DUPLEX STAINLESS STEELS (KNOWN SINCE 1930) D. S: Honavar. As late as 1982, the Welding Handbook of American Welding society (AWS) did not recognize DSS as a separate group, but included it in ASS, e.g. Type 329, one of the older grades of DSS. Reservations about welding of Gr.329 were high because of its behaviour. Casting grade CD4 M Cu, developed in 1950s was known for brittleness when welded. Early 1980s marked the beginning of rapid development of DSS based on studies of metallurgical behavior and corrosion ‘resistance. Rise in application requiring superior resistance to pitting corrosion and stress corrosion cracking which could not be met by ASS grades, provided scope for development of DSS within the limitations of Nitrogen addition up to about 0.2% i.e. PRE of about 35. The VOD* process helped to bring down carbon to less than 0.03%, but nitrogen could not be increased beyond 0.2%. Then the new process of AOD** was a breakthrough i.e. increase of nitrogen addition beyond 0.2% and up to 0.3%, and thereby opened up the way to super duplex stainless steel with PRE greater than 40. Thus, rapid development of SDSS from 1990 can be attributed to: 1 Understanding of the key role of Nitrogen in controlling the ferrite austenite balance and thereby resistance to pitting and crevice corrosion, and enhancing by almost 100% the YS and UTS levels of ASS. Thus, YS of ASS 210 MPa (30 KSi) & DsS 425 MPa (60 Ksi) 2. Introducing the higher levels of N at greater than 0.20% through the AOD process ‘Thereafter, commercial exploitation through possible variations took place, keeping pace with the industry needs in the hydrocarbon sector, oil and gas, chemical process industry. ‘And now, the HDSS has entered the market with Nitrogen at more than 0.4% and PRE of about 48 to tackle the highly corrosive conditions in sea water. Higher ferrite level results in making DSS more ferromagnetic and thereby have higher thermal conductivity and lower thermal expansion than ASS. Thus, their compatibility with carbon steels and low alloy steels in terms of these two physical properties becomes a plus, Point to controt stress level in welding with carbon steel in pressure vessels where SR is not involved. It has to be noted that low temperature precipitation reactions render DSS unsuitable if SR is called for. 3, 100% ferrite when chromium equivalent is greater than 1.85 x Ni equivalent. DSS base material grades have ratio of 2.2to 3.5. *VOD = VACUUM OXYGEN DECARBURISATION. ** AOD = ARGON OXYGEN DECARBURISATION.DUPLEX STAINLESS STEELS (Continued). 4. High Chromium content +N, é& often also Mo, impart to DSS superior resistance to both pitting and crevice corrosion (ASTM G 48—A & B). Duplex structure imparts very much higher strength (in relation to ASS) and allied with high corrosion resistance and very good resistance to stress corrosion. This exceptional combination of strength & corrosion resistance, fer superior to that of ASS, has helped to make DSS the preferred material of construction for: a) Tanks for corrosive media, b) Structural components ©) Tankers for chemicals, 4) Wide range of offshore applications. 5. Working temperature range: best -40 to +250°C, With limits of -60°C to +300°C. 6. Very rapid cooling, as with laser welding, tends to make austenitic welds less feritic, & has the opposite effect in duplex alloys, i.e, increase the ferrite. 7. Restricting heat input to under 1.6k)/mm & interpass temperature under 150°C helps to minimize each of the two risks 2) formatioin of intermetallic phases from long exposure to 600°C - 900°C range (same as for carbide precipitation), & b) greater micro segregation during solidification in more highly alloyed grades. 8. Problem of Precipitation Reactions: ‘A number of such reactions can take place over a range of temperature below 1000°C and these are time and temperature related. Many of these precipitations embrittle the duplex alloys and are to be avoided. Undesirable phases as well chromium nitride has to be avoided. Furthermore, the higher levels of CrMo & W tend to accelerate the formations of the precipitates, particularly, Sigma & Chi phases. This acceleration has the potential implication with respect to embrittlement during PWHT or multi pass welding. These Jower temperature reactions effectively limit the use of DSS to temperature below 280°C (535°F)”. . 9. ASTM A 240 for wrought DSS & A 890 for cast DSS, specify tensile property requirements.