Avesta Welding’s flux cored wires for welding super duplex stainless steel

Johan Ingemansson, Böhler Welding Group Nordic AB

Contents
-

Summary
What are the differences between duplex and super duplex stainless steels?
The most cost-efficient method for manual welding
Weld metal porosity
Why is the highly productive submerged arc welding (SAW) method not more
commonly used when welding super duplex steel?
How does the slag’s chemical composition affect welding results?
Why two variants of flux cored wire for super duplex stainless steel?
General rules for welding with Avesta 2507/P100-PWNOR and Avesta 2507/P100-PW
flux cored wires
Results:
o Welding procedure
o Corrosion testing (ASTM G48 method E)
o Chemical composition
o Mechanical values
o Bend testing
o Corrosion testing of PA, PF welded (normal condition) and pickled samples
(ASTM G48 method A, welded against a ceramic root backing)
o Welding data
References

Abstract
The use of duplex and super duplex steels is increasing worldwide. Thus, naturally
enough,
there is great interest in the most productive welding method with the highest
possible
quality – even when welding manually. The most productive manual method is flux
cored
arc welding (FCAW). This is especially true for position welding.
Avesta Welding has two variants of flux cored wires for welding super duplex
stainless steel.
One of these, Avesta 2507/P100-PWNOR, gives a pure weld metal that satisfies the
high impact
strength requirements in NORSOK M-601 and similar standards. The impact strength of
the
pure weld metal is a minimum of 45 J at -50°C. Our other wire, Avesta 2507/P100-PW,
has
slightly better weldability and slag removal. Nonetheless, the pure weld metal
still manages
32 J at -40°C.
To ensure that appropriate mechanical properties and corrosion resistance are
attained, both
variants are slightly over-alloyed with nickel (to give the optimum ferrite-
austenite balance).
With a critical pitting temperature (CPT) above 40°C, the weld metal demonstrates
high
resistance to pitting corrosion and stress corrosion in chloride-containing
environments
(corrosion testing as per ASTM G48-A).
Both variants have been developed for welding in all positions. They give a stable
arc and
full control of the weld pool and slag.

Avesta Welding’s flux cored wire for welding super duplex stainless steels

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What are the differences between duplex and super duplex stainless steels?
The distinction between “ordinary” duplex stainless steel and super duplex steels
is that the
latter have a pitting resistance equivalent number (PREN) above 40. Now a widely
accepted
concept in industry, PREN makes it easy to rank the corrosion resistance of
stainless steels.
However, PREN does not, for example, take microstructure into account. Thus, two
steels
with the same PREN may still have different resistance to corrosion.
Expressed simply, PREN is a number that states resistance to, primarily, pitting
(i.e. pitting
corrosion). PREN is easily calculated from the chemical composition of the
stainless steel in
question. Most often, the following formula is used: PREN = % Cr + (3.3 x % Mo) +
(16 x % N).
However, there are also other variants of the PREN formula. One of these includes:
0.5 x % W.
As is obvious from the above, a higher number means, in theory, better corrosion
resistance.
It also means that chemical composition is the factor distinguishing super duplex
from
ordinary duplex. Super duplex steels usually have higher molybdenum (Mo), nickel
(Ni),
nitrogen (N) and chromium (Cr) contents. Normally, super duplex steels also usually
demonstrate superior mechanical properties (yield strength and tensile strength).
Furthermore, super duplex steels have very high resistance to crevice corrosion,
stress
corrosion, general corrosion in acids, erosion corrosion and corrosion fatigue.
The above-mentioned excellent material properties, together with the almost twice
as high
mechanical strength (yield strength and tensile strength) compared to equivalent
austenitic
steels (e.g. 254 SMO), mean that various grades of super duplex steels are being
increasingly
used in various industries. Oil and gas, offshore, marine, pulp and paper,
foodstuffs, water
purification, water desalination, flue gas treatment, desulphurisation systems
(power
industry), marine oil and chemical tankers and chemicals production are just some
of these.
Examples of common names and designations of the market’s super duplex steels are
SAF
2507, Zeron 100, DP-3W, S32760 (1.4501), URANUS 52N+, S32550 (1.4507) and S32750
(1.4410).
ASTM

EN

Outokumpu

Cr

Ni

Mo
N

PRE

Rp0.2

S31254 1.4547

254 SMO

20

18

6.1

0.20

43

300

S32205 1.4462

2205

22

5.7

3.1

0,17

35

460

S32750 1.4410

2507

25

0.27

43

530

Table 1: Typical minimum values for hot-rolled plate at 20°C (as per EN 10088).
Note the difference in strength
(Rp0.2) between the austenitic steel (254 SMO) and the two duplex steels (2205 and
2507). Note also the
difference in chemical composition and pitting resistance equivalent number (PREN)
between “ordinary” duplex
2205 and super duplex 2507.

