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Duplex Stainless Steel Alloying Properties Piping Welding
Alloying Properties
Elements content of different types of duplex stainless steel
Chromium Nickel Molybdenum Nitrogen Manganese Copper Tungsten Carbon
Hyperduplex
27%
6.5%
5%
0.4%
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Chromium
There is a maximum limit to the chromium content of approximately 30%, where intermetallic phase precipitation can markedly reduce the ductility, toughness and corrosion resistance of these alloys. Chromium increases the pitting potential, the critical pitting temperature(CPT) and the critical crevice temperature(CCT), and improves the passive film stability in acidic environments.
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Nickel
Nickel is a strong austenite stablizer and is a principal addition to austenitic stainless steels. Nickel alloying is generally detrimental to crevice corrosion resistance in sodium chloride, and beneficial or without effect in pitting tests. In the duplex stainless steel, however, the main role of nickel is to maintain the ferrite-austenite balance, rather than modifying the corrosion resistance. Low nickel levels can result in formation of a high proportion of ferrite, thereby lowering toughness. Consequently most consumables for welding duplex stainless steels are over-alloyed to contain 7-10% of nickel.
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Molybdenum
Molybdenum is a ferrite stabilizing alloying element with a strong beneficial influence on general and pitting corrosion resistance and on the passivation properties. Molybdenum is favourable in most environments, but in strongly oxidising environments, such as warm concentrated nitric acid, grades containing molybdenum are less resistant than stainless steels without molybdenum. The addition of molybdenum should not exceed approximately 4% since it makes the material more susceptible to intermetallic phase precipitation by widening the sigma phase field.
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Nitrogen
Nitrogen is an interstitial element that stabilizes the austenite and has strong influence on several properties such as pitting corrosion, presence of molybdenum. The duplex grades consequently contain up to 0.4% nitrogen to give improved austenite formation when welding. Nitrogen significantly increases the strength of the duplex stainless steels, but also improves the ductility and toughtness of the alloy. Nitrogen delays the formation of intermetallic phases in duplex stainless steels in a similar way as in austenitic grades.
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Manganese
Manganese stabilises austenite and can partly replace nickel. Additions to stainless steel have been used to increase the solubility of nitrogen, which have a strong beneficial influence on the pitting resistance. It has been reported that manganese itself has a negative effect on the pitting resistance, but combined additions of nitrogen and molybdenum override this effect. Replacing nickel with manganese and nitrogen makes the price of the material more stable since the nickel price has fluctuated significantly.
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Copper
Copper is added to highly corrosion resistant austenitics and duplex grades to further improve the corrosion resistance in, for instance reducing acids such as dilute sulphuric acid.
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Tungsten
Tungsten has become more commonly used as an alloying element in commercial stainless steels where it is used as a compliment to molybdenum for improved corrosion resistance. When used in the PRE expression, the factor for tungsten is approximately half of that for molybdenum. Tungsten has, howerver, also been reported to promote formation of intermetallic phases and cause a more rapid embrittlement thatn molybdenum.
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Carbon
In most modern duplex alloys carbon is limited to levels of 0.03wt% to minimize the risk of formation of chromium carbides and thereby reduce the susceptibility of the duplex stainless steels to intergranular corrosion.
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Mechanical Properties
Yield 50ksi (345MPa) 25ksi (170MPa) 58ksi (400MPa) 65ksi (450MPa) 80ksi (550MPa)
Tensile 70ksi (485MPa) 70ksi (485MPa) 87ksi (600MPa) 90ksi (620MPa) 116ksi (800MPa)
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Physics Properties
Type
Density /g.cm-3
Resistivity /.cm
Magnetism
7.64 7.98
0.10 0.75
YES No
447 502
51(100C) 16.3(100C)
S32304
S32205 S32750
7.75
7.80 7.79
0.80
0.80 0.80
YES
YES YES
482
500 485
13.0(100.C)
13.0(100.C) 13.0(100.C)
17.0(100C)
17.0(100C) 17.0(100C)
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Pipe Welding
General Welding Guidelines Welding Procedure Qualification Welding Methods Post Fabrication Clean-up
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This material technical sheet is intended to supplement existing material standards and specification (eg., ASTM, ISO UNS) and project specifications for duplex stainless steel Materials supplied in accordance to this specification shall only be supplied by company approved manufacturers ASTM A789/ A789M UNS S31803 ASTM A790/ A790M UNS S31803
Electric arc or electric furnace and refined by AOD or equivalent process All material shall be delivered in the solution annealed (followed by water quench) condition Pitting Resistance Equivalent (PRE)=Cr+3.3Mo+16N. The PRE shall be greater than or equal to 34.0
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Per ASTM standard. If no harness required by ASTM standard, maximum shall be HRC28, HB271, or HV290 - Charpy V-notch (ASTM A370) -Not applicable when the maximum obtainable charpy specimen has a width along the notch of less than 2.5mm -Absorbed energy shall be 48J average and 36J single value minimum -Test temperature shall be minus 46 deg. -Specimens shall be oriented transverse to the rolling direction - Charpy V-notch (ASTM A370) -Not applicable when the maximum obtainable charpy specimen has a width along the notch of less than 2.5mm -Absorbed energy shall be 48J average and 36J single value minimum -Test temperature shall be minus 46 deg.
