Metrode Products Limited

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 DUPLEX & SUPERDUPLEX

FERRITIC-AUSTENITIC STAINLESS STEELS

CONTENTS

Page

1. Introduction 1

2. Base Materials 2

3. Consumables 3

4. Welding Guidelines 5

5. Properties 8

Appendix 1 22%Cr Duplex Data Sheet B60

Appendix 2 Zeron 100 Superduplex Data Sheet B61

Appendix 3 2507 Superduplex Data Sheet B62

 DUPLEX & SUPERDUPLEX

FERRITIC-AUSTENITIC STAINLESS STEELS

1. INTRODUCTION

Duplex and superduplex stainless steels are currently finding widespread use for a range of
applications. The excellent combination of strength and corrosion resistance has proved to be
invaluable, especially in the offshore and chemical industries. The more widespread application
of duplex and superduplex stainless steels is rapidly increasing into areas of general fabrication,
where it is replacing standard austenitic stainless steels such as 316L.

The different industry sectors and applications each have their own welding consumable
requirements. For this reason the range of consumables available is relatively large, each
consumable having particular attributes. For example, in the offshore industry, where fixed pipe
welding is prevalent and relatively stringent impact requirements are imposed, the 2205XKS,
Zeron 100XKS, 2507XKS and Supercore 2205P are used. In general fabrication where ease of
use and cosmetic appearance are important, with less emphasis on impact properties, Ultramet
2205 and Ultramet 2507 will be preferred. There is also an entirely separate area of use, covering
casting repairs which will be subsequently solution annealed, where lower nickel, matching
composition, consumables are sometimes used.

The Metrode product range has consumables for the MMA(SMAW), TIG (GTAW), MIG
(GMAW), FCAW and SAW processes which cover all of the potential applications. This
Technical Profile covers not only the extensive range of Metrode consumables for duplex and
superduplex materials, but also the practical aspects of welding these steels. The important
features of weld procedure qualification – corrosion (G48A), impact properties, hardness and
microstructure – are discussed and the procedural controls required to achieve the optimum
properties are examined.

Weld procedure records of successful procedures are provided together with the typical properties
achieved. This information is intended to give sufficient guidance to enable weld procedures to
be successfully carried out.

Page 1 Issue 2 February 2000

2. BASE MATERIALS

There is a wide range of base materials that can be broadly grouped into duplex and superduplex
alloys. There are many, essentially equivalent, materials from many different manufacturers.
Tables 1, 2 and 3 list the main base material specifications for wrought and cast duplex and
superduplex along with nominal composition and examples of the proprietary alloys available.

Table 1: Wrought alloys – standard duplex stainless steels

Examples of proprietary
UNS No EN 10088 Cr Ni Mo Cu W N PREN *
materials
S32304 1.4362 23 4 0.1 - - 0.10 24 SAF 2304 (Sandvik/Avesta)
UR35N (CLI)
(1)
S31803 1.4462 22 5 2.8 - - 0.15 32/33 UR45N (CLI)
SAF 2205 (Sandvik/Avesta)
(1)
S32205 1.4462 23 6 3 - - 0.18 35 2205 (Avesta)
UR45N+ (CLI)

S32550 1.4507 25 6.5 3 1.5 - 0.16 38/39 Ferralium 255 (Meighs)

S31260 - 25 7 3 0.5 0.3 0.16 37 DP3 (Sumitomo)

(1) UNS S32205, a variant of S31803 with analysis restricted to the upper range.

Table 2: Wrought alloys – superduplex stainless steels

Examples of proprietary
UNS No EN 10088 Cr Ni Mo Cu W N PREN *
materials
S32760 1.4501 25 7.5 3.5 0.7 0.7 0.23 40 Zeron 100 (Weir)

S32750 1.4410 25 7 3.8 - - 0.25 42 SAF 2507 (Sandvik/Avesta)

S39274 - 25 7 3.1 - 2 0.25 40 DP3W (Sumitomo)

S32550 1.4507 26 7 3.5 1.5 - 0.26 40 UR52N+ (CLI)

Ferralium SD40 (Meighs)

* PREN = Pitting Resistance Equivalent based on: Cr + 3.3Mo + 16N

PREW = Cr + (3.3Mo + 0.5W) + 16N includes the role of tungsten alloying

Table 3: Cast alloys – duplex and superduplex stainless steels

UNS No DIN ASTM A890 Equivalent wrought alloy

J92205 - 4A S31803 / S32205

J93370 1.4515/1.4517 - S32550

J93380 1.4508 6A S32760

J93404 5A S32750
1.4469

Page 2 Issue 2 February 2000

3. CONSUMABLES

Tables 4 and 5 summarise the Metrode range of duplex and superduplex welding consumables.
Full data sheets for these products are presented in Appendices 1-3.

