The Duplex Stainless Steel Engineering Essay

The Duplex Stainless Steel Engineering Essay

Abstraction:

Duplex chromium steel steel as the name suggests is a two phased metal holding equal composing of ferritic every bit good as austenitic classs of steel. This gives duplex alloy austenite ‘s first-class opposition to corrosion and stamina along with ferrites ability to increase its strength. Higher strength of duplex chromium steel steels reduces the cost of the merchandise as it requires lower weight merchandise. Duplex chromium steel steels have a on the job scope of -500C to 250 0C. Right now most of the applications of duplex chromium steel steels are in caustic environment in procedure industries, oil and gas industries and marine environment. Duplex alloys supply broad scope of corrosion opposition value and can be used consequently depending on the demand. There is no individual step of corrosion opposition nevertheless opposing opposition tantamount figure ( PREN ) is used as agencies of ranking the classs. Duplex chromium steel steel has a good weldability but hapless forming and machining belongingss due to high strength. But the major drawback of duplex chromium steel steel is the susceptibleness of ferritic stage to 4500C embrittlement. The purpose of duplex metal is to easy replace unstained steel as the taking steel metal. At present the planetary market portion of duplex chromium steel steels is in between 1 to 3 % .

Introduction:

Stainless steel is a steel metal, but it does non eat, rust or discoloration every bit easy as steel and are besides heat resistant. It contains lower limit of 10.5 % Cr [ 1 ] . The Cr content is responsible for the metals enhanced corrosion opposition. Stainless steel can be classified into ferritic chromium steel steel, martensitic chromium steel steel, austenitic chromium steel steel, precipitation indurating metal, duplex chromium steel steel. Austenitic steel have low strength and are susceptible to corrosion peculiarly in chloride environment. Ferritic chromium steel steel has first-class opposition to emphasize corrosion checking but is less malleable and are prone to hydrogen embrittlement. This led to the development of duplex chromium steel steel. Duplex steel are called semidetached house because they have two stage micro construction of austenite and ferrite holding approximately 50 % of each. Ferritic stage is responsible for the addition in strength and austenite provides better stamina and corrosion opposition [ 4 ] .

History of duplex chromium steel steel:

Duplex chromium steel steel is a freshly found metal of steel. Although the thought of duplex steel can be traced back to the 1920 ‘s, it emerged to prominence merely in the early 1980 ‘s, developed from dramatis personae Fe. The early classs of duplex steel were metals of Cr, Ni and Mo. These classs were developed to cut down the inter-granular corrosion jobs in the early high C austenitic chromium steel steel. AISI type 329 was extensively used after World War II and was used in heat money changer tubing for azotic acid service. 3RE60 was one of the first duplex classs to be developed specifically for improved opposition to chloride stress corrosion snap. Initially developed duplex chromium steel steel provided good public presentation features but had restrictions in the as-welded status and the heat affected zone of dyer’s rockets had low stamina and lower corrosion opposition than that of the base metal. Due to these restrictions duplex steel was ab initio used in unwelded status. The progresss made in the following coevals of duplex steel were the calculated add-on of N as an alloying component. This happened in the late 1970 ‘s. Nitrogen alloying of duplex chromium steel steels provided the needed heat affected zone stamina and corrosion opposition. Duplex unstained steel of class 2205 was widely used during this period peculiarly in gas assemblage line pipe and procedure application on off shore platforms [ 2 ] .

The first dedicated international conference for duplex metal was held in St Louis, Missouri, USA ( 1982 ) . At that clip the wrought semidetached house class was being established. By the clip the 3rd conference was held in Beaune, France ( 1991 ) , the modern duplex household including the super semidetached house class was established [ 3 ] . This rapid promotion is chiefly due to the progresss made in steel doing techniques peculiarly with regard to command of N content.

Morden semidetached house chromium steel steel can be divided into five groups. I ) Lean which contains no deliberate Mo add-on. two ) Standard semidetached house. three ) 25 Cr semidetached house which have opposing opposition tantamount figure ( PREN ) less than 40. four ) Super duplex PERN 40-45 with 25-26 Cr and increased Mo and N classs when compared to 25 Cr. V ) Hyper semidetached house with PREN in entree of 45 [ 2 ] .

Structure of duplex chromium steel steel:

The chief alloying elements for duplex chromium steel steel are Cr, Mo, N and Ni. To accomplish a stable construction for processing and fiction correct degree of each of these elements must be obtained. Duplex chromium steel steel contains increased sum of Cr ( 18 % -28 % ) and when compared to austenitic steel decreased sum of Ni ( 4.5 % -8 % ) . Molybdenum is used in some signifiers of duplex chromium steel steel. Low measure of Ni ensures that a full austenitic construction is non formed [ 1 ] .

