DOCSLIB.ORG

Corrosion Fatigue of a Superduplex Stainless Steel Weldment

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Corrosion Fatigue of a Superduplex Stainless Steel Weldment CORROSION FATIGUE OF A SUPERDUPLEX STAINLESS STEEL WELDMENT Thesis submitted to Dublin City University for the degree of Doctor of Philosophy. Author: Anthony John Comer, B.E. (Mechanical Engineering). (50161547) School of Mechanical and Manufacturing Engineering, Faculty of Engineering and Computing, Dublin City University. Supervisor: Dr. Lisa Looney Date: 02/12/2003 E-mail: [email protected] DECLARATION I hereby certify that this material, which I now submit for assessment on the programme of study leading to the award of Doctor of Philosophy is entirely my own work and has not been taken from the work of others save to the extent that such work has been cited and acknowledged within the text of my work. Date: December 2, 2003. PUBLICATIONS ARISING FROM THIS RESEARCH Comer A, Looney L, Corrosion fatigue of a welded superduplex stainless steel, Proc. International Conference on Advances in Materials and Processing Technologies, (AMPT), Dublin, Republic of Ireland, (July 2003). * Best Student Paper Comer A, Looney L, Corrosion fatigue of a superduplex stainless steel weldment, Proc. 2nd International Youth Symposium on Experimental Solid Mechanics (YSESM), Ravenna, Italy (May 2003). Comer A, Looney L, Fatigue and corrosion properties of a welded superduplex stainless steel, Proc. International Manufacturing Conference (IMC-19), Belfast, Northern Ireland, (August 2002). Comer A, Looney L, Corrosion fatigue crack propagation of a welded superduplex stainless steel, Poster presented at the 5th Sir Bernard Crossland Symposium, University of Ulster Jordanstown, Northern Ireland, (March 2002). ACKNOWLEDGEMENT I would like to acknowledge Dr. Lisa Looney for her exceptional supervision of this research. Her approach was at all times conscientious, encouraging, helpful and constructive. I would also like to acknowledge Weir Materials and Foundries, Manchester, UK, for sponsoring their material for this research. A special thanks to Dr. Roger Francis for much enlightening communication with regard to Zeron 100. In addition, I would like to thank Mr. Tim Healiss for his time and assistance while carrying out tests in Manchester. I would like to acknowledge the technical staff in DCU who were involved at various stages in this research particularly Mr. Liam Domican, Mr. Chris Crouch, Mr. Michael May, Mr. Martin Johnson and Mr. Keith Hickey. Last but not least, my special thanks to my family, parents Pat and Sean, Debra, Stephen, Sarah, Chloe and Martin for their continuous support and encouragement. DEDICATION This research is dedicated to Laura, who encouraged, advised and listened to me throughout the years of my research. Thank You for your patience and I hope You enjoy the read !! v TABLE OF CONTENTS DECLARATION........................................................................................................................... ii PUBLICATIONS.........................................................................................................................iii ACKNOW LEDGEM ENT.........................................................................................................iv DEDICATIO N................................................................................................................................v TABLE OF CO NTENTS............................................................................................................1 A B ST R A C T ....................................................................................................................................3 LIST OF TABLES........................................................................................................................ 4 LIST OF FIGURES...................................................................................................................... 6 1. INTR O D U CTIO N ................................................................................................................. 11 1.1 Project Background..................................................................................................... ] 1 1.2 The Current Study........................................................................................................ 14 1.3 N ovelty.............................................................................................................................. 20 1.4 Thesis outline................................................................................................................. 22 1.5 Acknowledgement........................................................................................................ 23 2. LITERATURE R EV IEW ................................................................................................... 24 2.1 Stainless Steels..............................................................................................................26 2.2 Duplex Stainless Steels............................................................................................. 34 2.2.1 Metallurgy...................................................................................................................35 2.2.2 Base metal v weld metal..........................................................................................37 2.2.3 Welding procedure................................................................................................... 39 2.3 Toughness of D uplex Stainless Steel Welds................................................... 45 2.3.1 Review of test data.................................................................................................... 47 2.4 Corrosion Resistance of Duplex Stainless Steels.........................................52 2.4.1 Localised corrosion.............. ................................................................................... 53 2.4.2 Review of test data....................................................................................................59 2.5 Hydrogen Embrittlement (HE)............................................................................... 63 2.5.1 Mechanistic models for hydrogen embrittlement............................................. 