A Primer for

DUPLEX Stainless Steel

John Grocki

2012

What are Duplex Stainless

Steels ?
A family of stainless steels whose:
structures are approximately 50/50
austenite and ferrite
physical properties are a combination of
the ferritic and the austenitic grades

Duplex Microstructure

What is the Family

Lean Duplex SS lower nickel and no
molybdenum 2101, 2102, 2202, 2304
Duplex SS higher nickel and
molybdenum - 2205, 2003, 2404
Super Duplex 25Chromium and higher
nickel and molybdenum plus 2507, 255
and Z100
Hyper Duplex More Cr, Ni, Mo and N 2707

Chemistry of Lean Duplex SS

Name UNS No.
2101
2102
2202
2304

S32101
S82011
S32202
S32304

High Cr

Cr

Ni

Mo

.04
.03
.03
.03

21
21.5
22
23

1.5 0.5
1.5 0.5
2
0.5
4
0.5

.22
.21
.22
.12

low Ni

0.2 N

Other
Mn=5
Mn=2.5

and no Mo

Chemistry of Duplex SS
Name UNS No.
2003
2404
2205
2205
High Cr

S32003
S82441
S31803
S32205

C
.03
.03
.03
.03

Cr

Ni

Mo

20
24
21.8
22.5

3.5
3.5
5
5

1.7
1.5
2.8
3.2

.16
.22
.12
.16

Moderate Ni and Mo

Other

and 0.16N

Cu

Chemistry of Super Duplex SS

and Hyper Duplex

Name UNS No.

2507 S32750
255
S32550
Z100 S32760

C
.03
.03
.03

Cr
25
25.5
25

Ni
7
5.5
7

Mo
4.0
3.4
3.5

N
Other
.28
Cu=.5
.20
Cu=2.0
.25 Cu=.75W=.75

2707

.03

27

6.5

4.8

.40

S32707

Higher Cr

More Ni and Mo
and others

.25+N

General Corrosion
Similar to relative austenitic alloys.
(e.g. 2202 and 2304 are similar
to 304 & 316)
General corrosion resistance can vary
greatly with changes in concentration, pH,
temperature and impurities. It is important
to discuss these variables for any
application!

Digester Pulp and Paper

Duplex vs. Austenitic

Duplex Grades
2202 /2101/2102
2304
2003 /2404

Austenitic Grades
304L
316L
317L
317LMN

2205
904L
255 / 2507 / Z100
6Mo Grades
2707
(increased resistance)

Localized Corrosion { PREN = Cr + 3.3Mo + 16N }

Grade
201LN
304L
316L
2202/2102/2101/2304
317L
2003
2404/317LMN
2205(S32205)
904L
Z100
255
2507
6Mo Grades
2707

PREN
18
19
24
26
30
30
33
35
35
41
42
43
45
49

316 LN TANKER
Transportation of H2SO4
Tank rinsed with Sea Water !

Chloride Stress
Corrosion Cracking
The greatest corrosion advantage for duplex
stainless steels is their improved resistance
to CSCC when compared to the austenitic
grades.
Only the 25% Nickel grades have similar
CSCC resistance.

Stress
Corrosion
Cracking

STRESS CORROSION CRACKING RESISTANCE

vs TEMPERATURE and ClNo SCC for
25Cr Super-Duplex

Temperature, C (F)
300 (570)

200 (390)

S31803
S31500

S32304

100 (210)

SCC
304/316L

0 (32)

No SCC
0.001

0.1

Cl- (% weight)

10

Mechanical Properties
Duplex Stainless Steels have roughly twice
the yield strength of their counterpart
austenitic grades.
This allows equipment designers to use
thinner gauge material for vessel
construction!