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Ferrite Content
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-Samples shall be etched using ASTM E407 etchant number 98 (K3Fe(CN)4 with KOH or NaOH) -Sample cross section shall be examined at OD, ID and Mid-wall locations -Examination shall be conducted at a minimum of 500X magnification. -Intermetallic phases or precipitates are allowed up to a max. of 0.05 percent. -All testing shall be conducted on a lot basis. A lot is defined as the same tubing diameter, thickness, heat and heat treatment charge, up to a maximum of 125 tubes. - All testing shall be conducted on a lot basis. A lot is defined as a maximum of 60 meters of pipe of the same diameter, thickness, heat and heat treatment charge.
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-10% of all tubes shall have ferrite content determined by fischer ferrite scope -Measurement technique shall be in accordance with company approved procedures -Ferrite content shall be between 35% - 55%
-In accordance with ASTM A789/ A789M and ASTM A450/ 450M -Weld repair of defects is not allowed -White Pickled
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-Product shall be handled, shipped and stored in such a manner as to prevent or minimize the possibility of free iron contamination -Product shall not be handled with bare steel hooks, chains or lifting forks without the use of protective insulating material -Only stainless steel wire brushes, designated for use only on stainless steel products, may be used for brushing and descaling -Suspected free iron contamination, such as evidenced by unusual stains or discoloration, shall be verified by ferroxyl testing in accordance with the procedure outlined in ASTM A380 -Free iron contaminated areas shall be cleaned and passivated, at the manufacturers expense, using the procedures outlined in ASTM A380 -EN10204 3.1B
Certification
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Material Receving
Material certificate review Physical check including magnetic check or PMI as required. Application of Material Traceability Number (MTN) To use chloride-free pen/marker suitable for stainless steel
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Facilities
Clean area with metallic iron dust free environment Non-carbon steel covering for all work surfaces To put neoprene rubber cover on flange end To put plastic end cap(pipe), prior to leave work.
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Tools
Stainless steel compatible files, grinding disc, wire brushes, saw blades etc. Cold cutting & beveling machine
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Woods/ Rubber Racks All Pipes/ Tubes to be Fitted with End Caps
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String
Acetone
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8 8
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Sponge Pluge
Acetone
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Acetone
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Acetone
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Acetone
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Thermal
Plasma cutting Laser cutting
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Sawing
Similar with austenitic stainless steel Powerful machine Proper blade alignment Coarse toothed blade Slow to moderate cutting speed Heavy feed Generous flow of coolant
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Shearing
More force and heavier equipment will be required to shear stainless steel compared to carbon steel Carbon steel thickness shear limit Austenitic stainless steel max thickness shear limit Duplex stainless steel 3/16 max. A general clearance guide is to use a clearance of 5% of the metal thickness between shear knives To counter the shearing force required for duplex stainless steel, the hold down pressure on the clamps may have to be increased Blades must be sharp
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Abrasive Cutting
Abrasive wheels, rotating at high speed can be used for straight line cutting of sheet and thin gauge plate and for cut-off operations on relative small sections. Thick section cut-off operations are usually done wet Use uncontaminated vitrified or resin-bonded wheels Do not induce over-heating
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Same equipment as for 304/316 Optimum parameter vary slightly Two types of plasma cutting machine
Mainly advantages of second one:
The nozzle can be recessed within a ceramic shield gas, thereby protecting the nozzle from double arcing, if no shield gas were present, the ceramic shield gas cup could be deteriorated because of the high radiative heat produced by the plasma jet. It can protect the cutting surface from oxidation caused by oxygen.