Table 4: Filler materials for welding 22%Cr duplex stainless steels

Parent material Wrought Cast

UNS S32304 & S31803 UNS J92205 & J93370
Filler material Overmatching analysis Matching analysis *
Final condition As-welded Solution annealed (1120°C + WQ)
TIG / MIG ER329N
Filler wire 1.6, 2.4 & 3.2mm ø: TIG
1.2mm MIG & Mechanised/Orbital TIG
PREN: 35 min
MMA SUPERMET 2205 SUPERMET 2506
Electrodes Rutile coated Rutile coated
General purpose: downhand Downhand welding and repair of castings
2.5 – 5.0mm ø 2.5 – 5.0mm ø
PREN: 38 PREN: 36
ULTRAMET 2205
Rutile coated
AWS: E2209-16
All-positional: structural SUPERMET 2506Cu
2.5 – 4.0mm ø Rutile coated
PREN: 35 min AWS: E2553-16
2205XKS Downhand welding and repair of
Basic coated Cu-bearing alloy castings
(maximum weld toughness) 2.5 – 5.0mm ø
AWS: E2209-15 PREN: 38
All-positional: pipework
2.5 – 5.0mm ø
PREN: 35 min
Flux Cored Wire SUPERCORE 2205 & SUPERCORE 2205P
(FCAW) Rutile Flux Cored
Downhand All-positional: pipework
AWS: E2209T0-4 AWS: E2209T1-4
1.2mm ø, Argon +20% CO2
PREN: 35 min
Sub-Arc (SAW) ER329N 1.6 & 2.4mm ø
Wire / Flux SSB Flux 25kg drum
Basic: (BI ≈ 3)
PREN: 35 min

* "Matching analysis preferred, but in practice overmatching consumables have proved acceptable, eg
Supermet 2205.

Page 3 Issue 2 February 2000

Table 5: Filler materials for welding 25%Cr type superduplex stainless steels

Parent material Wrought Cast

UNS S32760, S32750, S32550, S39274 UNS J93380 & J93404
Filler material Overmatching analysis Matching analysis **
Final condition As-welded Solution annealed (1120°C + WQ)
TIG / MIG
ZERON 100X ZERON 100M
Filler wires
1.6, 2.4 & 3.2mm ø: TIG
1.0mm MIG & Mechanised/Orbital TIG
PREN: 40 min
MMA
ZERON 100XKS SUPERMET 2507Cu
Electrodes
Basic coated (max weld toughness) Rutile coated + Cu/W alloyed
All-positional: pipework Downhand welding and repair of
2.5 – 5.0mm ø similarly alloyed castings
PREN: 40 min 2.5 – 5.0mm ø
PREN: 40 min

2507XKS *
Basic coated (max weld toughness)
All-positional: pipework
2.5 – 4.0mm ø
PREN: 40 min

ULTRAMET 2507 *
Rutile coated
All-positional: structural
2.5 – 4.0mm ø
PREN: 40 min
Sub-Arc (SAW)
ZERON 100X 1.6 & 2.4mm Ø ZERON 100M 2.4mm ø
Wire / Flux
SSB FLUX 25kg drum
Basic (BI=3)
PREN: 40 min

* For welding UNS S32760 Zeron 100XKS is preferred, especially for service in sulphuric acid.

** 'Matching analysis' preferred, but in practice overmatching consumables have proved

acceptable, eg Zeron 100XKS.

Page 4 Issue 2 February 2000

4. WELDING GUIDELINES

4.1 GENERAL GUIDELINES

Weld procedures for duplex and superduplex stainless steels need to be controlled to ensure weld
properties are achieved and also to ensure conformance with appropriate standards. Welding
guidelines for Zeron 100 are presented in Appendix 4, and Appendix 5 gives examples of some
successful weld procedures and the properties achieved. The general philosophy for welding
duplex and superduplex stainless steels is shown in Figure 1. Some of the specific areas of weld
procedure control that are closely defined in specification and application standards are explained
in more detail in section 4.2.