Room Temperature Strength

Grade
Min Tensile(KSI) Min Yield(KSI)
2101/2102
95
65
2202
94
65
2304
87
58
2003
90
65
2404
99
70
2205
95
65
2507
116
80
255
110
80
Z100
108
80
2707
133
101
201LN
95
45
304(L)/316(L) 70
25
317LMN
80
35
6Mo
94
43

%Elong.
30
30
25
25
25
25
15
15
25
15
45
40
40
35

ASME (allowable stress in KSI)

Grade @100F
2202
27.1
2304
24.9
2205
25.7
2507
33.1
255
31.4

200F
26.9
24.0
25.7
33.0
31.3

300F
25.1
22.5
24.8
31.2
29.5

400F
25.1
21.7
23.9
30.1
28.6

500F
25.1
21.3
23.3
29.6
28.2

600F
25.1
21.0
23.1
29.4
--

316/316L 20.0 17.3 15.6 14.3 13.3 12.6

316L
16.7 14.2 12.7 11.7 10.9 10.4
317LMN 20.5 18.9 16.7 15.6 15.1
-6Mo
24.9 23.2 21.3 19.8 18.3 17.3

Tank

Hardness

High hardness provides better wear resistance in abrasive

environments.
Grade
Hardness (BHN)
201LN
241
304L
215
316L
217
317L
217
317LMN
223
904L
220
6Mo
240
2102/2101
290
2202/2304
290
2404
290
2003/2205
293
Z100
270
255
302
2507
310

S32550
Feed Screw Flight

Thermal Expansion ( /Fx10 )

Grade
C- Steel
2102/2101
2202
2304
2205
2507 /255
Z100
2707
304L

@212F
6.66
7.16
7.05
7.22
7.22
7.22
7.22
7.00
9.11

392F
7.22
7.50
7.50
7.50
7.50
7.50
7.50
7.22
9.40

572F
-7.77
8.00
8.00
8.00
8.00
8.00
7.50
9.60

752F
7.77
8.05
-8.05
8.06
8.06
7.39
7.77
9.77

932F
--

8.33
8.33
8.33
7.56
10.00

Fatigue Strength
Higher strength means higher cyclicstresses can be applied without fatigue
failures.
This holds true even in corrosion fatigue
environments!

FATIGUE - CORROSION RESISTANCE

Synthetic sea-water rotating beam
bending of smooth samples

400

MPa

300

S31803/S32205
S32304

200
316L
105

106

317 LN
316L 2.5 Mo
107

60
45

KSI

30

Cycle to rupture

Fatigue and fatigue corrosion resistance of stainless steels are enhanced by the
use of duplex grades (higher mechanical properties, chromium content and
duplex microstructure

Fracture Toughness
Due to the high ferrite content the Duplex SS
have a ductile brittle transition temperature of
-50F.
This restricts the minimum operating
temperature to -50F.
In certain circumstances the Duplex SS may be
used down to -100F.

Mo, W, Si

1000C/ 1832F

M7 C3 carbide, Cr N nitride HAZ

s

phase
Cr N nitride
2
c
phase
g phase
2
M C carbide
23 6
R Phase

Cr
Mo
W
Si

Cr, Mo, Cu, W

p phase
e phase (Cu)
a' phase
G. phase...

300C/572F
Cr, Mo, Cu, W

Time

Possible precipitations in super duplex stainless steels within 25

40 minutes, while 2205 is ~1 hour and 2304 is ~8 hours for
significant precipitations

Fabrication

Welding
Welding procedures must be developed to
achieve acceptable corrosion resistance and
mechanical properties/toughness in the weld
zone.
Welding of Duplex SS is not difficult. It is
just different!
lean duplex = welder friendly!

WHAT ABOUT WELDED STRUCTURES ?

