SPECIAL EDITION

Duplex Steels:
Gas Shielded Arc Welding a Special Set of Rules

Thomas Ammann, Unterschleissheim

Duplex Steels:
Gas Shielded Arc Welding
a Special Set of Rules

1. Introduction and very good resistance to chloride-induced pitting corrosion.

1.1 Fields of application and typical properties
Since their development, ferritic-austenitic materials have been
used at an ever-growing rate. Their applications, primarily in the
oil and gas industry, petrochemical industry and pharmaceuticals,
are based on their good properties of corrosion resistance and
strength. Because of these properties, in many cases they are an
interesting alternative to common Cr-Ni steels and Ni-based
alloys.
Duplex steels are of two-phase microstructure (hence the name
Duplex), containing both austenite and ferrite. Because of
such specific microstructure, duplex steels combine to a certain
extent the advantages of two different sides. On the one side, there
are the ferritic and martensitic Cr steels. Due to their Cr contents
of 18 % and higher, they provide relatively high toughness values
as well as very good resistance to stress-corrosion-cracking
in chloride-containing agents. Their weldability, however, is
limited. Because of the high cooling rates that occur during
welding, such steels have a strong tendency to hardening and
embrittlement due to the formation of a martensitic micro-
structure. On the other hand there are the austenitic Cr-Ni steels.
As a rule, they provide good weldability, good impact toughness
The usable yield strengths and the resistance against stress-
cracking corrosion are significantly lower than those of
Cr steels.
The first austenitic-ferritic steels (Duplex) had carbon contents
mainly in the range from 0.1 % to 0.2 % and were thus suscepti-
ble to intercrystalline corrosion (IC). Consequently, austenitic-
ferritic steels with reduced carbon content and additions of
nitrogen were developed. Such materials combine good resistance
against IC and pitting corrosion, good weldability, fair mechani-
cal and technological properties and better workability. The chro-
mium content in duplex steels is in the range between 20 % and
26 %, while the nickel content is in the range from 3 % to 8 %.
Almost all grades of duplex steels additionally contain between
1.5 % and 5.5 % molybdenum. Such alloying further improves
resistance against pitting corrosion. An overview of currently
used duplex steel grades is given in Table 1.
An approximate and rough classification of duplex steels may be
made according to the Cr content. Two groups may be recognized,
i.e. steels with 22 % Cr and steels with 25 % Cr. Further, more
refined classification may be made according to the so-called
Pitting Resistance Equivalent (PRE, see Table 1). PRE is a value
calculated using an empiric formula in which the favourable

Table 1: Common duplex steel grades

Material DIN Designation Chem. Composition in % PRE

number C Cr Ni Mo N Other
1.4362 X2 CrNiN 23-4 0.030 22.024.0 3.55.5 0.10.6 0.050.20 Cu: 0.10.6 27
1.4410 X2 CrNiMoN 25-7-4 0.030 24.026.0 6.08.0 3.04.5 0.200.35 Cu: 0.51.0 42
1.4460 X3 CrNiMoN 27-5-2 0.050 25.028.0 4.56.5 1.32.0 0.050.20 34
1.4462 X2 CrNiMoN 22-5-3 0.030 21.023.0 4.56.5 2.53.5 0.100.22 35
1.4501 X2 CrNiMoCuWN 25-7-4 0.030 24.026.0 6.08.0 3.04.0 0.200.30 Cu: 0.51.0 / W: 0.5 1.0 44
1.4515 GX3 CrNiMoCuN 26-6-3 0.030 24.526.5 5.57.0 2.55.5 0.120.25 Cu: 0.81.3 42
1.4517 GX2 CrNiMoCuN 25-6-3-3 0.030 24.526.5 5.07.0 2.53.5 0.120.22 Cu: 2.753.5 38

2
effect of a particular alloying element upon the pitting corrosion
resistance is taken into the consideration:
PRE = % Cr + 3.3 % Mo + 30 % N
Figure 2: Microstructure of a duplex steel (1.4462), as delivered.
Etching Beraha II. Austenite grains appear white, Ferrite grains
appear dark. Magnification 750:1

Austenitic-ferritic steels characterized by PRE < 40 are classified

as duplex steels, while those steels with a PRE value greater than
40 are designated as super-duplex grades. Figure 1 shows the
simplified correlation between the pitting corrosion resistance
(critical pitting temperature, CPT) of different grades of austen-
itic and ferritic-austenitic steels and the PRE.

