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Welding duplex applications

the ESAB way

XA00097320


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The number of applications for duplex stainlesssteels has steadily increased. Demanding indus-tries like the petrochemical, process and pulp andpaper industry often act at the front line andexplore new materials that can meet their require-ments. Today, many duplex and superduplex appli-cations can be found within this field.

The positional flux-cored wires OK Tubrod 14.27(E2209 T1-1, T1-4) and OK Tubrod 14.28 (E2553T0-4) were originally designed for welding ofduplex and superduplex pipes and to meet therigorous weld metal requirements set by the off-shore industry. OK Tubrod 14.27 has a fast-freez-

ing slag system and can reach a deposition rate ofup to 3 kg/h. It has been used successfully forassembly welds in many chemical tanker projects.

Another example is the Cr-al loying flux OK Flux10.94 which, in combination with solid wire OK Autrod16.88, produces a weld metal with extra-high pit-ting corrosion resistance. Or electrode OK 67.53designed for welding thin-walled (e.g. 2 mm) duplexpipes for the pulp and paper industry.

ApprovalTo meet and exceed customer expectations, ESABhas been involved in intensive quality-improve-

ment programmes backed by certification frominternationally recognised independent qualityassurance organisations. They include ISO certifi-cation for manufacturing and product certificationfrom TV, Lloyds Register, DNV and many others.Most of ESAB stainless consumables are certifiedby at least one of these bodies.

