SANDVIK) L___ IMPROVED CORROSION PERFORMANCE IN oe SS eeCONTENTS ‘THE CHALLENGE 3 ABSTRACT 4 INTRODUCTION 5 WELDING CHALLENGES 6 EXPERIMENTAL PROCEDURE 8 RESULTS " DISCUSSION OF RESULTS 2 CONCLUSIONS 8 REFERENCES 8 s contacts 16 : APPENDIX 1 - WELDING CHECKLIST ” : 2 “Sandvik whitepaper Pocticalaspectsar weldingtor duplex anssupertlex stiles toeTHE CHALLENGE In the offshore oil and gas industry, achieving good corrosion resistance in the welds of duplex and super-duplex stainless steel pipes, tube and other infrastructure can be challenging, This is especially true for localized repair welding of parts exposed to harsh, chloride-containing environments. The challenge is to maintain the favorable mechanical strength and corrosion-resistant properties of the duplex material while avoiding intermetallic microstructural changes that can arise in the heat affected zone. Not only does this require a skilled welder, but a deep knowledge of joint preparations, filer metals, proper shielding and root, gases, welding techniques and even post-weld treatment. This white paper is part of a series from the Research and Development Department (R&D) within the Sandvik group. Itis based on published scientific papers with NACE International and other independent institutes. The content has been slightly modified in agreement with the author to make it more accessible for a broader range of professionals. Itis part of our ongoing efforts to open up new possi ies for the oil and gas industry, reinforcing our commitment: WE HELP YOU GET THERE. ‘Sukamal Naskar Weldng& Teenncal Cxget Sandi Wsterals Technology Email sukamal nackon@sandikccom Sandvik whitepaper [Practical aspect of welding ‘er cle and suparduplexstoinlese setABSTRACT For demanding offshore oil and gas applications, duplex (UNS $31803) and super duplex (UNS $32750 and UNS $32760) stainless steels provide excellent corrosion resistance and high mechanical strength. Duplex steels have heterogeneous microstructures: vith roughly 50% austenite anc 50% ferrite, amicra~ structuralblance that is achieved by controling the chemical composition and using special heat treat- rments'2, The high corrosion resistance of duplex steels ensures significantly more uptime than carbon steels and conventionalstainless steels, while the mechanical strength allows for ighter constructions, more com- pact system design and thus reduced welding, FINDING THE OPTIMAL BALANCE ‘When welding duplex and super-duplex steels, the biggest challenge is to maintain an optimized balance between the austenite-ferrte microstructure inthe finalweld metal as wellas the desired mechanical properties. The purpose of this paper isto share our knowledge regarding the various practical fabrication ‘especis of duplex and super-duplex stainless steel welding. The paper provides practical advice on how to bring out the best of these complex materials as well as recommendations on haw to retain the optimal balance: of the duplex / super-duplex microstructure during and efter welding, CORROSION TEST ON 10 WELDED SAMPLES Ten samples of super-duplex stainless steel pipe in two different sizes were welded and then tasted by liquic penetrant test (LPT), radiographic test ®T) and finaly ASTM G48 Method A corrosion bath test at 40°C for 24 haurs. 