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]
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]
Chemicals composition of grades from EN 10088-1 (2014) Standard are given in the table below: [9]
ISO Steel designation | EN Number | UNS equiv [10] | C, max. | Si | Mn | P, max. | S, max. | N | Cr | Cu | Mo | Ni | Other |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
X2CrNiN22-2 | 1.4062 | S32202 | 0.03 | ≤1.00 | ≤2.00 | 0.04 | 0.010 | 0.16 to 0.28 | 21.5 to 24.0 | - | ≤0.45 | 1.00 to 2.90 | - |
X2CrCuNiN23-2-2 | 1.4669 | 0.045 | ≤1.00 | 1.00 to 3.00 | 0.04 | 0.030 | 0.12 to 0.20 | 21.5 to 24.0 | 1.60 to 3.00 | ≤0.50 | 1.00 to 3.00 | - | |
X2CrNiMoSi18-5-3 | 1.4424 | S31500 | 0.03 | 1.40 to 2.00 | 1.20 to 2.00 | 0.035 | 0.015 | 0.05 to 0.10 | 18.0 to 19.0 | - | 2.5 to 3.0 | 4.5 to 5.2 | - |
X2CrNiN23-4 | 1.4362 | S32304 | 0.03 | ≤1.00 | ≤2.00 | 0.035 | 0.015 | 0.05 to 0.20 | 22.0 to 24.5 | 0.10 to 0.60 | 0.10 to 0.60 | 3.5 to 5.5 | - |
X2CrMnNiN21-5-1 | 1.4162 | S32101 | 0.04 | ≤1.00 | 4.0 to 6.0 | 0.040 | 0.015 | 0.20 to 0.25 | 21.0 to 22.0 | 0.10 to 0.80 | 0.10 to 0.80 | 1.35 to 1.90 | - |
X2CrMnNiMoN21-5-3 | 1.4482 | 0.03 | ≤1.00 | 4.0 to 6.0 | 0.035 | 0.030 | 0.05 to 0.20 | 19.5 to 21.5 | ≤1.00 | 0.10 to 0.60 | 1.50 to 3.50 | - | |
X2CrNiMoN22-5-3 | 1.4462 | S31803, S32205 | 0.03 | ≤1.00 | ≤2.00 | 0.035 | 0.015 | 0.10 to 0.22 | 21.0 to 23.0 | - | 2.50 to 3.50 | 4.5 to 6.5 | - |
X2CrNiMnMoCuN24-4-3-2 | 1.4662 | 0.03 | ≤0.70 | 2.5 to 4.0 | 0.035 | 0.005 | 0.20 to 0.30 | 23.0 to 25.0 | 0.10 to 0.80 | 1.00 to 2.00 | 3.0 to 4.5 | ||
X2CrNiMoCuN25-6-3 | 1.4507 | S32520 | 0.03 | ≤0.70 | ≤2.00 | 0.035 | 0.015 | 0.20 to 0.30 | 24.0 to 26.0 | 1.00 to 2.50 | 3.0 to 4.0 | 6.0 to 8.0 | - |
X3CrNiMoN27-5-2 | 1.4460 | S31200 | 0.05 | ≤1.00 | ≤2.00 | 0.035 | 0.015 | 0.05 to 0.20 | 25.0 to 28.0 | - | 1.30 to 2.00 | 4.5 to 6.5 | - |
X2CrNiMoN25-7-4 | 1.4410 | S32750 | 0.03 | ≤1.00 | ≤2.00 | 0.035 | 0.015 | 0.24 to 0.35 | 24.0 to 26.0 | - | 3.0 to 4.5 | 6.0 to 8.0 | - |
X2CrNiMoCuWN25-7-4 | 1.4501 | S32760 | 0.03 | ≤1.00 | ≤1.00 | 0.035 | 0.015 | 0.20 to 0.30 | 24.0 to 26.0 | 0.50 to 1.00 | 3.0 to 4.0 | 6.0 to 8.0 | W 0.50 to 1.00 |
X2CrNiMoN29-7-2 | 1.4477 | S32906 | 0.03 | ≤0.50 | 0.80 to 1.50 | 0.030 | 0.015 | 0.30 to 0.40 | 28.0 to 30.0 | ≤0.80 | 1.50 to 2.60 | 5.8 to 7.5 | - |
X2CrNiMoCoN28-8-5-1 | 1.4658 | S32707 | 0.03 | ≤0.50 | ≤1.50 | 0.035 | 0.010 | 0.30 to 0.50 | 26.0 to 29.0 | ≤1.00 | 4.0 to 5.0 | 5.5 to 9.5 | Co 0.50 to 2.00 |
X2CrNiCuN23-4 | 1.4655 | S32304 | 0.03 | ≤1.00 | ≤2.00 | 0.035 | 0.015 | 0.05 to 0.20 | 22.0 to 24.0 | 1.00 to 3.00 | 0.10 to 0.60 | 3.5 to 5.5 | - |
Mechanical properties from European Standard EN 10088-3 (2014) [9] (for product thickness below 160 mm):
ISO desig. | EN num. | 0.2% proof stress, min | Ultimate tensile strength | Elongation, min (%) |
---|---|---|---|---|
X2CrNiN23-4 | 1.4362 | 400 MPa (58 ksi) | 600 to 830 MPa (87 to 120 ksi) | 25 |
X2CrNiMoN22-5-3 | 1.4462 | 450 MPa (65 ksi) | 650 to 880 MPa (94 to 128 ksi) | 25 |
X3CrNiMoN27-5-2 | 1.4460 | 450 MPa (65 ksi) | 620 to 680 MPa (90 to 99 ksi) | 20 |
X2CrNiN22-2 | 1.4062 | 380 MPa (55 ksi) | 650 to 900 MPa (94 to 131 ksi) | 30 |
X2CrCuNiN23-2-2 | 1.4669 | 400 MPa (58 ksi) | 650 to 900 MPa (94 to 131 ksi) | 25 |
X2CrNiMoSi18-5-3 | 1.4424 | 400 MPa (58 ksi) | 680 to 900 MPa (99 to 131 ksi) | 25 |
X2CrMnNiN21-5-1 | 1.4162 | 400 MPa (58 ksi) | 650 to 900 MPa (94 to 131 ksi) | 25 |
X2CrMnNiMoN21-5-3 | 1.4482 | 400 MPa (58 ksi) | 650 to 900 MPa (94 to 131 ksi) | 25 |
X2CrNiMnMoCuN24-4-3-2 | 1.4662 | 450 MPa (65 ksi) | 650 to 900 MPa (94 to 131 ksi) | 25 |
X2CrNiMoCuN25-6-3 | 1.4507 | 500 MPa (73 ksi) | 700 to 900 MPa (100 to 130 ksi) | 25 |
X2CrNiMoN25-7-4 | 1.4410 | 530 MPa (77 ksi) | 730 to 930 MPa (106 to 135 ksi) | 25 |
X2CrNiMoCuWN25-7-4 | 1.4501 | 530 MPa (77 ksi) | 730 to 930 MPa (106 to 135 ksi) | 25 |
X2CrNiMoN29-7-2 | 1.4477 | 550 MPa (80 ksi) | 750 to 1,000 MPa (109 to 145 ksi) | 25 |
X2CrNiMoCoN28-8-5-1* | 1.4658 | 650 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.