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a. Dual flow plasma cutting power source c. Cutting surface without oxidation d. Secondary shielding gas
b. Dual flow plasma cutting machine d. Cutting gas e. The sketh of dual flow plasma arc
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Joint Design
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Preheating
Preheating may be only beneficial when used to eliminate moisture from the steel as may occur in cold ambient conditions or from overnight condensation. When preheating to deal with moisture, the steel should be heated to about 100 deg. Uniformly and only after the weld preparation has been cleaned.
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150 deg of maximum interpass temperature for lean and standard DSS, 100 deg for SDSS
To avoid problems in the HAZ, the weld procedure should allow rapid cooling of this region after welding. The temperature of the work piece is important because it provides the largest effect on cooling of the HAZ.
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PWHT
PWHT is not need
It is likely to be harmful because heat treatment may precipitate intermetallic phases or alpha prime embrittlement casuing a loss of toughness and corrosion resistance. PWHT temperature in excess of 315 deg can adversely affect the toughness and corrosion resistance of DSS. ANY PWTH should include full solution annealing followed by water quenching.
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Lab Testing
Tensile
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Lab Testing
Tensile
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Lab Testing
Tensile
For pipe having an outside diameter of 3in. (75mm) or less, reduced-section specimens conforming to the requirment given in below figure.
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Lab Testing
Side Bend
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Lab Testing
Root & Face Bend
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Lab Testing
Guided-Bend Test Procedure
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Lab Testing
Guided-Bend Test Procedure
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Lab Testing
Hardness (NORSOK STANDARD M-601)
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Lab Testing
Macro-Examination (ASME IX - 2010)
The examination of the cross sections shall include only one side of the test specimen at the area where the plate or pipe is divided into sections, adjacent faces at the cut shall not be used. Acceptance creteria
Visual examination of the cross sections of the weld metal and heat-affected zone shall show complete fusion and freedom from cracks There shall be not more than 1/8in. (3mm) difference in the length of the legs of the fillet.
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Lab Testing
Micro-structural Examination
Acceptance Criteria
The micro-structure shall be suitably etched and examined at 400 X magnification and shall have grain boundary with no continuous precipitations and the inter-metallic phases, nitrides and carbides shall not in total exceed 0.5%
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Lab Testing
Impact Test
Requirement
Impact testing of welds shall be according to following table, full size specimens shall be applied where possible. If two types of materials are welded together, each side of the weld shall be impact tested and fulfill the requirement for the actual materal. The weld metal shall fulfil the requirement for the least stringent of the two.
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Lab Testing
Impact Test
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Lab Testing
Corrosion Testing
The test specimen shall have a dimension of full wall thickness by 25mm along the weld and 50mm across the weld. The test shall expose the external and internal surface and a cross section surface including the weld zone in full wall thickness. Cut edges shall be prepared according to ASTM G48. The specimen shall be pickled (20%HNO3 + 5% HF, 60 deg., 5min). The exposure time shall be 24 hours. The test temperature shall be 40 deg. The acceptance criteria
No pitting at 20X magnification Weight loss shall not exceed 4.0 g/m2
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Lab Testing
Ferrite Content
Acceptance Criteria
For the stainless steel Type 22 and 25 Cr duplex the ferrite content in the weld metal root and in the last bead of the weld cap shall be determined in accordance with ASTM E562 and shall be in the range of 30% to 70%.
Austenite
Ferrite
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Welding Methods
GTAW (Gas Tungsten Arc Welding) SMAW (Shielded Metal Arc Welding) GMAW (Gas Metal Arc Welding) FCAW (Flux Core Wire Arc Welding) SAW
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High Frequency
Can avoid the contamination of the tungsten Cause interference with hi-tech electrical equipment and computer systems.
Lift arc
Has been developed where the electrode is touched onto the plate and is withdrawn slightly. An arc is produced with very low amperage, which is increased to full amperage as the electrode is extended to the normal arc length.
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No. 2-25 ppm No. 3-50 ppm No. 5-200ppm No. 6- 500ppm No. 8-5000ppm No. 9-12500ppm
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Weld discoloration
Weld discoloration causes a loss of corrosion resistance due to the destruction of the passive layer. Heavy weld discoloration or heat tint should be avoided by inert gas shielding and by pruging the back side of welds with an inert gas. Heat tint cannot be totally avoided and must be removed during postweld clean-up.
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