67 2.5.2 Review of test data....................................................................................................69 2.6 Corrosion Fatigue behaviour..................................................................................73 2.6.1 Crack initiation resistance.......................................................................................76 2.6.2 Crack propagation resistance............................................................................... 83 2.7 Limitations of published data..................................................................................88 3. EXPERIM ENTAL W O R K ................................................................................................89 3.1 Weldment Fabrication & Basic Integrity A ssessment................................90 3.1.1 Weldment fabrication...............................,................................. .........................90 3.1.2 Tensile strength.........................................................................................................93 3.1.3 Toughness...................... .............................................................................................94 3.1.4 Hardness...................................................................................... ...............................96 3.1.5 Non destructive tests (NDT)...................................................................................98 3.2. Microstructural and Corrosion Assessment of Weld m etal...............100 3.2.1 Microstructural examination.............................................................................100 3.2.2 SEM & image analysis...... ........................................................................... 104 3.2.3 Calculation of percentage ferrite................................................................. 106 3.2.4 Energy dispersive X-ray (EDX).................................................................... 109 3.2.5 Localised corrosion....................................................................................... 110 3.2.6 Residual stress determination....................................................................... 116 3.3 Crack Propagation.....................................................................................................117 3.3.1 Sample type selection......................... ...........................................................117 3.3.2 Crack propagation set-up..................... ................................. ....................125 3.3.3 FEA analysis of angular misalignment........................................................134 3.3.4 Test procedures...............................................................................................140 3.3.5 Fracture surface analysis..............................................................................149 4. RESULTS & DISCUSSION ............................................................................................ 150 4.1 Weldment Fabrication and Basic Integrity Assessment..........................150 4.1.1 Weldment fabrication.....................................................................................151 4.1.2 Tensile strength...............................................................................................153 4.1.3 Toughness......................................................................................................
Load more

Recommended publications
  • Energy Metals Inc: Master Distributor for High-End Alloys
    The global magazine for corrosion resistant alloy users, suppliers and fabricators .YEARS. KCI Publishing Celebrates .1989 - 2019. cover story: Energy Metals Inc: Master distributor for high-end alloys In this issue... • Renewables: growth is fast, but there is still a long way to go • Welding dissimilar metals: duplex pipe to carbon valve • The world’s first 3D printed, smash-proof guitar • The heat beneath our feet: geothermal energy www.stainless-steel-world.net Energy & Renewables Volume 31, July/August 2019 [ Super Duplex ] Ferralium 255 – The original super duplex stainless steel Considered to be the very first super duplex stainless steel on the market, Ferralium® 255 was launched in 1969. After 50 years of successful application and continuous development, the history of this unique alloy is shared in further detail. By Rodney Rice The initial patent The origins of Ferralium as the first super duplex stainless steel (SDSS) can be dated back to a patent application made by Langley Alloys in 1967. Given the somewhat non- descript title “Improvement in Stainless Steels” it described the issues facing this family of alloys at that time, together with the answer to these issues. Austenitic stainless steels were well accepted in the market, with The development of North Sea oil in the UK led to a surge in the requirements for newer good corrosion resistance inferred alloys with greater levels of performance. Here are components for line shaft pumps by their relatively high chromium specified in Ferralium as an alternative to Alloy K-500. and nickel content. However, their tensile properties were generally low.
    [Show full text]
  • The Low Temperature Fracture Behaviour of the Super Duplex Stainless Steel Zeron 100
    The Low Temperature Fracture Behaviour of the Super Duplex Stainless Steel Zeron 100 by Alan Owen Humphreys A thesis submitted to the Faculty of Engineering of the University of Birmingham for the degree of DOCTOR OF PHILOSOPHY IRC in Materials for High Performance Applications, School of Metallurgy and Materials, The University of Birmingham, Edgbaston, Birmingham. B152TT September 1997 University of Birmingham Research Archive e-theses repository This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. ABSTRACT The micromechanisms of fracture in an austenitic/ferritic super-duplex stainless steel (Zeron 100) have been studied for a range of product forms, including cross-rolled plate, conventional (ingot) route and powder route extruded pipe, hot isostatically pressed (HIPd) powder, and weldments produced using both tungsten inert gas (TIG) and manual metal arc (MMA) techniques. The rolled plate material was also investigated after heat treatments at temperatures of 425 and 850°C, which were known to embrittle the material. The as-received microstructures were characterised using optical, scanning electron microscopy (SEM) and transmission electron microscopy (TEM) techniques, including energy dispersive X-ray (EDX) analysis. Macro-residual stresses and crystallographic textures have also been measured.
