How To Weld High Alloyed Stainless Steels Castings

How to weld high alloyed stainless steels
castings
VI National Foundry Conclave

1-2 March 2013
Hotel Le Meridien, Coimbatore
Martin Larén
2013/03/02
1
Welding high alloyed stainless steel castings –
Content
Introduction
Properties, microstructure, fabrication, requirements
Welding consumables
Special designed electrodes for duplex castings
Ferrite content in duplex castings
Repair welding
Post weld cleaning
2 | Böhler Welding Group Nordic AB | How to weld high alloyed stainless steels castings I March 2013
Introduction
Stainless steels castings

High alloyed stainless steels castings is widely used in for example chemical and
off shore industries. Examples of applications are valves, flanges, fittings, and
other pressure-containing parts where a combination of high strength and good
corrosion resistance is required.
There are many various requirements regards stainless steel casting f ex ASTM
A351 / A351M - 12b Standard Specification for Castings, Austenitic, for
Pressure-Containing Parts and ASTM A 995/A 995M Standard Specification for
Castings, Austenitic-Ferritic (Duplex) Stainless Steel, for Pressure-Containing
Parts1.
Introduction
Common stainless steel castings (name, specification and type)

Alloy / Common Name Specification Grade Type
304SS, J92600 ASTM A351 CF8 19Cr-9Ni
304LSS, J92500 ASTM A351 CF3 19Cr-9Ni
316SS, J92900 ASTM A351 CF8M 19Cr-10Ni-2Mo
316LSS, J92800 ASTM A351 CF3M 19Cr-10Ni-2Mo
316ModSS, J92804 ASTM A351 CF3MN 19Cr-10Ni-2Mo-N
309SS, J93503 ASTM A351 CH20, HK40 25Cr-13Ni
Alloy 20, J95150 ASTM A351 CN7M 20Cr-29Ni-3Cu-2Mo
317LSS, J92999 ASTM A351 CG3M 19Cr-11Ni-3Mo
317SS, J93000 ASTM A351 CG8M 19Cr-11Ni-3Mo
254 SMO, J93254 ASTM A351 CK3MCuN 20Cr-18Ni-6Mo-Cu-N
2205, J92205 (4A) ASTM A995 CD3MN 22Cr-5Ni-Mo-N
2507, J93404 (5A) ASTM A995 CE3MN 25Cr-7Ni-Mo-N
2507, J93380 (6A) ASTM A995 CD3MWCuN 25Cr-7Ni-Mo-N
Content
Introduction
Properties, microstructure, fabrication, requirements
Welding consumables
Special designed electrodes for duplex castings
Repair welding
Post weld cleaning
Chemical composition
Composition (weight-%) of some duplex and austenitc stainless steels
Outokumpu EN ASTM/UNS Cr Ni Mo N Others
LDX 2101® 1.4162 S32101 21.5 1.5 0.3 0.22 5Mn

LDX 2404® 1.4662 S82441 24.0 3.6 1.6 0.27 3Mn
2304 1.4362 S32304 23.0 4.8 0.3 0.10
Duplex
2205 1.4462 S32205 22.0 5.7 3.1 0.17
2507 1.4410 S32750 25.0 7.0 4.0 0.27
4307 1.4307 304 18.1 8.1 - -
4404 1.4404 316 17.2 10.1 2.1 -

Austenitic
904L 1.4539 N08904 20.0 25.0 4.3 - Cu
254 SMO® 1.4547 S31254 20.0 18.0 6.1 0.20 Cu
Position
Hot coil
600 LDX 2404®
2507
550
Srrenght, Rp0.2 [MPa], Min. values
LDX 2101®
500 2205
Duplex
450
2304
4565
400
350
4439
300 254 SMO
4404 4438 904L
Austentic
250
4307
200
4436
150
Corrosion resistance, ASTM G150 CPT (typical values)
Microstructure
Fully austenitic steels Duplex steels

Controlled cooling Controlled cooling
 Austenite 100%  Ferrite 50%
Microstructure
Solidification and microstructure