Ideally, the microstructure of a duplex steel consists of approxi-

mately 50 % austenite and 50 % ferrite (Figure 2). Such condi-
tions can be obtained after annealing at temperatures of 1,020 C
and 1,100 C, the hold time being approximately 5 min, and sub-
sequent quenching in water. In the Schaeffler diagram, duplex
steels are located in the middle of the austenite + delta ferrite
area. In Figure 3, the position of a duplex steel grade 1.4462
(AISI 2205) in the Schaeffler diagram is marked. For the calcu-
lation of the corresponding Niequ value the nitrogen content has
been additionally taken into account (30 % N).

Initially, any duplex steel solidifies from the liquid state com-
pletely into delta ferrite, which is then in the solid state and par-
tially transformed into austenite on further cooling. In the equi-
librium state the transformation temperature is at approximately
1,250 C. The amount of austenite that will be present in the
microstructure at ambient temperature depends on the content
of alloying elements and cooling conditions, i.e. the cooling rate.

Figure 1: Comparison of CPTs of different materials in Figure 3: Structural diagram acc. to Schaeffler. The range of
dependence of the PRE [acc. to Grfen/Kuron] chemical composition of a 1.4462 duplex steel is marked.

Critical pitting temperature CPT (C) NiEq = % Ni + 30 . % C + 0.5 . % Mn

100 30
te
28 rri
26 Fe
80
X 3 CrNiMnMoNbN 23 17 5 3
24 0% %
5
1.4529 Austenite %
22 Au 10
20 + Msten 20
%
60 18 art ite
en %
1.4462 16 sit 40
1.4439 1.4563 e
14 Austenite + Ferrite
1.3964 80 %
40 12
A
1.4539 10 + uste
1.4436
8
Martensite
+ FMar nite 100 %
1.4429 err ten
20 6 Martensite ite site
FeCl3 6 H2O 10 % w/w 4 + Ferrite
1.4435
1.4404 Test duration: 24 h 2 Ferrite
0 0
25 30 35 40 45 50 55 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Pitting resistance equivalent CrEq = % Cr + % Mo + 1.5 . % Si + 0.5 . % Nb + 2 . % Ti

PRE = % Cr + 3.3 . % Mo + 30 . % N Boundaries of analysis for duplex steel 1.4462