    [Show full text]
  • Super Duplex Stainless Steel ZERON® 100 for the Oil and Gas Industry
    Oil and Gas Applications The Global Leader in Specialty Metals ZERON® 100 Super Duplex Stainless Steel Super Duplex Stainless Steel ZERON® 100 for the Oil and Gas Industry Specifications UNS: S32760 W. Nr./EN: 1.4501 ASTM: A 182 (Grade F55), A 240, A 276, A 314, A 473, A 479, A 789, A 790, A 815, A 890, A 928, A 988, A 995, EN 10028-7, EN 10088-2, EN 10088-3, EN 10272, EN 10216-5, EN 10217-7 ASME: B16.5, B16.34, B16.47, B31.3, Section VIII Division 1 Case 2244-2, 2245-1, Section III Division 1 Case N-564-2, SA-240, SA-182 (Grade F55), SA-479, SA -815, SA-789, SA-790 NACE: ISO 15156 / MRO175 Part 3 API: 5LC BSI: PD 5500 - Enquiry Case 5500/87 Chemical Composition, % Ni Cr Mo Mn Cu Si C N S P W Fe MIN 6.0 24.0 3.0 – 0.5 – – 0.2 – – 0.5 – MAX 8.0 26.0 4.0 1.0 1.0 1.0 0.03 0.3 0.01 0.03 1.0 balance ZERON 100 Advantages • ZERON 100 is a 25% chromium superduplex stainless steel. • The high alloy content gives ZERON 100 excellent corrosion resistance in both sweet and sour brines. • ZERON 100 has excellent resistance to both chloride and sulfide stress corrosion cracking. • Good low temperature impact properties and fracture toughness. • The high strength gives ZERON 100 excellent erosion resistance. • ZERON 100 is listed in ASME codes for vessels and pipes. • The high strength allows for reduction in weight of the pipework systems.
    [Show full text]
  • Data Sheet Zeron® 100 Uns S32760
    DATA SHEET ZERON® 100 UNS S32760 THE GLOBAL LEADER IN SPECIALTY ALLOYS corrosion resistant alloys ZERON® 100 Data Sheet Contents Specifications, Chemical Composition, Applications and Features.........................................................................................................2 Performance Profile.................................................................................................................................................................... 3 Mechanical Properties................................................................................................................................................................. 3 Physical Properties..................................................................................................................................................................... 4 Corrosion Resistance................................................................................................................................................................... 5 Manufacturing............................................................................................................................................................................ 6 Applications................................................................................................................................................................................ 6 1 Specifications UNS S32760 (J93380 Castings) W.Nr./EN 1.4501 (1.4508 Castings) ASME B16.5, B16.34, B16.47, B31.3, Section VIII Division 1
    [Show full text]
  • Titanium Gaining Favor in Seawater Service Rob Henson Uniti, LLC The
    Titanium Gaining Favor in Seawater Service Rob Henson Uniti, LLC The technical case for titanium application to seawater service was well established in the early 1970’s and performance of titanium over the last 40 years has validated the technical case. Widespread use of titanium for process plant application has grown significantly over the last 40 years in spite of comparative cost with competing alloys. This challenge began to reverse in the early 2000’s as global expansion of titanium production accelerated and the cost for competing alloys continued to rise. With expanding global production (see FIGURE 1) the application base for titanium was able to expand and this expansion allowed the stocking of service centers worldwide to support existing and developing applications. Concurrent with this improved market position for titanium the global nickel and copper industries faced increasing demand, rising energy prices and most importantly declining ore grades. Producing commodities from low grade resources requires higher energy input and capital intensive plants for the processing of large tonnage and low grade run‐of‐mine ore. FIGURE 1 GLOBAL TITANIUM SPONGE PRODUCTION USGS minerals information This business case for titanium was demonstrated in 2010 with the largest ever industrial project for titanium when the Ras Al Khair desalination plant was constructed utilizing near 6000 MT of titanium tubing. The application of titanium on this large scale was a result of the proven 40 year history of titanium in power generation and thermal desalination service together with the improved delivery for titanium products and the rising price of copper alloys. With titanium often the economic choice for seawater application the importance of the technical case cannot be overstated and should be revisited.
