UNS S30400 Research Articles

Microstructural characterization and corrosion behaviour of heat treated standard stainless steels in tar sand

This paper aims to investigate the corrosion behaviour of heat-treated standard duplex stainless steel (UNS S32205) in the recovery of bitumen from Nigerian-rich tar sand, using sodium hydroxide (NaOH) as the process solution. Appropriate material family needs to be identified for the exploitation of tar sand resources to ensure sustainable extraction of bitumen. UNS S32205 offers exceptional mechanical properties and excellent corrosion resistance which makes it a great material choice for demanding applications, including offshore platforms and construction projects. Samples of UNS 32205 were heat-treated and immersed in the digested tar sand, maintaining a process temperature of 90°C. The microstructure of the corrosion coupons was studied using SEM/EDS (Scanning Electron Microscope/Energy Dispersive Spectroscope), and the corrosion rate of the samples was derived using gravimetric technique following ASTM G31 standard. The SEM micrographs indicated varying degrees of pits associated with the passivity of UNS 32205 and an imbalance between its ferrite and austenite phases due to the presence of secondary precipitates formed during heat treatment.The normalized sample, having a corrosion rate of 0.053 mm/year, exhibited the best corrosion resistance, followed by oil quenching (0.054 mm/year), then annealing (0.076 mm/year), and water quenching (0.077 mm/year), where they all showed improved corrosion resistance over the as-received sample having a corrosion rate of 0.078 mm/year.

Analysis of UNS S31603 ferrous joint made by rotary friction welding

Analysis of UNS S31603 ferrous joint made by rotary friction welding

High-throughput first-principles study on the effect of Ni segregation on the formation of Cr-depleted zone and corrosion resistance of S32205 duplex stainless steels

Recent studies have found that in the absence of Cr carbide precipitation, co-segregation of Cr and other elements at the interface between α-Fe and γ-Fe can also lead to the formation of Cr-depleted zones, leading to intergranular corrosion. The study employed three-dimensional atomic probes, focused ion beams, and high-throughput first-principles calculation techniques to investigate the impact of Ni atoms on the α-Fe/γ-Fe interface of UNS S32205 duplex stainless steels. The goal was to analyze the formation of Cr-depleted zones and interface corrosion resistance. The results indicate that both Ni and Cr atoms are segregated at the interface between α-Fe and γ-Fe phases; The strong interaction between Ni and Cr atoms hinders Cr segregation at the interface and slows down the formation of Cr-depleted zones; co-segregation of Ni and Cr can improve the stability of the α-Fe/γ-Fe phase interface, reduce the generation of microcracks, and reduce the stability of Cl atom adsorption in the cracks. This establishes the theoretical basis for further suppressing the formation of Cr-depleted zones and preventing intergranular corrosion.

Effect of PVD deposition method on indentation and friction wear characteristics with hydrogen embrittlement of CrN coated stainless steel for electric vehicle hydrogen valves

In this investigation, a chromium nitride layer was deposited on general austenite stainless steel (UNS S31603) by means of the physical vapor deposition coating method to improve the hardness, wear resistance, and hydrogen embrittlement resistance. Accordingly, the purpose of this investigation is to study the effect of different physical deposition methods on mechanical characteristics due to hydrogen embrittlement. Both the indentation and friction characteristics of the chromium nitride layer with in response to hydrogen embrittlement were examined. The ion beam-assisted deposition (IBAD) and arc ion plating (AIP) methods were used to densely deposit the coating layer with a thickness of approximately 2.0∼2.5 μm, and the hardness increased by around 1180.9 HV and 1638.6 HV, respectively, when compared with the base material (292.6 HV). In terms of the coating layer deposited using the IBAD method, all the base material was exposed after hydrogen embrittlement for 3 h, whereas in the case of the coating deposited using the AIP method, the base material began to be exposed locally following hydrogen embrittlement for 12 h. For the IBAD- and AIP-deposited coatings, the average friction coefficient was calculated as 0.52 and 0.34, respectively. In the case of the coating layer deposited using the IBAD method, the average friction coefficient increased by 0.29 after hydrogen embrittlement for 3 h, whereas the average friction coefficient of the coating layer deposited using the AIP method increased by 0.04 after hydrogen embrittlement for 48 h. Therefore, it can be seen that the AIP method is significantly better than IBAD in terms of mechanical characteristics with hydrogen embrittlement.

