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Duplex Stainless Steel
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Lean duplex stainless steel
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Standard Duplex Stainless Steel
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Superduplex stainless steel
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Hyperduplex stainless steel
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Alloying Properties
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Duplex Stainless Steel Types
Type Cr Ni Mo N PRE
Lean 20-24% 1-5% 0.1-0.3% 0.1-0.22% 24-25
Standard 21-23% 4.5-6% 2.5-3.5% 0.1-0.22% 33-35
Superduplex 24-29% 4.5-8% 2.7-4.5% 0.1-0.35% >40
Hyperduplex 27% 6.5% 5% 0.4% 49
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Chromium
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Nickel
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Molybdenum
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Nitrogen
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Manganese
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Copper
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Tungsten
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Carbon
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Mechanical Properties
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Physics Properties
Average
Specific Heat Coefficient of Thermal
Type Density Resistivity Magnetism Capacity Linear Expansion Conductivity
/g.cm-3 /μΏ.cm / J / KG K /10-6˚C-1(0-100) /W(mK)-1
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Pipe Welding
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General Welding Guidelines
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Diffences Between ASS & DSS
Problem of ASS
Hot cracking
Adusting the composition of the filler metal to provide a significant
ferrite content minimizes these problems, for the more highly
alloyed austenitic SS where the use of a nickel-base filler metal is
necessary and austenitic solidification is unavoidable.
The problem is managed by low heat input, often requiring many
pases to build up the weld.
Methodes to improve the hot cracking resistance
Limit the content of sulfur, phosphorus and carbon
Produce duplex microstructure, ferrtie content is 3 ~ 8%
Add proper content of manganese (4 ~ 6%)
Properly welding parameters (short arc, low heat input and narrow
gap)
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Diffences Between ASS & DSS
Problem of DSS
HAZ problem
DSS have very good hot cracking resistance due to the high ferrite content.
The HAZ problems are loss of corrosion resistance, toughness, or post-weld
cracking.
To avoid these problems, the welding procedure should focus on minimizing
total time at temperature in the “red hot” range rather than managing the
heat input for any one pass.
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Selection of Base Metal
Sufficient Nitrogen
The important of the base metal containing sufficient
nitrogen has been repeatedly emphasized.
If the starting material cooled slowly through the 700 to
1000 deg. Range, or if it is allowed to air cool into this
range for a minute or so prior to water quenching then
these actions have used up some of the “time on the clock”
Purchasing Guidelines for Duplex 22% Cr Stainless Steel Process
Tubing & Piping
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Selection of Base Metal
Scope This material technical sheet is intended to supplement existing material standards and
specification (eg., ASTM, ISO UNS) and project specifications for duplex stainless steel
Manufacturer Approval Materials supplied in accordance to this specification shall only be supplied by company
approved manufacturers
Manufacturing Process Electric arc or electric furnace and refined by AOD or equivalent process
Heat Treatments All material shall be delivered in the solution annealed (followed by water quench) condition
Pitting Resistance Equivalent Pitting Resistance Equivalent (PRE)=Cr+3.3Mo+16N. The PRE shall be greater than or
equal to 34.0
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Selection of Base Metal
Product Form Duplex 22% Cr Stainless Steel Duplex 22% Cr Stainless Steel
Process Tubing Seamless Pipe
Per ASTM standard. If no harness required by ASTM standard, maximum shall be HRC28,
Hardness HB271, or HV290
- Charpy V-notch (ASTM A370) - Charpy V-notch (ASTM A370)
Impact Testing -Not applicable when the maximum -Not applicable when the maximum
obtainable charpy specimen has a width obtainable charpy specimen has a width
along the notch of less than 2.5mm along the notch of less than 2.5mm
-Absorbed energy shall be 48J average and -Absorbed energy shall be 48J average and
36J single value minimum 36J single value minimum
-Test temperature shall be minus 46 deg. -Test temperature shall be minus 46 deg.
