A Primer For Duplex Stainless Steels
A Primer For Duplex Stainless Steels
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P A P E R
3 D 2
Co-author
RICK JENKINS
GENERAL MANAGER
National Metal Distributors, Inc.
PO Box 1499
Vancouver, Washington 98668
USA
T: 360-883-0569
F: 360-883-0764
E: rick@nmd2000.com
BIOGRAPHY
Mr. Grocki has been involved in the
development, application, and
fabrication of corrosion and heat
resisting stainless steels and nickel
alloys for more than 30 years. He
holds a B.S. in Material Science
C O R R O S I O N
ABSTRACT
The progress made in stainless
steel metallurgy since the 1970s
has resulted in 2205 becoming a
recognized cost effective and
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KEYWORDS
HISTORY
INTRODUCTION
Over the last 15 years, use of
duplex stainless steels has
increased extensively in industrial
applications, particularly in chemical
process, seawater desalination, offshore industries and chemical
Table 1a. Lean duplex materials and their typical chemical composition.
Table 1c. Super and hyper duplex and their typical chemical composition.
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THE FAMILY
CORROSION RESISTANCE
Duplex materials will typically offer
a comparable or improved
resistance to general corrosion
relative to the equivalent austenitic
material. They provide good
performance in both reducing and
oxidizing acids as well as caustic
environments. General corrosion
resistance can vary greatly with
changes in concentration, pH,
temperature, and impurities. It is
important to evaluate these
variables for any application to
ensure the proper grade is selected.
Localized corrosion (pitting and
crevice) resistance is often
characterized by the PRE N (Pitting
Resistance Equivalent Number). The
PRE N is calculated by using a
regression
formula
which
summarizes the cumulative effect of
those alloying elements which affect
pitting performance, commonly
expressed as:
PREN = Cr + 3.3Mo +16N.
Duplex materials have PRE Ns
ranging from 2649. It is important
to note that a PREN differential of 13
points will generally provide similar
performance while a differential of at
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Source: IMOA
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performance,
compared
to
austenitics in abrasive or abrasive /
corrosive environments. Table 4 [3]
shows ASTM maximum hardness
values.
Thermal
expansion
characteristics of duplex materials
are between those of austenitics and
carbon steel, but significantly closer
to carbon steel materials. This allows
for easier dissimilar metal joint
design and fabrication and less need
Source: Industeel
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INTERMETALLIC PHASES
The precipitation of intermetallic and
' phases at elevated temperatures
can have an effect on both the
toughness and corrosion resistance
of duplex materials. The ' occurs
at
temperatures
between
~350550C (6621022F) and
affects the toughness quickly enough
that these materials are not used at
temperatures above 315C (599F).
The intermetallics, or sigma phase,
form at temperatures between
5501000C (10221832F) and
reduce both toughness and
corrosion resistance, drastically
affecting the alloys performance.
The speed at which phases
precipitate, and the temperature
range for precipitation, are both
increased with increasing alloy
content. Hence, lean duplex grades
are thermally stable for up to eight
hours while super duplex grades
may have only 3040 minutes at the
same temperature before being
affected. Figure 4 [2] shows the
relative time-temperature range for
precipitations in duplex materials.
ASTM A923[8] was developed to
provide acceptance testing for
excessive intermetallics in 2205 and
has since been modified to include
the super duplex grades. Because
lean duplex grades are so thermally
stable,
A923 tests are not
acceptable fzor them, and alternate
tests
are
being
developed
specifically for those grades.
Source: Industeel
Figure 4. Temperature ranges for phase precipitations. (2304 ~8 hours for significant
sigma vs. 2205 ~1 hour ).
FABRICATION
Fabrication of duplex stainless steels
has long been a concern of
fabricators and end users. The key
to successful fabrication is
recognizing that these materials are
different, not more difficult to work
with when compared to austenitic
C O R R O S I O N
Source: Industeel
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materials
and
making
the
appropriate changes in processing
to accommodate these differences.
Duplex materials can be cut
using any of the standard cutting
methods, however, higher strength
and hardness will affect shearing and
sawing operations. For example,
shearing is limited to thinner
thickness when compared to
304L/316L: maximum thickness will
be 85% for lean duplex and 2205
and 65% for super duplex grades.
Machining of standard and
higher alloy duplex materials is
considered more difficult than
machining austenitics. Higher
hardness, work hardening, and
tenacious chips all contribute to
more rapid tool wear and create the
difficult reputation. Allowing for the
extra wear and using rigid
equipment and proper tooling will
provide results comparable to those
achieved
with
austenitics.
Conversely lean duplex materials
machine better than austenitics and
are considered similar to special
quality machining grades of 304L
and 316L [9].
