Duplex stainless steel

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An ingot of 2507 duplex stainless steel F55.tif
An ingot of 2507 duplex stainless steel

Duplex stainless steels [1] [2] [3] [4] [5] are a family of stainless steels. These are called duplex (or austenitic-ferritic) grades because their metallurgical structure consists of two phases, austenite (face-centered cubic lattice) and ferrite (body centered cubic lattice) in roughly equal proportions. They are designed to provide better corrosion resistance, particularly chloride stress corrosion and chloride pitting corrosion, and higher strength than standard austenitic stainless steels such as type A2/304 or A4/316. The main differences in composition, when compared with an austenitic stainless steel is that the duplex steels have a higher chromium content, 20–28%; higher molybdenum, up to 5%; lower nickel, up to 9% and 0.05–0.50% nitrogen. Both the low nickel content and the high strength (enabling thinner sections to be used) give significant cost benefits. They are therefore used extensively in the offshore oil and gas industry for pipework systems, manifolds, risers, etc. and in the petrochemical industry in the form of pipelines and pressure vessels. In addition to the improved corrosion resistance compared with the 300 series duplex stainless steels also have higher strength. For example, a Type 304 stainless steel has a 0.2% proof strength in the region of 280 MPa (41 ksi), a 22%Cr duplex stainless steel a minimum 0.2% proof strength of some 450 MPa (65 ksi) and a superduplex grade a minimum of 550 MPa (80 ksi). [6]

Contents

Grades of duplex stainless steels

Microstructures of four kinds of duplex stainless steel in each direction Microstructures of four kinds of duplex stainless steel in each direction.jpg
Microstructures of four kinds of duplex stainless steel in each direction

Duplex stainless steels are usually divided into three groups based on their pitting corrosion resistance, characterised by the pitting resistance equivalence number, PREN = %Cr + 3.3%Mo + 16%N. [7]

Standard duplex (PREN range: 28–38)
Typically Grade EN 1.4462 (also called 2205). It is typical of the mid-range of properties and is perhaps the most used today
Super-duplex (PREN range: 38–45)
Typically grade EN 1.4410 up to so-called hyper duplex grades (PREN: >45) developed later to meet specific demands of the oil and gas as well as those of the chemical industries. They offer a superior corrosion resistance and strength but are more difficult to process because the higher contents of Cr, Mo, N and even W promote the formation of intermetallic phases, which reduce drastically the impact resistance of the steel. Faulty processing will result in poor performance and users are advised to deal with reputable suppliers/processors. [8] Applications include deepwater offshore oil production.
Lean duplex grades (PREN range: 22–27)
Typically grade EN 1.4362, have been developed more recently for less demanding applications, particularly in the building and construction industry. Their corrosion resistance is closer to that of the standard austenitic grade EN 1.4401 (with a plus on resistance to stress corrosion cracking) and their mechanical properties are higher. This can be a great advantage when strength is important. This is the case in bridges, pressure vessels or tie bars.

Chemical compositions

Chemicals composition of grades from EN 10088-1 (2014) Standard are given in the table below: [9]

Composition by weight (%)
ISO Steel designationEN NumberUNS equiv [10] C, max.SiMnP, max.S, max.NCrCuMoNiOther
X2CrNiN22-21.4062S322020.03≤1.00≤2.000.040.0100.16 to 0.2821.5 to 24.0-≤0.451.00 to 2.90-
X2CrCuNiN23-2-21.46690.045≤1.001.00 to 3.000.040.0300.12 to 0.2021.5 to 24.01.60 to 3.00≤0.501.00 to 3.00-
X2CrNiMoSi18-5-31.4424S315000.031.40 to 2.001.20 to 2.000.0350.0150.05 to 0.1018.0 to 19.0-2.5 to 3.04.5 to 5.2-
X2CrNiN23-41.4362S323040.03≤1.00≤2.000.0350.0150.05 to 0.2022.0 to 24.50.10 to 0.600.10 to 0.603.5 to 5.5-
X2CrMnNiN21-5-11.4162S321010.04≤1.004.0 to 6.00.0400.0150.20 to 0.2521.0 to 22.00.10 to 0.800.10 to 0.801.35 to 1.90-
X2CrMnNiMoN21-5-31.44820.03≤1.004.0 to 6.00.0350.0300.05 to 0.2019.5 to 21.5≤1.000.10 to 0.601.50 to 3.50-
X2CrNiMoN22-5-31.4462S31803,

