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Welding Practice for the Sandvik Duplex Stainless Steels SAF 2304, SAF 2205 and SAF 2507 Presented by Frank Babish

Key Points
Metallurgical Considerations Welding Processes

Composition differences Base Metal and Filler Metal

Good Mechanical and Corrosion Properties of Welds Importance of Heat Input and Interpass Temperature

Role of Nitrogen
Post Weld Cleaning Dissimiliar Joining Joint Design

Characteristics of
Duplex stainless steels
Excellent resistance to stress corrosion cracking
Very high mechanical strength Excellent resistance to pitting and crevice corrosion

High resistance to general corrosion in a variety of environments

Low thermal expansion High resistance to erosion corrosion and corrosion fatigue Good weldability Lower life cycle cost

Duplex microstructure
The austenite islands (light) are embedded in a continuous ferrite (dark) matrix. The duplex microstructure typically contains 45-65% austenite and 35-55% ferrite.

Austenite

Ferrite

Yield Strength 0,2% Austenitic vs Duplex Stainless Steel

SAF 2507 SAF 2304

600 500 400 300

SAF 2205

6Mo+N 316L 904L

200
100 0

Coefficient of expansion (x10-6)C-1

Austenitic stainless steels Duplex stainless steels Carbon steel

approx. 17 approx. 13 approx. 11,5

Thermal expansion, per C (20-100C)

Duplex

Carbon steel AISI 316L

0 5 10 15
-6 20 (x10 )

Solidification mechanism of Duplex stainless steel

As duplex stainless steels solidify the grain structure transform from a fully ferritic material to a balanced austenite and ferrite microstructure

Solidification mechanism of a Duplex Stainless Steel

HAZ of weld in SAF 2507

Stress strain curves Austenite, ferrite and duplex

1000
austenite duplex (2205) ferrite

800

Stress [MPa]

600

austenite duplex

400

ferrite

200

0,0

0,2

0,4

0,6

0,8

Strain

Reasons for the high strength of duplex stainless steels

Content of ferrite Fine grained structure Nitrogen

Embrittling of Duplex Stainless Steels

Welding Processes
Conventional Processes
GTAW GMAW SAW SMAW FCAW

Avoid
Autogenous Low Energy Processes Or Perform PWHT

Filler Metals for the Welding of Duplex Stainless Steels

Parent Welding metal process Sandvik Filler metal Chemical composition, wt-% Sandvik C Si Mn P S Cr max. max. max.

Ni

Mo

Ferrite All weld metal, % 30-40 30-40 30-40 30-40 30-40 30-40 30-40 30-40 30-40

SAF 2304 TIG, MIG, SAW MMA SAF 2304 TIG, MIG, SAW and MMA SAF 2205 FCAW

23.7.L 23.8.LR

0,020 0,4 1,5 0,020 0,015 23 0,030 <0,9 0,5 0,030 0,025 25 0,5 <1,0 <0,5 <1.0 1,6 0,8 0,8 1.5 0,020 0,030 0,030 0.030 0.015 0,025 0,025 0.025 22,5 22,5 22 22.5

7 9 8 9 9 9

3 3 3 3

0,14 0,12 0,14 0,12 0,15 0.15 0,25 0,25 0,25

2209 0.020 2209-16,17 0,030 2209-15 0,04 2209LT 0.030

SAF 2507 TIG, (MIG), SAW 25.10.4.L 0,020 0,3 MMA 25.10.4.LR 0,030 0,5 25.10.4.LB 0,040 0,4

0,4 0,020 0,020 25 10 4 0,7 0,030 0,025 25 10 4 0,9 0,030 0,025 25,5 9,5 4

Mechanical properties of the Duplex Stainless Steels

Sandvik UNS Yield strength 0,2% offset 1,0% offset MPa ksi. MPa ksi. min. min. min. min. 400 450 58 65 450 500 65 73 Tensile strength Elong. A5 % min. 25 25 Hardness Vickers approx. 230 260

MPa min.
600-820 680-880

ksi. min.
87-119 99-128

SAF 2304 S32304 SAF 2205 S31803

SAF 2507 S32750

550

80

640

93

800-1000 116-145

25

290

Mechanical Properties of All Weld Metal

Filler metal Welding Sandvik process Rpo,2 Rp1,0 MPa MPa Rm MPa A5 % Z % Impact strength, J RT -40C