Figure 1: Welding duplex & superduplex stainless steels

Page 5 Issue 2 February 2000

4.2 PREHEAT, INTERPASS & HEAT INPUT CONTROLS

Preheat Is not normally required. Preheat should only be used on material below about 5°C
(41°F) or which is not dry.

Interpass With standard duplex stainless steel, interpass temperatures are normally restricted
temperature to 150oC (300°F) maximum. This is in line with a number of specifications/codes:
NORSOK M601, Shell ES106 and ES124; all 150°C (300°F) maximum.

Heat input For the filling runs of a joint fairly high heat inputs are required before any
noticeable effect is seen on the properties of duplex stainless steel welds. A range
of 0.5 – 2.5 kJ/mm (12.5-62.5kJ/in) has been proposed as acceptable based on
work at TWI, but the maximum is often restricted to lower heat inputs, eg Shell
ES106, 0.5 – 2.0 kJ/mm (12.5-50kJ/in); Shell ES124, 0.5 – 1.75 kJ/mm (12.5-
45kJ/in).

The procedural controls required are described here generally for duplex and superduplex stainless
steels, in practice the control for duplex stainless steels, in practice the control for duplex stainless
steels can be more relaxed than for superduplex.

4.3 DISSIMILAR JOINTS

Duplex and superduplex stainless steels are inevitably joined to other alloys. For most commonly
used engineering alloys, this does not present any problem, provided the appropriate consumable
used. Diagrams such as the Schaeffler diagram can prove useful in selecting the correct filler
material.

There will generally be a number of consumables which will provide an acceptable technical
solution for any dissimilar joint, so the selection will often be based on practical aspects. For
example, to reduce the number of procedures and consumables utilised, if duplex (2205)
consumables are being used, these can conveniently be used for joints between duplex and CMn,
low alloy and most austenitic stainless steels. The same applies to superduplex consumables.

Duplex and superduplex consumables can also be used for surfacing CMn and low alloy steels
without any intermediate buffer layers. Figure 2 summarises the selection of weld metals for
dissimilar joints involving duplex and superduplex stainless steels.

Page 6 Issue 2 February 2000

Figure 2: Duplex & superduplex stainless steel dissimilar butt joints
Recommended filler wires *

* Only wires are listed for brevity – associated MMA and FCW are also suitable.

** Consumable may need to be selected to meet minimum strength requirements

of the CMn/low alloy steel.

Page 7 Issue 2 February 2000

5. PROPERTIES

5.1 TENSILE

The tensile properties of duplex and superduplex weld metals comfortably achieve the
requirements of the associated base materials. Transverse tensile tests made using the correct
consumable fail in the base material.

Typical tensile properties for the various welding processes in duplex and superduplex are given
below in Table 6.

Table 6: Typical tensile properties

UTS, 0.2% Proof Stress, Elongation, %

RoA, %
MPa (Ksi) MPa (Ksi) 4d 5d
TIG ER329N 800 (116) 600 (87) 32 29 65

MIG ER329N 800 (116) 600 (87) 32 29 50

SAW ER329N + SSB 800 (116) 600 (87) 32 30 50

2205XKS 810 (118) 660 (96) 28 26 45

Ultramet 2205 850 (123) 675 (98) 27 25 40

Supermet 2205 850 (123) 650 (94) 30 28 40

Supercore 2205 / 2205P 800 (116) 650 (94) 27 25 40

TIG Zeron 100X 920 (133) 725 (105) 25 24 40

MIG Zeron 100X 920 (133) 725 (105) 25 24 40

SAW Zeron 100X + SSB 920 (133) 725 (105) 25 24 40

Zeron 100XKS 900 (130) 700 (102) 24 22 45

2507XKS 900 (130) 700 (102) 28 25 45

Ultramet 2507 950 (138) 750 (109) 25 22 40

Although the consumables listed in Table 6 are primarily for use in the as-welded condition, they
are also used in the solution annealed condition – typically >1120°C (2050°F) / 3hrs + WQ.
Following a solution anneal, the elongation will increase and the UTS will be slightly reduced but
the major difference in tensile properties will be the reduction in 0.2% proof stress. Even
following a full solution anneal heat treatment, the weld metal will meet the requirements of the
appropriate base material.