Consumables designed

to give a long life


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Product data

OKTubrod14.27

OKTubrod14.37

OKTubrod14.28

OK Flux 10.93/OKAutrod16.86

Duplex rutile, all-positional, flux-cored wire

Duplex rutile,down-hand, flux-cored wire

Superduplexrutile all posi-

tional flux-coredwire

Basic flux/duplexsolid wire for SAWwelding

AWS A/SFA A5.22E2209 T1-1 and T1-4EN 12073T 22 9 3 N L P M 2T 22 9 3 N L P C 2

AWS A/SFA A5.22E2209 T0-1 and T0-4EN 12073T 22 9 3 N L R M 3T 22 9 3 N L R C 3

AWS A/SFA A5.22E2553 T1-4

EN 760SA AF 2 DCEN 12072S 22 9 3 N L

C 0.03 Si 0.9 Mn 0.9Cr 22 Ni 9 Mo 3 N 0.15

C 0.03 Si 0.9 Mn 0.9Cr 22 Ni 9 Mo 3 N 0.15

C 0.03 Si 0.7 Mn 1.0Cr 25 Ni 9.5 Mo 4 N 0.25

C 0.03 Si 0.5 Mn 1.4Cr 22 Ni 9 Mo 3 N 0.15

Rp0.2 600 MPaRm 760 MPaA5 33%Charpy-V-20C 50 J

Rp0.2 600 MPaRm 760 MPaA5 33%Charpy-V+20C 50 J-40C 35 J

Rp0.2 710 MPaRm 890 MPaA5 25%

Charpy-V+20C 40 J-40C 27 J


FN 30-45/30C/35

FN 30-45/27.5-30C/36

FN 30-50/27.5-30C/34

FN 30-45/60C/

43

TV, GL,DNV, LR,Rina, CO,UDT, ABS

TV, GL,DNV, LR,

TV,DNV,CO

Product name Classification Typical all weld metalchemical composition

Mechanicalproperties

Ferritecontent/CPT*/PRE**

Approvals

OK 67.50

OK 67.53

OK 67.55

OK 68.53

OK 68.55

OK Autrod 16.86/OKTigrod 16.86

OK Autrod 16.88/OK Tigrod 16.88

MMA

MIG/TIG

Duplex acid-rutile MMAstick electrode

Duplex rutileMMA stickelectrode

Duplex basicMMA stickelectrode

Superduplexbasic-rutile MMAstick electrode

Superduplexbasic MMA stickelectrode

Duplex solid-wire electrode

Superduplexsolid-wireelectrode

AWS A/SFA 5.4E2209-17EN1600

E 22 9 3 L R 32

AWS A/SFA 5.4(E2209-16)EN1600E 22 9 3 L R 12

AWS A/SFA 5.4E2209-15EN1600E 22 9 3 LB 22

EN1600E 25 10 4 L R 32

EN 1600E 25 9 4 L B 42

C 0.03 Si 0.7 Mn 0.6Cr 22 Ni 9.5 Mo 3.3 N 0.16

C 0.03 Si 1.1 Mn 0.7Cr 22 Ni 9.5 Mo 3.3 N 0.17

C 0.03 Si 0.6 Mn 0.9Cr 22 Ni 9.5 Mo 3.3 N 0.16

C 0.03 Si 0.6 Mn 0.6Cr 25.5 Ni 10 Mo 4 N 0.25

C 0.035 Si 0.5 Mn 0.9Cr 25.5 Ni 9.5 Mo 4 N 0.25

C 0.02 Si 0.5 Mn 1.6Cr 22.5 Ni 9 Mo 3 N 0.15

Rp0.2 660 MPaRm 820 MPaA5 25%Charpy-V+20C 50 J


Rp0.2 650 MPaRm 800 MPaA5 28%Charpy-V+20C 100 J-20C 85 J-40C 75 J-60C 65 J

Rp0.2 700 MPaRm 850 MPaA5 30%

Charpy-V+20C 50 J

Rp0.2 700 MPaRm 900 MPaA5 28%Charpy-V+20C 90 J-40C 55 J-60C 45 J

Rp0.2 600Rm 760 MPaA5 30%Charpy-V+20 C >100 J

FN 30-45/27.5-30C/35.5

FN 30-45/27.5-30C/36

FN 30-45/60C/43

FN 30-45/60C/43

FN 30-45/25-30C/35

FN 30-50/50-60C/42

FN 35/27.5-30C/35.5

TVCODNV, GL

CWB

TVDNVCO

DNVTVCWB

AWS A/SFA 5.9ER2209EN 12072G/W 22 9 3 N L

EN 12072-99G/W 25 9 4 N L

C 0.02 Si 0.4Mn 0.4Cr 25 Ni 10 Mo 4 N 0.25

Rp0.2 670 MPaRm 850 MPaA5 28%Charpy-V

+20C 80 J (MIG)+20C 150 J (TIG)

TV(opitional)DNVGL

OK Flux 10.94/OKAutrod16.88

Basic Cr-alloyingflux/super duplexsolid wire forSAW welding

C 0.02 Si 0.5 Mn 0.5Cr 25 Ni 9.5 Mo 4 N 0.25

C 0.03 Si 0.5 Mn 1.4Cr 22 Ni 9 Mo 3 N 0.15



FN 30-50/60C/43

FN 30-50/27.5-30C/34

OKFlux 10.93Backing/OK Flux 10.93/OK Autrod 16.86

Basic backingflux for one-sidedwelding of duplex

stainless steel

EN 760SA AF 2 DCSA AF 2 DC

EN 12072S 22 9 3 N L

EN 760SA AF 2 Cr DCEN 12072S 25 9 4 N L

Description

FCAW

SAW

OSW

*CPT= Critical Pitting Temperature (CPT) in ferric chloride, according to ASTM G48 **PRE=% Cr+ 3.3%Mo+16%N

Composition and property data are subject to change without notice.


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Duplex chemical tankersTodays, modern chemical tankers are highlysophisticated ships with the latest technology forsafe cargo handling. The cargo range from crudechemicals to edible oils, fruit juices and even wine.

Nowadays, most chemical cargo tanks are con-structed of duplex stainless steel due to its goodcorrosion resistance and high strength. Severalthousand tonnes of duplex stainless steel are usedto build a mid-sized chemical tanker.

It need to be joined using different weldingprocesses, offering the shipyard the most produc-tive and cost-effective solution.

ESABs experience of this application datesback to the late 1980s when the first chemicaltankers built of duplex were welded with our con-sumables. Today, ESAB is able to supply and sup-port a wide product range that covers all theprocesses and materials for the production ofchemical tankers.

Applications

Fabrication of a block section consisting of a tank coverwith vertical corrugated walls in duplex stainless steel.The positional welding is performed with flux-cored wireOK Tubrod 14.27.


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One-Sided Welding - a way to

high productive panel fabrication

ESAB has developed a highly-productive alterna-tive to the standard two-sided joining of the pan-els in chemical tankers using one-sided SAW(OSW) welding procedures with a special backingflux and with the support of a copper backing.

Using this technique, the panels do not need tobe moved from the welding station, turned andreplaced before completing the weld. Instead, the

jo int can be comple ted from one side. Needless tosay, this is a cost-effective alternative that caneasily be implemented with a low investment cost.

Please contact your nearest ESAB dealer orsales office if you are interested in this solution.You can also contact us at [email protected] more information.

ONE-SIDED SAW-SINGLE WIREOne-sided SAW of 22 mm duplexsteel with multi-pass single wire.

Al l distances are given in mm.

ONE-SIDED SAW-TANDEM WIREOne-sided SAW of 22 mm duplexsteel with multi-pass tandem wire.

Joint figuration suitable for theone-sided SAW of panels induplex chemical tankers.

Strong points High strength and good toughness Good general corrosion resistance High resistance to pitting corrosion Not sensitive to st ress corrosion cracking

Weak points

Should not be used at working temperatures ofmore than approximately 250C. Above this tem-perature embrittlement can occur.

Heat input and interpass

temperature recommendationsThe general heat input and interpass temperaturerecommendations for welding duplex and super-duplex stainless steels are: 0.5-2.5 kJ/mm for duplex grades,

e.g. EN 1.4462, UNS S31803 0.2-1.5* kJ/mm for superduplex grades

e.g. UNS S32750

Duplex stainless steels- a summary

22% Cr duplex: Timax=200CSuper duplex. Timax=150C

(Super duplex steels are particularly sensitive tohigh heat input and interpass temperatures.)*The heat input should not exceed 1 kJ/mm when

welding thin plates.