Chromium elements leads to the formation of ferrite as it forms organic structure centred three-dimensional constructions of Fe. It besides increases the corrosion opposition of chromium steel steel. But at higher Cr content more of Ni is required to organize a duplex construction. Higher Cr besides promotes the formation of intermetallic stages.

Molybdenum enhances Cr ‘s ability to provided opposing opposition in unstained steel. Addition of Mo becomes three times more effectual than the add-on of Cr when the Cr content in unstained steel is about 18 % . Like Cr Mo is besides a ferrite former and besides increases the opportunities of chromium steel steel organizing damaging intermetallic stages. Its use is restricted to 4 % in duplex chromium steel steels.

Nitrogen is a strong austenitic former and it besides increases the roughness and cranny corrosion opposition of duplex chromium steel steels. It is a low cost alloying component and most effectual solid solution beef uping component. Nitrogen delays the formation of intermetallic stages plenty to allow processing and fiction of the duplex classs. It is used in duplex chromium steel steel holding high content of Cr and Mo, to countervail their inclination to organize sigma stage.

Nickel leads to the alteration of crystal construction of unstained steel from organic structure centred to confront centred three-dimensional construction. Nickel is far less effectual when compared to nitrogen in detaining the formation of intermetallic stages in duplex chromium steel steel face centred three-dimensional construction is responsible for the addition in stamina of duplex chromium steel steel [ 2 ] .

The ferrite formers like Cr ( Cr ) , molybdenum ( Mo ) , Si ( Si ) and tungsten ( W ) are balanced by austenite formers like Ni ( Ni ) , C ( C ) , manganese ( Mn ) , Cu ( Cu ) and N ( N ) in the formation of duplex chromium steel steel construction [ 5 ] . The table1 gives some of the composing of duplex chromium steel steel.

Class

EN No/UNS

Type

Approx Composition

Chromium

Nickel

Moment

Nitrogen

Manganese

Tungsten

Copper

2101 LDX

1.4162/

S32101

Thin

21.5

1.5

0.3

0.22

5

DX2202

1.4062/ S32202

Thin

23

2.5

0.3

0.2

RDN 903

1.4482/

S32001

Thin

20

1.8

0.2

0.11

4.2

2304

1.4482/

S32001

Thin

23

4.8

0.3

0.10

2205

1.4462/

S31803/

S32205

Standard

22

5.7

3.1

0.17

2507

1.4410/

S32750

Superintendent

25

7

4

0.27

Zeron 100

1.4501/

S32760

Superintendent

25

7

3.2

0.25

0.7

0.7

Ferrinox

255/

Uranus 2507Cu

1.4507/

S32520/

S32550

Superintendent

25

6.5

3.5

0.25

1.5

Table 1: composing of duplex chromium steel steel [ 5 ]

In some of the late formed classs N and Mns have been used to cut down the Ni content which reduces the cost.

Phase formation in duplex chromium steel steel:

In add-on to ferrite ( ? ) and austenite ( ? ) a assortment of other unwanted stages may organize in duplex chromium steel steel in the temperature scope of 300- 10000C during aging or wrong heat intervention. Extra stages include ? stage, Cr2N, CrN, secondary austenite, ? stage, R stage, ? stage, M7C3, M23C6, Cu and ? stage. Furthermore in scope 300-5000C, spinodal decomposition of ferrite can happen. ? stage is most of import of these as it has important influence on stamina and corrosion behavior. Table 3 shows the stages in duplex chromium steel steels.

Table 3: stages in duplex chromium steel steel [ 6 ] .

Sigma ( ? ) stage is a Cr and Mo rich stage. It is found in big figure of duplex chromium steel steels because most them contain significant sum of Mo and Cr, which leads to the formation of sigma stage. This has to be taken into history during production as sigma adversely affects both hot ductileness and room temperature ductileness. Precipitation of sigma stage frequently occurs at ternary junctions or at ferrite- austenite stage boundaries. Precipitation of sigma can be influenced by heat intervention temperature. A high solution heat intervention temperature tends to increase the volume fraction of ferrite which will be diluted with regard to ferrite-forming elements. It decreases the rate of sigma formation [ 6, 7 ] .

The formation of Cr nitrides has become more of import with the increased usage of N in duplex unstained steel peculiarly in ace semidetached house in the temperature scope of 700-9000C. Chromium nitrides formation occurs when rapid chilling takes topographic point signifier high solution temperature because of ace impregnation of N in ferrite. Sigma stage is avoided by chilling from a high solution temperature, but this makes conditions for Cr nitrides formation becomes more favorable. This complicates heat intervention for N alloyed duplex chromium steel steel.

