!

Advantages of Duplex
Strong Stress corrosion cracking resistant Pitting / crevice corrosion resistant Erosion resistant Fatigue resistant

Fabricator Comments
Fabrication similar to 300-series
But: much stronger More sensitive to extreme parameters

Duplex distorts less during welding Good availability Increase in duplex use noticed Specifications extremely important

Fabrication of Duplex Stainless Steel:

Different not Difficult

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Good Material
ASTM S31803 Chrome Molybdenum Nickel Nitrogen 21.0-23.0 2.5-3.5 4.5-6.5 0.08-0.20 ASTM S32205 22.0-23.0 3.0-3.5 4.5-6.5 0.14-0.20

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Imbalance
High ferrite (> 70%):
low ductility loss of corrosion resistance susceptibility to hydrogen cracking

High austenite (> 80%):

low SCC resistance low strength

Avoid imbalance

Phase Balance
1. Ferritic solidification from melt 2. Partial transformation to austenite afterwards (austenite islands)
Change from ferrite to austenite takes time

Practical Considerations:
Rapid quench high ferrite content Applies to Welding:
Heat affected zone (HAZ) Arc strike and weld spatter Very low heat input (e.g. TIG root) Autogeneous weld Wash pass Spot weld

Phase Balance

Nitrogen and nickel accelerate formation of austenite

Modern duplex steels are higher nitrogen alloyed High nickel filler material (2209)

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Sigma Phase
Sigma phase embrittles steel Sigma phase lowers corrosion resistance
Avoid sigma phase!!

Sigma Phase
Sigma forms between 1300 and 1800F

Keep time in this interval short Quench quickly

Sigma Phase Formation

1000C

-Phase
600C

Time

No Sigma Phase Formation

1000C

-Phase

Cooling Curve
Time

600C

Sigma Phase Formation

1000C

-Phase

Cooling Curve Time

600C

Sigma Phase

Mo

Cr

Sigma Phase

Clean Duplex

Duplex with Sigma

Practical Considerations:
Time in critical temperature range adds up. Applies to:
Multi-pass welds Mill quench rate

Multiple Passes: Time adds up

-Phase

Time

Slow Mill Cooling: Not much time for welding

-Phase

Time

Sigma Phase
Avoid flame straightening or hot spot fit-up, adds to time at critical temperature Weld repair adds to time at critical temperature

Sigma Phase
Nitrogen delays sigma formation
High nitrogen duplex stainless steel

Influence of Nitrogen Content on Sigma Phase

+N

-Phase

Time

Sigma Phase
Cool quickly through range Avoid excessive heat input Control interpass temperature

below 300F

Sigma Phase
Mainly in higher alloyed duplex Time before sigma phase formation: 2205 >> 2507

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Installation of 2205 Piping in Alaska

Courtesy of Arco Exploration and Production Technology

Field welding of 2205 piping in welding shed

Courtesy of Arco Exploration and Production Technology

Welding
Always use filler metal, even for repair Use 2209 (high nickel) filler metal No wash passes Interpass temperature below 300F Heat input 0.5 - 2.5 KJ/mm

Good Welding Qualification

Toughness Corrosion resistance
e.g., ASTM A 923

ASME requirements Metallography

Service relevant properties are most important

Inadequate Welding Qualification

Ferrite measurement Hardness testing Tensile testing Bending testing PRE calculation Visual examination

Inadequate Welding Qualification

Welders cannot tell whether they did a good job from appearance of weld

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Hot Forming
Avoid critical temperature range for sigma phase Duplex is very soft between 1750 and 2100F

easy to form

Hot Forming
Limited temperature window Full solution annealing after hot forming

Fabrication - Important Considerations

Good material (S32205) AusteniteFerrite balance Sigma phase Welding Hot forming Cold forming

Rolling of 2205 cylinders

Cold Forming
Duplex ductility lower than austenitic

avoid sharp bend angle

Duplex much stronger than austenitic

higher forces necessary more spring-back do not form more than 10-15% before annealing

Duplex cold works readily

Solution Annealing
Solution Annealing Temperature

-Phase

Time

Solution Annealing (1)

Annealing above 1900F
Annealing brings sigma phase and alpha prime back in solution

Rapid quench
Appropriate quench rate ascertains proper phase balance

Solution Annealing (2)

Ideal structure by solution annealing (But: Support part in furnace!!! Strong softening leads to deformation)

Summary
Duplex = Austenite + Ferrite Duplex stainless steels can replace Types 304 and 316 stainless steels

stronger more corrosion resistant more erosion resistant

Fabrication is different - not difficult