Shielding and backing gasesSuitable shielding gases for welding duplex stain-less steels are:TIG Ar or Ar-He mixturesMIG Ar-O2 (1-3%), Ar-CO2 (1-3%) or

Ar-He-O2 (1-3%) mixturesFCAW Ar-CO2 (25%) mixtures or pure CO2

Shielding and backing gases with nitrogen addi-tions can be used in critical applications toimprove corrosion resistance. When using pulsedMIG, pure Ar is recommended for the best results.


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26

26 8

10 12 14 16

18202224

2835

45

50

5560

65

70

75

80

85

90

18 20 22 24 26 28 30

18 20 22 24 26 28 30

18

16

14

12

10

18

16

14

12

10

95

100

A

AF

FA

F

4

1

3

2

4

0

Creq = Cr + Mo + 0.7 Nb

Nieq=Ni+35C+20N+0.25

Cu

6

Ferrite content prediction

The phase balance of the weld metal and the heataffected zone (HAZ) is vital when it comes toobtaining good properties in welds in d uplex stain-less steel. An excessively high ferrite content willcause brittleness, whereas a lack of ferrite willcause a loss of resistance to stress corrosioncracking. The weld metal ferrite content shouldnormally be in the range of FN 30-100 (approxi-mately 22-70%).

The WCR-92 diagram is a useful tool for calcu-lating the ferrite content of weld metals. The loca-tion of some ESAB consumables and the use ofthe diagram is illustrated below.

The WRC 1992

constitution diagram

The Creq and Nieq of the steel and the all-weldmetal are calculated from their chemical composi-tions, plotted on the diagram and joined by a line.This line represents all the possible compositionsof the weld metal for different degrees of dilution.In the present example, a 30% dilution has beenused and the predicted ferrite content of the weldis approximately FN 45.

Location of:1 Base material, SAF 2205 (EN 1.4462), remelted.

2 Duplex MMA weld metal, deposited with OK 67.50.

3 Duplex MIG weld metal, deposited with

OK Autrod 16.86.

4 Superduplex MMA weld metal, deposited with OK 68.53.

X Location of weld in SAF 2205 (EN 1.4462) welded with

OK 67.50 MMA electrode assuming 30% dilution.

(Published in Welding Journal by D.J. Kotecki and T.A. Siewert)


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Before welding A slightly wider root gap and joint angle thanthose used for standard stainless steel should beused to obtain good p enetration. Use ceramic backing to facilitate root pass weld-ing. The joint and the adjacent base metal should bethoroughly cleaned. Only stainless brushes should be used for cleaning. Preheating is normally not recommended. Dry electrodes should always be used. ESAB cansupply the duplex electrodes in ESAB VacPacwhich is an effective system for handling weldingelectrodes. Three pack-age sizes are adaptedto match consumptionduring a normal workingshift. This eliminatescostly re-drying proce-dures.

During welding

The heat input should be related to the platethickness and welding method. A heat input whichis too low or too high should be avoided (see heat

input recommendations). Avoid striking the arc outside the joint. Arc

Rules of thumb

strikes can act as initiation points for pitting corro-sion and cracks. Maintain proper arc length and stick-out to avoidnitrogen pick-up. A correct root gas shield is important. Suitablebacking gases are high-purity Ar and mixturescontaining N2 and H2. Excessive weaving should be avoided. It canresult in an overly high heat input.

After welding

Thorough cleaning after welding is essential toobtain good corrosion resistance. All slag and

oxide on and around the weld must be removed. Brushing should be done manually and only withstainless brushes. Rotating brushes can result in micro-crevices inthe weld metal. Subsequent heat treatment is normally not need-ed. Duplex steels and weld metals can, however,be solution heat treated (see steel producersrecommendations). Stress relieving should be avoided as this cancause embrittlement of the steel and the weldmetal. The flame straightening of deformed plates can

be used, if the recommended procedure from thesteel supplier is followed.

Recommended ESAB consumables

Contact your nearest ESAB dealer or our website,www.esab.com, for more product information.

* Austenitic stainless of the AWS 309L or 309LMo type.

Steel types MMA MIG TIG FCAW SAW

Lean and 22%Cr OK 67.50 OK Autrod 16.86 OK Tigrod 16.86 OK Tubrod 14.27 OK Flux 10.93/ duplex grades OK Tubrod 14.37 OK Autrod 16.86

OK 67.53

OK 67.55

25%Cr and OK 68.53 OK Autrod 16.88 OK Tigrod 16.88 OK Tubrod 14.28 OK Flux 10.94/superduplex grades OK 68.55 OK Autrod 16.88

Mild steel to OK 67.50 OK Autrod 16.86 OK Tigrod 16.86 OK Tubrod 14.27 OK Flux 10.93/duplex grades OK 67.51 OK Autrod 16.53* OK Tigrod 16.53* OK Tubrod 14.37 OK Autrod 16.86

OK 67.53 OK Autrod 16.54* OK Tigrod 16.54* OK Tubrod 14.22* OK Autrod 16.53*OK 67.65 OK Autrod 16.54*OK 67.60*OK 67.62*OK 67.70*OK 67.75*


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