Secondary austenite stage formation takes topographic point due to the fact that at high temperature the fraction of ferrite in duplex steel is higher than in finished merchandise and upon chilling and aging at lower temperatures in the scope of 600-9000C that ferrite decomposes to austenite and the coveted stage proportion is obtained. The freshly formed secondary austenite has same composing has bulk austenite. This enriches environing ferrite with Cr which in bend leads to nucleation of sigma stage.

Chi ( ? ) stage is normally found in duplex chromium steel steel but in low measures when compared to sigma stage. The qi stage has inauspicious consequence on stamina and corrosion belongingss but its consequence is frequently hard to divide from sigma stage as both the stages coexist. Chi stage is of lower importance when compared to sigma stage as it is of lower volume fraction, but it can non be wholly ignored.

R stage has been found to precipitate in duplex chromium steel steel in the temperature scope of 550-7000C. It is Molybdenum rich compound. It has a rhombohedral crystal construction. R stage formation reduces stamina and critical roughness temperature. Both intergranular and intragranular precipitates have been observed. Intergranular precipitates are considered to be more hurtful with respects to opposing as they contain every bit much as 40 % Mo.

Nitride ? stage was late observed in duplex dyer’s rocket metal 22Cr- 8Ni- 3Mo [ 6 ] . It was found with in the grains and led to embrittlement and opposing corrosion in stuff aged isothermally at 6000C. ? stage has a cubelike construction.

Carbides which are C rich as in M7C3 precipitate in the temperature scope of 950- 10500C this can be avoided by chilling past this temperature scope in less than 10 proceedingss, while carbide like M23C6 precipitates at temperatures below 9500C. Carbides precipitate largely at the ?/? grain boundaries, but precipitates at ?/? and ?/? boundaries have besides been observed. But carbides precipitates are of less importance as new coevals semidetached house steels largely super duplex chromium steel steels have low C content [ 6 ] .

Copper atoms have been found in Cu rich semidetached house chromium steel steels. Copper particles promote the nucleation of austenite. Copper precipitates have besides been observed in Cu denudation super semidetached house chromium steel steel. Another stage that was late found in 22Cr- 5Ni- 3Mo is the ? stage nevertheless its effects on stuffs is non known [ 6 ] .

4750C embrittlement has been observed in duplex chromium steel steels. It was evaluated by agencies of mechanical trial like hardness trial and impact trial, magnetic measurings and scanning negatron microscopy. The best public presentation of shaped duplex chromium steel steel was obtained in solution treated status. However two hardening and embrittlement procedures may happen when these metals are heated: ( a ) sigma stage precipitation in the scope of 7000C to 9000C and ( B ) precipitation of Cr rich stage in the scope of 3000C to 6000C. Cr rich precipitate leads to progressive hardening and reduces stamina of the stuff, and it occurs due to spinodal decomposition. It is called 4750C embrittlement because it occurs quickly at this temperature, but this may besides happen at temperature every bit low as 3000C after 1000s of hours and temperature every bit high as 6000C in a few proceedingss depending on the chemical composing of duplex steels [ 1 ] .

Properties of duplex chromium steel steels:

Duplex chromium steel steel has about equal proportions of ferrite and austenite. Thus duplex chromium steel steel combines some of the characteristics of these two categories, but it tend to be closer to ferrite and carbon steel [ 4,2 ] .

Duplex chromium steel steels are about twice every bit strong as regular austenitic or ferritic chromium steel steel.

Duplex chromium steel steels have better stamina and ductileness when compared to ferrite but are non every bit good as austenite metal

Corrosion opposition largely depends on the composing of the metal. For chloride roughness and cranny corrosion opposition Cr, Mo and N content are most of import. Duplex chromium steel steels have a scope of corrosion opposition similar to that of austenitic chromium steel steels. Duplex chromium steel steel has a broad scope and can be matched for corrosion opposition with austenitic and ferritic steel classs. Piting opposition tantamount figure ( PERN ) is largely used as agencies of ranking the classs.

PERN = % Cr + 3.3 – % Mo + 16 – % N

Table 2 compares duplex steel with some austenitic and ferritic steel classs.