S32205

0.03≤1.00≤2.000.0350.0150.10 to 0.2221.0 to 23.0-2.50 to 3.504.5 to 6.5-
X2CrNiMnMoCuN24-4-3-21.46620.03≤0.702.5 to 4.00.0350.0050.20 to 0.3023.0 to 25.00.10 to 0.801.00 to 2.003.0 to 4.5
X2CrNiMoCuN25-6-31.4507S325200.03≤0.70≤2.000.0350.0150.20 to 0.3024.0 to 26.01.00 to 2.503.0 to 4.06.0 to 8.0-
X3CrNiMoN27-5-21.4460S312000.05≤1.00≤2.000.0350.0150.05 to 0.2025.0 to 28.0-1.30 to 2.004.5 to 6.5-
X2CrNiMoN25-7-41.4410S327500.03≤1.00≤2.000.0350.0150.24 to 0.3524.0 to 26.0-3.0 to 4.56.0 to 8.0-
X2CrNiMoCuWN25-7-41.4501S327600.03≤1.00≤1.000.0350.0150.20 to 0.3024.0 to 26.00.50 to 1.003.0 to 4.06.0 to 8.0W 0.50 to 1.00
X2CrNiMoN29-7-21.4477S329060.03≤0.500.80 to 1.500.0300.0150.30 to 0.4028.0 to 30.0≤0.801.50 to 2.605.8 to 7.5-
X2CrNiMoCoN28-8-5-11.4658S327070.03≤0.50≤1.500.0350.0100.30 to 0.5026.0 to 29.0≤1.004.0 to 5.05.5 to 9.5Co 0.50 to 2.00
X2CrNiCuN23-41.4655S323040.03≤1.00≤2.000.0350.0150.05 to 0.2022.0 to 24.01.00 to 3.000.10 to 0.603.5 to 5.5-

Mechanical properties

Mechanical properties from European Standard EN 10088-3 (2014) [9] (for product thickness below 160 mm):

Mechanical properties at room temperature of solution-annealed austenitic–ferritic stainless steels
ISO desig.EN num.0.2% proof stress, minUltimate tensile strengthElongation, min (%)
X2CrNiN23-41.4362400 MPa (58 ksi)600 to 830 MPa (87 to 120 ksi)25
X2CrNiMoN22-5-31.4462450 MPa (65 ksi)650 to 880 MPa (94 to 128 ksi)25
X3CrNiMoN27-5-21.4460450 MPa (65 ksi)620 to 680 MPa (90 to 99 ksi)20
X2CrNiN22-21.4062380 MPa (55 ksi)650 to 900 MPa (94 to 131 ksi)30
X2CrCuNiN23-2-21.4669400 MPa (58 ksi)650 to 900 MPa (94 to 131 ksi)25
X2CrNiMoSi18-5-31.4424400 MPa (58 ksi)680 to 900 MPa (99 to 131 ksi)25
X2CrMnNiN21-5-11.4162400 MPa (58 ksi)650 to 900 MPa (94 to 131 ksi)25
X2CrMnNiMoN21-5-31.4482400 MPa (58 ksi)650 to 900 MPa (94 to 131 ksi)25
X2CrNiMnMoCuN24-4-3-21.4662450 MPa (65 ksi)650 to 900 MPa (94 to 131 ksi)25
X2CrNiMoCuN25-6-31.4507500 MPa (73 ksi)700 to 900 MPa (100 to 130 ksi)25
X2CrNiMoN25-7-41.4410530 MPa (77 ksi)730 to 930 MPa (106 to 135 ksi)25
X2CrNiMoCuWN25-7-41.4501530 MPa (77 ksi)730 to 930 MPa (106 to 135 ksi)25
X2CrNiMoN29-7-21.4477550 MPa (80 ksi)750 to 1,000 MPa (109 to 145 ksi)25
X2CrNiMoCoN28-8-5-1*1.4658650 MPa (94 ksi)800 to 1,000 MPa (120 to 150 ksi)25

