Austenitic-ferritic Duplex Stainless Steel Research Articles

Mechanical Properties and Microstructure of Austenite—Ferrite Duplex Stainless Steel Hybrid (Laser + GMAW) and SAW Welded Joint

The purpose of the research was to develop a technology for producing thick-walled duplex steel welded joints. The material used in the research was X2CrNiMoN22 duplex steel in the form of a 15 mm thick plate. The welded joint was produced by the modern, high-performance Hybrid Laser Arc Welding (HLAW) method. The HLAW method involves welding a joint using a laser, the Gas Metal Arc Welding (GMAW) method and the Submerged Arc Welding (SAW) method. The HLAW method was used to make the root pass of the double butt welded joint, while the filler passes were made by the SAW method. The obtained welded joint was subjected to non-destructive and destructive testing. The non-destructive and macroscopic tests allowed the joint to be classified to the quality level B. Microscopic examinations revealed the presence of ferritic-austenitic microstructure in the base material and the weld, with different ferrite content in specific joint areas. The analysed joint had high strength properties (tensile strength (TS) ~ 790 ± 7 MPa) and high ductility of weld metal (~160 ± 4 J) heat-affected zone (~216 ± 26 J), and plasticity (bending angle of 180° with no macrocracks). At the same time, hardness on the cross-section of the welded joint did not exceed 280 HV10.

Effect of Phase-Selective Nanoscale Precipitates on the Bauschinger Effect in Austenitic–Ferritic Duplex Stainless Steels

The Bauschinger effect in austenitic–ferritic duplex stainless steel 1.4462 was investigated using tension–compression tests combined with electron backscatter diffraction (EBSD). A major focus was on the impact of phase-selective nanoscale α′ precipitates formed in the ferritic phase due to 475 °C embrittlement. Contrary to the general knowledge that coherent precipitates have only a short-range effect and thus no significant influence, a strong increase in the Bauschinger effect was detected. Based on EBSD data and cyclic micro-indentations in individual grains, it was demonstrated that α′ precipitates enhance the phase difference between austenite and ferrite and increase deformation incompatibility and local dislocation density gradients at phase boundaries. Thus, despite their small size and coherence, α′ precipitates lead to long-range back stresses that significantly enhance the Bauschinger effect. In addition, the influence of precipitation was shown to depend on the extent of pre-strain during initial loading. The insights demonstrate that the influence of precipitates on the Bauschinger effect is highly complex and always needs to be analyzed with respect to precipitation characteristics, microstructure, and external boundary conditions.

On the M23C6-Carbide in 2205 Duplex Stainless Steel: An Unexpected (M23C6/Austenite)—Eutectoid in the δ-Ferritic Matrix

This study is focused on isothermal and anisothermal precipitation of M23C6 carbides from the fully ferritic structure of the (γ + δ) austenitic-ferritic duplex stainless steel X2CrNiMo2253, (2205). During isothermal heat treatments, small particles of K-M23C6 carbide precipitates at the δ/δ grain-boundaries. Their formation precedes γ and σ-phases, by acting as highly potential nucleation sites, confirming the undertaken TEM investigations. Furthermore, anisothermal heat treatment leads to the formation of very fine islands dispersed throughout the fully δ-ferritic matrix. TEM characterization of these islands reveals a particular eutectoid, reminiscent of the well-known (γ-σ)—eutectoid, usually encountered in this kind of steel. TEM and electron microdiffraction techniques were used to determine the crystal structure of the eutectoid constituents: γ-Austenite and K-M23C6 carbides. Based on this characterization, orientation relationships between the two latter phases and the ferritic matrix were derived: cube-on-cube, on one hand, between K-M23C6 and γ-Austenite and Kurdjumov-Sachs, on the other hand, between γ-Austenite and the δ-ferritic matrix. Based on these rational orientation relationships and using group theory (symmetry analysis), the morphology and the only one variant number of K-M23C6 in γ-Austenite have been elucidated and explained. Thermodynamic calculations, based on the commercial software ThermoCalq® (Thermo-Calc Software, Stockholm, Sweden), were carried out to explain the K-M23C6 precipitation and its effect on the other decomposition products of the ferritic matrix, namely γ-Austenite and σ-Sigma phase. For this purpose, the mole fraction evolution of K-M23C6 and σ-phase and the mass percent of all components entering in their composition, have been drawn. A geometrical model, based on the corrugated compact layers instead of lattice planes with the conservation of the site density at the interface plane, has been proposed to explain the transition δ-ferrite ⇒ {γ-Austenite ⇔ K-M23C6}.