    [Show full text]
  • 2 Duplex Stainless Steels
    CRANFIELD UNIVERSITY School of Applied Sciences PhD THESIS Hydrogen Embrittlement Susceptibility of Super Duplex Stainless Steels Jalal Alsarraf CRANFIELD UNIVERSITY School of Applied Sciences PhD THESIS Academic Year 2006 - 2010 Jalal Alsarraf Hydrogen Embrittlement Susceptibility of Super Duplex Stainless Steels Supervisor: Dr. M. J. Robinson April 2010 © Cranfield University 2010. All rights reserved. No part of this publication may be reproduced without the written permission of the copyright owner. ABSTRACT This thesis describes the metallurgical and environmental factors that influence hydrogen embrittlement of super duplex stainless steels and presents a model to predict the rate at which embrittlement occurs. Super duplex stainless steel has an austenite and ferrite microstructure with an average fraction of each phase of approximately 50%. An investigation was carried out on the metallurgical and environmental factors that influence hydrogen embrittlement of super duplex stainless steels. Tensile specimens of super duplex stainless steel were pre-charged with hydrogen for two weeks in 3.5% NaCl solution at 50º C at a range of applied potentials to simulate the conditions that exist when subsea oilfield components are cathodically protected in seawater. The pre-charged specimens were then tested in a slow strain rate tensile test and their susceptibility to hydrogen embrittlement was assessed by the failure time, reduction in cross-sectional area and examination of the fracture surface. The ferrite and austenite in the duplex microstructures were identified by analysing their Cr, Ni, Mo and N contents in an electron microscope, as these elements partition in different concentrations in the two phases. It was shown that hydrogen embrittlement occurred in the ferrite phase, whereas the austenite failed in a ductile manner.
    [Show full text]
  • ZERON100 Data Sheetdata ZERON100
    M A T E R I A L D A T A S H E E T Industrial Piping Products ZERON100 DataSheet ZERON 100 / UNS S32760/ DIN 1.4501 Exceptional Corrosion Resistance Super Duplex Steel Introduction ZERON 100 is a highly alloyed super duplex stainless steel for use in aggressive environments. Its combination of properties makes ZERON 100 the optimum choice in a range of industries. ZERON 100 is not recommended for uses which involve extended exposure to temperatures greater than 300°C (572°F) as this causes a substantial reduction in toughness. Chemical Composition ( Typical ) Mechanical Properties ( typical ) Element Limits Parameter Value min max Yield 0.2 % ( ksi/Mpa), Min 550 Carbon 0.000 0.030 Tensile (ksi/Mpa), Min 750 Manganese 0.000 1.000 Elongation ( % in 50mm ), Min 25 Silicon 0.000 1.000 Reduction in Area, % 50 Phosphorus 0.000 0.030 Hardness (HB), Max 270 Sulphur 0.000 0.010 Chromium 24.000 26.000 Physical Properties Molybdenum 3.000 4.000 Nickel 6.000 8.000 Parameter Value Copper 0.500 1.000 Density ( Kg/m3 ) 7800 Nitrogen 0.200 0.300 Elastic Modulus ( Gpa ) 200 Tungsten 0.500 1.000 Co-eff of Expansion ( µm/m/°C ) 13 Iron Remainder Thermal Condc. (W/m.K) 15 Electric Resistivity (nΩ.m) 800 Corrosion Data ZERON 100 is highly resistant to corrosion in a wide range of organic and inorganic acids. The copper content gives excellent resistance to corrosion in many non-oxidizing acids. It is also highly resistant to strong alkalis. Commercial acid applications often contain chlorides and other impurities which can cause corrosion of some stainless steels.
