Jornal of Manutscruring ocesses 25 (2017) 134-152 Contents lists available at ScienceDirect Journal of Manufacturing Processes journal homepage: www.elsevier.com/locate/manpro. Review Effect of welding processes and conditions on the microstructure, Devore mechanical properties and corrosion resistance of duplex stainless steel weldments—A review Jagesvar Verma, Ravindra Vasantrao Taiwade* Department of Metturgclané Mateos Engineering, Vsesvaraya Notional Insitute Technolgy (VNT} South Amacai Rnd, Nagp 440010 Moko, nia ARTICLE INFO ABSTRACT ‘Arce ston Dual phase dupex stainless stel comprised with erite and austenite shows its trength and corosion Received 23 August 2016, resistance in many aggressive environments based on outstanding performance over the lst 20 years Received in revised ox establishment is 2 great attention for researchers, manufacturers and end users. The current world Tonovernber 2016 iene ane ‘wide rapid growth, demand, and consumption of duplex: stainless steels, particulary in petrochemical, ae! ‘marine, power plan and other engineering applications. where the multiphase stees are being ulized ‘ens olin 2 December 2018 that require welding fr fabrication of components. On the other hand, largest production and appli- tations sectors are captured y austenitic stainless steels globally, bat the Ni price volatity breaching oa the backbone of producers and end wer n such conditions or he ost enbli,jonng ost Dantas els metals ao reece the overal indus ned ong duper lye sa chllengng due to number of tenant Citing recitates and etallargial changes On the ther and inappropriate welding conditions ‘Wedin onions imbalance phase aio of austenite ads to soliton cackng.coreion suscep. and lower ductility. As the demand for higher productivity i increasing worldwide in many domains like oil Pipeline, shipbuilding sectors ete, where the thick sections are used, which endorses the requitement of higher heat input. optimization of interpass temperature. cooling rate. proper selection of consum- ables, defect ce joints for fast and rapid productivity. However, many advanced techniques like plasms laser, PEGTAW, A-TIG and hybrid welding processes are developing to fulfill the requirements for higher productivity without distortion. But high eritization is another issue with those processes. Moreover suitability and standardization of duplex alloys for high current and large heat input ae still in doubt. Even, no comprehensive accounts of the dissimilar welding operation on the effect of processes and ‘viding conditions are found in the iteature. Tis review paper systematically highlights the effect of ‘welding processes and conditions on microstructure, mechanical properties and corrosion resistance of duplex stainless stels and its various combinations on the basis of strveture-property €o-telationship. (© 2016 The Society of Manufacturing Engincers Published by Elsevier Lid. llrightsreserved, Contents 1. tntroduction 135 2. Phase formation in duplex stainless stels 4. Selection of consumable : . 138 4. Welding behavior on mechanical and corrosion resistance of DSS (2205) and super DSS (2507) fat 5. Dissimilar metas welding of DSS and super DSS with other alloys 45 6 Currentiesues and future perspective 149 61. Curcent issues 149 responding autho. ax: 91 7122223230. smal adress jageshwarverm28@ malcom (Verma) raiwadevnit@gmalcom (RY. Talwade). utp. do. ar 1016jjapr0.2016.11.003 1526-6125/0 2016 The Society of Manufacturing Engineers Published by Elsevier Ld Al ight reserved1. Vem, RU, Twade/Jursl of MonyoturingPoceses 25 2017) 134-152 as. 52, Future perspective 7. Conetusions : Acknowledgment References. 1. Introduction The astounding success of duplex stainless steels (DSSs) com- pared to austenitic stainless steels (ASSs) isa result of nickel (Ni) Price volatility in the market year on year (1. Another issue with ASSs is lower sustainability in many aggressive environments [2 ‘Therefore, the industries are trying ta look or alternatives with low Ni content and comparable performance as that of conventional ASSs [3]. Duplex stainless steels give a promising performance in many corrosive environments having superior localized corrosion resistance due to half ferrite and half austenite percentage [4.5] The increased applications in many industries like shipbuilding, ‘offshore, chemical industries, paper and pulp