Electrochemical corrosion behaviour of UNS S32205 duplex stainless steel dependent on sigma phase precipitation

Abstract In this study, the microstructure and electrochemical corrosion behavior of the UNS S32205 alloy were investigated. Firstly, the phase diagram of the studied samples was determined by Thermo-Calc 2022 software, and the solution treatment temperature was designated. The studied samples were cooled by various cooling rates following the solution treatment at 1050 °C for 30 min. The samples were characterized by optical microscope, scanning electron microscope, and XRD analysis. Also, electrochemical corrosion behavior was investigated by potentiodynamic polarization, cyclic potentiodynamic polarization and electrochemical impedance spectroscopy analyses. Microstructural examinations revealed that decreasing cooling rate causes the precipitation of the sigma phase, and the ratio of the sigma phase was increased up to 29 % by the decreasing cooling rate. Furthermore, it was determined that precipitation of the sigma phase reduces the E pit values, and the sample with the highest amount of sigma exhibits the lowest corrosion resistance. On the other hand, presence of the sigma changed the electrochemical impedance spectroscopy behavior of the UNS S32205 and double-layered model fit the results.

Characteristics of negative creep aging and its microstructure-oriented tensile behavior

UNS S17400 steel was creep-aged under a constant stress of 300 MPa at 480 °C and 600 °C for 1, 3, and 5 h, and its microstructural phase evolution was investigated. During the initial creep aging at 480 °C for 15 min, negative creep strain occurred because of the stress-assisted precipitation, which resulted in Cu-rich precipitates impeding the movement of dislocations. By contrast, the sample creep-aged at 600 °C had a typical creep-strain curve comprising a primary creep stage and secondary steady-state stage. The creep stress accelerated the growth of Cu-rich precipitates and austenite γ phase reversion, which were clearly observed in samples creep-aged at 600 °C. The reverted γ phase formed due to the stress-assisted aging at 480 °C for 3 h, as well as at 600 °C due to the elevated temperature aging. The samples with the longer creep aging times decreased in tensile yield strength but increased in strain hardening rate. Strain hardening after strain softening was observed in the sample creep-aged at 600 °C for 5 h, which had the highest strain hardening rate. Strain hardening was attributed to the dislocations becoming entangled with nanoscale Cu-rich precipitates, the formation of microtwins, and the presence of deformation-induced martensite.

Penetration depth, phase balance and corrosion behaviour in activated TIG welding of UNS S32205

The aim of this research is to investigate the impact of a flux containing 80% TiO2 and 20% CeO2, under protective atmosphere (100% Ar, 98% Ar-2% N2, and 95% Ar + 5% N2) on penetration depth, phase equilibrium, and corrosion behaviour of autogenous A-TIG welds generated at constant current density. The reason for choosing cerium in the flux composition and nitrogen in the shielding gas is their effect on the phase balance of austenite and ferrite in this alloy. Metallography, ferritoscopy, and potentiometry were employed in the examination of the welds. The use of a two-component flux increased the penetration depth in TIG welding by up to 87%. Adding 2% and 5% nitrogen gas to the shielding gas in active TIG welding further increased the penetration depth to 117% and 130%, respectively. The results of ferritoscopic analysis reported the amount of austenite in the base metal and conventional TIG weld as 48% and 32%, respectively. However, the use of two-component flux increased the amount of austenite in the weld metal to 39%. Additionally, the addition of 2% and 5% nitrogen to the shielding gas in active TIG welding increased the amount of austenite in the weld metals to 60% and 76.6%, respectively. According to cyclic potentiodynamic polarization studies, active TIG welding with different nitrogen gas concentrations showed improved general and pitting corrosion properties in weld metals compared to conventional TIG welding. Consequently, weld metal resulting from active TIG welding with 2% nitrogen gas exhibited corrosion properties almost identical to that of the base metal.