Micromechanics driven design of ferritic–austenitic duplex stainless steel microstructures for improved cleavage fracture toughness

Ferritic–austenitic duplex stainless steels are known to offer favorable combinations of good mechanical properties and corrosion resistance to be used for structural purposes. Lean duplex grades have already been introduced for consideration to replace standard 18–8 austenitic stainless steels in various industrial applications. Ferrite and austenite represent different deformation behaviors and contribute to the resulting fracture toughness characteristics. Micromechanical crystal plasticity based assessment of this cleavage fracture behavior is the subject area of current work. The objective is to bridge cleavage fracture models to full field crystal plasticity imaging based modeling of microstructures of ferritic–austenitic duplex stainless steels. The goal is to introduce means to computationally assess the effects of different multi-phase microstructural morphologies to cleavage fracture toughness and develop both the respective constitutive and cleavage fracture modeling capabilities. Such means can be used as an aid to develop better cleavage resistant, while in the current context lean, steel grades. Three different steels are investigated with differing austenite phase morphologies, and their behavior with respect to fracture mechanical response evaluated by micromechanical modeling. The effect of austenite fraction and morphology in terms of improving fracture toughness, a critical parameter concerning these steel grades and improvement of their cleavage fracture properties, is investigated. Deleterious features such as large ferrite grain size and microstructural property mismatching are identified and their implications to fracture toughness and development of applicable modeling capabilities for ferritic–austenitic duplex steels discussed. Simple design task of varying the austenite phase fraction is performed using synthetic microstructural modeling and the results evaluated with respect to their influence on the fracture toughness ductile-to-brittle transition.

VHCF damage in duplex stainless steel revealed by microbeam energy-dispersive X-ray Laue diffraction

Microstructure of austenitic-ferritic duplex stainless steel loaded in the Very High Cycle Fatigue regime was investigated using microbeam energy-dispersive X-ray Laue diffraction. Scanning electron microscopy analysis of the surface shows that damage in the form of fatigue cracks is initiated at grain boundaries assisted by slip bands observed in austenite grains. Energy-dispersive X-ray Laue diffraction was then used to scan a damaged area containing both a fatigue crack and slip bands, in order to measure the changes in microstructure. Results from the X-ray data from the austenite grain indicates slip activation of the most favored slip system tilted by 45° with respect to the external loading direction, dividing the grain into two regions on either side of the slip band. In the ferrite phase, in front of the crack, variations in the angle and energy spectra of the diffraction peaks indicate the presence of lattice curvature and a strain gradient. In regions around the crack, diffraction peaks spatially split into several sub-peaks indicating the presence of fine granular areas separated by polarized dislocation walls. Possible reasons for the observed structural evolution are discussed and the advantages of using energy-dispersive X-ray Laue diffraction in fatigue damage analysis are illustrated.

Cyclic Deformation Induced Residual Stress Evolution and 3D Short Fatigue Crack Growth Investigated by Advanced Synchrotron Tomography Techniques.

Diffraction and phase contrast tomography techniques were successfully applied to an austenitic–ferritic duplex stainless steel representing exemplarily a metallic material containing two phases with different crystal structures. The reconstructed volumes of both phases were discretized by finite elements. A crystal plasticity finite-element analysis was executed in order to simulate the development of the experimentally determined first and second order residual stresses, which built up due to the manufacturing process of the material. Cyclic deformation simulations showed the single-grain-resolved evolution of initial residual stresses in both phases and were found to be in good agreement with the experimental results. Solely in ferritic grains, residual stresses built up due to cyclic deformation, which promoted crack nucleation in this phase. Furthermore, phase contrast tomography was applied in order to analyze the mechanisms of fatigue crack nucleation and short fatigue crack propagation three-dimensionally and nondestructively. The results clearly showed the significance of microstructural barriers for short fatigue crack growth at the surface, as well as into the material. The investigation presented aims for a better understanding of the three-dimensional mechanisms governing short fatigue crack propagation and, in particular, the effect of residual stresses on these mechanisms. The final goal was to generate tailored microstructures for improved fatigue resistance and enhanced fatigue life.

