DUPLEX

STAINLESS STEEL



















High performance laser fused Structural Sections



Duplex
High performance laser fused Structural Sections


Introduction
Stainless steels are used predominantly for their corrosion resistance in moderate to highly aggressive
environments. For construction purposes, carbon steel normally is the common choice due to low cost,
long experience, applicable design rules and a large variety of strength classes. However, different
stainless steel types can also provide a very wide range of mechanical properties and they have the
advantage of no need for surface protection. Duplex stainless steels in particular, with twice the
mechanical strength of conventional austenitic and ferritic stainless steels, have a potential for use in
constructions. Since the introduction of this family of steels about seventy years ago, they have been
used widely.
Duplex has been used or is being considered as substitutes for stainless steel types 304L, 316L, 904L or
254SMO depending from environment and corrosion aspects. Some examples of industry end uses are
structural supports for offshore oil & gas industry, chemical process industry, desalination and water
treatment, chemical tankers, architecture, building & construction, pulp and paper industry, pollution
control, etc. The list keeps growing as more industries become aware of the advantages of Duplex.


Laser fusion of structural sections in Duplex

Laser fusion of Duplex differs substantially from the
process used for austenitic stainless steel grades. While the
process parameters vary only slightly, the big difference
lies in the microstructure that results from the ultra-rapid
cooling of the weld pool.

It is characteristically for duplex grades to roughly have a
50% austenitic and 50% ferritic microstructure. The
alloying elements are balanced in order to achieve this
distribution after a classical solution annealing treatment.
There is a certain variance in the distribution and up to a
65:35 ratio in favour of one or the other of the two
microstructures is considered normal.

During laser fusion the base material melts and then
solidifies extremely rapidly. The cooling speed normally is
in excess of 500C/s, which means that the segregations
found with conventional welding methods are totally
avoided when using laser fusion. On the other hand, this
same rapid cooling rate could cause a preference for the
ferritic microstructure if not counterbalanced.

Fig. 2 Laser fused Duplex beam
Corrosion resistance of structural sections in Duplex

Thanks to technical improvements in this field, today the classical balanced duplex microstructure is
achieved without the necessity of a final solution annealing. In an as welded condition the corrosion
resistance of the weld and heat affected zone of a Duplex structural sections produced by laser fusion is
equivalent to a hot rolled or extruded structural section.

Duplex resistance to localized corrosion, such as pitting and crevice attack is extremely performing. A
numerical relationship between pitting resistance and alloying content has been developed to compare
stainless steels (Fig.1). This is known as pitting resistance equivalent number or PRE
N
(PRE
N
= Cr + 3.3
x %Mo + 16 x

Duplex
High performance laser fused Structural Sections


Fig.1 - Pitting and crevice corrosion resistance


Chemical analysis PRE
N
Grade type (EN)
C
max
Cr Ni Mo N
max
average
304L (1.4307) 0,03 17,5-19,5 8,0-10,0 --- 0,11 18
316L (1.4404) 0,03 16,5-18,5 10,0-13,0 2,0-2,5 0,11 24
904L (1.4539) 0,02 19,0-21,0 24,0-26,0 4,0-5,0 0,15 36
254 SM0 (1.4547) 0,02 19,5-20,5 17,5-18,5 6,0-7,0 0,25 >40
2101 (1.4162) 0,04 21,0-22,0 1,35-1,7 0,1-0,8 0,25 26
2304 (1.4362) 0,03 22,0-24,0 3,5-5,5 0,1-0,6 0,20 26
2205 (1.4462) 0,03 21,0-23,0 4,5-6,5 2,5-3,5 0,22 35
2507 (1.4410) 0,03 24,0-26,0 6,0-8,0 3,0-4,5 0,35 >40



Mechanical properties of structural sections in Duplex


Fig. 3 Crash test on laser fused beam
Laser fused structural sections have a monolithic structure
with a controlled area of heat input and a small, barely
noticeable seam at the juncture of the components.
Extensive destructive testing has shown that the fracture
points in laser fused sections rarely lie in the weld area
itself. External stresses and loads applied to the sections
are transmitted to the neighbouring parent material, which
then fails according to its own mechanical characteristics
(Fig. 3).
The mechanical characteristics of the weld and heat
affected zone of laser fused structural sections in Duplex
are no constraint in industrial applications.