3
1.2 Filler materials corrosion resistance as the unaffected parent metal. Mechanical
properties are often also impaired. A disposition to form eliqua-
As a rule, the filler materials used for the welding of duplex steels tions and an increase in grain size are the reasons for this.
are of the same type as the base material. The filler material is
usually 2 4 % higher in Ni-content than the base material. This Whenever a Duplex- or Superduplex weld joint has to meet the
is to provide a well-balanced austenite ferrite ratio in the weld highest demands in terms of corrosion resistance and mechani-
metal through the austenite-supporting effect of nickel. This cal properties, the use of an overalloyed filler material is advis-
ratio would be excessively shifted to the higher ferrite content able. SG-NiCr20Fe14Mo1WN (FM 50, 2.4849, UNS NO6650) is
side due to the high cooling rates encountered in welding. Table 3 an example of such an alternative. This Ni-based alloy with a
gives a brief overview of common Duplex filler metals and their PRE between 55 and 60 provides highest resistance against
composition. stress corrosion cracking and pitting, combined with mechanical
properties similar to those of common Duplex- and Superduplex
Occasionally, particularly for welding the root pass on the 22 % steel grades [4, 5, 6].
Cr steels, filler materials with a higher Cr content are used with
the aim of improving the pitting corrosion resistance [1]. It 2. Welding procedures and techniques
must, however, be borne in mind that these filler materials, just
like the respective base materials, are more prone to producing 2.1 General recommendations
intermetallic phases. Thus, impact toughness may be impaired,
and therefore welding parameters must be carefully selected and Due to their chemical composition, duplex steels are susceptible
closely controlled. Table 2 provides an overview of the possible to the formation of precipitations if they are exposed to excessively
combinations of base and filler materials. high temperatures for too long a time. Here it is important to
mention the 475 C-embrittlement and the formation of sigma-
Table 2: Recommended combinations of base metal and and chi-phases. The risk of such phenomena increases with
filler metal higher Cr contents. Therefore, service temperature for duplex
steels is limited to 250 C and for super-duplex steel to 220 C [3].
Material Filler material
number ~1.4462 ~1.4410 ~1.4501 ~2.4849 The heat input that is encountered during welding may impair
1.4362 + + + corrosion resistance and mechanical properties, particularly
1.4410 + + + when interpass temperatures are specified too high, or if due to
1.4460 + + + + the particular shape of the workpiece, the heat cannot be carried
1.4462 + + + off efficiently. So a general requirement is to apply the lowest
1.4501 + + + possible heat input during welding. Opposite requirements, i.e.
1.4515 + + + higher temperatures and lower cooling rates, would be neces-
1.4517 + + + sary for the best transformation properties of these materials.
Since the solidification is primarily ferritic, and transformation
Filler materials for TIG and MIG welding are essentially the into austenite happens in the solid state, too high a cooling rate
same. While in GMAW it is basically not possible to weld with- may partially suppress formation of austenite, leading to an
out a filler wire, in TIG welding it is feasible under certain con- unwanted and increased content of ferrite in the weld metal.
ditions to make a joint without applying a filler material, provided
that special shielding gases are used. Thus an acceptable aus- The upper limit for the heat input is thus defined by the start of
tenite-ferrite ratio in the weld deposit can be maintained (see intermetallic phases formation, while the lower limit is set by
section 4). the requirement to provide an acceptable austenite-ferrite ratio.
In the references, different values for the line heat input, a mea-
Due to the unfavourable heating and cooling conditions during sure for the total heat input, may be found. For example, in [1] the
welding, similar filler materials usually do not provide the same recommended linear energy input ranges from 5 to 25 kJ/cm for

Table 3: Commonly used filler metals for duplex steels

Filler DIN-Designation Chem. Composition in % PRE

metal C Cr Ni Mo N Mn Other ()
~1.4462 SG X2 CrNiMoN 22-9-3 < 0.025 23.0 9.0 3.0 0.14 1.6 37
~1.4410 SG X2 CrNiMoN 25-9-4 < 0.020 25.0 10.0 4.0 0.25 0.4 46
~1.4501 SG X2 CrNiMoCuWN 25-9-4 < 0.020 25.5 9.5 3.7 0.22 1.5 Cu: 0.8 / W: 0.6 44
2.4849/alloy 50 SG-NiCr20Fe14Mo1WN < 0.020 19.021.0 Bal. 10.012.0 0.050.15 < 0.5 W: 1.02.0 60

