Duplex and Super Duplex Cast Stainless steels

Elaine Thomas Director of Metallurgy Bradken-Atlas Tacoma, Washington

Welcome to the world of Castings

When metal solidifies it crystallizes.

Body Center Cubic = Ferrite

Face Centered Cubic = Austenite

Microstructure
Austenite Formers:
Carbon Nickel Nitrogen Manganese

Ferrite Formers:
Chromium Silicon Molybdenum Niobium (Columbium)

Schoeffer diagram
ASTM A800 VOLUME PERCENT FERRITE (SCHOEFFFER)
Cr e = %Cr + 1.55Si + 1.4Mo + Cb - 4.99 Ni e = %Ni + 30*C + 0.5*Mn + 26(N-0.02%) +2.77
80 70 60 50 40 30 20 10 0 0.9 1.1 1.3 1.5 1.7 1.9 2.1

x = CRe/NIe

COMPOSITION RATIO

 Mars Fontana Looking for a more corrosion resistant stainless steel alloy than 17-4-PH Using 17-4 as a starting point he invents CD4MCu

First Duplex stainless steels

Notice how CD4MCu is related to 17-4 PH The nitrogen was not added to CD4MCu until the 1970s. AOD enabled nitrogen to be added easily.
MO 17-4 PH CD4MCu 2.0 CR 17.0 24.0 NI 4.0 4.8 CU 2.8 2.8 N% 0.1800

Duplex Stainless Steels are made of Ferrite and Austenite

100X CD4MCuN or 1B Bradken-Atlas 11

Austenite + Ferrite = Great Stuff!

Better Stress-Corrosion Cracking (SCC) resistance than Austenitic (CF or 300 series) Better pitting & crevice corrosion resistance Higher Strength than Aus SS (CF or 300 series) Better resistance to embrittlement than Martensitic (CA or400 series) (e.g. more weldable)

Duplex SS has higher strength than Austenitic SS: CF8 Tensile ksi min 70 Yield ksi min 30 CD4MCu 100 70

CD4MCu the early years

The alloy is brittle in the un heat treated condition Poor weldability Cracked in service

AOD improves CD4MCu

Adds nitrogen making it Weldable, strong, and increases pitting and crevice corrosion Low sulfur improves toughness, ductility, and weldability Clean steel

Sigma - Ferrites Mr. Hyde

Very Brittle!!! Sigma forms between 1200 and 1700F. The microstructure may appear to have a ferrite matrix, but when etched it may appear blue. Ferrite Scope notices that the ferrite is missing!

Heat Treating Duplex

Need a hot temperature and plenty of time at that temperature to dissolve the sigma 2075F 3 to 5 hours water quench

Sigma & Alpha prime Phases

Forms between 1200F and 1800F. Alpha Prime forms from 885F Very Brittle! Spend as little time in these ranges as possible. Brittle phases will dissolve above 1900F.

Microstructure of Duplex SS 400X KOH stain

Austenitic Pools in a Matrix of Ferrite 40 to 60% Ferrite

Greatly improved corrosion resistance over the CF/300 series- especially in Chlorides With the strength of the martensitic - CA;400 series

 Cast Duplex grades

1A no Nitrogen! 25Cr-5Ni-Mo-Cu 1B 25Cr-5Ni-Mo-Cu-N 2A 24Cr-10Ni-Mo-N 3A 25Cr-5Ni-Mo-N 4A 22Cr-5Ni-Mo-N

Lean grade low Mo 1B 2205 work horse 4A 22Cr-5Ni-Mo-N Super duplex

Duplex have better Corrosion Properties than the Austenitics

SCC Pitting Chloride H2S Acids

Pren = Cr + 3.3MO + 16N

When Pren is > 40 the duplex stainless steel is considered to be a super duplex. Pren means pitting resistance number Nitrogen levels about 0.15% to 0.25%

Bradken-Atlas

23

Super Duplex
5A and 6A Higher Mo Much better corrosion resistance to Cl at hotter temperatures - up to 50C. Hotter than this - go to Super Austenitic SS

 Super Duplex grades

5A 25Cr-7Ni-Mo-N 6A 25Cr-7Ni-Mo-N-W

Super Austenitic Stainless 6% Mo

CK3MCuN 904L CN3M (alloy 20) OK in section thickness under 6 inches Over 12 inches the solidification encourages segregation and thus sigma. Pour very cold to lessen the amount of sigma.

Super Austenitic SS

CN3M 21CR-24Ni-6Mo-N CK3MCuN 23Cr-21Ni-6Mo-N

63-25-30 80-38-35

Duplex Stainless Steels Currently Produced

Cast Specifications Grade 1A 1B 3A 4A CD3MN CD4MCu CD6MN ASTM A890 A890 A890, A995 A890, A995 A890, A744 A890, A995 A351 A995 UNS J93370 J93372 J93371 J92205 J92205 J93370 J93372 J93371 Wrought Specifications AISI UNS 957 957 963 959 959 957 963 Atlas Alloy

2205 2205

S31803 S31803

Super Duplex Grades

Cast Specifications Grade 5A 6A CD3MWCuN CE3NM ASTM A890, A995 A890, A995 A890, A995 A890, A995 UNS J93404 J93380 J93380 J93404 Wrought Specifications AISI 2507 Zeron 100 Zeron 100 2507 UNS S32750 S32760 S32760 S32750 Atlas Alloy 958 962 962 958

Thank you!

Forging wrought steel

By rolling steel the grains of crystals elongate Even if the plate is re heat treated after rolling to eliminate elongated grains, the metal remembers the directionality.