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Bjrn Holmberg,
Avesta Welding AB, P.O. Box 501, SE-774 27 Avesta, Sweden
Summary
Materials
Welding
For the experiments, 3, 5, 10, 12 and
30 mm plates were used. Pipe
welding in fixed position (6G) was
carried out in 8", t = 3.7 mm and
in 17", t = 10 mm pipes. Welds No.
15-17 were carried out from both
sides, all others were single-side
welded. The welding procedures are
shown in Table 2, page 3. For the
welding of plate material SMAW,
GTAW or SAW was used. For pipe
welding GTAW and SMAW were
used.
acom
3-1997
Introduction
The requirements for modern duplex
stainless steel weldments have in
many cases been too stringent in the
past. In some cases these stringent
requirements have in fact caused
serious problems for welding engineers. The aim of this paper is to
propose more realistic requirements
to designers and to help fabricators
to select filler material, welding
methods and welding parameters
to fulfil those requirements. This is
realized by presenting a number of
welding trials including evaluation of
properties and examination of
microstructures.
Testing
The microstructure was studied by
optical microscopy and by a
modified electron probe micro analyser. The ferrite content in the weld
metal was measured with Feritscope
(MP3). The ductility was measured by
bend and impact testing.
ASTM G-48A testing was undertaken with test pieces in two conditions; with welded surfaces both
totally cleaned and in welded
condition but with the cap brushed
with a rotating disc. New specimens
were used at each exposure.
AVESTA SHEFFIELD
CORROSION MANAGEMENT
AND APPLICATION
ENGINEERING
Diam.
(mm)
Chemical composition, %
C
Si
Mn
Cr
Nb
PRE(N)
3.1
3.1
3.0
.168
.158
.158
35
35
36
Impact
strength (J)
+20C -40C
53
-
2205-PW
2.50
3.25
4.00
.023
.025
.029
.89
.82
.82
.90
.82
.81
22.3
22.6
23.4
9.5
9.8
9.8
2205 BAS
2.50
3.25
4.00
.026
.028
.027
.43
.44
.34
.64
.98
.94
23.5
23.4
23.3
9.5
9.3
9.4
3.2
3.0
3.0
.16
.146
.156
36
36
36
84
67
60
50
2205 super
2507/P100 Rut.
4.00
4.00
.022
.031
.88
.46
.60
1.37
23.5
25.4
9.4
10.3
3.6
3.6
.188
.211
38
41
37
-
24
-
2205 wire
2205N wire
2205/Flux 805Cr
1.6
1.6
2.4
.014
.014
.016
.49
.49
.57
1.58
1.58
1.28
22.5
22.5
23.5
8.8
8.8
8.5
3.1
3.1
3.0
.130
.230
.128
35
36
35
183
150
149
1.6
1.6
1.6
.014
.008
.002
.39
.04
.02
.42
.03
.15
25.3
21.9
22.5
9.6
64.4
60.8
4.0
9.1
15.9
.280
.01
.03
3.7
-
43
52
76
120
110
Ni
Mo
Table 1b.
Chemical composition of parent materials
PRE(N) =%Cr + 3.3 x %Mo + 16 x %N.
Type
Avesta Sheffield
Thickn.
(mm)
Chemical composition, %
C
Si
Mn
Cr
Ni
Mo
2205 plate
3-30
.016-.022
21.5-22.2
5.5-5.7
2.9-3.1 .140-.184
Results
X-ray
In the first trials, welds No. 19 and 20
showed an unacceptable amount of
porosity. They were therefore rewelded. With the first welds, Nos 19
and 20, 10 and 13 beads, respectively, were used. With the re-welding
27 and 20 beads, respectively, were
used. The X-ray investigation result
after re-welding showed no porosity.