23.7.L 23.7.L 23.8.LR

22.8.3.L 22.8.3.L 22.9.3.LR 22.9.3.LT

TIG SAW1) MMA

TIG SAW1) MMA FCAW

525 503 627

610 578 512 620 672 687 645

595
681

708 671 773

760 775 734 816 851 878 850

34 34 26
28 33 33 30 28 27 28

58
46

171 101 62
207 139 52 56 150 91 46

156 72 46
160 84 44 43 116 64 33

664 -

53 44 64 47

25.10.4.L TIG 25.10.4.L SAW1) 25.10.4.LR MMA

757

1)Using

Sandvik 15W flux

Mechanical properties of welded joints. Cross-weld tensile test

Parent metal Sandvik SAF 2304 Filler metal Sandvik 23.7.L 23.7.L 23.8.LR 22.8.3.L 22.8.3.L 22.9.3.LR 22.9.3.LT 25.10.4.L 25.10.4.L 25.10.4.LR Welding Rp0.2 process min. TIG SAW1) MMA TIG SAW1) MMA FCAW TIG SAW1) MMA 400 400 400 450 450 450 450 550 550 550 MPa typical 446 452 462 553 588 588 585 645 628 628

SAF 2205

SAF 2507

1)Using

Sandvik 15W flux

Charpy-V impact strength of welded joints

Parent metal Sandvik SAF 2304 Filler metal Sandvik 23.7.L 23.7.L 23.8.LR 22.8.3.L 22.8.3.L 22.9.3.LR 22.9.3.LT 25.10.4.L 25.10.4.L 25.10.4.LR Welding process TIG SAW1) MMA TIG SAW1) MMA FCAW 55 TIG SAW1) MMA Impact energy, J RT -40C 213 105 46 282 54 52 44 110 100 58 74 17 38 133 42 43

SAF 2205

SAF 2507

78 58 39

1)Using

Sandvik 15W flux

Typical CPT Values from G-48A Tests for Parent Metals and Welded Joints
Sandvik SAF 2304
All weld metal Joint Joint Joint 23.7.L 23.7.L 23.7.L 23.8.LR TIG TIG SAW1) MMA Ar Ar Ar -

Filler metal

Welding process

Shielding gas

Root gas

CPT C ~15
<15 <15 <15 <15

SAF 2205
All weld metal Joint Joint 22.8.3.L 22.8.3.L 22.8.3.L TIG TIG TIG Ar Ar Ar - 2% N2 Ar 90 N2 + 10 H2 (or pure N2) -

30
20-23 20-23 23-25

All weld metal Joint All weld metal Joint

22.8.3.L 22.8.3.L 22.9.3.LR 22.9.3.LR

SAW1) SAW1) MMA MMA

20-25 20-25 20-25 20-25

SAF 2507
All weld metal Joint Joint Joint All weld metal Joint All weld metal Joint
1)Using

80
Autogenous TIG welding 25.10.4.L TIG 25.10.4.L TIG 25.10.4.L TIG 25.10.4.L 25.10.4.L 25.10.4.L 25.10.4.LR 25.10.4.LR TIG SAW 1) SAW 1) MMA MMA Ar Ar Ar Ar + 2% N2 Ar 90 N2 + 10 H2 (or pure N2) 90 N2 + 10 H2 (or pure N2) 40 40-45 40-45 40-50 45-55 40-50 40-50 40-50 40-50

Sandvik 15W flux

Quench annealing of Duplex Steel welds

Sandvik SAF 2304 SAF 2205 SAF 2507

Holding temperature C 930 - 1050 1020 - 1100 1080 - 1120

Quenching media Water Water Water

High quenching temp Rapid cooling

Low quenching temp. Slow cooling

Intermetallic phase

Recommended heat input

Steel SAF 2304 SAF 2205 Heat input 0,5 - 2,5 kJ/mm 0,5 - 2,5 kJ/mm Interpass temperature <250C <250C