Phase Stress Measurement of Centrifugally Cast Duplex Stainless Steel by Neutron Diffraction

Residual stress can be easily generated during material processing and affect the performance of structural components. Phase stress distribution in austenitic-ferritic duplex stainless steels (DSSs) is complicated due to the different material properties between the two phases. In this study, residual phase stress distribution along the thickness direction of centrifugally cast DSS hollow cylinder was measured by pulsed neutron diffraction with the time-of-flight (TOF) method. The triaxial phase stress distribution along the thickness direction shows that the phase stress of austenitic phase is generally in tension and higher than that of ferrite phase. From the outer surface to the inner surface, the macro-stress distributes from −400 MPa to 200 MPa. The mechanism of macro-stress formation was deduced by taking into consideration the thermal shrinkage behavior during the cooling process of water quench after the solution heat treatment. Furthermore, the lattice strain and phase stress evolution under the uniaxial tensile loading was evaluated by in-situ neutron diffraction measurement. The results indicated that the magnitude of phase stress could be affected by plastic working as well. All these measurements were conducted at Japan Proton Accelerator Research Complex (J-PARC).

Influence of Parameters of Laser Beam Welding on Structure of 2205 Duplex Stainless Steel

Abstract Laser welding is used in modern industry, having many advantages comparing to traditional welding technologies. Nowadays, industry sectors such as shipbuilding, automotive and aviation can’t be imagined without laser processing technologies. Possibility of increase of welded joint properties, autogenous welding and high level of process automation makes the technology of laser welding perspective part of the industry. Physical multidimensional processes complexity requires a deeper understanding of the impact of laser welding parameters on the quality of welded joints for industrial implementation. The paper presents results of microstructure investigations of laser beam welded stainless steel under various welding parameters. Welded joints was achieved by Ytterbium fiber laser type without the use of the filler material. Material for test was 2205 ferritic-austenitic duplex stainless steel (DSS) plates with thickness of 8 mm in delivery condition. The objectives of this research was to investigate influence of laser welding parameters on weld geometry of butt-welded joints. Investigations of bead shape revealed correlation between laser beam focus position and weld penetration depth.

An overview of the recurrent failures of duplex stainless steels

Abstract The favourable combination of mechanical and corrosion properties of ferritic-austenitic duplex stainless steels (DSSs) makes this class of materials widely employed in many industries (e.g. petrochemical, nuclear, pulp and paper). Despite their wide and growing usage, the DSS components might be subjected to various types of mechanical and environmentally induced failures during their life cycle, especially when the component is exposed to temperatures in the range of 300 to 900 °C, which might promote the precipitation of stable and deleterious phases. For instance, the precipitation of sigma, alpha-prime and M23C6 phases - the latter more often observed in high carbon DSS – might induce the premature failure of DSS components due to the mechanical embrittlement and the sensitization of the microstructure during thermal exposure (either in processing, such as welding, or in service). Additionally, the ferrite phase features a ductile-to-brittle temperature, which defines the lower service temperature of DSS components. In this sense, the main properties of DSSs will be compared with the properties of austenitic stainless steels (ASSs) and ferritic stainless steels (FSSs) to provide the reader a broader view about boundary conditions for the selection and use of DSSs. The main phase transformations and microstructures of the DSSs will be concisely presented and microstructural, fractographic and crack propagation characterization of selected in-service failures will illustrate the role of these stable and deleterious phases on the life of DSS components.

UGI 4362

Abstract UGI 4362 is an austenitic ferritic duplex stainless steel with good strength and corrosion resistance. It has superior yield strength, ultimate tensile strength, and corrosion resistance compared with 316L stainless. This datasheet provides information on composition, physical properties, elasticity, and tensile properties. It also includes information on corrosion resistance as well as forming and heat treating. Filing Code: SS-1289. Producer or source: Schmolz + Bickenbach USA Inc..

Effects of long-term thermal aging on bulk and local mechanical behavior of ferritic-austenitic duplex stainless steels

Ferritic-austenitic cast duplex stainless steels (CDSS) undergo significant thermal aging embrittlement in service in light water nuclear reactors. Cast CF–3 and CF–8 duplex stainless steels have been laboratory aged for up to 17,200 h at four different temperatures (280 °C, 320 °C, 360 °C, 400 °C) in order to characterize the evolution of microstructure and mechanical properties. Standard Charpy V-Notch (CVN) impact testing and tensile testing have been conducted to measure the progression of embrittlement of the steels. Concurrently, nanoindentation measurements were performed to measure the hardening of the individual ferrite and austenite phases. Atom probe tomography (APT) analysis of the constituent phases is used to investigate the relationship between spinodal decomposition of the ferrite and the mechanical property evolution during aging. The effects of the local microstructure and property changes in the ferrite phase on the overall bulk mechanical property degradation of these steels are discussed.