4
a duplex steel with approximately 22 % Cr, while in [2] a range of
715 kJ/cm is given. Due to the fact that there is a wide range of
possible parameters, there is no general recommendation in
terms of most appropriate values. For each particular job, appro-
priate parameters should be chosen and tested.
2.2 t12/8 -time
Besides considering the linear energy input, there is also the
concept of t12/8 -time for describing the cooling conditions. The
t12/8-time denotes a time required for cooling down the welding
point from 1,200 C to 800 C. This method of determining the
cooling conditions is generally rather complicated, since it is
done applying thermo-couples which are introduced into the
welding pool. An acceptable value for the t12/8-time range of
approximately 10 s is given [2]. If the value is within this range,
acceptable properties of material would be achieved.
2.3 Preheating and interpass temperatures
As a rule, preheating of the base material is not generally re-
quired. If it is taken into consideration that significant ferrite-aus-
tenite transformation occurs in the temperature range between
1,200 C and 800 C, a preheating temperature of 200 C maxi-
mum cannot essentially decrease the cooling rate. On the con-
trary, the cooling time in the temperature range between 800 C
and 500 C will be increased, and in this range major precipita-
tion processes occur. For this reason, preheating is likely to have
a negative effect [1].
Preheating temperatures exceeding 150 C must be avoided in
any case, since the base material is not protected against precip-
itate formation. For the same reasons, in multipass welding, the
interpass temperature of 150 C must not be exceeded.
dioxide are generally applied. In comparison with the gases used
for welding of unalloyed steel, the content of active gases is
lower. Argon-oxygen gas mixtures (the most common percent-
age of oxygen is between 1 % and 3 %) produce very stable electric
arc and spatter-free processes. In comparison with the Ar-CO2
mixtures, the penetration pattern is less convenient and the weld
surface is more oxidized. The penetration depth might be
increased by applying higher oxygen content, but then oxidation
of the joint surface is stronger. For this reason, Ar-CO2 gas mix-
tures with a CO2 content of 2 %3 % are widely used. Carbon
dioxide produces deeper penetration with lower oxidization
(Figure 4).
Further improvement may be achieved through the addition of
helium to the gas mixture. Compared to argon, helium has a
higher thermal conductivity and a higher ionization potential. It
provides favourable and smooth blending of the weld joint pro-
file. In comparison with pure argon or Ar-CO2 gas mixtures, the
higher arc voltage means that the input energy is significantly
greater using the same parameters, Figure 4. This can be advan-
tageous, particularly if the requirement for a balanced
ferrite/austenite ratio is considered.
Figure 4: Influences of shielding gases on weld geometry,
penetration profile and linear energy, spray arc mode
Filler wire diameter:
1.2 mm
Parent metal:
1.4462
Filler metal:
~ 1.4462
Wire feed speed:
8.5 m/min

Welding speed:
3. Shielding gases for GMAW 59 cm/min.
Plate thickness:
8 mm
Generally the same shielding gases are used for the welding of
duplex steel as for the austenitic steels (see Table 4). Shielding Gas Ar+3 % O2 Ar+2.5 % CO2 Ar Ar+25 % He
Voltage (V) 28 29 31 34
MIG welding under pure argon is hardly used anymore, since Current (A) 250
the arc is unsteady and the penetration is poor. Active gas mix-
tures rich in argon and containing additions of oxygen or carbon
Energy [ ]
kJ
cm
7.1 7.4 7.9 8.6

Table 4: Shielding gases for MAG welding of duplex steels

Name EN439 AWS A5.32 Composition in vol. %

Ar He O2 CO2
CRONIGON 2 M 12 SG-AC-2.5 Bal. - - 2.5
CRONIGON He 20 M 12 (1) SG-AHeC-20/2 Bal. 20 - 2
CRONIGON He 50 M 12 (2) SG-AHeC-50/2 Bal. 50 - 2
CRONIGON S 1 M 13 SG-AO-1 Bal. - 1 -
CRONIGON S 3 M 13 SG-AO-3 Bal. - 3 -