    [Show full text]
  • ZERON 100 Swimming Pools
    REPORT THE USE OF ZERON 100 SUPERDUPLEX STAINLESS STEEL IN SWIMMING POOLS Prepared by: Roger Francis Corrosion Services Manager Approved by: Glenn Byrne Managing Director CIRCULATION Division Engineering Job No. Reference No. Report No: TN1503 Iss No. 1 Date: Dec 2008 Copyright © Rolled Alloys 2008 Rolled Alloys Company Confidential Ltd co. registered in USA Rolled Alloys is the owner of the Copyright in this (Delaware)-#37-1540008, PO Box 1287, document. The document and its text, images, diagrams, Northbrook, Illinois data and information it contains must not be copied or 60065. UK Company reproduced in whole or in part, in any form or by any Number FC027795 VAT General Release Y Reg No. GB 803 8704 36 means, without the prior written consent of Rolled Alloys THE USE OF ZERON 100 SUPERDUPLEX STAINLESS STEEL IN SWIMMING POOLS SECTION DESCRIPTION YRAMMUS 0.1 NOITCUDORTNI 0.2 EHT YOLLA 0.3 NOISORROC ECNATSISER 1.3 retawaeS 2.3 ssertS noisorroC gnikcarC 0.4 ECIVRES ECNEIREPXE 0.5 SNOISULCNOC TABLES Table 1 The nominal composition of some common stainless steels. Table 2 The minimum mechanical properties at room temperature of some common stainless steels. FIGURES Figure 1 Maximum depth of crevice corrosion in seawater plus 1mg/l chlorine at 16° C. Figure 2 Chloride limits to resist crevice corrosion for some stainless steels. Figure 3 Maximum depth of crevice corrosion in seawater plus 1mg/l chlorine at 40° C. Figure 4 Microsection showing SCC of 316L exposed to simulated condensed water. Figure 5 Microsection showing slight corrosion of Zeron 100 exposed to a simulated condensed water.
    [Show full text]
  • Frequently Asked Questions the Global Leader in Specialty Metals ZERON® 100 Super Duplex
    Frequently Asked Questions The Global Leader in Specialty Metals ZERON® 100 Super Duplex ZERON 100 is a 25% chromium super duplex stainless steel. Duplex stainless steels are a family of stainless steels with dual phase structure. Roughly 50 percent of the structure is ferrite (like 400 series stainless) and 50 percent is austenite (structure of 300 series stainless). ZERON 100 is a more highly alloyed and higher performance grade of stainless steel than 316L or the common duplex grade, 2205. 2205 contains 22 Cr, 5.5 Ni, and 3.1 Mo. By comparison, ZERON 100 contains 25 Cr, 7 Ni, 3.5 Mo with nitrogen, tungsten, and copper additions. For this reason ZERON 100 is termed a super duplex stainless steel. Questions Answers 1. What are some ZERON 100 has found its most significant usage in seawater applications, sour gas applications, and in sulfuric acid service. As a result, it has been typical applications utilized extensively in seawater reverse osmosis desalination systems, offshore oil & gas exploration, downhole oil wells, and in mining and flue gas where ZERON 100 is desulfurization applications. successfully used? 2. What alloys would I ZERON 100 is commonly used as an upgrade to 2205 and 316L stainless. It is an alternate to other superduplex stainless steels such as 2507 or alloy consider ZERON 100 255. It is also considered to replace higher nickel alloys such as 904L, 6% molybdenum stainless steels (AL-6XN® and 254 SMO®), and in some cases to potentially replace? alloy 625 and C-276. 3. How does ZERON ZERON 100 (S32760) differs from 2507 Iso-Corrosion curves (0.1 mm/y) for some stainless steels in dilute sulfuric acid 100 compare to other (S32750) because of its additions of copper superduplex grades? and tungsten.