8ased an these tests, this paper provides an ‘overview of which temperatures, shielding and root gas. mixes and other parameters are optimalto avoid the formation of any detrimental intermetallic phases or Welding defects. Tne results of these tests are high- lighted in the results section and summary. ey words: Duolox stainless steak suaer-duplen Stanlss steel welding, corrosion es, ere, ustonte “THE PURPOSE OF THIS PAPER IS TO SHARE OUR KNOWLEDGE REGARDING THE VARIOUS PRAC- TICAL FABRICATION ASPECTS OF DUPLEX AND SUPER DUPLEX STAINLESS STEEL WELDING. ‘SUKAMALNASKAR Sandvik white paper |Prctcalospec of woking or plex and suparduplexstonless setINTRODUCTION Over the past decades, duplex stainless steels have built strong reputation in the offshore oll and gas Industry due to a number of attractive feature mechanical strength, corrosion resistance and lighter constructions than those built using carbon steels. Their two-phase microstructure, with approximately fequalamounts of austenite and ferrte,imparts ahigher strength than corresponding austenitic grades and pro- Vides good resistance to stress corrosion cracking. The lower nickel contents of duplex grades, typically nthe range of 5-10% compared with 8-25% in the austenitic, grades, gives cost advantages. However, the welding of duplex stainless steels must be handledwith care to avoid ‘embrittlement or the formation of impurities the weld, BALANCED TWO-PHASE MICROSTRUCTURE Duplex and super-duplex stainless steels are characterized by a two-phase microstructure that contains approximately 45-65% sustenite, which is embedded asislands ina matrix of 25-55% ferrite, Since both phases prevent grain growth, means that "DUPLEX STAINLESS STEELS HAVE BUILT A STRONG REPTATION IN THE OFFSHORE OIL AND GAS INDUSTRY DUE TO A NUMBER OF ATTRACTIVE FEATURES: MECHANICAL STRENGTH, CORROSION RESISTANCE AND LIGHTER CONSTRUCTIONS THAN THOSE BUILT USING CARBON STEELS. SUKAMAL NASKAR, duplex stainless steels have a fine grain structure. What's more, due to ahigher concentration of grain boundaries per unit surface area, super duplex stain- less steels offer very high strength, ‘CHROMIUM & MOLYBDENUM STABILIZERS For the most part, such corrosion resistant alloys (CRAs) are produced using chromium (Cr, nickel {NI molybdenum (Mo} and nitrogen (N}. Chromium and molybdenum serve mainly as ferrite stabilizers while nickel and nitrogen are used as austenite stabilizers, Toobtain the desired ferrite-austenite mix, al these. alloying elements need to be in balance in the base materials as wellas suitable welding consumables, PRE MEASUREMENT ~A GOOD BENCHMARK One key benchmark for assessing localized corra- sion and checking weld quality is the pitting corrosion resistance equivalent number PRE}, as defined below. PRE = %Cr + 3.3 (%6Mo) + 16 (@4N) In addition to determining the susceotibilty ofan alloy to pitting, this formula is widely used as a guide forthe usability of corresponding welding filles. Typically UNS 831803 hes a PRE value of 35 whereas UNS $3275 ‘and UNS $22760 have PRE values of 42. Such values provide an indication of the pitting resistance of an alloyin elation to the alloying content. The very high mechanical properties of duplex and super-duplex stainless steels are achieved asa result of the ferrite and austenite structure along with fine grain structure. ‘Tne tensile properties are governed by ferrite phase while toughness properties are governedby austenite phase in conjunction with fine grain structure, Sandvik white paper [Practica aspects of eling for lex and super duplex stainless selWELDING CHALLENGES ‘The welding of duplex and super duplex stainless steel for offshore and subsea operations can pre sent a number of challenges due to the sudden intro- duction of extreme heat followed by rapid cooling. During welding or other types of heat treatment, whether isethermalor non-isothermal, several struc- tural changes may occur in the microstructure of duplex stainless steels, FERRITE PHASE - MORE SUSCEPTIBLE For the most part. these changes affect the ferrite phase with its richer concentrations of chromium (Cri ‘and molybdenum {Mo}. Another reason the ferrite LOW COOLING IN THE TEM- PERATURE RANGES OF 550°C. TO 900°C CAN LEAD TO THE FORMATION OF DIFFERENT TY- PES OF INTERMETALLIC