5
4. Shielding gases for TIG welding
Compared to the MAG process, heat input during TIG welding
is controllable in a wider range. However, the rules already
described regarding the linear energy input and cooling rate are
valid here too.
The standard shielding gas for TIG welding of duplex steels is
pure argon. With this gas the majority of welding jobs may be
performed safely and cost-effectively. Argon/hydrogen mixtures
that are frequently used for welding of austenitic steels with the
aim of increasing welding speed, are not recommended, because
under certain circumstances hydrogen-induced cracking may
appear due to the high ferrite content in the material.
Argon/helium mixtures offer increased heat input, particularly
advantageous for the duplex steels, and this has a favourable
effect upon the viscosity of the base material and provides a
wider range of acceptable welding parameters. Arc voltage and
linear energy input are also increased as the content of helium
is raised. An overview of shielding gases used for TIG welding
of duplex steels is given in Table 5.
Duplex steels are TIG welded applying filler material in most
cases. Duplex filler material usually contains a slightly higher
percentage of Ni than the base material. As contrasted with the
MAG process, in certain cases the use of filler material may be
avoided, for example for butt welds of thin sheets. The advantage
in such cases is that the welding speed may be increased if filler
material is not applied. This leads to shorter welding times,
resulting in cost reduction. This welding technique is possible
through the use of nitrogen-containing shielding gases. While
the increased content of Ni in the filler material provides a bal-
anced ferrite/austenite ratio, this task is taken by nitrogen from
the shielding gas during welding without filler material. Nitrogen
is a strong austenite-forcing element, and during welding it is
introduced into the base material, stimulating the formation of
austenite there. In any case, it should be noted that electrode
wear is more intensive because of the nitrogen content, i.e. the
electrodes have to be ground more frequently than if welding is
carried out in a pure argon shield.
Table 5: Shielding gases for TIG welding of duplex steels
Name EN439 AWS A5.32
Argon I1 SG-A
VARIGON He 30 I3 SG-AHe-30
VARIGON He 50 I3 SG-AHe-50
VARIGON He 70 I3 SG-AHe-70
VARIGON N 2 S I 1 + 2 N2 SG-AN-2
VARIGON N 3 S I 1 + 3 N2 SG-AN-3
VARIGON N He S I 3 + 2 N2 SG-AHeN-20/2
6
5. Application examples
As an example, N-containing shielding gases have already been
used in orbital TIG welding of tubes made of grade 1.4462
duplex steel, (Figure 5). The wall thickness of the tube was 2 mm,
outer diameter was 54 mm. Welding without filler material has
been applied. Measurement of ferrite content in the weld metal
was not conducted by metallographic examination, but with a
magneto-inductive method instead. The values of mean ferrite
content presented may only be taken as indications of tendencies.
It is noticeable how strong nitrogen reduces ferrite content in
the weld metal in comparison to pure argon, and, on the other
hand, how the addition of helium (VARIGON N He) stabilizes
the welding process and improves fusion.
The second example involves welding an overlap joint without
filler material, again on the 1.4462 duplex steel grade. In this
particular case, welding was performed applying a shielding gas
containing 10 % of N2 (balance was Ar). The effect of the nitrogen
may be easily recognised, as presented in Figure 6. The contrac-
tors requirements for this application were that ferrite content
in the weld metal should not exceed 70 %, and this target was
achieved by using VARIGON N shielding gas. A cost analysis
pointed out that the achieved increase in welding speed from
7 cm/min to 13 cm/min provided a significant cost cut. Addition-
ally, a content of nitrogen in the shielding gas can improve the
corrosion resistance according to the CPT-test.
6. Shielding gases for root protection
