Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.

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ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

RESEARCH ARTICLE OPEN ACCESS

Duplex 2209 Weld Overlay by ESSC Process

Er. Manoj Kumar1, Dr. Abhishek Kamboj2
1
M.tech research Scholar,Haryana Engineering College
2
Associate Professor, Haryana Engineering College

ABSTRACT
In the modern world of industrialization the wear is eating metal assets worth millions of dollars per year. The
wear is in the form of corrosion, erosion, abrasion etc. which occur in the process industries like oil & gas,
refineries, cement plants, steel plants, shipping and offshore working structures. The equipments like pressure
vessels, heat exchangers, hydro processing reactors which very often work at elevated temperatures face
corrosion in the internal diameter. Duplex 2209 weld overlay on ferrous material is developed for high corrosion
resistance properties and having high productivity by Electroslag strip cladding process due to its less dilution
~10% as compared to SMAW , GTAW or FCAW process. Because of Low Dilution ~10% undiluted chemistry
can be achieved with single layer as compared to other weld overlay processes. The facility was developed in-
house to carry out weld overlay by ESSC and Testing.

I. INTRODUCTION restricted to less than about 7.5% in ASS and 4% in

Duplex stainless steel are called “Duplex” Duplex SS[1,2].
because they have a two-phase microstructure Nitrogen increases the pitting and crevice
consisting of grains of ferritic and austenitic corrosion resistance of austenite and Duplex SS. It
stainless steel. When duplex stainless steel is also increases strength and is most effective solid
melted it solidifies from the liquid phase to solution strengthening element and low cost
completely ferritic structure. As the material cools element. The improved toughness of nitrogen
through temp above about 1040 deg C to room bearing duplex SS is due to their greater austenite
temperature, about half of the ferritic grains content and reduced intermetallic content. Nitrogen
transfer to austenitic grains. The result is a does not prevent the precipitation of intermetallic
microstructure of roughly 50% austenite and 50% phases but delays the formation of inter- metallics
ferrite. This is accomplished by increasing enough to permit processing and fabrication of
Chromium and decreasing Ni as compared to ASS duplex stainless steel. Nitrogen is added to highly
grades & by adding Nitrogen (a strong austenite corrosion resistant austenite and duplex stainless
promoter) to speed the rate up of austenite steels that contain high chromium and
formation during cooling[1]. molybdenum contents to offset their tendency to
A minimum 10.5% Chromium is form sigma phase. Nitrogen is the key element,
necessary to form a stable Chromium passive film apart from aiding austenite formation, it plays a
that is sufficient to protect steel against role in partitioning of alloying element Cr,Mo
atmospheric corrosion. The corrosion resistance of between ferrite and austenite.
SS increases with increasing Chromium content. During welding, there is a danger that the
Chromium is a ferrite former, meaning that the austenite formed from ferrite from heating, will
addition of Chromium promotes the BCC structure contain only the low amount of N that was in the
of iron. At higher Chromium contents, more nickel ferrite from which it was formed. if heating time is
is necessary to form an austenite or duplex sufficient ,Nitrogen can diffuse from the original
structure. Higher Chromium also promotes the austenite to restore equilibrium.But, if the heating
formation of intermetallic phases. Chromium also time is too short, the so called secondary austenite
increases the oxidation resistance at elevated will have low N & therefore lower pitting corrosion
temperatures. resistance.
Molybdenum acts to support Chromium in Nitrogen helps to alter phase stability ,
providing pitting corrosion resistance to stainless making austenite stable to higher temperature,&
steels. When the Chromium content of a SS is at this prevents welds from becoming excessively
least 18%,addition of Mo become about three times ferritic and disturbing the desirable 50 to 50
as effective as Chromium addition against pitting ratio[1,6].
and crevice corrosion in Chloride-containing
environment.Molybdenum is a ferrite former and 1.1 Characteristics of Duplex stainless steels
also increases the tendency of a SS to form  Excellent resistance to stress corrosion
detrimental intermetallic phases.Therefore,it is cracking

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Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

 Very high mechanical strength  Lower life cycle cost[1]

 Excellent resistance to pitting and crevice Duplex stainless steel is having higher
corrosion critical crevice corrosion temperature as well as
 High resistance to general corrosion in a critical pitting corrosion temperature as compared
variety of environments to austenitic stainless steel material as shown in
 Low thermal expansion below Fig.1 and Duplex stainless steel is having
 High resistance to erosion corrosion and lower corrosion rate than austenitic stainless steel
corrosion fatigue in formic acid Concentration as shown in Fig.2[2,5]
 Good weldability