PHASES: THAT ARE DETRIMENTAL TO THE MECHANICAL AS WELL AS COR- ROSION PROPERTIES OF DUPLEX AND SUPER DUPLEX MATERIALS.” SUKAMAL NASKAR, phase is more prone to structural change is the more ‘compact lattice in the crystal structure, so-called Body Centered Cubic (BCC), which leads to diffusion rates of alloying elements that are almost 100 times faster than ‘those in the austenite phase with its Face Centered Cubie FCO) crystal structure UNDESIRABLE PHASE CHANGES Slow cooling in the temerature ranges of S50°C to 900°C can lead to the formation of different types of in- termetallic pnases thatare detrimental to the mechanit ccalas wellas corrosion properties of duplex and super duplex materials. Essentially, the higher the degree of alloying elements, the greater the possibly to form intermetallic phases and thus the more challenges in the fabrication process, INTERMETALLIC PHASES MORE LIKELY IN ALLOYS Due to the higher alloy contentin super duplexes ‘such as UNS $32760 and UNS $32750, they are more prone to the precipitation of intermetallic phases lke ‘the sigma phase, chi phase and R phase than a duplex. like UNS $31803. Since both duplex and super-duplex stainless steels are rich in Gr and Mo, they are also ‘more likely to form sigma phase than a lean duplex. However, by increasing the concentrations of Crand Mo, itis possible ta shorten the Time-temperature transformation (TTT) curves of the sigma phase, thereby increasing the stabilty region of sigma phase. A.quantitative chemical analysis using electron microprobe analysis (EPMA) shows that Cr, Mo and Si were enriched in sigma’. The addition of nitrogen helps to suppress the formation of sigma by reducing the difference between Cr and Mo cantent in the ferrite and austenite phases. Sandvik white paper |Proctcalospeci of welding or lex and suparduplexstoinless tetWELDING CHALLENGES SIGMA PHASE RISKS OF EMBRITTLEMENT. Sigma phases a tetragonally close-packed structure that is very bitte in nature an thus has a negative ef- fect on the mechanical properties of the duplex, Since sigma phase isbrittle in nature, hardness levels can bbe used to determine its presence in the base metal as wellas weld metal, However, upto 4% presence of sigma phase has no significant impact on hardness! hence hardness measurement is not appropriate to cconchide the presence of sigma phase. CORROSION-RESISTANCE CHALLENGES Aparl from reducing mechanical strength, sigma phase elso has a negative impact on the corrosion-resistant propertios of the duplex. Corrosion properties are reduced at lower temperature due to the formation of, secondary austenite, While thermogynarically stable, the eustonite formed at low temperature also contains lower amounts of Cr. Mo and, most likely nitrogen than, primary austerite. This altered chemical composition results in lower PRE values at some localized areas on the average matrix, making secondary austenite more. susceptible to the formation of pitting. AVOIDING CHIAND R PHASES Inaddition to the detrimentaleffects of sigma phase and secondary austenita, cuplox stools can precipitate cchi phase, 8 phase and chromium nitrides. Tungsten can be used a8 an alloying element to stabilize the chit phase ang help move the TTT curves towards a shorter time period. The R phase is molybdenum rich interme- tellic compound and usually forms al 550-700°C, but, its practical importance is less since ittakes longer to nucleate, (CHROMIUM NITRIDE ISSUES: The biggest challenge when welding duplex steels is the presence of chromium nitrides and sigrna phase together in the weld metal 2s well as base metal of ne duplex family. Chromium nitride is formed during iso- thermal heat treatment in the temperature range of 700, = 900°C follawing too fast cooling tromhigh tempera ture. While