industries, petro- ‘chemical, desalination plants, oil and gas industries promote DSSs [67 Apart from that the scientifically valuable report is delivered in, many conferences, boosted the huge demand of DSSs worldwide. These conferences were organized regularly since 1982, that is St Louis (USA). Den Hauge (Netherland, 1986), Beaune (France, 1991), Yokohama (Japan) in 1993, York (UK) in the year 1994, Further, i 1997 Maastricht (Netherland), 2000 Venice (Italy) and Grado (italy) in 2007 to tll now. These conferences covered an excel- Tent combination of valuable scientific contributions and technical Presentations, including metallurgical aspects (i.e. phase precip- itations, corrosion resistance and mechanical properties of DSSS) ‘on the basis of industrial experiences in many areas of applica- tions of standard (type 2205), lean (type 2304) and super-duplex (type 2507) stainless steels. The above grades were confirmed as very valuable grades with excellent performances were customized by more than 20 years of successful service applications experi- cence. Alithe mentioned international conferences finally concluded that there is a great demand of DSSs in the replacement of 300- seties $$ [8-12]. Further, many countries (like, Malta, Cyprus, Saudi ‘Arabia, Sharjah, Spain and West Indies) implemented DSSs com- bined with other alloys in different sectors like multi-stage flash (MSF) plants, large seawater reverse osmosis (SWRO) plants, brack- ish water reverse osmosis (BWRO), large multi-effect desalination (MED) plants and bleaching plants |13-16} ‘Among the stainless stee! categories, the global production of DsSs represents less than 200KT, that is around 1% of the total global production of SSs, even though the consumption is about 100%. International stainless stee! forum (ISSF) documented that the production of DSss was 0.6% in 2004, which inereased to 1% in 2007. In Feinox 2008 conference it was forecasted that the produc- tion of DSSs will be increased by 4% forthe year of next 2020 asit is shown in Fig. 1.On the other hand, the demand of ASSS was 63.1% inthe year 2004 [17], which was 62% in 2007, due to Ni price fuc- {uation and based on this situation, the production was forecasted to 53% till 2020 as its illustrated in Fig. 1 [18], In 2013 the ASSs production was 53.4% while 54.6% in 2074, However, the SS producers and end users are greatly affected by the high and volatile price of Ni, which fluctuates day-to-day. The Ni supplies have not been able to keep pace with the world- ‘wide increased demand of SSs Since Ni is the major constituent in ‘widely used classical ASSs (300-series), therefore, the other alter- natives low Ni andor Ni-free grades are known as 200-series (201, 202, Cr-Mn) and 400-series (ferritic grades) has been developed ‘and used in many moderate corrosive environments and structural sectors are illustrated in ig. 1. From ig. titisclear that the produc 149 150 150 150 tion of 200-series was around 10% in 2007 and predicted around 6% ‘upto 2020, Moreover, the production scenario of 200-seriesin 2013 ‘was 19.8%, which decreased alittle bit (18.9%) in2014, On the other hand, the demand and production of 400-series are increasing due {0 low-cost and other favoring reasons such as good thermal con- ‘ductivity, easy to recycle and helps to save planet resources. 2007 production of 400-series was around 27%, which was forecasted 37% up to 2020. nthe present situation, the production in 2013 was 25.5% and 25.2% in 2014, Changing from 300-series to 400-series ‘means that the manufacturer becomes more competitive and the consumer may get a safe product at a very low price. Inthe year 2015, the global real demand for SS products reached 37.7 million tonnes, with a modest increase of around 2% from 37.1 million tonnes in 2014, The annwal average growth of Ss was around 8% since 2011-2014, In 2015, total worldwide steel pr duction was 1.6 billion tonnes in which about 2.6% were only $85 {19-21} ‘The scenario shows the futuristic increasing demand of DSSs, While the 70% market globally captured by ASSS that enforces the users toward the use of dissimilar combination with ASSS in the future in many aggressive environments. Even, Matsuyama's ‘municipal water tank in Japan was constructed by using three dis similar combinations of SS (2205 DSS, 304 and 316 ASS) [22]. [tis reported (23] that to jin the similar and dissimilar metals, welding js