Characterization of Desulfovibrio desulfuricans biofilm on high-alloyed stainless steel: XPS and electrochemical studies

Results on D. desulfuricans biofilm formation on austenitic-ferritic duplex (2205 DSS) and superaustenitic (904L) stainless steels are presented. Surface characterization including the structure, configuration and chemical composition of biofilms were carried out using scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). Electrochemical impedance spectroscopy (EIS) measurements were used to monitor the attachment activity of bacteria on the steels' surface and to determine the effect of bacteria on passivity. It was proved that investigated steels are rapidly colonized by bacteria. The presence of biofilm caused significant ennoblement of 904L steel surface, while retarded the attainment of high passive state of 2205 DSS. XPS analysis revealed significant sulphidation of the biofilm and its layered structure. Accumulation of sulphides and hydroxides was proved in the outermost layer, while the increasing contents of disulphides, organometallic and CN bonds were detected in the internal part of the biofilm. Irreversible bondings between steel matrix and biofilm had also been observed.

High temperature embrittled duplex stainless steels: influence of the chemical composition on the fatigue crack propagation

Abstract: Austenitic-ferritic (duplex) stainless steels are successfully used in chemical, nuclear, oil and gas industries, due to their good mechanical properties and excellent generalized and localized corrosion resistance in many environments and operating conditions (for example, chloride induced stress corrosion). The aim of this work is the analysis of the influence of the chemical composition and of the high temperature embrittlement processes in three different duplex stainless steels. Scanning electron microscope (SEM) fracture surface analysis was performed to investigate the fatigue crack propagation micromechanisms.

Study of Micro Deformation of Austenitic-Ferrite Duplex Stainless Steel by Nanoindentation Method

Based on the technology of the nanoindentation, the basic mechanical properties and cyclic deformation behavior of the austenite phase and ferrite phase in an austenitic-ferritic duplex stainless steel was studied. Firstly, from the displacement monotonic indentation experiment, the differences between the basic mechanical properties (e.g. hardness and elastic modulus) of austenite phase and ferrite phase are compared. Then, with the incremental load controlled loading-unloading conditions applied, the indentation depth evolution rule and the indentation creep behavior was studied. Finally, with the load controlled cyclic indentation experiments being conducted, the cyclic evolution rule of displacement into surface were observed, and the influence of different load level on the micro cyclic deformation behavior of each phase were discussed.

Hydrogen behavior in SAF 2205 duplex stainless steel

This paper describes austenitic-ferritic duplex stainless steels, SAF 2205, in the presence of hydrogen. The duplex stainless steels (DSS) properties include excellent resistance to stress corrosion cracking, high strength and good weldability. Those steels are preferably used in industries combining hydrogen and loads. Hydrogen location in addition to hydrogen binding energy with the steel's defects are of great importance for the analysis of hydrogen embrittlement model in that steel. It is known from previously published works that the susceptibility to hydrogen embrittlement will depend on the competition between reversible and irreversible traps; meaning a direct relation to the hydrogen's state and position in the steel. In this work, we examine the local hydrogen concentration, trapping and distribution by two modern and advanced techniques: thermal desorption spectrometry (TDS) and we support it by time of flight-secondary ion mass spectrometer (ToF-SIMS). In this paper, we support and give for the first time new insights and better understanding to the hydrogen embrittlement mechanism in SAF 2205.The trapping energies levels were calculated using TDS and Lee and Lee's model. This model revealed reversible in addition to irreversible trapping sites. Also the trapping controlling mechanism was found to be a combination of detrapping controlled mechanism and diffusion controlled mechanism. The use of ToF-SIMS for local imaging the distribution of hydrogen species supports the discussion of the different hydrogen traps in this type of steel. The hydrogen embrittlemet phenomenon in SAF 2205 will be discussed in details in that paper.