*for thickness ≤ 5 mm (0.20 in)

The minimum yield stress values are about twice as high as those of austenitic stainless steels.

Duplex grades are therefore attractive when mechanical properties at room temperature are important because they allow thinner sections.

475 °C embrittlement

Aged DSS EBSD.png
Electron backscatter diffraction map of 128 hrs age hardened duplex stainless steel with the ferrite phase forming the matrix and austenite grains sporadically spread. The ferrite phase volume fraction is 58%. [11]
Aged DSS EBSD (austenite removed).tif
EBSD map with austenite grains excluded (white). The scale bar is 500 μm. Colours denote the crystal orientation and are taken from the inverse pole figure at the lower right corner. [12]

EBSD map with austenite grains excluded (white). The scale bar is 500 μm. Colours denote the crystal orientation and are taken from the inverse pole figure at the lower right corner. Duplex stainless is widely used in the industry because it possesses excellent oxidation resistance but can have limited toughness due to its large ferritic grain size, and they have hardened, and embrittlement tendencies at temperatures ranging from 280 to 500 °C, especially at 475 °C, where spinodal decomposition of the supersaturated solid ferrite solution into Fe-rich nanophase () and Cr-rich nanophase (), accompanied by G-phase precipitation, occurs, [13] [14] [15] which makes the ferrite phase a preferential initiation site for micro-cracks. [16]

Heat treatment

Recommended hot forming and annealing/soaking temperatures
UNS No. GradeEN No.Hot forming temperature rangeMinimum soaking temperature
S323041.43621,150 to 950 °C (2,100 to 1,740 °F)980 °C (1,800 °F)
S322051.44621,230 to 950 °C (2,250 to 1,740 °F)1,040 °C (1,900 °F)
S327501.44101,235 to 1,025 °C (2,255 to 1,877 °F)1,050 °C (1,920 °F)
S325201.45071,230 to 1,000 °C (2,250 to 1,830 °F)1,080 °C (1,980 °F)
S327601.45011,230 to 1,000 °C (2,250 to 1,830 °F)1,100 °C (2,010 °F)

Duplex stainless steel grades must be cooled as quickly as possible to room temperature after hot forming to avoid the precipitation of intermetallic phases (Sigma phase in particular) which drastically reduce the impact resistance at room temperature as well as the corrosion resistance. [17]

Alloying elements Cr, Mo, W, Si increase the stability and the formation of intermetallic phases. Therefore, super duplex grades have a higher hot working temperature range and require faster cooling rates than the lean duplex grades.

Applications of duplex stainless steels

Duplex stainless steels are usually selected for their high mechanical properties and good to very high corrosion resistance (particularly to stress corrosion cracking).

Further reading

See also

Related Research Articles

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<span class="mw-page-title-main">Maraging steel</span> Steel known for strength and toughness

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<span class="mw-page-title-main">Intergranular corrosion</span> When crystallite boundaries are more corrosive than their interiors

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<span class="mw-page-title-main">Austenitic stainless steel</span> One of the 5 crystalline structures of stainless steel

Austenitic stainless steel is one of the five classes of stainless steel by crystalline structure. Its primary crystalline structure is austenite and it prevents steels from being hardenable by heat treatment and makes them essentially non-magnetic. This structure is achieved by adding enough austenite-stabilizing elements such as nickel, manganese and nitrogen. The Incoloy family of alloys belong to the category of super austenitic stainless steels.