A comparison of microstructure and mechanical characteristics correlation of the joint specimens for duplex stainless steel UNS S32304 and super-duplex stainless steel UNS S32750: The role of post-weld heat treatment

The present investigation studies the impact of post-weld heat treatment (PWHT) on the microstructure and mechanical characteristics of joints made by gas tungsten arc welding between duplex stainless steel and super-duplex stainless steel specimens. The PWHT process was considered at 1100 °C for 10 minutes followed by water quenching on UNS S32304 and UNS S32750 materials. Scanning electron microscopy, optical microscopy, X-ray diffractometry (XRD), and energy dispersive X-ray analyses have been applied in microstructure evolution, including recognizing local chemical contents and elemental distribution. To analyze the mechanical characteristics of samples, tensile and hardness tests were performed. It was shown that after applying PWHT, the morphology of the austenite varied becoming mostly intergranular/spheroidal in shape, accompanied by an improvement in the percentages of austenite. This investigation indicates the PWHT results in restoring an equal percentage of both phases. The phase percentages, based on both ASTM E1245 and ASTM E562, show a good agreement between the austenite and ferrite phases of weld materials. According to XRD, the phases are mainly ferrite and austenite with different lattice parameters with no evidence of unwanted intermetallic phases. It was concluded that the PWHT process plays a crucial role in the ductility of joint specimens due to the phase balance between austenite and ferrite.

Evaluation of methods used for simulation of heat-affected zones in duplex stainless steels

The weldability of duplex stainless steels partly depends on the ferritization of the high-temperature heat-affected zone (HT-HAZ). This area is rather narrow, and it can be challenging to visualize and determine its actual impact on the properties. To address this, various methods were applied to study the grain growth and austenite reformation in the HT-HAZ of the lean duplex grade UNS S32101. Thermo-mechanical Gleeble® simulations were conducted at 1360 °C with different holding times and cooling rates. Subsequently, the grain size and ferrite content were measured on polished and etched cross-sections. Bead-on-plate welds were performed on the same heat of 6-mm plate thickness using the gas tungsten arc welding (GTAW) process. The shielding gas was Ar + 0–8% N2 to illustrate the effect of nitrogen additions on the HT-HAZ morphology. The arc was either stationary, welding at one spot for 0.5–120 s, or travelling at different speeds to generate varying heat inputs and temperature gradients. The thermo-mechanical simulations approximated the results obtained by travelling arc welding and allowed for a more comprehensive investigation. Stationary arc welding was not suitable for HT-HAZ studies as it quickly caused nitrogen depletion and resulted in significantly higher ferrite contents compared to the travelling arc welds.

Characteristics of high-temperature heat-affected zones in duplex stainless steels

AbstractThe level of ferritization in the high temperature heat-affected zone (HT-HAZ) affects the weldability of duplex stainless steels. The modern grades show different sensitivity and especially the nitrogen content has been proposed to control the grain growth and austenite formation. In this work, 3-, 4- and 5-mm thick UNS S32101, UNS S32304, UNS S32205 and UNS S32750 with a nitrogen range of 0.09–0.28 wt.-% were considered. Gas tungsten arc welding (GTAW) was conducted bead-on-plate with pure argon (Ar) and Ar + 2% N2 as shielding gas. Measurements of the HT-HAZ width and ferrite content were compared with values reported for welds and thermo-mechanical Gleeble® simulations in existing literature. The HT-HAZ width decreased with the material thickness and the nitrogen content in the base metal, while only the nitrogen alloying had a clear effect on the phase balance. Nitrogen additions to the shielding gas efficiently counteracted weld metal nitrogen loss and improved the austenite formation as compared to 100% Ar but had no clear effect on the HT-HAZ width nor ferrite content. A positive influence of the base material nitrogen content on the phase balance could be validated with thermodynamic simulations using Thermo-Calc and DICTRA, but the negative effect of high cooling rates was underestimated.