Class

EN No/UNS

Type

Typical PREN

430

1.4016/

S43000

Ferritic

18

304

1.4301/

S30400

Austenitic

19

441

1.4509/

S43932

Ferritic

19

RDN 903

1.4482/

S32001

Duplex

22

316

1.4401/

S31600

Austenitic

24

444

1.4521/

S44400

Ferritic

24

316L 2.5 Moment

1.4435

Austenitic

26

2101 LDX

1.4162/

S32101

Duplex

26

2304

1.4362/

S32304

Duplex

26

DX2202

1.4062/ S32202

Duplex

27

904L

1.4539/

N08904

Austenitic

34

2205

1.4462/

S31803/

S32205

Duplex

35

Zeron 100

1.4501/

S32760

Duplex

41

Ferrinox 255/

Uranus 2507Cu

1.4507/

S32520/

S32550

Duplex

41

2507

1.4410/

S32750

Duplex

43

6 % Mo

1.4547/

S31254

Austenitic

44

Table 2: comparing of duplex steel with austenitic and ferritic class [ 5 ] .

Duplex steels have really good emphasis corrosion snap ( SCC ) opposition similar to that of ferritic metal.

At low temperatures the ductileness of duplex chromium steel steel is better than that of ferritic classs. Duplex can be used at temperatures every bit low as -500C.

Duplex steels can non be hardened by heat intervention. However they can be work hardened

Machinability

Duplex chromium steel steels are machinable, but due to their high strength machining is hard and clip consuming. Besides factors such as low volume fraction of non-metallic inclusions and the low C content in duplex chromium steel steel besides contribute. Machinability can be improved by adding non-metallic inclusions. This has is employed in semidetached house of type 22Cr- 5Ni- 3Mo by increasing the sulfur contant, nevertheless this leads to cut down corrosion opposition and stamina.

Duplex steel have good weldability but non as easy to weld as austenite class. Most of the welding procedure can be used to weld duplex steels. Low thermic enlargement in duplex classs help in cut downing deformation and residuary emphasis station welding [ 1, 2 ] .

Applications of duplex chromium steel steels:

Duplex chromium steel steels have high strength and first-class corrosion opposition. It provides surrogate options to nickel rich austenitic steels in aggressive environment. Duplex chromium steel steels non merely supply more corrosion opposition but are besides low in expensive Ni. Because of its higher output strength when compared to austenitic chromium steel steels it is possible to cut down subdivision thickness of duplex chromium steel steels. This will besides cut down the cost and weight when compared with austenitic class. It can be used in broad temperature scope for -500C to 2500c [ 5 ] . 2205 is the most extremely used class of duplex steels. 2205 has a composing of 22 % Cr and 5 % Ni. It is a 2nd coevals semidetached house chromium steel steel. 2205 duplex steel has higher opposing opposition and better chloride emphasis corrosion checking opposition when compared to 300 series austenitic chromium steel steel.

Duplex steels are typically used in:

Chemical processing, conveyance and storage.

Oil and gas geographic expedition and offshore rigs

Marine environment

Pollution control equipment

Pulp and paper fabrication industries

Chemical procedure workss

Civil technology applications like building of roads, Bridgess and edifices.

Flue gas desulfurization workss

Desalination workss

Food and drink industry

Bio fuels sector [ 1, 2 ]

Drawback of duplex chromium steel steels:

Duplex chromium steel steels have high strength, high corrosion opposition and good weldability. However the high strength of semidetached house steels has its ain disadvantages when we look at it in footings of formability and machinability. Applications that require high grade of formability will govern out duplex chromium steel steels. Even when ductileness in adequate higher forces are required to organize the stuff. The metallurgy of duplex steel is complicated when compared to austenitic or ferritic classs. If non give proper processing unwanted stages can be formed in duplex chromium steel steels, which will take to embrittlement [ 5 ] .

Decision:

Duplex chromium steel steel metal is a comparatively new metal and it is still in the developmental phase. Right now a batch of research and development is traveling on, on this subject and a batch of attempt is being put into it to happen the right composing so as to be able to replace austenitic class which is right now more widely used than duplex steels. Even though a batch of involvement is put into the merchandise its overall market portion is approximately 1 % . Like any new merchandise this excessively is confronting reluctance from user to seek it out particularly in civil sector. The higher cost could be the ground why it is non used in building field where there are broad scopes of low cost metal. Though it is non a cryogenic it can be used in operating conditions every bit low as -500C and has a broad scope up to 2500C. 4750C embrittlement is one of the major hindrances for the growing of duplex chromium steel steel. Duplex chromium steel steels could be a really alternate in the field of building even though it is of high cost it does supply long life and low care and could besides be used in caustic environment. With betterments still being made with duplex chromium steel steels, it would shortly replace the present 300 series of unstained steel.