the solubility of nitrogen in ferrite is lower, itincteases at higher temperatures. However ithas significantly nigher solubilty in austenite, At higher temperature, due to increasing temperature gradient for cooling, nitrogen does not have enough time to diffuse in austenite and has Imites amount of austen- ite formation. As a result, when ferrite formations are ‘SIGMA PHASE IS A TETRA- GONALLY CLOSE-PACKED STRUCTURE THAT IS VERY BRITTLE IN NATURE AND THUS. HAS A NEGATIVE EFFECT ON THE MECHANICAL PROPERTIES OF THE DUPLEX.” SUKAMAL NASKAR, supersaturated with nitrogen, chromium nitrides form at the ferrite grains or at grain boundaries of 8/6 or Bly, ADVANTAGES OF NITROGEN With duplex stainless steels, nittogenis beneficialinthe rapid heating and slow cooling occuring in welding op~ ‘erations. Higher nitrogen contentincreases the refor mation rate of austenite in the weld metal and HAZ (heat affectedone), giving shorter distance for nitrogen to diffuse from austenite to ferrite. Nivogen has 16 times, influence on PRE value and hence can significantly contribute to pitting corrosion resistance on weld metal aswellas base metal BENEFITS OF SOLUTION ANNEALING When manufacturing duplex and super-duplex base tubes and pipes, solution annealing is pert ofthe final ‘operations to prevent intermetallic phases or defects, However, due to structural integrity and economic. easibily, welded joints do not go through the solution annealing process. As a sult, the biggest challenges, {or duplex and super duplex welding are to avoid intermetallic phases, oblain the desired microstructure ‘and maintain the proper ferrite-austenite phese balance throughout the matrix to achieve the desired mechanical and corrosion properties Naturally, tube and materials fabricators in the oilanc {92s industry must carry out welging in carefulaccord- ance wilh sirict guidelines. Repair welding is even more ‘complex since one isnot starting with fresh joints. This ‘can present tougher challenges in terms of passing the 24-hour corrosion test for ASTM G48 metnod A, ‘Tne fabrication of duplex and super duplex stainless steel tubes enc pipes with welding processes and ‘corresponding consumable selection depends on the several project technical requirerrants. Sandvik white paper |Prctcal aspect of welding or plex and suparduplestanless setWELDING CHALLENGES SELECTING THE RIGHT CONSUMABLES The selection of suitable welding consumables de- pends on anumber of key criteria: corrosion testing impact testing, the ferrite number or ferrite percentage requirement on welding metal and HAZ (heat affected zone. The right welding filer materlalis selected for duplex steels UNS $32205 or UNS $31803, depending on the ASTM G48 Methos A corrasion testing require~ ‘ment at 20°C; 22°C and 25°C. The mast suitable con- surmables for super duplexes lixe UNS $32750 or UI 832760 are selected on the basis of corrosion testing temperatures at 40°C, 42°C and 60°C, Welding consumables are selected on the basis of three wolding options: 1. Welding of root pass, second pass (cold pass) ill pass and cap pass by matching weld metal chemis- try tobase etal 2. Welding of oot pass by over alloying welding con- sumable followed by cold pass, fil pass and cap pass by matching welding consumables to base materia 3. Welding of root pass, second pass (cold pass) pass and cap pass by over matching welding metal chemistry to base metal ‘Among the above options, option two is most monly used for duplex steels to achieve safe welding with optimal esults. Since the pipe walls of duplex +r duplex materials are generally thinner than, carbon or low alloy steels, he most commonly used welding process is gas tungsten are welding (GTAW), REPAIR WELDING IS EVEN MORE COMPLEX SINCE ONE IS NOT STARTING WITH FRESH