Heat-Affected Zone Microstructural Study via Coupled Numerical/Physical Simulation in Welded Superduplex Stainless Steels

Superduplex stainless steels (SDSS) are known for their combination of good mechanical properties and excellent corrosion resistance, enabled by the microstructural balance between austenite and ferrite and an amount of alloying elements. Their application in welded components is, however, limited by the possibility of the precipitation of intermetallic phases and microstructural misbalance, which might hinder their properties, especially in the heat-affected zone (HAZ). This work introduces a methodology that relies simultaneously on physical and numerical simulations to study the HAZ in a UNS S32750 SDSS. Dimensions of the fusion zone and thermal cycles were calibrated for a numerical model using preliminary welding trials. Numerically simulated cycles for each heat input (HI) were physically reproduced in a Gleeble® simulator, and the heat-treated samples were characterized and compared with real specimens welded using the same parameters. Thermal curves resulting from the numerical simulations were successfully replicated by the Gleeble®, indicating adequate application of the desired HI. The hardness and microstructural results from simulated and welded specimens were also found to be quite similar. Therefore, the proposed methodology showed itself adequate not only for the study of duplex stainless steels, but also of materials with similar thermal and mechanical properties, including the extrapolation of welding parameters.

Tribocorrosion assessment of low-temperature plasma nitrided super duplex stainless steel

The tribocorrosion of low-temperature plasma nitrided UNS S32750 super duplex stainless steel was investigated according to procedures for passivating materials. Nitrided and non-treated samples were compared through two reciprocating sliding tests in NaCl solution: the continuous test, without significant passive layer growth, and the intermittent one, with repassivation. Open circuit potential and linear polarization resistance (LPR) characterized the electrochemical response. LPR was successfully introduced to evaluate the polarization resistance evolution during the continuous test. Corrosion and mechanical wear components were quantified. The mechanical wear dominated, and nitrided samples showed lower wear volume loss. After the intermittent test, their values were further reduced. Such improvement was explained by the higher load bearing capacity and repassivation ability of the nitrided surfaces.

On the Microstructural Transformations and Mechanical Performance of Laser Beam Welded UNS S43000 Ferritic Stainless Steel

On the Microstructural Transformations and Mechanical Performance of Laser Beam Welded UNS S43000 Ferritic Stainless Steel

Characterization Using Point Defect Theory of the Microstructure Effect on Passivity Stability in Austenitic Stainless Steel

The influence of the microstructure on the resistance to pitting potential in austenitic stainless steel UNS S31603 is evaluated to explain the effect of the distribution of features such as carbides. Different microstructures were obtained by processing, via surface laser melting (SLM) and sensitized at 600°C, 700°C, and 800°C. The test solution used for electrochemical testing included a buffer pH 8 brine at room conditions. The characterization of the passive conditions is done by using potentiodynamic, potentiostatic, and Mott Schottky techniques. The results show that the UNS S31603 samples produced by SLM have higher passive layer stability. The correlation with the microstructural features attributes this to a lack of inclusions and carbides characteristic of the SLM process. The analysis of the experimental results using the point defect model description of the passive layer behavior indicates that the stability of the passive layer is a priori inversely proportional to both the metal cation and anion vacancy diffusivities. Experiments reveal the close dependence and explain the properties of the passive layer with respect to a point defect model.

Fatigue life of super duplex stainless steel sheets (UNS S32750) as influenced by micro plasma arc welding parameters: an investigation using the surface response method

Fatigue life of super duplex stainless steel sheets (UNS S32750) as influenced by micro plasma arc welding parameters: an investigation using the surface response method

Microstructural characteristics of different heat-affected zones in welded joints of UNS S32304 duplex stainless steel using the GMAW process: analysis of the pitting corrosion resistance

Abstract The influence of specific microstructural characteristics on the properties of single-pass welding joints was assessed by optical processed images, transmission electron microscopy, microhardness measurements and corrosion tests conducted in various regions of the heat-affected zone (HAZ) in a lean duplex stainless steel. The welded joints were obtained with heat inputs of 1.5 and 2.5 kJ/mm using a gas metal arc welding (GMAW) process with a shielding gas enriched in Ar. Three selected regions in the HAZ showed different ferrite grain sizes and austenite fractions. The place in the welded joint where the HAZ was narrowest, and therefore experiences the highest cooling rate, is most prone to the formation of cubic CrN metastable nitrides. Conversely, the place where the HAZ was wider promotes the precipitation of stable Cr2N nitrides with more coalesced intragranular austenite (IGA) particles, where presumably random interfaces predominate. The HAZ region where the cooling rate was the highest presented more pitting corrosion resistance.