Microstructure
All welds for which duplex filler had
been used showed a ferrite level
inside the welds between 23 and
53%. Traces of nitrides were found in
the HAZ in some welds. The highest
amounts in the weld metal were
.37-.53
PRE(N)
1.40-1.52
N
34-35
Process*
Root Cap
141
111
141
111
141
111
141
111
Filler**
Root Cap
A
D
B
E
C
E
C
D
Gas types
Shielding
Ar
Ar
Ar + 3%N2
Ar
Purging
Ar
Ar
Ar + 3%N2
Ar
Total No
of beads
2
2
2
2
Parent***
materi al
PI
3.0
PI
3.0
PI
3.0
PI
3.0
3b
3c
141
141
111
111
C
C
D
D
Ar + 3%N2
Ar + 3%N2
Ar + 3%N2
N2+ 10%H2
1.3
0.9
0.9
0.9
2
2
PI
PI
5.0
5.0
5
5b
6
7
8
9
10
141
141
141
141
141
141
141
111
111
111
111
111
111
12
A
G
B
C
B
H
H
D
D
E
D
F
E
1
Ar
Ar + 3%N2
Ar
Ar
Ar
Ar
Ar
Ar
N2+ 10%H2
Ar
N2+ 10%H2
Ar
Ar
Ar
1.4
1.1
1.1
1.4
1.0
1.3
1.5
0.8-1.2
0.8-1.2
0.9-1.3
1.0-1.3
0.7-1.3
0.8-1.6
0.9-2.0
9
6
8
8
7
8
5
PI
PI
PI
PI
PI
PI
PI
12
10
12
12
12
12
12
18
141
111
Ar + 3%N2
N2+ 10%H2
1.1
0.8-1.5
28
PI
30
11
12
13
13b
14
141
141
141
141
141
141
111
141
141
141
B
H
C
C
G
B
D
C
C
G
Ar
Ar
Ar + 3%N2
Ar + 3%N2
Ar + 3%N2
Ar
Ar
Ar + 3%N2
N2+ 10%H2
Ar + 3%N2
0.6-0.8
0.5-1.2
0.5-0.9
1.2
0.5-0.9
0.3-0.5
0.6
0.4-0.5
0.8
0.3-0.4
3
2
3
2
3
Pi
Pi
Pi
Pi
Pi
3.7
3.7
3.7
3.7
3.7
19
20
141
141
141
111
C
C
C
E
Ar + 3%N2
Ar + 3%N2
N,+ 10%H2
N2+ 10%H2
2.0
2.0
0.6-1.4
0.6-0.9
27
20
Pi
Pi
10
10
15
16
17
111
111
111
111
111
111
J
E
F
J
E
F
0.9
1.0
1.3
0.8-1.1
1.0-1.3
0.9-1.3
9
8
7
PI
PI
PI
12
12
12
111 = SMAW
141 = GTAW
12 = SAW
** A=P12
B = 2205 N
C = 2205
D = 2205-PW AC/DC
E =2205 basic
F = 2205 sup. rutile
G=P16
H=2507/P100
I = 2205 + flux 805
J = 2507/P 100 rutile
*** Pi = pipe; wall (mm)
PI = plate; thickn. (mm)
N.B. Weld Nos 15, 16 and 17 are welded from both sides. All other welds are single-side welded.
Figure 1.
Weld No. 5. First bead duplex with microfissure in sigma phase, 400x. Root:
GTAW; filler PI 2 wire. Hot pass: SMAW;
filler 2205-PW.
Figure 2a.
Micro-probe mapping of the HAZ in weld
No. 1 (GTAW, filler P 12 with Nb). Fusion
line in the middle, weld metal below.
P12 gave a slightly wider low-nitrogen
ferrite zone in the HAZ compared to weld
No.14.
Figure 2b.
Micro-probe mapping in the HAZ in weld
No. 14 (filler P16, no Nb).
Weld
Root
Cap
3xT cracked
at 80C
3xT cracked
at 103C
2xT cracked
at 85C
3xT small cracks
3xT OK
5b
2xT cracked
at 65C
2xT cracked
at 85C
Figure 3a. p
Weld metal impact strength from GTAW,
SAW and SMAW basic coatings.
No.
Figure 3b.
Weld metal impact strength from super
duplex fillers with higher silicon and
oxygen contents.
Table 3.