Solidification and transformation of
Duplex steels duplex welds
The solidification starts with a

completely ferritic structure ()
followed by partly transformation into
austenite () below 1000C.
The amount of austenite is dependent
on composition and cooling rate.
During cooling carbides, nitrides,
sigma-phase and other inter-metallic
precipitations may form.
Decomposition of ferrite occurs in the
range 350-525°C (475°C
embrittlement).
9 | Böhler Welding Group Nordic AB | How to weld duplex stainless steels I June 2012
Microstructure
The ferrite content is influenced by several factors:

Chemical composition
 Composition of filler
Low ferrite
 Dilution with parent metal
Cooling time (1200  600°C)
 Heat input
 Material thickness
 Interpass temperature
High ferrite
Typical ferrite levels are within 25-65%
Post Weld Heat Treatment will reduce ferrite content in WM
Microstructure
Micro structure fully austenitic steels
• Entirely austenitic in the solution heat-treated

condition.
• May contain traces of secondary precipitates
(sigma phase).
• The contents are very low and do not normally
BASE MATERIAL affect mechanical properties or corrosion
resistance.
• Secondary precipitates can arise if the material is
exposed to temperatures between 600 and
1,000°C  minimize exposure.
• No ferrite that can dissolve impurities  increased
risk of solidification cracking.
WELD METAL
Fabrication
Hot forming
High alloyed stainless steels are in general prone to precipitations when
subjected to temperatures below app. 900C. Precipitations lowers both
ductility and corrosion resistance.
General guide lines for heat treatments:
LDX 2101® 2205 SAF 2507TM 254 SMO
Hot forming (C) 900-1100 950-1150 1025-1200 1000-1200
Solution heat treatment (C) 1020-1080 1020-1100 1040-1120 1150-1200
Stress relieving (C) 1020-110 1020-1100 1040-1120 300-400
12 | Böhler Welding Group Nordic AB | How to weld duplex stainless steels I June 2012
Fabrication
Heat treatment
High alloyed stainless steels shall in

general not be PWHT.
Duplex;
Risk of embrittlement due to inter-
metallic phases in the temperature
range 600-900C and due to ferrite
decomposition at 350-525°C.
Time at these temperatures should be
minimised.
During PWHT the ferrite will partly
transform into secondary austenite.
Reduction of impact strength to 50% compared to
solution annealed condition
Requirements
Repair welding
Shall be made using qualified procedures and welders acc. To ASTM A488.
The composition of the deposit may be similar to that of the casting or a suitable
alloy with desired corrosion resistance and mechanical properties.
PWHT after Major weld repair
Major repairs requires post weld heat treatment.
Major repair = weld exceed 20% of wall thickness or 25 mm.
PWHT shall be in accordance to standard.
In order to meet requirements the welding consumables for duplex castings
requires ferrite controlled to the upper limit, typical 45-55%. The reason is that the
austenite-ferrite balance will be changed during PWHT and the ferrite content will
be heavily reduced.
Content
Introduction
Properties, microstructure, fabrication
Welding consumables
- Special designed electrodes for duplex castings
Post weld cleaning
Welding consumables (standard types)
C Cr Ni Mo N Other Ferrite
®
Base material LDX101 0,03 21,5 1,5 0,3 0,22 Mn 5,0 50%
SMAW 3D LDX 2101 3D 0,04 23,5 7,0 0,3 0,14 Mn 0,7 30-35%
FCW LDX 2101-PW 0,03 24,0 9,0 0,4 0,13 Mn 0,9 30-35%
Solid wire LDX 2101 0,02 23,0 7,0 <0,5 0,14 Mn 0,5 40-50%
Base material 2205 0,02 22 5,7 3,1 0,17 − 50%
SMAW 2205 3D 0,02 23,0 9,5 3,0 0,15 - 30-35%
FCW 2205-PW 0,03 22,7 9,0 3,2 0,13 - 35-45%
Solid wire 2205 0,02 23,0 8,5 3,1 0,17 - 45-50%
Base material 2507 0,02 25 7 4 0,27 −
SMAW 2507/P100 3D 0,02 25,5 9,2 3,6 0,24 - 30-35%
FCW 2507/P100 0,02 25,3 9,8 3.7 0,23 - 30-40%
Solid wire 2507/P100 0,02 25,0 9,5 4,0 0,25 - 40-50%
Base material 904L 0,01 20 25 4,3 - Cu 2 -
SMAW 904L 0,02 20,5 25,0 4,5 - Cu 1,5 -
Solid wire 0,01 20,0 25,5 4,5 - Cu 1,5 -
®
Base material 254 SMO 0,01 20 18 6,1 0,20 - -
SMAW P12-R Bas 0,02 21,5 Rem 9,5 - Nb 2,2 -
SMAW P16 0,01 23,5 Rem 15,5 - Nb <0,1 -
FCW P12-PW 0,02 21,5 Rem 9,0 - Nb 3,3 -
Solid wire P12 0,01 22,0 Rem 9,0 - Nb 3,6 -
Solid wire P16 0,01 25,0 Rem 15,0 - Nb<0,1 -
Welding consumables
Special designed electrodes for welding of duplex castings