Duplex filler metal

WE NEED
CORROSION
RESISTANCE

CONTROL OF FERRITE
in HAZ
< 70 %
in welds
20-40 % SAW, SMAW
25-60 % TIG, MIG, PLASMA
CONTROL OF OXYGEN CONTENT
SAW with appropriate basic flux

CONTROL OF HYDROGEN CONTENT

Degasing of welding consummables...
No hydrogen in shielding gas

TOUGHNESS
AT LOW TEMPERATURE

CONTROL OF NITROGEN LEVEL

Add N2 to the shielding gas
CONTROL OF THERMAL CYCLE
Heat input adapted to plate
thickness/weld geometry
Minimum and Maximum

WHAT ABOUT WELDED STRUCTURES ?

Austenitic filler metal
CONTROL OF FERRITE
Not required for when using
fully austenitic filler metal

WE NEED
CORROSION
RESISTANCE

CONTROL OF OXYGEN CONTENT

SAW with appropriate flux basicity

CONTROL OF HYDROGEN CONTENT

Degasing of welding consummables...
No hydrogen in shielding gas

TOUGHNESS
AT LOW TEMPERATURE

CONTROL OF NITROGEN LEVEL

Not required for when using
austenitic filler metal
CONTROL OF THERMAL CYCLE
HAZ is the only concern when
using a fully austenitic filler material

Formulinox
Formulinox.xlsm

Standard Specifications
Grade
ASTM
2101*
A240
2202
A240
2304*
A240
2003*
A240
2205(S31803)*
A240
2205(S32205)*
A240
255* Z100*
A240
2507*
A240
2707
A789/A790

ASME
(Sect VIII Div I)
-code case 2418
-Code Case 2669
SA240
yes
-code case 2503
SA240
yes
-no
SA240
yes
SA789/790 tube/pipe
-code case

Standard Specifications
Grade
2101
2202
2102
2304
2003
2205(dual)
255
2507
Z100
2707

Bar
X
X
X
X
X
X
X
X
-

W/S Pipe
X
X
X
X
X
X
X
X
X(s)

W/S Tube
X
X
X
X
X
X
X
X
X(s)

Fittings
X
X
X
X
X
X
X
X
X

Cost Comparison
Cost ratio based on 304L=1.0 (3/8 pattern mill plate)

Duplex
2202 2101
2102
2304
2003/2404

2205
255/2507
Z100

= 0.83
= 0.83
= 0.96
= 1.26

Austenitic
201LN
= 0.86
304L
= 1.00

316L

= 1.25

317L

= 1.66

= 1.16
= 1.85
= 1.90

317LMN = 2.04
904L
= 2.72
6Mo
= 2.83 3.46
Ni = 8.46 Mo = 12.76 Cr = 1.32

Cost Advantage
If a vessel design uses the Duplex SSs additional
strength to decrease wall thickness savings of up to
25% may be achieved for the fabrication vs. a
comparable austenitic grade.
Machining cost savings may be considerable.
Physical property advantages must be evaluated for
process and fabrication cost savings.

DUPLEX COST SAVINGS

If you save weight (wall thickness reductions) :
You reduce the amount of material needed for the project
You reduce the labor costs (weldings of thinner plates)
You reduce transportation costs
You reduce erection costs
You reduce structural costs (concrete)
THINK ABOUT TOTAL COSTS

Iceberg

CALRES
Corrosion Solutions Calres.xlsm

Some Duplex SS Precautions

Thermal history control, to reduce the risk of
forming secondary phases(sigma and alpha
prime), is minimized for lean duplex.
Good procedures must be developed for welding,
forming, machining and heat treatment. Duplex SS
are not difficult to work with but they are
different! And lean duplex are the easiest!

Duplex SS must be used for applications which

operate between -50F and +600F.

What DUPLEX Means!

A family of excellent engineering materials!
A family of excellent cost effective materials!

Comparable to austenitics in corrosion resistance

with improved CSCC.
Twice the strength of austenitics.
Advantageous physical properties.
Covered by standard and end user specifications.
Advantages with both material cost and engineered
fabrication cost.