SAF 2507

0,2 - 1,5 kJ/mm

<150C

Welding recommendations

Sandvik SAF 2304 SAF 2205 SFA 2507

Heat input kJ/mm 0,5 - 2,5 0,5 - 2,5 0,2 - 1,5

Interpass temperature C <250 <250 <150

The roll of Nitrogen

Nitrogen is a very important alloying element in DSS Improves corrosion resistance Improves austenite reformation At TIG welding, the loss of nitrogen is compensated for by using Ar + 1 - 2%N2 as a shielding gas

Ferritic area in SAF 2507 weld owing to the loss of nitrogen in fusion line

Shielding gas Ar 99,99%

Nitrogen addition to the shielding gas

Ar 99,99%

Ar + 5% N2

Ferrite content in TIG-welds, SAF 2507

Filler metal Sandvik

25.10.4.L 25.10.4.L 25.10.4.L

Shielding gas
Ar Ar Ar + 5% N2

Root gas
Ar 90% N2 + 10% H2 90% N2 + 10% H2

Ferrite content, vol-% + error with 95% confidence interval

55 + 4,5 59 + 4,0 33 + 4,0

Nitrogen Content in TIG welds of SAF 2507. N=0,25% in the filler metal

Filler metal Sandvik 25.10.4.L 25.10.4.L 25.10.4.L

Shielding gas Ar Ar + 3% N2 Ar + 6% N2

Root gas 90% N2 + 10% H2 90% N2 + 10% H2 90% N2 + 10% H2

Weight-% N in deposit 0,23 0,27 0,33

GMAW SHIELDING GASES

General recommendations:
Short arc welding gives very convex beads. Ar+30 He+1 O2 Spray arc welding Ar+30 He+1 O2 (22Cr duplex)

Ar+2 CO2(Super duplex)

Pulsed arc welding Ar+30 He+1 O2 (22Cr duplex) Ar(99,996%) for super duplex

Nitrogen Analysis from the Top of a TIG weld

% Nitrogen in position (oclock) 3 5 6 7 11

Welder No. 1 0,17 0,18 0,15 0,16 0,19

Analysis at
12 0,19 Top side

Welder No. 2

0,18 0,20
0,22 0,21

0,19 0,21
0,21 0,21

0,19 0,20
0,20 0,20

Top side Root side

Top side Root side

Welder No. 3

In all cases the filler metal had a nitrogen content of 0,25%

Stress relieving temperatures

325 + 25C for 10 hours

Post Weld Cleaning

Pitting potential

Pickling bath or pickling paste HNO3-HF

360

220

120

80

Wire brush

Blasting

Dissimilar Joints
SAF Carbon steel AISI 200 and 300series
22.8.3.L 22.9.3.LR 22.9.3.LT 22.8.3.L 22.9.3.LR 22.9.3.LT 25.10.4.L 25.10.4.LR

AISI 904L, Sanicro 28, 254 SMO, etc.

22.8.3.L 22.9.3.LR 22.9.3.LT 22.8.3.L 22.9.3.LR 22.9.3.LT Sanicro 60 Sanicro 60

2304

22.8.3.L 22.9.3.LR 22.9.3.LT 22.8.3.L 22.9.3.LR 22.9.3.LT 25.10.4.L 25.10.4.LR

2205

2507

Joint preparation One sided butt welding

Joint preparation Butt welding from both sides

Tube to tube sheet welding. Joint preparation

45 >1.5 x WT >3 mm (0.12) or >1.5 x WT

>WT

r >1.5 x WT

Hydrogen pick-up from covered electrodes Sandvik 25.10.4.LR

MMA
H2, ml/100 g

15

10

0
Dried covering Covering exposed to laboratory air Moist covering

Hydrogen pick-up from SAW flux

SAW
15
H2, ml/100 g

10

0
Dried flux Moist flux

Hydrogen pick up from shielding gas at TIG welding

15
H2, ml/100 g

TIG - no root gas

10

0
Shielding gas Ar + 5% H2 Shielding gas Ar + 10% H2

Hydrogen pick up from shielding gas and root gas at TIG welding
15
H2, ml/100 g

TIG - with root gas

10

0
Shielding gas Ar Root gas Ar Shielding gas Ar Root gas 90% N2 + 10% H2

Conclusions
Key Areas Good Weldability Uses Conventional Welding Processes Joint Design Role of Nitrogen Heat Input Important Interpass Temperature