FN
Type Name C Si Mn Cr Ni Mo N PRE
(WRC-92)
SMAW Avesta 2205-HF 0.018 0.8 1.0 22.7 8.9 3.2 0.13 55 35.3
SMAW Avesta 2507/P100-HF 0.020 0.4 1.3 25.2 8.8 4.2 0.24 57 42.9
Properties as welded and after PWHT
Impact
Impact strength, Ferrite content, Fischer
Name strength, ASTM G48
PWHT (J) Feritescope (%)
AW (J)
Req. at
-50C -50C AW PWHT AW PWHT Req.
-50
Avesta 2205-HF 47 115 >50 >25 >30 56 39 35-45
Avesta 2507/P100-
42 91 >50 >40 >50 53 43 35-45
HF
Welding consumables
PWHT (5A)
Temperature = 1120°C, Holding time = 30 min followed quench in water.
Welding consumables

Impact toughness vs Ni-content in 2507/P100
Ferrite content
Introduction
Welding consumables
Post weld cleaning
Ferrite content
Manual Point Counting (MPC)

 ASTM E562
 widely used, especially on base material
Image Analysis (IA)

 ASTM E1245
 generally better option
Magnetic methods
 ”Fischer feritscope”
 rough estimate, many influencing factors
FERITSCOPE®
 widely used and often required
Ferrite content
 The ferrite content in the weld metal depends largely on the process, the heat
input and the chemical composition of the filler
 The ferrite content of the Heat Affected Zone, HAZ, is high but not as dependent of
this as the weld metal because of non fusion and identical chemistry of the base
material
 Example from IA in an Outokumpu project together with Institut de la Soudure in
France:
Ferrite content
 Example, 10 mm 2205, FCAW

 The subsequent bead heats the underlying bead, secondary austenite forms
on the upper part of this bead.
 Image Analysis gives 38% Ferrite ± 8%
Ferrite content
Introduction
Welding consumables
Repair welding
Post weld cleaning
Repair welding
Pre-weld cleaning
To ensure good weldability and reduce the need for
post-weld cleaning, all joint surfaces must be
thoroughly cleaned before welding.
Dirt, oil and grease must be removed using, for
example, a cleaning agent such as Avesta Cleaner
401 or 410.
All rough edges must be completely removed by
gentle grinding. Oxides, paints and primers must be
entirely removed not only in the joint but also in the 50
mm from the joint edges.
Repair welding
• Pre-heating not necessary. Welding outside in humid and cold

weather condition requires a slight pre-heating (max 40°C) to
avid moist in the joint
• Interpass temperature
- LDX 2101, 2404 max 150°C
- 2304, 2205 max 200°C
- 2507, 254 SMO max 100°C
• Heat input
- LDX 2101, 2404 0.3-1.5 kJ/mm
- 2304, 2205 0.5-3.0 kJ/mm
- 2507 0.3-1.5 kJ/mm
- 254 SMO  < 1.5 kJ/mm
Repair welding
Hot cracking is a certain risk when welding fully austenitic

steels. The risk is increased if:
• dissimilar joints with carbon steel
• high degree of restrain
• wrong welding parameters
| Böhler Welding Group Nordic AB | How to weld high alloyed stainless steels castings I March 2013
Repair welding
3 potential problems for duplex steels