Fig. 1

Fig. 2

1.2 Chemical Composition of Dupex 2209 pitting etc., to the substrate. To the manufacturer of
Element % Composition pressure vessels, surfacing techniques are getting
Nickel 8.5-10.5 more and more important. Components reach sizes
Chromium 22-24 such that their fabrication calls upon the use of clad
Molybdenum 2.5-3.5 materials[3,6].
Carbon 0.04 max There are different processes to obtain a clad
Manganese 0.5-2.0 material:
Sulfur 0.03 max
 Clad plates produced by rolling which are
Silicon 1.0 max
mostly only available in standardized
Phosphorous 0.04 max
dimensions and grades
Table 1
 Explosion clad plates
Cladding is a welding process in which a  Clad plates made by welding
material with desired properties is deposited on the Further Clad Plates made by welding can be done
surface of a base material. The common C/Mn or using various techniques:-
low alloyed inexpensive base metal has mainly a  Submerged arc welding (Wire electrode)
load carrying function. The deposited sophisticated  Submerged arc welding (Twin Wire electrode)
material imparts surface properties such as  Submerged arc welding (Strip Electrode)
corrosion resistance; wear resistance, erosion and  Electro slag strip welding

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ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

 Shielded metal arc welding strip cladding, the penetration and hence the
 Flux cored arc welding dilution are reduced in electro slag strip cladding
Among all the welding processes because the absence of arc, typical dilution levels
submerged arc and electro slag strip cladding offer lying between ~10% [4].The use of a conductive
maximum deposition rate, better bead slag and resistance heating instead of an electric arc
characteristics and trouble free operation using permits higher current densities to be used in ESSC
unsophisticated welding equipments[6,7]. without increasing penetration. Thus deposition
In selecting a particular weld overlay and rates higher than that possible with SASC can be
cladding system, the following criteria may need to achieved in ESSC without increasing the degree of
be considered: Deposit rate (kg/hr), productivity dilution[2,3,4].
hardness, corrosion resistance, availability of The flux used in ESSC contains, in
consumables with the required metallurgical and addition to oxides like Titanium oxide and iron
mechanical properties, welding techniques, Quality oxide. A large quantity fluoride of Calcium and
of weld & automation technologies. Sodium in order to achieve the required electrical
conductivity. The high Calcium fluoride content in
II. PROCESS DESCRIPTION the flux has been shown to decrease dilution level
The electro slag strip cladding is a and also reduce the oxygen content in the deposited
technique, in which a strip electrode is cladding to a level which is just one third compared
continuously fed into a shallow layer of electrically to submerged arc surfacing. Furthermore the
conductive flux. The heat required to melt the strip, solidification rate of the electroslag weld metal is
the slag forming flux and the surface layer of the lower, facilitating the escape of gases and the rise
base metal is generated by resistance heating due to of slag particles to the surface. This reduces
the welding current flowing through the molten porosity and inclusion content[2,3,8].
conductive slag. In relation to the submerged arc

Fig.3

III. EXPERIMENTATION AND TESTING

Discuss the detail about the experimental data, base metal, filler metal, and welding procedure, welding
parameters of welded specimen and testing.

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Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

3.1 Experimentation was conducted as per following flow chart

Flow chart shows how experimentation was conducted

3.2 Base Metal and Strip Metal 309LMo as a buffer lyer and Duplex 2209 as a clad
The base plate of SA 516 Grade 70 low layer .Table 3.1 shows the chemical composition of
carbon steel of 60 mm received in normalized heat base metal & strips used.
treated condition. The strips used were of S.S

Elements Base Metal SS 309 LMo Duplex 2209

Carbon, C 0.27 0.04 0.04
Silicon, Si 0.15 - 0.40 1.0 1.0
Sulfur, S 0.035 0.03 0.03
Phosphorous, P 0.035 0.04 0.04
Manganese 0.85 - 1.20 0.5-2.5 0.5-2.0
Chromium - 22-25 22-24
Nickel - 12-14 8.5-10.5
Molybdenum - 2-3 2.5-3.5
Table 2

3.3 Welding Parameters 309LMo)

Material thickness : 60 mm Strip for Clad : Sandvik 22.8.3L (~ EQ 2209)
Plate size : 500 X 300 X 60 mm thick Flux : Sandvik 37S
Joint design : weld overlay on CS base plate Weld Bead Height : 9-10 mm- Double Layer
Strip for barrier : Sandvik 21.13.3L (~ EQ

