LEXAL Consumables for welding duplex steels.

The SAF answer to welding duplex steels.

Duplex steels are easy to weld provided that certain metallurgical rules are observed. The specific combination of a welding heat cycle and a chemical analysis of the deposited metal is what produces a duplex deposited metal.
P/5003

LEXAL

METALLURGY OF THE WELD

A duplex steel solidifies in the ferrite phase () following which some of the ferrite () is converted to austenite (). Although the chemical analysis is identical to that of the base metal, the welding heat cycle is too quick to enable sufficient austenite () to form with its attendant corrosion resistance and excellent mechanical properties. This is why the consumable products are usually enriched with elements favouring the austenitic phase (Ni, N2).

INFLUENCE OF THE WELDING HEAT CYCLE

In combination with a specific analysis of the molten metal, the welding heat input must be high enough to obtain sufficient conversion of ferrite () to austenite (). However, the chemical analysis of duplex and super duplex steels including various elements which tend to form unwanted phases, including nitrides, intermetallic phases, etc if the welding heat input is too high. This imposes an appropriate range of heat input, which, given the chemical balance of our range, is as great as possible. The applicable range can run from 8 to 22 kJ/cm.

DIAGRAM WRC 92
18

Nieq = Ni + 35C + 20N + 0.25Cu

17 16 15 14 13 12 11 10 9 17

Austnite FN
%
0

A-F
0 2 6 4 8 12 10 2 4

10 12

F-A
14 16

18 22 26 30 20 24 28 35 40 45

14 18 16 20 30 25
LEXAL*

35 40 55 63 48 60

50 55 60 65 70 75 80 85 90 95 100

Ferrite
27 28 29 30 31

18

19

20

21

22

23

24

25

26

Creq = Cr + Mo + 0.7Nb

EXAMPLES OF PROCESS APPLICATIONS

Applications first pass on tube filler passes on tube plate hardsurfacing-repair Process TIG TIG-MIG-coated electrode coated electrode - submerged arc coated electrodes

THE ADVANTAGES OF DUPLEX STEELS

DUPLEX steels are being used more and more in industrial sectors such as petroleum production, chemicals, petrochemicals, and energy supply and are beginning to make inroads into the construction and agriculture/foodstuffs industries. Their success is due to the combination of good corrosion resistance and high mechanical specifications.

METALLURGY OF DUPLEX AND SUPER DUPLEX STEELS

The term "duplex" comes from the microstructure of this steel, which is made up of two phases : ferrite and austenite, in proportions by volume of close to 50/50 %. This equilibrium is obtained by analysis of the steel. The corrosion resistance characteristics and mechanical properties are closely related to this equilibrium of the ferrite () and austenite () phases and to the chemical analysis : Chromium (22% - 25%), Molybdenum (0-4%) Silicon favour the ferrite phase (), Nickel (6% - 8%), Nitrogen (0.10% - 0.25%) Copper (0 - 0.2%) favour the austenite phase ().

CORROSION RESISTANCE
As well as their high resistance to generalized corrosion, these steels are frequently used to solve the problem of pitting corrosion. Their resistance to pitting corrosion is given by their Pitting Resistance Equivalent Number PREN = % Cr + 3.3% Mo + 16% N. The higher the PREN, the greater the resistance to corrosion. The distinction between duplex and super duplex steels lies in their PREN :

PHYSICAL AND MECHANICAL PROPERTIES

In the -50C to +250C temperature range, duplex steels have better characteristics than standard stainless steels :

high mechanical strength, low coefficient of thermal expansion, higher thermal conductivity than austenitic steel, ferromagnetic properties, resistance to fatigue and corrosion fatigue.

DUPLEX : PREN = 25 - 40 SUPER DUPLEX : PREN > 40.