Characterization of phase properties and deformation in ferritic-austenitic duplex stainless steels by nanoindentation and finite element method

The phase properties and deformation behavior of the δ–ferrite and γ–austenite phases of CF–3 and CF–8 cast duplex stainless steels were characterized by nanoindentation and microstructure-based finite element method (FEM) models. The elastic modulus of each phase was evaluated and the results indicate that the mean elastic modulus of the δ–ferrite phase is greater than that of the γ–austenite phase, and the mean nanoindentation hardness values of each phase are approximately the same. The elastic FEM model results illustrate that greater von Mises stresses are located within the δ–ferrite phase, while greater von Mises strains are located in the γ–austenite phase in response to elastic deformation. The elastic moduli calculated by FEM agree closely with those measured by tensile testing. The plastically deformed specimens exhibit an increase in misorientation, deformed grains, and subgrain structure formation as measured by electron backscatter diffraction (EBSD).

A Comparative Study on the Cyclic Behavior of Austenite/Ferrite Phases Characterized by the Nanoindentation

The cyclic deformation behavior of the austenite and ferrite phase in an austenite-ferrite duplex stainless steel was studied by using the load-controlled cyclic nanoindentation approach. The results showed that the maximum penetration depth onto both austenite and ferrite phases increased continuously while the rate decreased gradually and finally reached to a constant during the repeated indentation. Both transient state and quasi-steady state were observed for the penetration depth per cycle on both of the austenite and ferrite phases with the increased cycles. By contrast, both the penetration depth and rate per cycle into the austenite phase were larger than those into the ferrite phase. This was ascribed to the stress-induced densification in the austenite and ferrite phases and strain-induced transformed martensite in the austenite phase.

Decomposition and Precipitation Process During Thermo-mechanical Fatigue of Duplex Stainless Steel

The so-called 748 K (475 °C) embrittlement is one of the main drawbacks for the application of ferritic-austenitic duplex stainless steels (DSS) at higher temperatures caused by a spinodal decomposition of the ferritic phase. Thermo-mechanical fatigue tests performed on a DSS in the temperature range between 623 K and 873 K (350 °C and 600 °C) revealed no negative influence on the fatigue lifetime. However, an intensive subgrain formation occurred in the ferritic phase, which was accompanied by formation of fine precipitates. In order to study the decomposition process of the ferritic grains due to TMF testing, detailed investigations using scanning and transmission electron microscopy are presented. The nature of the precipitates was determined as the cubic face centered G-phase, which is characterized by an enrichment of Si, Mo, and Ni. Furthermore, the formation of secondary austenite within ferritic grains was observed.

Application of a Modified Stress−Strain Approach for the Fatigue‐Life Prediction of a Ferritic, an Austenitic and a Ferritic–Austenitic Duplex Steel under Isothermal and Thermo‐Mechanical Fatigue

The isothermal and thermo‐mechanical fatigue behavior of the ferritic–austenitic duplex stainless steel X2CrNiMoN22‐5‐3 is investigated in the temperature range of 100–600 °C. Furthermore, isothermal and thermo‐mechanical fatigue tests on single‐phase ferritic and austenitic reference steels are carried out within the same temperature range. A recently developed fatigue‐lifetime description is applied and modified for all tests as well as on the different steels individually, providing appropriate fatigue‐life predictions.

Mechanisms inhibiting short fatigue crack propagation at loading amplitudes close to the conventional fatigue limit

Recent experiments in the very high cycle fatigue (VHCF) regime showed that the traditional differentiation regarding the existence of a fatigue limit based on the crystal structure of the material is unsustainable. On the one hand it was proved that bcc materials can show fracture even after ten million load cycles, which is contrary to former assumptions. On the other hand fcc materials can exhibit a real fatigue limit, e.g., due to the existence or formation of a second phase. In the present study, the propagation behavior of microstructurally short fatigue cracks in an austenitic-ferritic duplex stainless steel, which contains both bcc and fcc crystal structure, was investigated by means of high frequency fatigue testing at a testing frequency of about 20 kHz up to one billion load cycles. Not fractured samples were investigated by means of high resolution SEM in combination with automated electron back scatter diffraction (EBSD) analysis and focussed ion beam (FIB) cutting after one billion load cycles in order to reveal the mechanisms, which are responsible for inhibition and blocking of short fatigue crack propagation. The investigations showed that fatigue cracks can permanently be arrested at phase boundaries or even within a grain. The investigated material exhibits a real fatigue limit despite occuring crack initiation. Depletion of plastic deformation at the crack tip as driving force for fatigue crack propagation seems to be the reason for the permanent crack arrest. The utilization of the observed inhibition mechanisms of short fatigue crack propagation may help to improve the fatigue resistance of metallic materials by adjusting its microstructural parameters systematically.