Deformation Behavior and Texture Evolution of Ferrite and Austenite Phases in Lean Duplex Stainless Steel

To avoid cracks during hot rolling, a short process of direct cold rolling following solution treatment of the casting billet for preparing lean duplex stainless steel plates is proposed. The effect of cold rolling reduction on the microstructure, texture, and mechanical properties of UNS S32101 is investigated. The results show that dislocation slip is the main character in ferrite, which leads to dislocation tangles, dislocation cells, high‐density dislocation walls, and deformed microbands. However, twinning and strain‐induced martensite transformation (SIMT) occur in austenite, and the SIMT mechanism of austenite follows the classical model γ → ε → α′ and γ → α′, with the orientation relationship of Kurdjumov–Sachs ( and ) and Nishyama–Wassermann (N–W) ( and ). Meanwhile, at 50%, there is a transition from Cu texture to Brass texture in the austenite phase. At 12.5%, the yield strength is 344 MPa higher than that of the traditional hot rolling process, and the elongation remains about 35%. With the increasing cold rolling reduction, the elongation decreases while the strength rises significantly. Strengthening dislocations, fine‐tuning grains, and SIMT are the primary contributors to the improvement in strength.

Improved Test Methods and Models for Localized Corrosion Assessment of Stainless Steels in Aqueous Chloride Media with Low Dissolved Oxygen

Experimental foundation has been established for improving corrosion models for stainless steels exposed to neutral aqueous chloride media with low levels of dissolved oxygen (DO). Accurate repassivation potentials were measured for UNS S31603 and UNS S32205 alloys in chloride electrolytes at room and elevated temperatures using Tsujikawa-Hisamatsu electrochemical (THE) and cyclic potentiodynamic polarization (CPP) methods. It was observed that the repassivation potential values measured using the CPP method were lower than the ones obtained from THE method for the same environmental conditions. Cyclic polarization scans in aqueous chloride media were conducted at different reverse scan rates resulting in varied repassivation potentials. Medium-term corrosion potentials were measured in chloride media with controlled dissolved oxygen levels ranging from 20 ppb to 400 ppb. These results were used as inputs for improving model prediction for repassivation and corrosion potentials. In an extension of previous modeling studies, an improved mechanistic repassivation model was developed based on a new generalized theory that explicitly accounts for the adsorption of water rather than treating it as an ever-present background. With a flexible definition of the repassivation current density, the new repassivation model reproduces the experimental repassivation potentials obtained using THE and CPP methods. The dependence of corrosion potential on DO has been modeled using a mixed-potential model. It has been demonstrated that the effect of agitation (caused by the bubbling of oxygen) needs to be accounted for to describe the corrosion potential, especially at low DO, where mass transport is important. The combined model correctly predicts the occurrence of localized corrosion when tested against exposure data from the literature.

Optimization of duplex stainless steel UNS S32205 end milling with noise factor analysisy

Optimization of duplex stainless steel UNS S32205 end milling with noise factor analysisy

Integrity Assessment of Stress Corrosion Cracking Susceptibility of Duplex UNS S32205 and Austenitic UNS S31653 Stainless Steel Reinforcements

Herein, the stress corrosion cracking (SCC) susceptibility of duplex (UNS S32205) and austenitic (UNS S31653) stainless steel (SS) reinforcements was evaluated using integrity assessment criteria. Mechanical properties were analyzed and compared by different SCC susceptibility factors. The integrity assessment was conducted applying Cosenza, Creazza, and Ortega ductility criteria, following three different standards (ACI 318-19, ASTM A615, and FIB). A conventional carbon steel (UNS G10080) reinforcement was also evaluated for comparative purposes, whose high residual stress value (>280 MPa) promoted a high corrosion growth rate. Duplex UNS S32205 SS grade showed a significant decrease in elongation, leading to failure after ductility assessment at high chloride concentrations. Fractographic analysis of both SS grades, duplex and austenitic, revealed less than 40% brittle areas at 8 wt.% Cl−, while UNS G10080 had over 85% at 4 wt.% Cl−.