Requirements are now being seen which specify tensile properties at moderately elevated
temperatures, eg 120 - 160°C (250-320°F). The graph on the next page, Figure 3, shows the
general trend for the reductions in strength to be expected on testing at temperatures up to ~160°C
(320°F).

Page 8 Issue 2 February 2000

 Figure 3: Hot Tensile Properties for duplex and superduplex weld metals

1000
Duplex 0.2% proof
Duplex UTS
900 Superduplex 0.2% proof
Superduplex UTS
Strength, MPa

800

700

600

500

400
0 50 100 150 200 250
Temperature, oC

5.2 TOUGHNESS

CVN toughness versus temperature curves describe a shallow sloping relationship, free from the
pronounced ductile-brittle transition characteristics of CMn weld metals. Consequently CVN
values show low scatter and overall, reflect a more consistent pattern of weld toughness than
achieved from CMn weld metal. See Figures 4 and 5.

Figure 4: 22%Cr type standard duplex stainless steel butt weld CVN toughness

Page 9 Issue 2 February 2000

Figure 5: 25%Cr type superduplex stainless steel butt weld CVN toughness

Weld metal oxygen content, in the form of oxide/silicate micro-inclusions, strongly influences
toughness. As oxygen increases, toughness is reduced. Gas shielded TIG, PAW and MIG
processes promote lower weld metal oxygen levels than flux shielded MMA, FCAW and SAW
processes.

CVN absorbed energy (joules), for standard 10 x 10mm (0.4 x 0.4in) test specimens, and lateral
expansion values show a close relationship up to the 100J level:

Lateral Expansion (mm/in) ≈ Charpy Energy (J)

100

Since lateral expansion values are not significantly affected by CVN specimen size, they can be
used as a useful indicator of potential full-size CVN performance.

Correction factors, based on the sub-size test specimen ligament cross-sectional area, provide a
useful conversion to potential 10 x 10mm (0.4 x 0.4in) impact values, eg:

Specimen size, mm (in) 10 x 10 10 x 7.5 10 x 5 10 x 3.3

(0.4 x 0.4) (0.4 x 0.3) (0.4 x 0.2) (0.4 x 0.1)
Ligament Area relationship 1 0.75 0.5 0.33
Typical test data, J (ft-lb) 95 (70) 56 (41) 41 (30) 27 (20)
Values corrected for 10 x 10 specimen, J (ft-lb) 95 (70) 75 (55) 82 (60) 82 (60)
J / cm2 (ft-lb/in2) 119 (546) 93 (430) 103 (469) 102 (469)

Page 10 Issue 2 February 2000

 Analysis of weld metal CVN values and Crack Tip Opening Displacement (CTOD) fracture
toughness suggests that 40J (29ft-lb) average, 27J (20ft-lb) minimum single values at the
minimum design temperature are sufficient to avoid the risk of brittle fracture. A corresponding
minimum CTOD value of 0.1mm (~0.004in) is considered appropriate.

Post-weld solution anneal (~1150°C/2100°F) + water quench heat treatment significantly

improves weld toughness performance.

5.3 HARDNESS

5.3.1 NACE

NACE requirements define maximum hardness levels for parent material to secure reliable
resistance to stress corrosion cracking (SCC) in H2S-bearing ('sour') media. The following table
shows the maximum hardness allowed as defined in NACE MR0175-97 (note the most recent
revision of MR0175 should be referred to).

Grade Duplex Superduplex

UNS S31803 UNS S32750 UNS S32760

eg SAF 2205 eg SAF 2507 eg Zeron 100
Condition Sol. Ann. + Cold Worked Sol. Ann Sol. Ann. + Cold Worked
232°C max. 232°C. 120g/l Cl-
0.002MPa H2S max. 0.01MPa H2S max. 0.02MPa H2S
1100MPa YS max.
Hardness;
36 max. 32 max. 34 max.
HRC

5.3.2 Weld Metal & HAZ

NACE hardness limits are used in fabrication specifications covering weldments.

The weld root zone is subject to strain hardening induced by thermal contraction stresses. Each
weld deposition strain ≡ hardening event.

Root weld metal hardness directly relates to the number of weld beads in the joint. For example,
8in (219mm) diameter x 18.3mm (0.75in) wall thickness Zeron 100 superduplex stainless steel
pipe TIG welded in the ASME 5G position using Zeron 100X filler wire and completed in 30
passes shows weld metal and HAZ root hardnesses higher than the corresponding cap hardnesses
(Figure 6).