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Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

Fig.3 Barrier Layer

Fig.4 Clad Layer

Fig.5 Specimen Marking & Prepartion

Parameters Range
Welding current (I) 1150-1300 A
Voltage (V) 24-26V
Travel Speed 170-180 mm/min
Pre heat 100 degree Celsius
Interpass Max 175
Electrode extension (Stick Out) 25-30 mm
Height of Flux 30-35mm
Polarity DCEP
Table 3

3.4 Post Weld Heat Treatment (PWHT) IV. RESULTS

PWHT was performed at 610 -620⁰ C for  Visual Examination : Bead Finish- Good
135 minutes after completion of testing with  Non Destructive Testing
heating rate 50⁰ C/ hr and cooling rate 40⁰ C /hr.  Dye Penetrant Testing : Acceptable as per
ASME Sec IX .
 Ultrasonic Examination : Satisfactory

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Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

Fig.6
 Macro Examination : No porosity, No Lack of Fusion & complete fusion of weld metal & base metal

Fig.7

 Bend Test : satisfactory

Fig.8

Fig.9

Test Number of Degree of Acceptance Results

Performed Sample Tested Bend Standard
Side Bend Test 4 180⁰ ASME Sec IX Satisfactory

 Chemical Composition was found satisfactory from 4mm fusion line

Height % Element
(mm) C Ni Cr Mo Mn N
Reqd 0.04 Max 8.5-10.5 22-24 2.5-3.5 0.5-2.0 0.08-0.20
value
Top 0.016 8.70 22.57 3.05 1.16 0.16
8.0 0.019 9.02 22.32 3.06 1.19 0.16
7.0 0.018 9.34 22.08 3.04 1.18 0.15
6.0 0.020 9.31 21.83 3.03 1.23 0.14
5.0 0.018 9.30 21.75 3.07 1.18 0.14
4.0 0.019 9.39 21.70 3.03 1.22 0.14
3.0 0.040 *12.17 *16.55 *2.41 1.32 0.011
 CORROSION TESTING AS PER ASTM 923 METHOD C

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Er. Manoj Kumar. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -2) March 2017, pp.92-98

Result observed: satisfactory

Acceptance criteria [6] R.A Daemen: submerged arc stainless steel
The corrosion rate is calculated in strip cladding: the development of welding
accordance with the weight loss & it should be less products for surfacing with a type of 316 L
than 10 mdd( milligrams per square decimeter per low ferrite stainless steel alloy. Welding
day) Research supplement January-1970.
Initial weight of specimen : 43.161g [7] S.Pak “Electro slag and Submerged Arc
Weight after 24 hours : 43.1603 g stainless steel strip cladding.”published by
Weight loss : 0.0007 g (0.70 mg) ESAB in Svetsaren No.3,1996
Corrosion rate : 2.2150 mdd (acceptable) [8] J. Garg,“reuse of slag in stainless steel
cladding and its effect on chemistry of
cladding in SAW process”Journal of
Environmental research &
Development(March 2012).

Fig.10 Corrosion Specimen (ASTM 923 METHOD

C)

V. CONCLUSION
Typical to weld Duplex 2209 welded
successfully meeting the requirement of ASME Sec
IX & Sec IIC.

VI. SCOPE OF FUTURE WORK

As a future work, we will establish
corrosion test as per customer requirement such as
ASTM G-48 method A-pitting corrosion & method
B –Crevice Corrosion, ASTM G-36 etc.

REFERENCES
[1] E. M. Sherif , “ Corrosion of Duplex
Stainless Steel Alloy 2209 in Acidic and
Neutral Chloride solutions and its
passivation by Ruthenium as an alloying
element.”International journal of
electrochemical Science 7 (2012)
[2] S. D. Kahar ," Corrosion Behavior of
Electro Slag Strip Cladding Weld Overlays
in Different Acid Solutions ”, Int. Journal of
Engineering Research and applications Vol.
3, Issue 4,july-aug 2013 pp.590-595, 2012
[3] M. Patel," Application of Electro Slag Strip
Cladding for reactors in Hydrogen Based
Refinery”2009-IIW india
[4] A.Eghlimi “dilution and ferrite number
prediction in pulsed current cladding of
super duplex stainless steel using RSM”
ASM international (2013).
[5] T. Kannan: “effect of flux cored arc welding
process parameters on duplex stainless steel
clad quality”. Journal of materials
processing technology 176(2006).

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