The most cost-efficient method for manual welding

Just as other industries, welding is always seeking to reduce costs. It does this
primarily
through making it possible for welders to carry out jobs in the shortest possible
time (e.g. by
selecting a welding method that, with the highest possible productivity, gives
acceptable
quality for the application in question).

Avesta Welding’s flux cored wire for welding super duplex stainless steels

2012-10-18
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TIG welding (GTAW) generally gives higher quality welded joints. However, the
method is
rather slow and requires optimal gas shielding. Nonetheless, the high quality of
the weld
metal means that the TIG process is normally used for depositing the root bead and
a couple
of beads thereafter (i.e. the hot passes). Currently, the rest of the joint is most
often welded
using a more efficient/productive method.
Covered electrodes (SMAW, MMA welding) have gradually been replaced by solid wires
(MAG welding, GMAW) or flux cored wires (FCAW). Using flux cored wires is the most
productive of the previously mentioned welding methods. This is particularly
noticeable in
position welding (see figure 1).

Figure 1: The productivity difference in the PG (3F) position using three different
welding methods (same arc
time).

Weld metal porosity

When using solid wires (MAG welding, GMAW), it can, in many cases, be difficult to
get a
satisfactory result as regards porosity. This is because of the relatively high
nitrogen (N)
content in the parent metal (2507) – see figure 2. Here, flux cored wires (FCAW)
can be a
better option.

Figure 2: Radiograph of porosity in super duplex weld metal, position PA (1G),

welded using solid wire (GMAW,
MAG welding). Note that this welding position is considered the best for avoiding
porosity.

Even with flux cored wires (FCAW), the weld metal may exhibit small, but
acceptable,
porosity. This has primarily been noticed in overhead welding (PE, 4G) – see figure
3.

Avesta Welding’s flux cored wire for welding super duplex stainless steels

2012-10-18
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Figure 3: Radiograph of porosity in super duplex weld metal, position PE (4G),

welded using flux cored wire
Avesta 2507/P100-PW (FCAW). Note that this welding position is considered the
worst/most difficult for avoiding
porosity. However, the small number of discernible pores is acceptable here.

Compared with solid wires (MAG welding, GMAW), flux cored wires (FCAW) usually also
give considerably less spatter, improved wetting properties and a more even
distribution of
energy in the arc. This gives better side penetration (see figure 4) and reduces
the risk of lack
of fusion.

Figure 4: Note the good side penetration of the weld using flux cored wires (FCAW,
FCW) compared to that using
solid wires (GMAW, MAG).

Another pure saving, one which usually surprises many people, is how large the
difference
in costs for shielding gases actually is. Welding with solid wires (MAG welding,
GMAW)
usually requires a three-component gas. The expensive helium makes up a
considerable part
of this (normally around 30%). Flux cored wires (FCAW), on the other hand, use a
significantly cheaper two-component gas mixture (Ar +15 – 25% CO2).

Why is the highly productive submerged arc welding (SAW) method not more
commonly used when welding super duplex steel?
In normal cases, the relatively highly productive submerged arc welding (SAW)
method is
recommended for welding other stainless steels, e.g. ordinary duplex (2205) and
austenitic
steels (316L, etc.).
SAW generally gives a high quality weld metal. However, for super duplex grades,
the high
heat input inherent in the method leads to a large decrease in, primarily,
corrosion
resistance. Impact strength may also be affected. This is because the high heat
input leads to
slow cooling, which can result in an altogether too high content of intermetallic
phases.
These are formed (precipitated) in the weld metal’s and the parent metal’s
microstructure
(primarily sigma and chi phases) and can drastically impair the above-mentioned
properties.
The precipitation problem can be avoided by a well-controlled solution heat
treatment,
adapted to the material.

Avesta Welding’s flux cored wire for welding super duplex stainless steels

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With the right know-how, these intermetallic phases can be kept to a low level and
satisfactory results achieved using multipass welding. For example, in the
previously
mentioned TIG welding of root beads and subsequent passes, the following procedure
should be used: Without exceeding the recommended heat input (max. 1.5 kJ/mm), weld
a
relatively large root bead. For the subsequent 1 – 2 beads, weld using 70 – 80% of
the heat
input used for the root bead. The interpass temperature should be under 100°C. As a
rule of
thumb, it can be said that, apart from the root bead, all beads are to be welded
with a heat
input below 1.0 kJ/mm.
If the heat input is too low (normally under 0.5 kJ/mm), the cooling rate will be
too high. This
can also be harmful as it may result in the ferrite content in the weld metal and
the heataffected zone being too high. Too high a ferrite content (generally over
70%) impairs
corrosion properties and impact strength.

How does the slag’s chemical composition affect welding results?