Bend testing to 180 angle.
Table 4.
Pitting corrosion test results in ASTM G48-A.
Weld
No.
1
2
3
3B
3C
Weight loss
at pitting
(mg)
30.1
1.8
0.8
0.2
4
5
5B
6
7
17.5
32.5
40.0
27.5
20.0
35.0
45.0
22.5
-
0.4
73.4
283.9
1.0
-
8
9
10
11
12
22.5
25.0
20.0
32.5
22.5
25.0
27.5
22.5
35.0
40.7
2.2
0.7
4.2
3.9
13
13B
14
15
16
20.0
30.0
30.0
27.5
27.5
22.5
32.5
32.5
30.0
-
2.2
7.6
1.5
2.5
-
17
18
19
20
30.0
22.5
25.0
17.5
32.5
25.0
27.5
20.0*
5.7
7.2
8.0
1.1
Pitting location
As-welded root
Test temperature
no pitting pitting
22.5
20.0
Weight loss
at pitting
(mg)
1.0
1.7
Pitting location
cap
H
root
F
H, F
22.5
22.5
25.0
25.0
3.9
3.8
P, H
P, H
W, F
12.5
0.9
P, H
W
27.5
-
32.5
20.0
22.5
52.2
5.3
1.8
22.5
-
27.5
22.5
36.6
6.2
H, W
H, W
22.5
1.5
20.0
25.0
-
22.5
27.5
22.5
5.2
4.0
2.5
17.5
22.5
20.0
22.5
22.5
25.0
22.5
16.3
6.5
3.8
1.1
H
H, W
H
H
cap
root
W
H
F
W
P
P
H (W)
F
W
W
H
H
W
F
W
H
H
H
H
P, H
H
grinding
marks
H
H
H
W
H, W
F
W
F
H
H
H
Discussion
In these types of weld metals the
contents of ferrite, secondary
austenite, nitrides, oxides and sigma
phase will in varying degree affect
the mechanical properties and
corrosion resistance. It is also very
important to realize that, for example,
ferrite content, secondary austenite
level and so on, are not material
properties in themselves. The ductility
is acceptable when duplex filler is
used, but not when duplex fillers are
welded on top of nickel base fillers.
The notably higher impact strength in
weld Nos 10 and 19 is a result of
welding procedures giving clean
weld metals with very few oxides.
When standard rutile electrodes are
used, the amount of oxides will
References
1. R. Gunn: "Comparison of Corrosion and
Mechanical Properties of Weldments in
Wrought 25% Cr and Super Duplex
Stainless Steels", Duplex Conf. '94, Glasgow,
UK, paper 32.
2. "Recommended Practice for Pitting Corrosion
Testing of Duplex Stainless Steel Weldments
by the Use of Ferric Chloride Solution", TWI
5632/16/93.
3. L. degrd et al.: Proc. Duplex Stainless
Steel '91, Beaune, France, Les ditions de
Physique P441.
Conclusions
Pitting resistance of single-sided
GTA-welds with conventional
2205-fillers and pure argon may be
enhanced by using either nitrogen
additions to the shielding- and
backing gas or by using super
duplex fillers.
Pitting resistance increases by 2.55C when nitrogen is added to the
shielding-purging gas.
GTAW weldments with standard
duplex fillers in as-welded
condition can give a CPT value of
22.5C with N2 addition. The same
temperature is also valid for the
HAZ/fusion line.
Standard duplex covered electrodes with PRE(N) >35 give
sufficient pitting resistance.
The highest impact strength in
duplex weldments can be obtained
with GTAW. Rutile coated electrodes give the lowest impact
strength.
Due to lack of ductility, duplex
fillers should not be welded on top
of nickel base fillers.
The corrosion resistance and
mechanical properties do not vary
significantly for normal heat input
(0.3-2.0 kJ/mm) or for a ferrite
level between 23 and 53%.
Welding with a few thick beads
increases the tendency to porosity.
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responsibility whatsoever for errors or omissions or information found to be misleading or any opinions or advice gen.
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ISSN 1101-0681