<span class="mw-page-title-main">Embrittlement</span> Loss of ductility of a material, making it brittle

Embrittlement is a significant decrease of ductility of a material, which makes the material brittle. Embrittlement is used to describe any phenomena where the environment compromises a stressed material's mechanical performance, such as temperature or environmental composition. This is oftentimes undesirable as brittle fracture occurs quicker and can much more easily propagate than ductile fracture, leading to complete failure of the equipment. Various materials have different mechanisms of embrittlement, therefore it can manifest in a variety of ways, from slow crack growth to a reduction of tensile ductility and toughness.

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SAF 2205, is a Alleima-owned trademark for a 22Cr duplex (ferritic-austenitic) stainless steel. SAF derives from Sandvik Austenite Ferrite. The nominal chemical composition of SAF 2205 is 22% chromium, 5% nickel, 3.2% molybdenum and other alloying elements such as nitrogen and manganese. The UNS designation for SAF 2205 is S31803/S32205 and the EN steel no. is 1.4462. SAF 2205 or Duplex 2205 is often used as an alternative to expensive 904L stainless steel owing to similar properties but cheaper ingredients. Duplex stainless steel is available in multiple forms like bars, billets, pipes, tubes, sheets, plates and even processed to fittings and flanges.

SAF 2507, is a Alleima-owned trademark for a 25Cr duplex (ferritic-austenitic) stainless steel. The nominal chemical composition of SAF 2507 is 25% chromium, 7% nickel, 4% molybdenum and other alloying elements such as nitrogen and manganese. The UNS designation for SAF 2507 is S32750 and the EN steel no. is 1.4410. SAF derives from Sandvik Austenite Ferrite.

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SAE 316L grade stainless steel, sometimes referred to as A4 stainless steel or marine grade stainless steel, is the second most common austenitic stainless steel after 304/A2 stainless steel. Its primary alloying constituents after iron, are chromium, nickel (10–12%) and molybdenum (2–3%), up to 2% manganese, with small (<1%) quantities of silicon, phosphorus & sulfur also present. The addition of molybdenum provides greater corrosion resistance than 304, with respect to localized corrosive attack by chlorides and to general corrosion by reducing acids, such as sulfuric acid; while sulfur is added to approve ease-of-tooling/machinability. 316L grade is the low carbon version of 316 stainless steel, which improves relative corrosion-resistance. When cold worked, 316 can produce high yield and tensile strengths similar to Duplex stainless grades.

<span class="mw-page-title-main">Ferritic stainless steel</span> High chromium, low carbon stainless steel type

Ferritic stainless steel forms one of the five stainless steel families, the other four being austenitic, martensitic, duplex stainless steels, and precipitation hardened. For example, many of AISI 400-series of stainless steels are ferritic steels. By comparison with austenitic types, these are less hardenable by cold working, less weldable, and should not be used at cryogenic temperatures. Some types, like the 430, have excellent corrosion resistance and are very heat tolerant.

<span class="mw-page-title-main">475 °C embrittlement</span> Loss of plasticity in ferritic stainless steel

Duplex stainless steels are a family of alloys with a two-phase microstructure consisting of both austenitic and ferritic phases. They offer excellent mechanical properties, corrosion resistance, and toughness compared to other types of stainless steel. However, duplex stainless steel can be susceptible to a phenomenon known as 475 °C (887 °F) embrittlement or duplex stainless steel age hardening, which is a type of aging process that causes loss of plasticity in duplex stainless steel when it is heated in the range of 250 to 550 °C. At this temperature range, spontaneous phase separation of the ferrite phase into iron-rich and chromium-rich nanophases occurs, with no change in the mechanical properties of the austenite phase. This type of embrittlement is due to precipitation hardening, which makes the material become brittle and prone to cracking.

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