MARKET EVOLUTION OF DUPLEX QUARTO PLATES

(2000/2008) in KT
2007 2008

2000

2001

2002

2003

2004

2005

2006

20

15

10

10

10

15

10

Offshore :
Tubes, blast walls, topsides
flow lines

10

12

13

New applications :
hydrometallurgy, water,
structures, other

0,5

1,5

2,5

Desalination

0,5

0,5

1,5

15

18

21

Pulp + Paper

10

10

10

Chemicals, Fertilizers,
Petrochemicals

12

14

Pollution control

0,5

0,5

10

Distribution

10

12

15

16

42

39

35

38

46

63

80

Total SS production

660

700

720

680

760

800

850

900

950

% Duplex

6%

5.5
%

5%

5.5
%

6%

8%

9%

10%

10.5
%

Chemical tankers
Terminals

TOTAL (KT)

90

100

DESALINATION: INDUSTEEL REFERENCES

2002-2006
Austenitic
grades

Duplex
grades

41

Power Generation

Two shapes of scrubbers

Cylindrical/Rectangular type scrubbers
Materials of Construction
2205, 255, 2507, 2304, 6Mo and Clad
thick plates in carbon steel lined with rubber
Fiberglass and Stebbins Tile

Rectangular type scrubber using stiffeners

and thin plates in :

Stainless Steel
Or carbon steel lined with rubber

Pulp and Paper

Industry
Duplex References
Black and White Liquor Vessels
S31803, and S32304

Digesters S32205

44

Pulp and Paper

Industry
Duplex References

Batch digesters
for Potlatch (USA)
S31803

Duplex Bridges

46

MALIZIA BRIDGE IN SIENA (Italy)

BRIDGE DATA
- Total length :
51.5 m [169 ft]
- Deck width :
15.8 m [ 52 ft]
- Deck height :
1.2 m [ 4 ft]
- Arch height :
10.0 m [ 33 ft]
- Steel used for the deck :290 t
- Steel used for the arch : 50 t
- Contractor : COMUNE DI SIENA
- Project study :SETECO Ingegneria s.r.l.
- Project : Ing. Raffaello Fontani
- Architect : Arch. Paola DOrsi

June 5, 2007

International Bridge Conference Pittsburgh

47

MALIZIA BRIDGE IN SIENA (Italy)

Final assembly
June 5, 2007

International Bridge Conference Pittsburgh

48

Duplex Stainless Structures

Location

Type of equipment

Grade

Tons

Constructor

Main constructor

Architect

1989
Arche de la Dfense - Paris (F)

Lift structure

S31803

50

1993
Bibliothque nationale Franois Mitterrand
Paris (F)

Wind bracing

York Millenium Bridge (UK)

Bridge anchor plates

302

500

CFEM/Rinaldi

Dominique Perrault

2000
S31803

Cimolai

2001
The Spire of DUBLIN (IR)

Monument

316L

130

SIAC Radley

30

Cimolai
CMN Cherbourg

Dublin City council

Ian Ritchie

2004
Arco Ponte Malizia - Siena (I)
Les Braves - Omaha Beach (F)

Bridge structure
Sculpture

S32304
316L/S31803

Anilore Banon

2005
Ministre de la culture "Les Bons enfants" Paris (F)
Tay Bridge (UK)

Building

S32304

500

Lauboeuf

Bearing of bridge

S32304

30

PPC/Freyssinet

Piove di Sacco - Padova (I)

Bridge structure

S32304

125

Sculptures Tallagh Town Centre in Dublin

Sculpture

S31803

30

Mont Saint-Michel

Tide protection gates

S31803

36

Castaldo Spa
Royceton
Construction Design &
Management
CM Paimboeuf

Ministry of Culture of
Communication

Francis Soler

2006

Eileen Mac Donagh

Luc Weizmann

May 29th, 2007

June 5, 2007

International Bridge Conference Pittsburgh

50

Thank you for Your Attention

You really deserve a DRINK now!