|
INTRODUCTION
SAF
2205 (UNS No S31803) is a second generation duplex
stainless steel having a nominal composition of 22%
chromium, 5.5% nickel, 3% molybdenum and 0.14%
nitrogen. This composition results in a stable
microstructure containing about 45% ferrite and 55%
austenite. SAF 2205 is characterized by:
-
good
resistance to stress corrosion cracking.
-
high
resistance to general, crevice and pitting
corrosion;
-
high
resistance to erosion corrosion and corrosion
fatigue;
-
high
mechanical strength;
-
attractive
physical properties;
-
good
weldability
Austenitic stainless steels generally exhibit
excellent corrosion resistance in most corrosion
environments, but can fail by stress corrosion
cracking in hot chloride solutions under certain
circumstances.
Ferritic stainless steels are generally resistant to
cracking under these conditions. However, the
use of ferritic stainless steels is limited due to
weldability constraints in section thickness above
approximately 2 mm. It is considered that the
presence of ferrite in duplex stainless steels
inhibits crack propagation.
Duplex steels are not totally immune to chloride
stress corrosion cracking and have been made to crack
in terms of somewhat unrealistically severe but
popular 42% boiling magnesium chloride solution
test. More significantly SAF 2205 has not
cracked after extremely long test periods in less
aggressive solutions which would cause failure in
austenitic stainless steels such as types
304L/316L/317L.
The
high proof strength of SAF 2205 roughly twice that of
the traditional austenitic stainless steels allows for
thickness reduction and hence weight savings.
The impact toughness of the steel is good with a
ductile to brittle transition temperature of
approximately - 55oC.
SAF
2205 has a lower co-efficient of thermal expansion and
a slightly higher thermal conductivity than austenitic
stainless steels. This is of particular
advantage when designing heat exchangers. This is of
particular advantage when designing heat
exchangers. The higher thermal conductivity
improves heat transfer and the lower thermal
expansions reduces the stresses incurred due to the
difference in thermal expansion between the carbon
steel shell and the stainless steel used for the
tubes. The co-efficient of thermal expansion of
SAF 2205 is close to that of carbon steel.
The
material is suitable for use in production tubing and
flowlines for the extraction of oil and gas from sour
wells, in refineries and in process solutions
contaminated with chlorides. SAF 2205 is
particularly suitable for heat exchangers where
chloride-bearing water or brackish water is used as a
cooling medium. The steel is also suitable for
use in dilute sulphuric acid solutions and for the
handling of organic acids.
The
high strength of SAF 2205 makes the material an
attractive alternative to the austenitic steels in
structures subjected to heavy loads.
2.
TECHNICAL DATA
MECHANICAL
PROPERTIES
SAF 2205 has higher tensile and proof strengths than
the austenitic stainless steels. The mechanical
properties of a number of steels are given
below. SAF 2205 is normally delivered in the
fully annealed condition but proof strengths in the
region of 1 000 MPa can be achieved by cold
working. The relatively high hardness of SAF
2205 makes it suitable for use in corrosion abrasion
applications.
Mechanical
Properties at Room Temperature*
|
|
SAF
2205
|
SX
304L
|
SX
316L
|
|
Tensile
strength (min)
|
620
MPa
|
485
MPa
|
485
MPa
|
|
0.2%
Proof Strength (min)
|
450
MPa
|
170
MPa
|
170
MPa
|
|
Elong.
(in 50mm) (min)
|
25%
|
40%
|
40%
|
|
Hardness
(max)
|
290
HB
|
183
HB
|
217
HB
|
*ASTM
A240-87
It is
worth noting that while the allowable design stresses
are about 40% higher for the duplex grades in the ASME
Pressure Vessel Design Code they are about 100%
higher, or even more, in the European codes, which are
based entirely on yield strength. The high
allowable design stresses for the duplex grades can be
utilized to reduce wall thicknesses and cut costs
considerably.
Impact
Strength
SAF 2205 possesses good impact strength both at room
and sub-zero temperatures. The DBTT for SAF 2205
parent plate is in the region of - 55oC.
The impact strength for welded SAF 2205 is also good
although impact strength values in the as-welded
condition are slightly lower than for the parent
plate. It has been shown that the impact
strength of the weld metal and heat affected zone is
good down to - 50oC having an impact
strength of a minimum of 27 joules. Welding had
been carried out by the gas shielded arc welding
process.
If very
high impact strengths are required in the welded
condition at sub-zero temperatures, quench annealing
is recommended.
Properties
at Elevated Temperatures
If exposed to temperatures exceeding 300oC
for prolonged periods, SAF 2205 undergoes
microstructural changes and the impact strength at
room temperature is lowered. These changes do
not affect the performance of the steel at the
operating temperature as has been demonstrated by the
good performance of heat exchanger tubes.