Figure 6: Zeron 100 butt weld Rockwell C hardness values

Page 11 Issue 2 February 2000

 Vickers Hardness (HV) is more applicable for the examination of specific weld zones, eg HAZ.
(HV 10kg hardness indentation ≈ 1/10 size of HRC 150kg.)

If HV is used, care should be taken in correlating to HRC and it is recommended the new Welding
Institute (UK) HV/HRC correlation (Figure 7) is used rather than ASTM E140 which was
developed for CMn steels.

Figure 7: TWI HV/HRC comparison

The TWI HV/HRC correlation curve, based on statistical interpretation of hardness measurements
from a wide range of 22%Cr duplex and 25%Cr superduplex weldments, is more realistic for
equating hardness values derived by the two test methods. The limitations of the previous ASTM
E140 CMn steel correlation curve are highlighted, particularly with respect to meeting NACE
MR0175 HRC hardness requirements for 'sour' service applications.

5.4 CORROSION

The corrosion performance of duplex and superduplex weld metals is often assessed during
procedure qualification using the ASTM G48A test.

Typical acceptance criteria include: nil pitting, maximum test specimen weight loss of 20mg or
4-5g/m2 (~0.001lb/ft2)of surface tested. Accurate, meaningful, weight loss determination demands
careful attention to test specimen preparation: polishing (eg 1200 grit) of all edges and surfaces
not under test.

To obtain uniform results, some specifications allow pickling and repassivation – eg 20% HNO3
+ 5%HF, 60°C (140°F), 5 minutes as in NORSOK M-601 Rev 2.

Page 12 Issue 2 February 2000

 Ar/1-2%N2 gas shielding (+ pure argon purge) enhances weld metal nitrogen level, to boost pitting
resistance, and may be essential practice where:

- the specified G48A test temperature exceeds the argon shielded ER329N root weld critical
pitting limit (~25°C/77°F) and Zeron 100X filler metal usage is prohibited.

- nitrogen losses from argon shielded Zeron 100X TIG root bead weld metal jeopardises
satisfactory G48A test performance at ~40°C (104°F).

- restoration of pitting resistance where early removal of backing gas protection causes root
surface oxidation and susceptibility to attack.

With multi-pass TIG welding, Ar + N2 usage should be restricted to initial root runs to avoid
excessive nitrogen build-up, and the associated risk of weld porosity.

Pitting attack of specimen surfaces not under test, eg edge 'endgrain' micro-structure, is generally
not considered a relevant part of acceptance criteria, though may cause problems meeting weight
loss limits, where applicable.

Figure 8: Pitting diagram

5.5 MICROSTRUCTURE & FERRITE CONTENT

The properties of duplex and superduplex stainless steel are dependent on the duplex ferritic-
austenitic microstructure.

Round-robin tests have shown point counting (ASTM E562) of weld joints (weld metal & HAZ)
to have very low reproducibility from one laboratory to another. For this reason, it is
recommended that, for weld metals, ferrite content be measured in FN (ferrite number) using
suitably calibrated magnetic instruments.

Page 13 Issue 2 February 2000

Despite the better reproducibility of FN measurements and IIW recommendations, procedure
specifications still tend to be written around point counting with a ferrite content of about 25-65%
normally being specified.

Once the filler and hence weld metal composition has been selected, the cooling rate during
welding is the factor that primarily controls the ferrite content. Slower cooling rates reduce the
ferrite content – hence high heat inputs and preheating reduce the ferrite content.

The WRC diagram can be used as a convenient method for estimating the potential ferrite content,
in FN, from the analysis. There is always likely to be some discrepancy between calculated and
measured ferrite values.

There is a move towards acceptance criteria being based on actual corrosion and mechanical
properties rather than weld metal microstructure.

The 'Position Statement' from IIW in Appendix 7 helps to clarify the position in the case of
dispute. Other useful references include:

- Gooch, T G & Woollin, P: 'Metallurgical examination during weld procedure qualification for
ferritic-austenitic stainless steels'; Stainless Steel World 1999 conference, November 1999,
The Hague.

- Kotecki, D J: 'Standards and industrial methods for ferrite measurement'; 1998 Welding
Journal, May 49-52.

Page 14 Issue 2 February 2000