the most important tool and to achieve the large productivity a large heat input is required (for example to join the oi pipeline) ‘Nowacki and Rybicki 24) have published the paper oneffectof heat input on Stainless steel structure, but no systematic studies on the influence of large heat input on corrosion behavior for DSSs have been proposed so far. ‘The authors have already contributed to studies of welding and, corrosion behavior of low Ni SS in the mild environment (25-27). Bur, in a highly aggressive environment, low Ni DSSs are the better choice and this review motivate the authors to further studies on this alloy. In current review authors try to critically analyze the results, of other researchers based on their investigations on the effect of ‘welding conditions (effect of allowable and exceeding range heat input) different processes (including high and low arc energy as ‘well as solid-state joining processes), and welding consumables ‘on mechanical properties an corrosion resistance of DSS 2205 and super DSS 2507 (due toits versatility than other grades of DSSs) and also emphasize its dissimilar combination with carbon steels (CSS) [ASSs, fervtic stainless steels (FSSs) and other popular alloys. The ‘other family of DSS has not been included in this review because limited work has been carried out. Authors also try to summarize the results on phase evolution during solidification and selection of consumables for D5Ss and its various combinations incorporating, ‘with some of the advanced techniques, current issues and future perspective. 2. Phase formation in duplex stainless steels Alteration in microstructural features affects the properties and corrosion resistance, hence it is of great importance to control the ‘microstructure during welding with recommended ferrite content and should free from detrimental phases, such as nitrides, car= bides or intermetallics [28]. The microstructure of DSS base metal (BM) is mainly composed of austenite and ferrite phase as itis15 {Lema RU, Tawade jure of Monyfataring Processes 25 (2017) 134-152 10% case [5200 J orapa, 2300 | s7mpa, 2 Duplex] 95%na. mao | otra. may o« ae « Ea Fig Sales tested and forecast 18, ra Fi. 2. Microraph of duplex base meta (a) opel micrograph [2]. () SEM micrograph (0) (€) TEM micrograph 31) shown in Fig. 2 with high-resolution SEM and TEM micrographs 29-31), Basically, the DSSs weld solidify in fully ferritic mode (the frst phase, which nucleates directly from liquid) and austen- ite nucleate below the ferritic solvus temperature in the sequence Of | (liquid) + L+6— 8+ (where “®" is delta ferrite and "y" is austenite). This solidification mode is based on Creq/Nieq ratio and ‘can be better understood by the Fe-Cr-Ni pseudo-binaty diagram, Which is a significantly important tool to envisage the mode of solidification [32-36] as itis illustrated in Fig. . The composition ‘of a typical DSSs falls in the a phase fleld. For most of the SS ‘compositions, the y phase is expanded so that the ferrite phase is separated into high-temperature ferrite and low-temperature fer- rite and in practice high-temperature ferrite is denoted as 8 fervte, and low-temperature ferrite, which forms by the transformation fof austenite, as c ferrite. It is evident from Fig. 3 (Pseudo binary (Fe-Cr-Ni) diagram plotted using equivalent relationship) that fer- rite exists continuously from solidification to room temperature for DSSs and therefore, all ferrite is denoted as a ferrite due 10 continuously transformation with the same composition (37 Inpractice, the DSSs are quite resistant to solidification cracking because of low impurity If the Creg/Niag ratio is greater than the value 1.95 the mode is fully ferritic, However. for DSSs BM, the typi cal range isbetween2.25 1035, where the ratio for super DSS 2507 {is 2.25 and for DSS 2205 is 2.62 as reported by Lippold and Sieurin etal and is illustrated in Fig. 3 [38,39] due to the more diffusivity of CCrand Moin fecrite phase |37| In general, the different morphology ‘of austenite develops inthe welded region during solidification as, itis shown in Fig. 4 [40], a continuous network of austenite defined as a grain boundary allotriomorphs or grain boundary austenite (GBA), the first phase, which directly nucleates from ferrite matrix [41], Nucleation of GBA is reported in the temperature range of 1350-800°C [41]. Further, widmanstatten austenite (WA) grain forms from this GBA. although enriched in Ni compared to the fer~ rite matrix, It has the lowest amount of Cr, Mo, and nitrogen than GBA (41-44), with a near Kurdjumov-Sachs orientation relation ship mechanism [45 In sequence, intragranular austenite (IGA), formed as a result of the cooling rate effect, which required greater diving force and precipitates later at a lower temperature, which is prone to pitting corrosion (suitable site for pitting) due to lower alloying elements such as Mond Cr}isshown in Fig. 5a-c,inWwhich Fig. Sb represents the area of intense pitting. occurred mostiyin-y2 (or secondary austenite side. However yp forms on reheating below1. Vem, RU, Twade/Jursl of MonyoturingPoceses 25 2017) 134-152 vy Tablet Inermetaic hse Formation in DSS 48-50, Phases in DSS ‘Approximate chemical Temperature range 0) Laie constan m (averased) phase Fe-cr-ao Chromium aide ca Chromium aude GN Grice Mc Catide FeuChatiow Fe-cr-Mo FeyMonNy 01000 700-00 50-1050, 00-250 “00-900 550-850, 550-150 550-600 ‘aa? Stoswole-0487 e052, b-0600,c~1211 ‘at 30H044,b-0484,c-0.2867 Scume-ta3 320647 Cte Nieg —> 05 125 148 1.95 2.62 40 > > Aaa Fig. 3. Pseudo binary (Fe-Cr-Ni) diagram plotted using equivalent relationship 3839) (ptcal mcrgraph of welded reson), 8 solvus [41~43,46,47], Simultaneously, thermal cycles also cause to precipitates the many other undesirable phases [like, CrN, CraN, MyC5, Ma3Cs (M=Fe or Cr) known as secondary phases] nd [sigma (@), chi (0.5. R, and 7 phases known as intermetallics] as itis ilus- ‘tated in Fig. 6 and tabulated in Table 1 [48-50]. However, phase is a hard brittle intermetallic compound enriched with Cr, Mo, i and more detrimental than other mentioned phases. Precipitation often tarts attriple junctions o at ferrite/austenite boundaries and continues at incoherent twin boundaries and finally intragranu- larly. The temperature range of precipitation from 600 to 1000°C. However, the fastest precipitation rate isin between 850-900°C. Moreover, « precipitation could be controlled by modifying solu tion annealing temperature [51]. Similarly the x-phase may occur inaustenitc, fervitic, and DSSs, which gives inverse effect on corro- sion and mechanical properties. The -phase precipitate presents in the binary Fe-Cr system. While x-phase precipitates only in the Fe-Cr-Mo ternary and Fe-Cr-Ni-Ti quaternary systems, with a composition of FeygCrj2Moyo [52]. It has a composition similar to that ofthe o-phase, but in compare to -phase. carbon can dissolve in the y-phase. Due to this property. the y-phase was defined and distinguished in contrast to 6-phase [52 The precipitation of CraxCo carbide can also occur in DSS weld and BM with similar above mentioned negative effects caused by the formation of « phase. Another precipitate like Cra3Cg and Cra alsooccur inthe regions of high energy (such asat grain boundaries) And this precipitate favored by the decreased solubility of carbon and nitrogen in austenite [53]. The migration of ferrite/austenite interface boundary into the growth of carbides with “lamellar” ang "larva" patterns having. cule to cube orientation relationship, ‘with the austenite by eutectoid reaction & <=My3C5+2 (52.54), it precipitates at temperatures of 950-1050°C and below 950°C respectively (50]-On cooling below 1300°C austenite phase forms by the diffusion mechanism, however, too low welding energy resulted in high ferrite contents (70 vol.) in the weld. This is also undesirable due to the formation of chromium nitride (CraN) pre- cipitation and is prone to occur in the ferrite domains, due to the Jow solubility of nitrogen inthis phase. The CrgN precipitation and high ferrite content decrease the low-temperature toughness. In addition, CrpN precipitates are also believed to be nucleation sites, Tor pitting]. This precipitation takes place at temperatures range (0f 700-900 °C [51] ‘Similarly, R phase is an intermetallic compound enriched in Mo and occurs in the range of 550-700°C. It has complicated trigo- nal crystal structure with the unit cell consisting of 159 atoms Similarly, 7 phase has a cubic crystal structure and it precipitates intragranulariy in isothermally aged materia at 600 °C (51. These phase formation in dissimilar joints are also very interesting due {o different composition and cooling rate that may create a com- plex microstructure in the weld, which may infer the