-Specimens shall be oriented transverse to
the rolling direction
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Selection of Base Metal
Product Form Duplex 22% Cr Stainless Steel Duplex 22% Cr Stainless Steel
Process Tubing Seamless Pipe
ASTM E562 ASTM E562
Ferrite Content -Ferrite content shall be determined oon a -Ferrite content shall be determined oon a
full cross section near the OD and ID full cross section near the OD and ID
surfaces and at mid-wall location surfaces and at mid-wall location
-Samples shall be electrolytically etched in -Samples shall be electrolytically etched in
either NaOH or KOH, and in such a manner either NaOH or KOH, and in such a manner
as to provide optimum contrast for austenite as to provide optimum contrast for austenite
and ferrite phase discrimination and ferrite phase discrimination
-Point cont shall be conducted at minimum -Point cont shall be conducted at minimum
of 500X magnification of 500X magnification
-A minimum of 30 fields and 16 points per -A minimum of 30 fields and 16 points per
field shall be used field shall be used
-Ferrite content shall be between 35%- 55% -Ferrite content shall be between 35%- 55%
-Ferrite content of the seam weld shall be
25%-60%
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Selection of Base Metal
Product Form Duplex 22% Cr Stainless Steel Duplex 22% Cr Stainless Steel
Process Tubing Seamless Pipe
-Samples shall be etched using ASTM E407 etchant number 98 (K3Fe(CN)4 with KOH or
Metallographic NaOH)
Examination -Sample cross section shall be examined at OD, ID and Mid-wall locations
-Examination shall be conducted at a minimum of 500X magnification.
-Intermetallic phases or precipitates are allowed up to a max. of 0.05 percent.
-All testing shall be conducted on a lot basis. - All testing shall be conducted on a lot
Extent of Testing A lot is defined as the same tubing diameter, basis. A lot is defined as a maximum of 60
thickness, heat and heat treatment charge, meters of pipe of the same diameter,
up to a maximum of 125 tubes. thickness, heat and heat treatment charge.
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Selection of Base Metal
Product Form Duplex 22% Cr Stainless Steel Duplex 22% Cr Stainless Steel
Process Tubing Seamless Pipe
-10% of all tubes shall have ferrite content determined by fischer ferrite scope
Non-destructive -Measurement technique shall be in accordance with company approved procedures
Ferrite -Ferrite content shall be between 35% - 55%
Measurement
-In accordance with ASTM A789/ A789M - In accordance with ASTM A790/A790M
Hydrostatic Test and ASTM A450/ 450M
-Weld repair of defects is not allowed
Repair of Defects
-White Pickled
Surface finish
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Selection of Base Metal
Product Form Duplex 22% Cr Stainless Steel Duplex 22% Cr Stainless Steel
Process Tubing Seamless Pipe
-Product shall be handled, shipped and stored in such a manner as to prevent or minimize
Handling, Shipment, and the possibility of free iron contamination
Storage -Product shall not be handled with bare steel hooks, chains or lifting forks without the use of
protective insulating material
-Only stainless steel wire brushes, designated for use only on stainless steel products, may
be used for brushing and descaling
-Suspected free iron contamination, such as evidenced by unusual stains or discoloration,
shall be verified by ferroxyl testing in accordance with the procedure outlined in ASTM
A380
-Free iron contaminated areas shall be cleaned and passivated, at the manufacturer’s
expense, using the procedures outlined in ASTM A380
-EN10204 – 3.1B
Certification
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Material Receving
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Handling & Storage
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Facilities
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Tools
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Clean Build Philosophy
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Clean Build Philosophy
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Clean Build Philosophy
Acetone
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Clean Build Philosophy
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Clean Build Philosophy
Sponge Pluge
Acetone
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Clean Build Philosophy
Sponge Pluge
Acetone
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Clean Build Philosophy
Ploshing 打磨
Remove all surface oxide films from both internal and
external surfaces to a minimum distance of 25mm using
the correct and autorized equipment 用允许的工具将管子
内外径距离坡口位置至少25mm内地氧化物移除
Sponge plug MUST still be in place 海绵塞子必须保持在原
位置 Min 25mm
Acetone
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Clean Build Philosophy
Fit-Up 组对(定位焊)
After sponge plug removal and final clean with Acetone
dampened cloth, commence Fit-Up and Tack in accordance with
the approval WPS 在最后清洁完成并移除海绵塞子后,开始根据
相关的焊接工艺规程进行组对
Sponge Plug MUST be returned to control point after removal
from pipe or fitting. 组对完成之后,海绵塞子必须返回原位置
Every registered “Sponge Plug” shall be accountable at the end
of each shift. 每个带有编号的海绵塞子在下一次使用前是可控的
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Clean Build Philosophy
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Clean Build Philosophy
Acetone
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Clean Build Philosophy
Wrapping Cellophane包裹的玻璃纸
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Cutting Duplex Stainless Steel
Mechanical
Sawing
Shearing
Abrasive Wheel Cutting
Water-Jet Cutting
Thermal
Plasma cutting
Laser cutting
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Sawing
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Shearing
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Abrasive Cutting
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Plasma and Laser
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Two types of plasma cutting
a. Dual flow plasma cutting power source b. Dual flow plasma cutting machine
c. Cutting surface without oxidation d. Cutting gas
d. Secondary shielding gas e. The sketh of dual flow plasma arc
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Joint Design
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Preheating
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HI and Interpass Temperature
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HI and Interpass Temperature
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PWHT
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Desired Phase Balance
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Welding Procedure Qualification
Requirement
Lab Testing
Tensile
Bend
Hardness
Macro-Sections
Micro-structural Examination
Impact Tests
Corrosion Testing
Ferrite Content
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Welding Procedure Qualification
Requirement
Because of the need to limit the total time at temperature
for the HAZ, the properties of duplex grades will be
sensitive to section thickenss and details of actual welding
practice. Therefore, “qualification” must be considered in a
broader sense, that is a demonstration that the welding
procedure that will be applied during fabrication will not
produce an unacceptable loss of engineering properties,
especially toughness and corrosion resistance.