All Duplex grades feature significantly better mechanical properties than common austenitic stainless
steels (see Fig. 4). Wear resistance and especially fatigue strength, which becomes an important
material property in structures where dynamic loads are present, are all closely related to yield
strength.

Fig. 4 Mechanical properties according to EN 10088


Tensile Strength
Rm N/mm
2

Yield Strength
Re 0.2% N/mm
2

Elongation
A5%
Hardness
Brinell
Grade type (EN) Min. Min. Min. Max.
316L (1.4404) 500 200 45 217
2101 (1.4162) 650 450 30 290
2304 (1.4362) 630 400 25 290
2205 (1.4462) 640 460 25 290
2507 (1.4410) 730 530 20 290
Duplex
High performance laser fused Structural Sections


Cost saving potential of structural sections in Duplex

The higher yield properties of Duplex are therefore an advantage for structural applications (see
Eurocodes for the design of steel structural). In the specific case of sections like beams, channels or
angles, Duplex offer a huge cost saving potential by using lighter sections without decreasing the
structural performance. The following charts show the cost saving potential of structural sections made
of Duplex type 2205 compared to structural sections in type 316L. Figure 6 shows the improved
buckling load of Duplex

compared to standard austenitic stainless steel. E.g. in case of a 12 feet long
W8x48 beam, Duplex 2205

can bear a 55% higher load compared to the same beam size in type 316L.


Fig. 6

















This means that Duplex

can reduce, under the same buckling load, the weight of an austenitic stainless
steel section by e.g. 35% using a W8x31 beam instead of a W8x48 at a bar length of 10 feet (Fig. 7).


Fig. 7















316L
316L
2205
2205
-- W8x48 2205
-- W8x48 316L
Duplex
High performance laser fused Structural Sections


The following chart (Fig. 8) clearly shows the advantages of higher yield properties in structural
sections based on single span performance. E.g. a W8x15 in Duplex

achieves the same structural
performance like an W8x28 in standard austenitic stainless steel.


Fig. 8





















This means that, under the same span load, the material saving potential of Duplex

is 50% compared
to austenitic stainless steel beams on a bar length of 16 feet (Fig. 9). By comparing the tension tie of
Duplex 2205 with type 316L the material saving is as well 50% by using lighter section with the same
structural performance (Fig 10).

Fig. 9





















Fig. 10










W8x24*
2205
W8x24*
2205
W8x24*
316L
W8x24*
316L
-- 2205
-- 316L
Duplex
High performance laser fused Structural Sections




Available structural sections in Duplex

The following structural sections are all available laser fused:

Equal angles
Unequal Angles
Channels
H Beams
I Beams
Tees


Standards & approvals

ASTM A240 - Plate, sheet &
strip
ASTM A276 - Bars & shapes
ASTM A479 - Bars for boilers
and other pressure vessels
ASME Code Case 2418 - Plate,
sheet and strip
EN 10088(1-5) European
standards for stainless steel
for general and construction







Conclusions

Switching to smart alloys like Duplex offers economic value in terms of reduced raw material surcharge
as well as improved mechanical properties.
Structural sections like beams, channels and angles made of Duplex achieve higher performance at a
lower cost. Duplex sections satisfy the needs of the engineers and designers for light and cost-effective
structures in stainless steel, which fulfil at the same time the criteria of safety and durability.












Europe:
Montanstahl AG fon +41 91 6416800
Via Gerrette 4 fax +41 91 6416801
6855 Stabio info@stainless-structurals.eu
Switzerland


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Stainless Structurals, LLC fon +1 904 781 6447
590 Beautyrest Avenue fon +1 877 739 6057 (Toll free)
Jacksonville fax +1 904 781 6444
32254 - Florida info@sss.usa.com
USA


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18 Boon Lay Way fax +65 6570 8912
Tradehub 21, #10-139 sales@ssasia.sg
Singapore 609966
Singapore
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