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]
UNS No. Grade | EN No. | Hot forming temperature range | Minimum soaking temperature |
---|---|---|---|
S32304 | 1.4362 | 1,150 to 950 °C (2,100 to 1,740 °F) | 980 °C (1,800 °F) |
S32205 | 1.4462 | 1,230 to 950 °C (2,250 to 1,740 °F) | 1,040 °C (1,900 °F) |
S32750 | 1.4410 | 1,235 to 1,025 °C (2,255 to 1,877 °F) | 1,050 °C (1,920 °F) |
S32520 | 1.4507 | 1,230 to 1,000 °C (2,250 to 1,830 °F) | 1,080 °C (1,980 °F) |
S32760 | 1.4501 | 1,230 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.
Duplex stainless steels are usually selected for their high mechanical properties and good to very high corrosion resistance (particularly to stress corrosion cracking).
Stainless steel, also known as inox, corrosion-resistant steel (CRES), and rustless steel, is an alloy of iron that is resistant to rusting and corrosion. It contains iron with chromium and other elements such as molybdenum, carbon, nickel and nitrogen depending on its specific use and cost. Stainless steel's resistance to corrosion results from the 10.5%, or more, chromium content which forms a passive film that can protect the material and self-heal in the presence of oxygen.
Martensitic stainless steel is a type of stainless steel alloy that has a martensite crystal structure. It can be hardened and tempered through aging and heat treatment. The other main types of stainless steel are austenitic, ferritic, duplex, and precipitation hardened.
Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states:
Maraging steels are steels that are known for possessing superior strength and toughness without losing ductility. Aging refers to the extended heat-treatment process. These steels are a special class of very-low-carbon ultra-high-strength steels that derive their strength not from carbon, but from precipitation of intermetallic compounds. The principal alloying element is 15 to 25 wt% nickel. Secondary alloying elements, which include cobalt, molybdenum and titanium, are added to produce intermetallic precipitates. Original development was carried out on 20 and 25 wt% Ni steels to which small additions of aluminium, titanium, and niobium were made; a rise in the price of cobalt in the late 1970s led to the development of cobalt-free maraging steels.
Titanium alloys are alloys that contain a mixture of titanium and other chemical elements. Such alloys have very high tensile strength and toughness. They are light in weight, have extraordinary corrosion resistance and the ability to withstand extreme temperatures. However, the high cost of processing limits their use to military applications, aircraft, spacecraft, bicycles, medical devices, jewelry, highly stressed components such as connecting rods on expensive sports cars and some premium sports equipment and consumer electronics.
A superalloy, or high-performance alloy, is an alloy with the ability to operate at a high fraction of its melting point. Key characteristics of a superalloy include mechanical strength, thermal creep deformation resistance, surface stability, and corrosion and oxidation resistance.
Marine grade stainless alloys typically contain molybdenum to resist the corrosive effects of NaCl or salt in seawater. Concentrations of salt in seawater can vary, and splash zones can cause concentrations to increase dramatically from the spray and evaporation.
In materials science, intergranular corrosion (IGC), also known as intergranular attack (IGA), is a form of corrosion where the boundaries of crystallites of the material are more susceptible to corrosion than their insides.
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.
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.
The SAE steel grades system is a standard alloy numbering system for steel grades maintained by SAE International.
Alloy steel is steel that is alloyed with a variety of elements in total amounts between 1.0% and 50% by weight, typically to improve its mechanical properties.
Michael A. Streicher was an American metallurgist and engineer who became internationally recognized for his work on the testing and development of corrosion-resistant stainless steel alloys. He published widely in technical journals and textbooks and received numerous patents for his inventions.
Zeron 100 is a super duplex stainless steel developed by Rolled Alloys. The alloy has excellent corrosion resistance combined with high strength. It typically contains 25% chromium and 7% nickel and 3.6% molybdenum along with copper and tungsten additions. Zeron 100 has a 50–50 austenitic–ferritic structure. It also has greater resistance to chloride pitting, crevice corrosion and stress corrosion cracking than exhibited by the standard 300 series stainless steels.
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.
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.
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.
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.