THE LEXAL RANGE FOR W

COATED ELECTRODES
2570/35 2570/36

FLUX CORED WIRE

SUBMERGED ARC WIRE/FLUX COMBINATION

2570/30

2570/07

The electrode coating is a rutile-basic covering. The core is homogeneous (duplex steel), enabling the technical aspects of the product to be taken into account. Weldability is ideal for welding in all positions. The molten metal has been characterized by ASTM corrosion test G 48 A. With SAFDRY version (SV) electrodes can be used without drying.
PRODUCT NAME :
LEXAL E 22.9.3 N LEXAL E 22.9.3 N SV LEXAL E 22.9.3 N HR SV

Flux cored wire with automatic slag removal and very good weld bead appearence with no requirement of finition. Welding in all positions including vertical down for the type T 22.9.3 N and special bead appeareance of the filet in flat position for the type TA 22.9.3 N. Weld deposit satisfies to corrosion test G 48 A of ASTM. For penetration runs, we recommand ceramic support KERASAF (see leaflet 1515-7606).
PRODUCT NAME :
LEXAL T 22.9.3 N LEXAL TA 22.9.3 N

1877/27

The SUBMERGED ARC process is used for automatic flat downhand welding of thick plate in high productivity applications. The flux for use with a homogeneous DUPLEX wire is a basic flux. The molten metal passes ASTM corrosion test G 48 A.
PRODUCT NAME :
wire : LEXAL S 22.9.3 N flux : LEXAL F 500

STANDARDS :
wire : flux : W. Nr 1-4462 AWS A 5.9 ER 2209 DIN 32 522 BFB 6 64445 Ac 9K

COVERING TYPE :
basic rutile

TYPE :
flux cored wire with slag
DIN 8556 W. Nr AWS A 5.4* E 2293 n CR 26 1-4462 E 22 09.16

MECHANICAL PROPERTIES :
typical values for the wire/flux combination (A81 324)
Ys 0,002 Mpa 710 Uts Mpa 820 E5d % 26 CVN - 50 C J 60

STANDARDS :
NFA 81 343 EZ 22 93 LR 26

STANDARDS :
W. Nr 1-4462

alternating current Uo 60 V direct current +ve to llectrode

WELDING CURRENT :

CHEMICAL ANALYSIS : ASSOCIATED GAS :

Ar+CO2 (M21), ATAL 5A typical values on metal excluding dilution (A 81 324)
C 0,014 Ni 8,1 Si 0,5 Cr 22,8 Mn 1,6 Mo 3,2 P 0,020 N 0,16 S 0,010 Ferrite % vol 45

WELDING POSITION :
all positions flat and filet for HR version

WELDING CURRENT :
DC + to wire

MECHANICAL PROPERTIES :
typical all welded values (A81 344)
Ys Mpa 700 Uts Mpa 810 E5d % 22 CVN + 20 C J 55 CVN - 40 C J 50 - 35 (HR)

WELDING POSITION :
LEXAL T 22.9.3 N : all positions LEXAL TA 22.9.3 N : special flat position

APPROVALS :
DNV - LRS - GL

MECHANICAL PROPERTIES :
typical as welded values
Ys Mpa 620 Uts Mpa 825 E5d % 30 CVN - 20 C J 40

CHEMICAL ANALYSIS :
typical values on deposit (NF EN 266847)
C 0,016 Ni 9,5 Si 1 Cr 22,8 Mn 1,6 Mo 3,2 P 0,020 N 0,16 S 0,010 Ferrite % vol 40

CHEMICAL ANALYSIS :
typical values (NFEN 26847)
C 0,025 Ni 9,2 Si 1 Cr 22,7 Mn 1,6 Mo 3,0 P 0,020 N 0,16 S 0,010 Ferrite % vol 35

APPROVALS :
DNV - LRS - GL * Due to certain differences with the corresponding standard, the proposed classification does not have any absolute nature.

APPROVALS :
DNV - LRS - GL

1881/79

WELDING DUPLEX STEELS

TIG FILLER METAL
1415/53 1415/08

MIG WIRE
1877/01

2570/21

TIG filler products are used in particular for first passes on tubes. The grades are usually homogeneous with the DUPLEX products to be welded. The molten metal passes ASTM corrosion test G 48 A. A specific associated gas (ARCAL 39) contains nitrogen, which compensates for the loss of nitrogen from the weld pool can be used with this product.
DESIGNATION :
LEXAL W 22.9.3 N

MIG filler can also use a specific gas containing nitrogen. The nitrogen from the gas compensates for the loss of nitrogen from the weld pool. The molten metal passes ASTM corrosion test G 48 A.
DESIGNATION :
LEXAL G 22.9.3 N