Duplex materials can be cold
formed to the same shapes as
austenitic grades. However, higher
strength and greater springback will
require adjustments to the
thicknesses formed, and to bend
tooling. For example, when
compared to a thickness of
304L/316L (maximum forming
thicknesses are: 2304 = 65%, lean
duplex and 2205 = 50%, and super
duplex = 40%). Springback will
require over bending to ~115 to
achieve a 90 angle compared to
~98 for 304L/316L. Cold work will
harden duplex stainless steel,
requiring intermediate and / or final
annealing depending on the amount
of cross-section reduction.
Hot-forming of duplex materials
is also possible. The temperature
for hot-forming must be wellcontrolled, as too low a temperature
will result in cracking of the ferrite
phase and too high a temperature
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STANDARDS
The various duplex materials are
covered by ASTM standards for
most or all product forms. Coverage
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COST EVALUATION
With their lower nickel and
molybdenum contents the duplex
materials are lower in cost and more
price stable than their corresponding
austenitic grades. A relative cost
comparison of various alloys is
shown in Table 7. Fabrication costs
are similar once a good welding and
fabrication procedure has been
established. This means that for
identical fabrications the duplex
materials will offer a cost advantage.
If the design can take advantage of
the higher strength of the duplex
materials then significantly greater
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manufacture
of
the
main
components (shell, bottom, and
roof), were taken into account. All
the accessories such as piping,
flanges, openings, and ladders are
not integrated into the investment
costs. The cost of transport of the
plates is also not considered. The
approach takes into account only
the initial cost of metallic materials
and the fabrication costs such as
Source: Industeel
Source: Industeel
Note: UR B6 and UR B26 are Industeel trade marks for grades N08904 and N08925.
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M A R K E T E V OL UT I ON OF DUPL E X QUA R T O PL A T E S
Table 8. Growth of duplex plate(2000/2008)
usage from 20002008.
in K T
2 007 2008
2000
2 001
2002
2 003
2004
2 005
2006
C hemical tankers
T erminals
20
15
10
10
10
15
10
O ffs hore :
Tubes , blas t walls ,
tops ides flow l ines
10
12
13
N ew applications :
hydrometallurgy,, water,
s tructures , o ther
0,5
1,5
2,5
D es alination
0,5
0 ,5
1,5
15
18
21
P ulp + P aper
10
10
10
C hemicals , F ertilizers ,
P etrochemicals
12
14
P ollution control
0 ,5
0,5
10
D is tribution
10
12
15
16
Total S S produc
T OTAL
tion (K T )
6460
2
700
39
7320
5
680
38
7460
6
800
63
8850
0
90
900
1900
50
% Duplex
6%
5.5%
5%
5.5%
6%
8%
9%
10%
1 0.5%
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SUMMARY
There are some concerns which
need to be recognized, but these
are generally dealt with by
REFERENCES
1.
2.
3.
4.
Table 9. Typical North American stock position for various duplex plate materials.
5.
6.
7.
International Molybdenum
Association, Practical
Guidelines for the Fabrication
of Duplex Stainless Steels,
Revised edition, p 7, 2001.
J.P. Audouard, Industeel,
private communication, 1999.
ASTM A240, 100 Barr Harbor
Drive, PO Box C700, West
Conshohocken, PA 194282959.
D. Bergstrom, Allegheny
Ludlum, private
communication, 2009.
Outokumpu, Duplex Stainless
Steel, 2007.
Sandvik, Seamless Tube and
Pipe SAF 27078 HD, 2008.
ASTM A923, 100 Barr Harbor
Drive, PO Box C700, West
Conshohocken, PA 194282959.
C O R R O S I O N
Source: NMD
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8.
International Molybdenum
Association, Practical
Guidelines for the Fabrication
of duplex Stainless Steels,
Revised Edition, pp 2527,
2001.
9. J. Peultier, ArcelorMittalIndusteel, private
communication, 2007.
10. ASTM International, 100 Barr
Harbor Drive, PO Box C700,
C O R R O S I O N
11.
12.
13.
14.
West Conshohocken, PA
19428-2959.
ASME Boiler and Pressure
Vessel Code, ASME, 3 Park
Avenue, New York, NY 100165990.
API, 1220 L Street NW,
Washington, DC 20005-4070.
AWWA, 6666 W Quincy
Avenue, Denver, CO 80235.
J. Peultier, ArcelorMittal-
S O L U T I O N S
C O N F E R E N C E
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Industeel, private
communication, 2008.
15. J. Peultier, IndusteelArcelorMittal, private
communication, 2009.
16. J. Hellinghausen, Ta Chen
International, Inc., private
communication, 2009.
17. R. Jenkins, National Metal
Distributors, Inc., private
communication, 2009.
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