• Fluidity and slag control slightly worse then for f ex 304 and 316
 Risk for slag inclusions (SMAW & FCW)
 Avoid narrow gaps and small joint angels
• The penetration into base material is less than f ex 304 and 316
Avoid narrow gaps and small joint angels
Risk for incomplete penetration
• High nitrogen content in base material increase the sensitivity
for porosity formation
 To thin or thick beads increase the risk
 Wrong joint preparation increase the risk due to high degree
of parent metal fusion & trapping of nitrogen gas in the
solidifying metal
 Inadequate gas protection
Repair welding
Imperfections must be removed and repair

• Grinding or plasma gauging to sound metal (use stainless tools)
• Protect the surrounding area from spatter (cardboard or choke paint)
• Consider the width and depth
• Penetrant testing
• Welding with suitable method
• Inspection
• Repair can be performed several times without harming the base metal
Establish repair procedure!!
Repair welding
Sequence for repair welding
Post weld cleaning
Introduction
Welding consumables
- Special designed electrodes
Repair welding
Post weld cleaning
Post weld cleaning
Slag Undercut
Heat oxide Iron Organic
contamination contamination
Spatter
Weld metal
Parent metal
Post-weld cleaning is critical in achieving fully satisfactory corrosion resistance.

In order to restore the corrosion resistance defects such as welding oxide, organic
contaminants and carbon steel contamination must be removed from weld and
parent metal surfaces.
Post weld cleaning
Grinding
Wrong grinding or grinding with coarse disc

may cause grinding scars that may work as
starting points for corrosion.
Coarse grinding must be followed by fine
grinding.
Post weld cleaning
Chemical methods
Removes the heat oxide and chromium depleted zone in a controlled way.
Pickling and passivation
1. Removes the discoloration, chromium

depleted zone as well as iron
contaminations.
2. The combination of hydro fluoric acid
and nitric acid penetrates the coarse
heat oxide (discoloration) and dissolves
weak areas by means of corrosion.
3. Favours the reforming of a resistant
Pickling DO NOT remove greas passive layer.
and fat
Summary
Summary
 Understand standard and special requirements
 Use right filler (duplex with controlled ferrite content)
 Careful joint preparation (grinding)
 Controlled heat input when welding (depending on steel grade)
 Clean weld area and no wind and draught
 No pre-heating
 Well controlled post weld treatment
 Use right process and products for post weld cleaning

How To Weld High Alloyed Stainless Steels Castings

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How to weld high alloyed stainless steels

VI National Foundry Conclave

Stainless steels castings

Common stainless steel castings (name, specification and type)

Composition (weight-%) of some duplex and austenitc stainless steels

Outokumpu EN ASTM/UNS Cr Ni Mo N Others

LDX 2101® 1.4162 S32101 21.5 1.5 0.3 0.22 5Mn

2507 1.4410 S32750 25.0 7.0 4.0 0.27

4307 1.4307 304 18.1 8.1 - -

4404 1.4404 316 17.2 10.1 2.1 -

254 SMO® 1.4547 S31254 20.0 18.0 6.1 0.20 Cu

Corrosion resistance, ASTM G150 CPT (typical values)

Fully austenitic steels Duplex steels

Solidification and microstructure

The solidification starts with a

The ferrite content is influenced by several factors:

Typical ferrite levels are within 25-65%

Post Weld Heat Treatment will reduce ferrite content in WM

Micro structure fully austenitic steels

• Entirely austenitic in the solution heat-treated

High alloyed stainless steels shall in

Special designed electrodes for welding of duplex castings

Avesta 2205-HF 47 115 >50 >25 >30 56 39 35-45

Special designed electrodes for welding of duplex castings

Special designed electrodes for welding of duplex castings

Manual Point Counting (MPC)

Image Analysis (IA)

 Example, 10 mm 2205, FCAW

• Pre-heating not necessary. Welding outside in humid and cold

Hot cracking is a certain risk when welding fully austenitic

3 potential problems for duplex steels

Imperfections must be removed and repair

Establish repair procedure!!

Sequence for repair welding

Post-weld cleaning is critical in achieving fully satisfactory corrosion resistance.

Wrong grinding or grinding with coarse disc

Pickling and passivation

1. Removes the discoloration, chromium

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