properties, ‘Moreover, cooling rate plays an important role to control the phase balance in the weld and heat affected zone (HAZ). It also consi erably affects the precipitation of many intermetallic phases and corrosion resistance ofthe materials. Since the cooling rate depends fon a number of variables, such as heat input, material proper- ties, process efficiency, preheat temperature and thickness of the ‘materials. In DSSs the temperature range 800-500°C is the criti- cal range for phase transformation. Whereas, in the range between 1200 to 800°C in particular time austenite reformation occurs and critical for achieving the correct phase balance in DSSS. It was reported that cooling rate 0.25-50ks~" would be best to achievebe {Lema RU, Tawade jure of Monyfataring Processes 25 (2017) 134-152 the correct frste/austnite phase balance, while a the same time iC limits the formation of sigma phase precipitate during the erit- ical 1200-800°C range. If the cooling is too rapid through this 1200-800°C zone, then CraN and more ferrite ean form, which lower the corrosion resistance. While slower cooling rate through this range wil favor austenite. However, Wang etal. reported that very fast cooling rte at 139°C)S under the 7°C plate (in DC pulsed current gas tungsten are welding technique) increases the austen- ite phase inthe weld and helps to achieve correct phase balance by ‘creating higher driving energy for nucleation af WA and IGA due to, the largest under cooling (42.58.57) “Therefore its expected thatthe different microstructural zones will exhibit corrosion susceptibility. For life prediction of materials practically in many susceptible environments, itis very impor- tant {0 understand the corrosion behavior ofthe DSSs, However in recent yeas, some advancement in characterization and elec- trochemical techniques like atomic force microscopy, magnetic force microscopy. scanning kelvin probe force microscopy, atomic and magnetic force microscopy and scanning electrochemical microscopy provide an emerging tool for a better study to measure thedetrimental and secondary phases as wells an electrochemical process of DSSs. This facts based on magnetic saturation measure- ment, which isthe reliable quantification of austenite, ferrite and secondary phases [5 Some of the detrimental phases are ilus- trated in i. Ge and f based on the open source by using mentioned advance technique (58). For measurements offerte, austenite and secondary phases in real time can also be successfully done by advanced in-situ technique which is based on a combined work of time-resolved X- tay diffacton and laser scanning confocal microscopy, which was ‘developed for direct observation of morphological development and simultaneous identification of phases, HAZ measurement, dut- ing thermal eyce of wen (59 Ina few cases, solidification cracking (of DSSs) may be a prob- lem ifthe proper phase balance was nat achieved, since melting and solidification phenomenon in fusion welding destroy the phase balance (60). Lippold et al. [61] reported that area near to fusion boundary is the most susceptible region for hot cracking because the fusion zone (FZ) of DSS fully ferrite during the final stages of solidification. But, ess susceptible than alloys with fully austenitic mrostructure, Fis. 7a and b illustrates the HAZ lquation crack- in, Hull (62) also originally hypothesized that boundary wetting bya liquid fim s more effective along austenitejaustenite and fer- rite/ferrite boundaries than that of ferrtejaustenite boundaries In practice, weld solidification cracking does not seem to be a serious fabrication problem with DSSs, but interestingly, some of the researchers like Gooch [63] and Nelson etal (64) have been reported solidification cracking of DSS, Fg. 7c illustrates the weld Solidification cracking, where the crack appeared mainly in the austenite phase. However, proper selection of filler metal resists the solidification cracking in DSSs [63]. Therefore, mare attention must be paid during the selection of consumables. 