    [Show full text]
  • ZERON 100 FGD Plants
    REPORT The Use of ZERON 100 In Flue Gas Desulphurisation Plant Prepared by: Roger Francis Corrosion Services Manager Approved by: Geoff Warburton Product Manager CIRCULATION Division Technical Job No. Reference No. Report No: TN780 Iss No. 6 Date: November 2008 Copyright © Rolled Alloys 2008 Rolled Alloys Company Confidential Ltd co. registered in USA Rolled Alloys is the owner of the Copyright in this (Delaware)-#37-1540008, PO Box 1287, document. The document and its text, images, diagrams, Northbrook, Illinois data and information it contains must not be copied or 60065. UK Company reproduced in whole or in part, in any form or by any Number FC027795 VAT General Release Y Reg No. GB 803 8704 36 means, without the prior written consent of Rolled Alloys THE USE OF ZERON 100 IN FLUE GAS DESULPHURISATION PLANT TABLE OF CONTENTS SECTION DESCRIPTION SUMMARY 1.0 INTRODUCTION 2.0 ZERON 100 3.0 CORROSION 3.1 General Corrosion 3.2 Crevice Corrosion 3.3 Erosion Corrosion 4.0 APPLICATIONS AND EXPERIENCES 5.0 CONCLUSIONS REFERENCES Table 1. The nominal composition of some common stainless steels. Table 2. Minimum mechanical properties of some stainless steels. Table 3. Critical crevice temperature for some stainless steels in a simulated anthracite FGD slurry at pH4. Table 4. Critical crevice temperature for some stainless steels in a simulated lignite FGD slurry at pH4. Figure 1. Schematic diagram of a typical FGD absorber tower (Babcock design). Figure 2. Iso-corrosion curves (0.1mm/y) for some stainless steels in sulphuric acid. Figure 3. Iso-corrosion curves (0.1mm/y) for some stainless steels in hydrochloric acid.
    [Show full text]
  • The Global Leader in Specialty Alloys
    DATA SHEET ZERON® 100 UNS S32760 THE GLOBAL LEADER IN SPECIALTY ALLOYS CORROSION RESISTANT ALLOYS ZERON® 100 Data Sheet Contents Specifications, Chemical Composition, Applications and Features.........................................................................................................2 Performance Profile.................................................................................................................................................................... 3 Mechanical Properties................................................................................................................................................................. 3 Physical Properties..................................................................................................................................................................... 4 Corrosion Resistance................................................................................................................................................................... 5 Manufacturing............................................................................................................................................................................ 6 Applications................................................................................................................................................................................ 6 1 Specifications UNS S32760 (J93380 Castings) W.Nr./EN 1.4501 (1.4508 Castings) ASME B16.5, B16.34, B16.47, B31.3, Section VIII Division 1
    [Show full text]
  • EXPERIENCES with ZERON 100 SUPER DUPLEX STAINLESS STEEL in the PROCESS INDUSTRIES Paper No
    P:\WP_Docs\TECH\Conference Papers\SSWORLD 99B.doc STAINLESS STEEL WORLD CONFERENCE 1999 EXPERIENCES WITH ZERON 100 SUPER DUPLEX STAINLESS STEEL IN THE PROCESS INDUSTRIES Paper No. 99007 R FRANCIS, G BYRNE, G R WARBURTON Weir Materials & Foundries Park Works Newton Heath Manchester M40 2BA United Kingdom A B S T R A C T The process industries have used 300 series stainless steels for many years where the corrosion resistance of carbon steel is inadequate. Where stainless steels have proved inadequate there has been a tendency to utilise high nickel alloys with a greatly increased cost. This paper introduces Zeron 100 super duplex stainless steel and shows how its superior corrosion and stress corrosion cracking resistance, plus its high strength, can be utilised to provide a cost effective alternative to both austenitic stainless steels and high nickel alloys. The composition, mechanical properties and corrosion resistance are discussed showing that the combination of high strength and excellent corrosion resistance make it eminently suitable for a wide range of industrial applications. The wide range of product forms in which Zeron 100 is available means that vessels, piping, valves and pumps can be made from a single alloy with no worries about galvanic compatibility. Zeron 100 has now been in service for up to ten years. The material is readily weldable with over one million joints now in service. The paper reviews examples of the applications of Zeron 100 including service experience in the petrochemical, chemical, fertiliser and mining industries. The high strength and hardness of Zeron 100 gives it excellent resistance to erosion and erosion-corrosion and it is widely used for pumps and piping in mining and processing applications.
    [Show full text]