JOINTS." SUKAMAL NASKAR, Gas tungsten are welding (GTAW, also known as tung- sten inert gas (T1G) welding, 's an are welding process ‘thatuses anon-cansumable tungsten elactrade to produce the weld. Other welding options are as follows: 1. Shielded metalare welding (SMAW) 2. Submerged ar welding (SAW) 3. s metal arc welding (GMAW) When using the GTAW process, duplex grade materials, are welded with AWS A5.9 ER2209 fller duplexes are welded with AWS A5.9 ER: welding consumables, other important factors in passing the ASTM G48 Method A corrosion testing include the following: shielding gas composition and flow rate; purging gas composition and flow welding technique: oxygen level: heat input: inter-pass temperature; welding position, tude and pipe ciameter tube and pipe thi st sample preparation; and welder silEXPERIMENTAL PROCEDURE Our corrosion testing of multi-pass welds was limited to two different sizes of super-duplex_ stainless stee! pipe UNS $32750: 1 inch/ Schedule 10nd? inch/ Schedule 160. The only welding process used was gas tungsten arc welding (GTAW), with welding consumables matched tothe base material: AWS A5.9 ER2594 welding wire. Ourmain objective was to eliminate possible causes 2.Ctoan envionment ‘Theweldingwasearried ostin 2 clean, ar conditioned ware Shop with wooden fors oy 2 Ssngle weldo’ using now hand ‘loves. Both te finer and? Inen pies wore cleaned wit scetone te remove alforeion Dariles, pais olend other 1.66 pipe welding certification test. ‘Thewetting wos done with SGpipefixedata as" angle to thease postion tepane of failure in the super- duplex UNS $32750 pipe, which had been welded with ler FR2594, following corrasion tested in accordance with the ASTM Ga8 method A for 2a hours at 40°C, ‘The main variables considered as parameters were: root pass heat input, second pass (cold pess) heat input, interpass temperature, shielding gas flow rato, purging gas flowrate and sample preparation. 4: Premixed gas eyinder The shielding ardpurging gas usea as Avgon'2%¢ntrogen, ‘supplied rom remixec gas eytnger, 3. Calibrated oxygen monitor ‘Wisntne hep ofa caloratoc ‘oxygen monitor: the oy Ipvelwas kept below 109 fapmon the oat sce during welding Procticalespect of weking or d.plexandsuper-duphx lanes see!EXPERIMENTAL PROCEDURE 5. Caliorated 5.Cleaning TIGrods welding machinos ‘withacetone CCaloratedwelcing machines An ronetres gracing dse ane were aouses curing the ‘welsing Bom shisteing gas and purging gas wasused fromro0: pags to oap pass of theweloing, A cabbrated d= talintrumest wae al alwelcing curr 9 during welcing Intorp2ss temperature was powerbrush were used the whiean ASME-quattiod welgerwas used during weld ino, Prone earth connection fo tothe tubes ane the walang machine was checked before {nc during welcing. Welding currentondthe vekoge were keprbelow 100°C aug measuredclose the welding weloing, rea a reduce amps oes de ssitance rom the powsr TIGtodewore also propery with acetone clean ay forelgnporiles the sure, Following welcing aliquid penetrant test LPT) and radiographic test (RT) were performed on all test cou- pons to check for any surface and subsurface welding defects prior to sending the samples to the laboretory for the ASTM G48 Method A corrosion testing, The filler metals in all the test coupons had a root-pass diameter of 1.6mm followed by 2.4mm in diameter unt the cap pass. The welaing trials wore conducted ina fabrication yard to simulate the actual fabrication envi- ronment for mass production instead of doing ‘an RAD facility, TABLE 1:SUMMARY OF TESTSAMPLES. “cuting pipes with bana saw Alltho piesworecutwitha band saw machine 8.Fi-up procedure Thepines wer Atter welding, alten samples according to the iffer- ent parameters, we sent tham for liquid (aye) penetrant lesting (LPT) and