3. Selection of consumable ‘The selection of consumable for similar and dissimilar weldi plays a crucial role in enhancing the mechanical properties, creat- ing the proper phase balance and avoiding solidification cracking [65]. Generally, i is recommended that the welding filler metals have 2 mote austenitic composition with 2-4% more Ni than the BM for improved mechanical properties and corrosion resistance ‘due (© when freezing speed is very high, the amount of austen ite/ferite ratio most be in balance. The tole of Niis to increase the austenite to compensate for decreases this phase owing to high ‘cooling rate [67]. The boosted Ni content filler metals nat yet stan- dardized, but also available in various trade names. Messer et a. {68} reported that the over-alloyed Ni-based fer metals may be preferred for welding super DSS. However, on the contrary, Gooch {69] addressed that the over-alloyed filler metal is not suitable with super DSS BM because the weld metal (WM) may be more Sensitive to precipitation of many intermetallic phase, which fur- ther reduces corrosion resistance and toughness. hese statements reflect the advance need of investigation and motivate the authors to further work. However, due to Ni price fluctuation [70], researchers moved toward the replacement of Ni-based alloy consumable, because it Js 10 times more expensive (61), and diversified forthe utiliza- tion of cost-efficient consumables, even it is also recommended thatthe carbon, phosphorus and sulphur level in the filler metals should be less or equivalent to BM [71]. The recommended con- sumable for DSS and super DSS, based onthe various researchers opinions are tabulated in Table 2 [72,73] Table 2 represents the recommended consumables for similar and dissimilar weld as per the different welding community, in sequence filler wire diameter, ‘welding parameters and shielding gases with eifferent processes for DSS and SDSS are also tabulated in Tables 3 and 4 respectively 174), For welding of various sections the consideration of inter- ass temperatures is also prime importance; the recommended values are mentioned in Table 5 [74]. Interpass temperature is the temperatute ofthe weld area between passes, also affects the cooling rate, and itis a very important factor during welding of Ss, since the maximum interpass temperature requited should bbe below 150° i interpass temperature are higher than recom- ‘mended, with excessively reduced cooling rate, which increased HAZ dimensions, expanded the coarse grain zone and diminishes the tensile and impact toughness, I is reported that both yield and ultimate tensile strengths ofthe weld are a function of inter- ‘as temperature. Higher interpass temperature reduces the Weld strength Additionally higher interpass temperatures will gener- allyimproveimpact toughnesstranstion temperatureby providing 2 finer grain structure. However, when interpass temperatures exceed ~260°C, this trend is reversed [75], For joining the thick section, the researchers are trying to study the effect of interpass temperature on the properties of the joint, resulting in a possible increasein productivity during welding. Inthis sequence. the recent new technique of joining implemented for joining pipeline con- struction and installation of thick D55s(214 mm) and reported the effect of interpass temperature (150°C and 290°C) on thick DSS 2205 weld by applying SAW in fling and finishing passes. Authors Concluded tht high interpass temperature (290 C) is more prone to corrosion and also lowers the impact toughness compared 0 130°. this is due othe imbalance phase proportion and formation ofmore precipitated in the weld and HAZ|76 ‘The consumable such as E/ER 2209 which is most popular and compatible with diffrent processes for joining similar and dis- similar DSSS shows better corrosion resistance and mechanical properties [44], Even in another case when E/ER2209 compared with other filler like ERSI6LSi and ERSOSLSI, in which ER2209 Weld showed better resistance fo localized corrosion due to the diference in filer chemical composition, However, in ER316LSi and ER308L5i fillers the presence of Si speed up the intermetallic phases and enhanced the corrosion, Author also studied the cor- rosion behavior of DSS 2205 BM and ail filler welds in 3.5% NaCl Solution and reported that the DSS 2205BM showed critical pit- ting temperature (CPT) inthe interval of 565°C. While ER2209 and ERS16LS) weld illustrated 44°C and 28°C respectively. In compar- ison to other two filers ER3OSLSi only manages the mechanical properties (77) Similarly. inthe dissimilar metal combination of 2205 DSS with AISI 316, duplex ER 2205 filer showed more tensile strength as compared fo ER 304 lr, due Co different chemical composition,