STANDARDS :
DIN 8556 SG X 2Cr Ni Mo 23.9.3 W. Nr 1.44 62 AWS A 5,9 ER 2209

ASSOCIATED GAS :
Ar + CO2 + H2 (M11), NOXALIC 12, Ar + He + CO2 + N2, ARCAL 129
W. Nr 1.4462 AWS A 5,9 ER 2209

STANDARDS :
DIN 8556 SG X 2Cr Ni Mo 23.9.3

MECHANICAL PROPERTIES :
typical all welded values (A81 314)
Ys 0,002 Mpa 670 Uts Mpa 810 E5d % 22 CVN + 20 C J 95 CVN - 50 C J 65

ASSOCIATED GAS :
Ar (I1), ARCAL 1, Ar + N2, ARCAL 39

WELDING POSITION :
all positions

CHEMICAL ANALYSIS :
typical values on deposit A 81 313/314
C 0,02 CVN - 50 C J 180 Ni 8 Si 0,5 Cr 22,7 Mn 1,5 Mo 3,2 P 0,010 N 0,17 S 0,010 Ferrite % vol 35

MECHANICAL PROPERTIES :
typical values on metal excluding dilution
Ys 0,002 Mpa 700 Uts Mpa 810 E5d % 34 CVN + 20 C J 210

CHEMICAL ANALYSIS :
typical values on deposit NFEN 26847
C 0,015 Ni 8,5 Si 0,5 Cr 22,5 Mn 1,6 Mo 3,3 P 0,010 N 0,2 S 0,010 Ferrite % vol 35

APPROVALS :
DNV (with ARCAL 39)

1877/48

Ordering information
Diameter mm PRODUCT Coated electrodes Length mm

Standard version References Quantity per packet

SV version mini vacuum packet of 1 kg in a carton. References

LEXAL E 22.9.3 N

LEXAL E 22.9.3 N HR
PRODUCT Flux cored wire

2,5 3,2 4 4
Diameter mm

300 350 350 450

Length mm

1081-1600 1081-1601 1081-1602 Packaging

210 145 80 -

1081-1610 1081-1611 1081-1612 1081-1606

Reference

Submerged arc welding wire/flux combination LEXAL S 22.9.3 N

LEXAL TA 22.9.3 N LEXAL T 22.9.3 N LEXAL F 500

1,2 1,2 1,6 2,4 3,2 2 2,4 3,2 1,0 1,2 -

1000 1000 1000 -

TIG filler metal

LEXAL W 22.9.3 N

MIG wire Ceramic support

LEXAL G 22.9.3 N KERASAF 07 KERASAF 08 KERASAF 09

* Metallic spool K 300 type (with adaptator 1090-4556) ** Metallic spool K 415 type

SAF is certificated by international organizations :

The German TV and the British Standards Institution (BSI), under standards including the European reference standard ISO 9002. With regular audits of our procedures, these organizations recognize the consistent quality and reliability of each and every electrode we ship. These rigorous inspection procedures are your guarantee of consistent high quality when you purchase SAF products.

DISTRIBUTOR'S STAMP
SAF - 13, RUE D'EPLUCHES - SAINT-OUEN L'AUMNE 95315 CERGY-PONTOISE - CEDEX FRANCE TEL. : + 33 1 34 21 33 33 - FAX : + 33 1 34 21 31 30 SAF WELDING PRODUCTS LTD - LOW MARCH LONDON ROAD - DAVENTRY NORTHANTS NN 11 4 SD TEL. : (01327) 70 55 11 - TELEFAX : (01327) 70 13 10

"SAF reserve the right to modify its products without prior notice. The information contained in this document is designed to help the user in this choice of product. SAF 1515-7501 The user should chek that the product chosen by him is suited to the application he envisages for it". 97 05 S 01 Ed. 2 Photos SAF : G. Rocskay S. Rosello et ELF

BE* 12 kg (other packaging with demand) BE* 12 kg (other packaging with demand) Sack : 25 kg bonded flux BE* 15 kg GBE** 25 kg GBE** 25 kg Packet : 5 kg Packet : 5 kg Packet : 5 kg BE* 15 kg BE* 15 kg 20 meter length 20 meter length 20 meter length

1090-5200 1090-5201 1096-1341 1095-2498 1095-2500 1095-2501 1076-5200 1076-5206 1076-5207 1090-0263 1090-0264 1090-4907 1090-4908 1090-4909