radiographic testing (RT), For all the samples, LPT and RT are regarded as acceptable forms of testing according o the American Society of Nondestructive Testing ASNT NDT Level-Ilcertiica- tion program. Finally all the samples were sent toa ‘SAC-SINGLAS accredited laboratory in Singapore for the corrosion testing as per ASTM G48 method A for period of 24 hours, Semole Dimension Heat /PRoot Heat P2ndpass WIFiV&cap Shleldinggas Purging gas number fowrate ow rate Sample? Tnen Bbe 2 Tas LPM Sample? Binsnsipe 22 B20 LPM Semple Ten pao 21 220) 25LPM Sample Pinenibe 70 056-058 PaLPw Samples Then pipe 128 085-090, 25LPM Sempre Zioraipe 085, 072-082 7a 5PM Sampte? Then sip 1 0.98-140 SUP TaLPwr Sampes Binenaipe 2 097 TSuP ‘ace Semple Tineh pe a7 080-13 TSUN Pi Sompieto Zinchope a7 e314 TBLPM Pa ‘ll te samates wer Heatinputwas al 5 androot gaps of3-4rm. at summarized Tale 1060) ne the une,RESULTS The test results of ASTM G48 Method A, at 40°C with ‘soaking time of 24hrs are summarized in Table 2. Sanstonumber Testing Conction Weight Loss Piingondition —_PrungLecation Sanpte Aswatded 253 gh Pring abserved oat e30 Sampte? Aswolded Tapa Ping aoeerve8 Roots cao Samples Peking passvation 1822 gi Ping observed ea Sample Peking kpassvation 1025 Ping abserved Tea Samptes Peking passivation 1249 in? Phting osnee8 Root op Somptes Peking passivation 825gh Pring observed Feat ecao Sanpie7 ening kpasswation 301 gm No pitting ooserved Nat Apotesbi Somotea Peng &passvaion 029.n To iting oaserved Nat Apotcobe Samples Peking &passvation 422g? Pricing cose Sample cros oat serpie® een 2 butraptatroot cap Snowe 9 Fusing kpassvaton _Oabam™ Tapia corered Natanprenore Sandvik whit paper Paciza specs welling disor spend stains steDISCUSSION OF RESULTS Most of the technical specification and codes re~ ferred to in this study are based on the standards of the Norwegian Petroleum Industry (NORSOK M-60") and specifically the international ASTM G48 Method A SAMPLE 1 Figures 98 10/1-neh pipe “The rt sample wos walaed with a ign icantly higher heat nou at toot aass and second pass. w tha very nigh gs Taw ate or both shieliing ard pursing gases. The vsualsrows tne same following carosion esting preparedin as welded canaten without sci pickIng and passivation conition Here we noted. ‘weight oss of 42.834 with visual ping occuring atthe root ‘welsaewela8caplocstion, Corrosion Test, with a temperature of 40°C and soaking time of 24 hrs. The acceptance criteria of the ASTM (G48 corrosion test s ‘no visual pitting at 20X magnif- cation’ and a “maximum weight loss of 4gim2" Figureo Figure 10 ‘SAMPLE 2 Figures 11 8121 24neh pipe ‘This 2-nc super auplnnas alzowelsecvwitha significantly higher heat input oroat pass and ecard pass wha very igh ga fow rate an both shielding and surg nggas. The corrosion test somple wos prepares an ae welded conation without acid poking and passivation condton. Theresuit ofthe est ‘Showed weight lose of 22,84ghn uth viuateting at root 2s wel ase cap locaton. Itisworvhnoting that 1=nch pipes are more difeultto weld than 2inen pipes due ta ther greter ervature and thickness to cortrolthe cerraet wslaing parameters. Goth Samale 1 ‘and Sample 2hoa wory high ges low rate which evgenty cle atproteet the weld metalaspecaly wellen tne rect sce ‘and eausen very high iting th egaifieant weigh oss. addition. samples 1 and 2 were preparea without acid ickling ‘and passivation. meaning twas not possioe o remove the Undesived oxides, foreign particles, heat tints anger Imouritie that cause sgafiean: weigh loss when exposee toaggressive acid media [10% fernc crlonde nesanyatate [FeCl 6H,0) solution) in ASTM G28 method Atos: Figure 11 Figure 12 Sandvik white paper |Proctcal aspect of welding or plex and suparduplexstoinless tetRESULTS DISCUSSION SAMPLES Figures 138 