To retain the corrosion resistance of duplex steel, proper root
shielding must always be applied. If an appropriate shielding
gas is applied for the root side, air is removed from the root and
the formation of a corrosion-inducing layer of tarnish is effec-
tively reduced or suppressed. Generally, the same gases may be
used for root shielding as for the austenitic grade steels. However,
in this case too, the hydrogen content of the root shielding gas
must be limited because of the higher content of ferrite in the
base material, to exclude the danger of hydrogen-induced crack-
ing. Therefore, argon and nitrogen, or their mixtures could be
Composition in vol. %
Ar He N2
100 - -
Bal. 30 -
Bal. 50 -
Bal. 70 -
Bal. - 2
Bal. - 3
Bal. 20 2
used. To further eliminate tarnish and improve corrosion resist-
ance, the residual oxygen must not exceed a concentration of 30
ppm at the root side. There is a general rule that pitting corrosion
resistance increases with lower residual oxygen on the root side
[1]. Appropriate devices for the measurement of residual oxygen
are available on the market.
7. Conclusion
Due to their two-phase microstructure consisting of ferrite and
austenite, duplex steel grades possess excellent mechanical and
technological properties and corrosion resistance. Particular
attention should be paid to heat input, selection of filler materi-
al and shielding gas in order to retain these interesting pro-
perties in gas shielded arc welding processes. The most impor-
tant requirement for welding is to provide the most balanced fer-
rite-austenite ratio in both the weld metal and the heat-affected
zone. The linear energy input and interpass temperature must
be limited. Generally, filler materials of identical or similar com-
position should be selected. Ar-CO2 or Ar-He-CO2 gas mixtures
are applied for GMA welding, while for TIG welding Ar, Ar-He
or Ar-He-N2 mixtures may be used.
In certain cases, the use of filler material may be omitted in TIG
welding, resulting in certain cost reducing effects. In such cases,
shielding gases should contain nitrogen.
8. References
[1] Noble, D.N., Gunn, R.N.: Welding of duplex stainless steels.
A readers digest. Stainless Steel Europe, August 1992.
[2] Geipl, H.: MAGM Welding (GMAW) of Corrosion Resistant
Duplex Steels 22 Cr 5 (9) Ni 3 Mo. Effect of Shielding Gas
and Process Variations. Linde Special Edition No. E 146,
Hoellriegelskreuth, 1989.
[3] Folkhard, E.: Metallurgie der Schweissung nichtrostender
Sthle. Wien, New York: Springer Verlag, 1984.
(Folkhard, E.: Metallurgy of the welding of non-corrosive
steels. Vienna, New York: Springer Verlag, 1984.)
[4] N.N.: Nicrofer 5020 hMo alloy 50 plus, Thyssen Krupp
VDM GmbH. Material data sheet No. 4144, April 2000.
[5] N.N.: Material data sheet UTP A 5020 Mo. UTP Schweiss-
material GmbH & Co. KG, Bad Krozingen. September 2001.
[6] Brill, U., Heinemann, J.: Corrosion behaviour of alloy 50
weldments. Presentation held at the Corrosion 2001 confe-
rence, USA. Paper No. 01483.
9. Author

Thomas Ammann, Grad. Degree in Engineering, Linde AG,

Linde Gas Division, Unterschleissheim, Germany.

Figure 5: Application example TIG-orbital welding with Figure 6: Application example overlap weld with N2-con-
N2-containing gases, without filler metal taining gases, without filler metal

Material:
Ferrite content in weld metal (%)
1.4462/AISI 2205 Plate 2.0 mm
(X2 CrNiMoN 22-5-3) Thickness: 1.5 mm
Workpiece dimensions: Material: 1.4462
Pipe 54 x 2 mm 90 %
Welding process: 80 %
Permissible Ferrite content

TIG-orbital, pulsed, I-joint, 75 71 70

w/o filler metal 70 % 74 70 %
65
Welding speed: 68 60
4.5 cm/min. 60 %
62 61 60
Pulse frequency: 51
50 %
2.2 Hz 50
Base-/Pulse current:
40 %
30A/60A

Shielding gas Argon VARIGONN3 VARIGONN He 30 % 30 %

Root protection Argon Nitrogen Nitrogen

20 %
Mean ferrite content* 58.4 % 42.8 % 48.3 % Base Argon VARIGON N3 N5 N10
*NDT, measured with a magneto-inductive measuring device material N2

7
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