Zeron 100 is a super duplex stainless steel developed by Rolled Alloys (formerly Weir Materials). 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.
The UNS Designation of the Zeron 100 is S32760. [1]
Zeron 100 with a composition of 25% chromium, 3.6% molybdenum and 0.7% tungsten has good pitting resistance to various chlorides and organics acids. Zeron 100 is made to meet a minimum pitting resistance equivalent (PREn) value of 40. The ferritic structure and alloy additions, such as nitrogen provide yield strengths that are twice that of 300 series stainless steels.
ZERON 100 plate is included in the ASTM A240 specification. Its minimum room temperature mechanical property requirements are 109,000 psi [751 MPa] (ultimate tensile strength), 80,000 psi [552 MPa] (0.2% offset yield strength) and 25% minimum elongation.
Zeron 100 has a copper addition which provides good resistance to sulfuric acid. For this reason, it is used in acid leach mining applications, steel pickling and other industries where sulfuric acid is encountered.
There are modified versions of Zeron 100 for specific applications. Zeron 100FG is a fastener grade of round bar. It is a cold drawn product with higher strength properties than standard Zeron 100. Zeron 100AFP is an advanced forging grade which has been developed for use in subsea oil and gas applications where good mechanical properties must be preserved at temperatures of about −70 °C.
Zeron 100 Super Duplex was born from a research project undertaken by Dr Cecil Roscoe at the University of Manchester, England.
Tasked by his then employer – Mather+Platt – with studying the effect of various alloying additions on the mechanical properties and corrosion resistance of Zeron 25, he concluded that an optimum corrosion performance could be obtained from a duplex stainless steel with a PREn value of 40, containing low carbon and alloyed with optimum levels of Cr, Ni, Mo, Cu, W and N.
This discovery marked the invention and first use of the term 'super duplex' stainless steels.
Dr Roscoe returned to Mather+Platt and, working under the General Manager Dr Kevan Gradwell, branded the new material 'Zeron 100', before completing his PhD on 'The Structure-Property Relationship in a Series of Duplex Stainless Steels' some months later.
Mather+ Platt successfully marketed Zeron 100 primarily in the manufacture of their advanced centrifugal pumps for the oil industries, with the wrought form of Zeron 100 licensed by Mather+Platt to British Steel.
Ownership of Zeron 100 passed to Weir Pumps with their acquisition of Mather+Platt in 1987. In 2008, ownership then passed to Rolled Alloys with their acquisition of Weir Materials and Foundry. [2]
Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's resistance to corrosion results from the chromium, which forms a passive film that can protect the material and self-heal in the presence of oxygen.
Surgical stainless steel is a grade of stainless steel used in biomedical applications. The most common "surgical steels" are austenitic SAE 316 stainless and martensitic SAE 440, SAE 420, and 17-4 stainless steels. There is no formal definition on what constitutes a "surgical stainless steel", so product manufacturers and distributors often apply the term to refer to any grade of corrosion resistant steel.
AL-6XN is a type of weldable stainless steel that consist of an alloy of nickel (24%), chromium (22%) and molybdenum (6.3%) with other trace elements such as nitrogen.
Alloy 20 is an austenitic stainless steel containing less than 50% iron developed for applications involving sulfuric acid. Its corrosion resistance also finds other uses in the chemical, petrochemical, power generation, and plastics industries. Alloy 20 resists pitting and chloride ion corrosion, better than 304 stainless steel and on par with 316L stainless steel. Its copper content protects it from sulfuric acid. Alloy 20 is often chosen to solve stress corrosion cracking problems, which may occur with 316L stainless. Alloy of the same name with the designation "Cb-3" indicates columbium stabilized.
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.
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.
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 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.
Incoloy refers to a range of superalloys now produced by the Special Metals Corporation (SMC) group of companies and created with a trademark by the Inco company in 1952. Originally Inco protected these alloys by patent. In 2000, the SMC published a 61-page document entitled "High-Performance Alloys for Resistance to Aqueous Corrosion" highlighting Incoloy, as well as Monel and Inconel products, and their use in fluid environments such as sulfuric acid, hydrochloric acid, hydrofluoric acid, phosphoric acid, nitric acid, other acids as well as freshwater environments.
Cobalt-chrome or cobalt-chromium (CoCr) is a metal alloy of cobalt and chromium. Cobalt-chrome has a very high specific strength and is commonly used in gas turbines, dental implants, and orthopedic implants.
SAF 2205, also known as Sandvik SAF 2205, is a Sandvik-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, also known as Sandvik SAF 2507, is a Sandvik-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.
Duplex stainless steels are a family of stainless steels. These are called duplex grades because their metallurgical structure consists of two phases, austenite and ferrite 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 304 or 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 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 stainless steels duplex 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).
Grupo Compás, which trades as Alloy Valve Stockist, is an industrial alloy valve stockist and distributor based out of Barcelona, Spain and is recognized as one of the fastest growing service companies in Spain. Their customers come from three areas of activity: chemical and petrochemical refineries, combined cycle plants and companies related to the natural gas business, such as BASF, Repsol YPF, Saudi Aramco, Galp, Petrobras, Petronas and Marathon Oil; integrated engineering companies, like Sener, Technip and OneSteel; and valve manufacturers, stockists and specialized distributors, like Econosto and MRC Transmark. Grupo Compás supplies end users internationally, though the bulk of customers come from the US, Australia and European Union.
Pitting resistance equivalent number (PREN) is a predictive measurement of a stainless steel's resistance to localized pitting corrosion based on its chemical composition. In general: the higher PREN-value, the more resistant is the stainless steel to localized pitting corrosion by chloride.
SAE 304 stainless steel is the most common stainless steel. The steel contains both chromium and nickel metals as the main non-iron constituents. It is an austenitic stainless steel. It is less electrically and thermally conductive than carbon steel. It is magnetic, but less magnetic than steel. It has a higher corrosion resistance than regular steel and is widely used because of the ease in which it is formed into various shapes.
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.