141 14nch pipe Forthe |-inch pipeused n Samle3, we appladsilarwelirg parametersbut. during sample preparation eppleg acid picking ‘whic ac NO, and hyo minutes, The esuR chows the we nto mandptting vasrot ob ppting i stilonserved ucest0 15.22) crved onthe cap ise aknough root Figure13 Figuro14 SAMPLE 4 Figures 188 16/2-nchpipes ‘The 2-ncnpipesin Sample 4 were welseswithlowerheatinpat compareto amples 1289 andthe sleding gas ow rate was leo skghtly reduced, wile keeping te purging aoe ow rat the ame, The d ference between the hea: nput ct root pass ana socand pass wasraticeable. iting was coservod atc wth weightloss but napttng sta, Figure 15 Figuro16 SAMPLES Figures 17 & 18/ 14h pipe The Isinch pipe mn Sample 5 was weldedwith lower heat inaut than samples 1,2 43 and xept snielaing gas fow ate ancpurgng 428 fowrate sare as sampls 12 &2, Te diferencovetwoen ‘oat pass and second pass heatinput was sigifearilyaferent. Peng was observed at root pass & cap pass th woight bs, ‘Teh gher gas ow rate caused a negative effect on me shielding oftherootwelgandhence signficane ptr, Figure17 | Figuret6 SAMPLES: Figures 19, 20,21 For this 2uinch cuplexpioe the heat inputan both aot pas ane signfcantlyrecucsd compare to sarmales 2.3.48 5. However, the gas low ale maskepl ihe some, Due towerheat input location was cbaerved wthlacko fusion re pitting Fg. 19) along wth areductonin weight oss compare t previous samples. omever iting was still observed onthecap sand root areas Fi. 20.21, Figure 19 Figure20 Figure21RESULTS DISCUSSION SAMPLES 7-8 Figures 22-2517) and Figures 24-25 8) Samples 7 anda were then weliea wth controled heatinput on rootat 11-12 4imm andsecand pass heat nout O88" Dm ‘nth enelsing gas fow rate about "sL?Mand purgine gasflon Fate TBLPM. Both samples showee nopiting ard we gross below agin. Sample? (F922 &23] as ‘inch pipe and dueto ‘more curvature itn iss wal hexness, weightloss was higher Ccompareto Sample 83.24 25), whichwasa inch pp Figure23 Figuro24 Figure25 SAMPLES 9-10 Figures 2627 (8) and Figures 28-29 10) ‘er the successful eorsion testing aerievedwith eamoles 7 fn 8 ne tedenangingthe wecing parameters er samples fandi0 to weldat ston tower neatinput on the oot pass and Second pass. The gas fow rate wasma ntanedat tie same lovel actor samples 7 ana. However,Samote 9aied ine corosian testasit exnbited slgneyhigher weight oss of 4129/m2. A single atzpet mas also observed 9.26) on the cross sacton| tthe sample between the weld beads, although no ping mas Ccaservadon eter oot or capsizes. Sample 10 passedthe st ‘without enypting anawith sgnicanily ower wp gh toss. The ap and toot photes for sar alas and TO are shown in figures F309. Senavik white pap Figure 26 Figure 28 Figure23 Figure30 rocticalespects of weking or d.plexandsuper-duph lanes see!© CONCLUSIONS Based on the results of the above experiment, we can clearly see that proper welding parameters play a vital ole in ensuring the integrity of the weld passes during the corrosion testing. Duplex family steels, are sensitive to heat input, shielding and purging gas along with other important parameters. For root pass welding, the heat input range of 0.91.2 kj/mmis, ‘optimal, while for second pass {cold pass) it needs to bbe 8-10% lower heat input than root pass, This helps to evois the formation of secondary austenite and hence promote good corrosion properties. OPTIMIZED HEAT LEVELS Insufficient heat input isnot desirable either since it may cause alack of fusion between welding beads, leading to failure in the corrosion test. What's more, it may lead to ahigher cooling rate, resulting in the for- mation of chrom ur nitride. Shielding gas end purging {988 of Ar+2% nitrogen is suitable for use in duplex family welding to attain pitting resistance with the austenite-ferrite