It would be conservative to qualify the welding procedure
at every thickness and geometry of welding because the
minor differences in setup may be significant in the results
achieved in production.
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Lab Testing
Tensile
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Lab Testing
Tensile
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Lab Testing
Tensile
For pipe having an outside diameter of 3in. (75mm) or less,
reduced-section specimens conforming to the requirment
given in below figure.
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Lab Testing
Side Bend
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Lab Testing
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Lab Testing
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Lab Testing
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Lab Testing
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Lab Testing
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Lab Testing
Micro-structural Examination
Acceptance Criteria
The micro-structure shall be suitably etched and examined at
400 X magnification and shall have grain boundary with no
continuous precipitations and the inter-metallic phases,
nitrides and carbides shall not in total exceed 0.5%
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Lab Testing
Impact Test
Requirement
Impact testing of welds shall be according to following table,
full size specimens shall be applied where possible.
If two types of materials are welded together, each side of
the weld shall be impact tested and fulfill the requirement for
the actual materal.
The weld metal shall fulfil the requirement for the least
stringent of the two.
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Lab Testing
Impact Test
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Lab Testing
Corrosion Testing
The test specimen shall have a dimension of full wall
thickness by 25mm along the weld and 50mm across the
weld. The test shall expose the external and internal
surface and a cross section surface including the weld
zone in full wall thickness. Cut edges shall be prepared
according to ASTM G48. The specimen shall be pickled
(20%HNO3 + 5% HF, 60 deg., 5min). The exposure time
shall be 24 hours.
The test temperature shall be 40 deg.
The acceptance criteria
No pitting at 20X magnification
Weight loss shall not exceed 4.0 g/m2
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Lab Testing
Ferrite Content
Acceptance Criteria
For the stainless steel Type 22 and 25 Cr duplex the ferrite
content in the weld metal root and in the last bead of the weld
cap shall be determined in accordance with ASTM E562 and
shall be in the range of 30% to 70%.
Austenite
Ferrite
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Welding Methods
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GTAW (Gas Tungsten Arc Welding)
Equipment
1. Power source. Transformer/Rectifier
(Constant Amperage type)
2. Inverter Power Source. (More
compact and portable)
3. Power Control Pannel (Amp. AC/DC,
gas delay, slop in/out, pulse, etc)
4. Power cable hose (of a suitable
amperage rating)
5. Gas flow-meter (correct for gas type
and flow rates)
6. Tungsten electrodes. (of a suitable
amperage rating)
7. Torch assemblies. (of a suitable
amperage rating)
8. Power reture cable. (of a suitable
amperage rating)
9. Welding Visor (With correct filter glass
rating)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
Electrode
The most common types of tungsten used are thoriated or
ceriated for DC and zironiated with AC (Aluminium alloys).
The vertex angle of the tungsten is often a procedural
parameter and therefore gringding needs to be very controlled
activity that should be carried out on a dedicated grinding
wheel.
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GTAW (Gas Tungsten Arc Welding)
Filler Metal
Matching with 2 – 4% more nickel than in the wrought product.
The nitrogen content is typically slightly lower in the filler metal
than in the base metal.
More highly alloyed DSS fillers are suitable for welding the
lower alloyed DSS.
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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GTAW (Gas Tungsten Arc Welding)
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Post Fabrication Clean-up
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Embedded Iron (Ferrous Contamination)
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Weld Spatter, weld discoloration,
flux, slag, arc strikes
All these defects may occur during welding. They can act
as crevices and initiate crevice corrosion in chloride-
containing environments.
Welding spatter
Weld spatter can be avoided during fabrication by using an
anti-spatter compound
Weld discoloration
Weld discoloration causes a loss of corrosion resistance
due to the destruction of the passive layer.
Heavy weld discoloration or heat tint should be avoided by
inert gas shielding and by pruging the back side of welds
with an inert gas.
Heat tint cannot be totally avoided and must be removed
during postweld clean-up.
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