One disadvantage of all welding methods that involve slag is that they generally
give a weld
metal that has comparatively low impact strength. In its turn, impact strength is
related to
the basicity of the slag. A higher content of basic substances gives a cleaner weld
metal with
better impact strength. However, weldability and slag removal are usually poorer.

Why two variants of flux cored wire for super duplex stainless steel?
Avesta Welding has two variants of flux cored wires for welding super duplex
stainless steel.
One of these, Avesta 2507/P100-PWNOR, gives a pure weld metal that satisfies the
high impact
strength requirements in NORSOK M-601 and similar standards. The impact strength of
the
pure weld metal is a minimum of 45 J at -50°C. Our other wire, Avesta 2507/P100-PW,
has
slightly better weldability and slag removal. The pure weld metal manages 32 J at
-40°C.
To ensure that appropriate mechanical properties and corrosion resistance are
attained, both
variants are slightly over-alloyed with nickel (to give the optimum ferrite-
austenite balance).
With a critical pitting temperature (CPT) above 40°C, the weld metal demonstrates
high
resistance to pitting corrosion and stress corrosion in chloride-containing
environments
(corrosion testing as per ASTM G48-A).
Both variants have been developed for welding in all positions. They give a stable
arc and
full control of the weld pool and slag.

General rules for welding with Avesta 2507/P100-PWNOR and

Avesta 2507/P100-PW flux cored wires
•
•
•
•
•

Weld in joints that have a root gap (a few exceptions).

Use a larger groove angle than is normal for joints in austenitic stainless steels.
In automated welding, use a reduced welding speed.
To avoid pores, do not deposit weld beads that are altogether too thick.
For fully satisfactory corrosion properties, pickle and passivate after welding.

Avesta Welding’s flux cored wire for welding super duplex stainless steels

2012-10-18
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Results

Figure 5. Note the difference in heat input between pass 1 (TIG welding, GTAW) and
passes 2 – 4 (flux cored
wire, FCAW).

Avesta Welding’s flux cored wire for welding super duplex stainless steels

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Figure 6: Corrosion testing of Avesta 2507/P100-PW weld metal – pickled samples

tested as per ASTM G48
method E at 40°C.

Avesta FCW
2507/P100-PW

Typical chemical compositions of pure weld metal, weight %

C
N
Cr
Ni
Mo
PREN
0.03
0.23
25.3
9.8
3.7
> 41

FN
≥ 30

Table 2: Chemical composition of Avesta 2507/P100-PW.

Product
(EN ISO)
E 25 9 4 N L

Tensile test, pure weld metal

Rp0.2
Rm
A5
MPa
MPa
%
650
850
30

Impact strength (ISO-V)

+20°C
-50°C

Z
%
38

60

Table 3: Mechanical values for pure weld metal from Avesta 2507/P100-PW

Tensile test

45
NOR

, welding position PA.

Impact strength (ISO-V)

Rp0.2
MPa

Rm
MPa

A5
%

Fracture

+20°C
J

-20°C
J

+46°C
J

706

844

28

Parent metal

52, 56,
63

51,
51, 52

37, 49,
44

Table 4: Mechanical values for weld metal from Avesta 2507/P100-PW

position PF, V-joint in 15 mm plate.
Avesta Welding’s flux cored wire for welding super duplex stainless steels

NOR

, shielding gas Ar + 18% CO2, welding

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Type
Side bend test

Mandrel diam., mm
4xt

Table 5: Avesta FCW 2507/P100-PW

Position

Condition

PA

As-welded
Pickled
As-welded
Pickled

PF

Bend angle
180°

Results
No cracks

NOR

. Bend test, V-joint, 15 mm plate welded against a ceramic root backing.

Weight loss, g/m

40°C
4.83*
1.52
5.23
0.95

Visual appearance
*Pitting corrosion visible to
naked eye; other corrosion
visible only with macroscope

Table 6: Results of corrosion testing as per ASTM G48 method A. 12 mm plate, V-

joint welded against a ceramic
NOR
root backing, Avesta FCW 2507/P100 .

Position
PA

Wire diam.
mm
1.2
Current
A
130 – 220

Voltage
V
23 – 31

Wire feed
m/min
6 – 12.5

Table 7: Recommended welding data for Avesta FCW 2507/P100-PW

NOR

Gas flow
l/min
15 – 18

Stick-out
mm

and 2507/P100-PW.

References
Avesta 2507/P100-PW and Avesta 2507/P100-PWNOR have already been introduced in
France,
Germany, the Netherlands, the UK, Denmark, Finland and Spain. Avesta 2507/P100-
PWNOR
has proved very successful for welding pipes in the offshore industry and pressure
vessels
subject to severe demands in respect of impact strength.

Avesta Welding’s flux cored wire for welding super duplex stainless steels

2012-10-18