phase balance. GAS FLOW RATE AND PREPARATION, Gas flow rate is also an important parameter in order to achieve adequate shielding to protect the weld ool from oxidation. Preparation of the samples also playeda decisive role in thei ably to pass the corro- sion test, ACKNOWLEDGEMENTS. FOR ROOT PASS WELDING, THE HEAT INPUT RANGE OF 0,9-1,2 KJ/MM IS OPTIMAL WHILE FOR SECOND PASS. (COLD HEAT) IT NEEDS TO BE 8-10% LOWER HEAT INPUT THAN ROOT PASS.” ‘SUKAMAL NASKAR PROPER PREPARATION Proper acid pickling and passivation provides better anti-corrosion properties that help to protect the inal weld joint after fabrication, The skill of the welder is. most important for passing any corrosion test and hence the need to use qualified and skilled welders for the fabrication of duplex family (CHECKLIST FOR FABRICATION A checlist for fabrication is very usefulte have better control ofthe actual fabrication facility for duplex fam ilywelding. Appendix 1 includes a sample checklist as arelerence, “hie works ublched with the permission of Sandvik Materials Technology AB tes ting cone by PTS Laneratoryin Singapore, REFERENCES. 1.4 Elme, TA, Palmer, £.0.Specht Meta Mate. Trans. A 38A 2007) 468 2.R.:Ramiez,C-L ppl, 2. Bran, Metal Ma 3.Y Maghora et a Meta1SC, 17,541, 1980 {4.8.Walien M.Noholls: Physical talugy 2c some charectevetie properties of ne Sancuk duplexst ness steels. Rl “rans. A, 3482002) 1575 Sandvik white paper |Prctcal aspect of welding or plex and suparduplexstanless setAPPENDIX 1 Welding checist for duplex and super duplex stainless steel welding & fabrication WELDING CHECKLIST FOR DUPLEX AND SUPER DUPLEX STAINLESS STEEL WELDING & FABRICATION ‘Checking Kem Yee Ne Base mater grade Base material form plate pipe) alaiafor pe Base mat Certiiate tyne (2.2/9.9. Base matalecting machine 5 Cutting cooknttyne ofthe eating roel Cuting aes ceanness Tackwelsing mevved Taexwaleing process ack wolcing ge Taexwaleing ier material oor phase Bevelangie Beveleonrguraion Backing pate uses? shielng gas compoation ‘Shiolsng gascortfieste ‘Shioling gas low rate Purging as corspostion Purging Purging gas fow rate duingwelang 25 ow ate before weg Purging ge Now rate ator wolaing iungsten dmension for 1S ungsten type Tungsten gna Grinding lsc types composition Pon Brush 5 Tnterpase cleaning Inlerpass eoaning mood Welaing evelstearing inside elsing consumable size Remarks (actual values eommente),APPENDIX 1 WELDING CHECKLIST FOR DUPLEX AND SUPER DUPLEX STAINLESS STEEL WELDING & FABRICATION ‘Checking nem Yes No. Remarks (actual values comments) elsing consumable charveal com Welaingfruprateral Welging ostion eachppaseeeaning Walang postion each segment Cold pass maintained ornot Root pass heat npr Cold passat Noofnaas ana Vsvalingpection after each pass ‘Gas purging equipment Welders quaication & Sk Time batean al the passes Terre YeRay Review NDE reg0rt/9oray ‘Selecrion o proper samplelocaton Proper picking! passivation Caxoet sample cimension eing machine eallorated Calration aa expire date Calbration date kexpie Accuraay vel Wetging ototy Deleng machine sth eonnacton Tong fester used orn Catoravon gate & oro Deling gloves cleanness pwelcing tie ime oxen between each ase Distorson centralCONTACT OUR R&D KNOWLEDGE CENTER Do you have further questions regarding welding, corrosion, temperatures, pressure, pitting and other subsea challenges? Iso, we'd be happy to hela you~ even with basic advice, Having worked with the oil and gas sector for '50 years and serving 100% of all major fabricators and oll companies in all offshore regions, we havea depth of knowledge to share. Please go to our R&D Knowledge Center to get in touch with our experts or to download white papers, case studies and other relevant product information, smt.sandvik.com/ollgas/knowledgecenter