Typical
short term elevated temperature strength values
are:
|
Temperature
|
Tensile
Strength
|
0.2%
Proof Strength
|
|
100oC
|
630
MPa
|
365
MPa
|
|
200oC
|
580
MPa
|
315
MPa
|
|
300oC
|
560
MPa
|
285
MPa
|
|
400oC
|
550
MPa
|
275
MPa
|
Generally
however use of SAF 2205 is not recommended above 300oC.
HARDNESS
SAF 2205 has a relatively higher hardness which is an
added advantage over standard stainless steels when
used in process flow containing solids, i.e. when the
conditions are erosive. Table 1 compares the
typical hardness of some steels.
TABLE
1 - COMPARISON OF HARDNESS OF SOME STAINLESS
STEELS
|
Steel
Grade
|
Hardness
HB (Typical Values)
|
|
Type
304
|
155
|
|
Type
316
|
160
|
|
Alloy
904L
|
160
|
|
Sanicro
28
|
160
|
|
SAF
2205
|
260
|
|
Mild
Steel
|
150
|
PHYSICAL PROPERTIES
The physical properties of SAF 2205 are compared with
those of Type SX 316L stainless steel and carbon
(mild) steel.
|
|
|
SAF
2205
|
SX
316L
|
CARBON
STEEL
|
|
Density
(Kg/m3)
|
|
7.85
x 103
|
8.0
x 103
|
7.86
x 103
|
|
Modulus
of Elasticity
(GPa)
at
|
20oC
100oC
200oC
300oC
400oC
|
200
190
180
170
160
|
195
190
185
177
167
|
206
-
-
-
-
|
|
Thermal
Conductivity
(W/mK)
at
|
20oC
100oC
200oC
300oC
400oC
|
16
17
19
20
21
|
15
16
17.5
19
20
|
62
57.5
54.5
49
44.5
|
|
Coefficient
of Thermal Expansion
(um/mK)
between
|
0-100oC
0-200oC
0-300oC
0-400oC
|
13.0
13.5
14.0
14.5
|
15.9
16.0
16.2
16.6
|
12.5
13.0
13.5
14.0
|
|
Specific
Heat Capacity
(J/kg
K)
at
|
20oC
100oC
200oC
300oC
400oC
|
470
500
530
560
600
|
500
-
-
-
-
|
455
-
-
-
-
|
CHEMICAL COMPOSITION
For comparison, the composition of some other steels
is given.
|
|
%C
max
|
%Si
max
|
%Mn
max
|
%P
max
|
%S
max
|
%Cr
|
%Ni
|
%Mo
|
%N
|
Other
|
|
Martensitic
1
AISI 410
|
0.15
|
1.00
|
1.00
|
0.040
|
0.030
|
11.5
13.5 |
0.75
max |
-
|
-
|
-
|
|
Ferritic
1
SX 430
|
0.12
|
1.00
|
1.00
|
0.040
|
0.030
|
16.0
18.0 |
0.75
max |
-
|
-
|
-
|
|
Austenitic
1
SX 316L
|
0.03
|
0.75
|
2.00
|
0.045
|
0.030
|
18.0
20.0 |
8.0
12.0 |
-
|
0.10
max |
-
|
|
Austenitic
1
SX 316L
|
0.03
|
0.75
|
2.00
|
0.045
|
0.030
|
16.0
18.0 |
10.0
14.0 |
2.0
3.0 |
0.10
max |
-
|
|
Duplex
1
SAF 2205
|
0.03
|
1.00
|
2.00
|
0.030
|
0.020
|
21.0
23.0 |
4.50
6.50 |
2.50
3.50 |
0.08
0.20 |
-
|
|
Duplex
2
1.4462
|
0.03
|
1.00
|
2.00
|
0.030
|
0.020
|
21.0
23.0 |
4.50
6.50 |
2.50
3.50 |
0.08
0.20 |
-
|
|
Duplex
3
Zeron 25
|
0.05
|
1.00
|
1.50
|
-
|
-
|
24.0
26.0 |
5.0
7.0 |
2.0
3.0 |
0.10
0.20 |
Cu
0.5% max
|
1.
ASTM A240-87
2. DIN X2 Cr Ni Mo N 225 (equivalent
to UNS S31803)
3. Proprietary Alloy.
3. CUTTING
Cutting
of SAF 2205 using the oxy-acetylene or oxy-hydrogen
process is not possible.
Cutting
is sub-divided into the following sections:
3.1
Shearing / Guillotining
The maximum capacity of the guillotine (for mild steel
shearing) should be downgraded by 50% for cutting SAF
2205 because of its greater shear strength, e.g. if
maximum shearing capacity is 16 mm then the maximum
shearing capacity will be 8 mm for SAF 2205.
Blade
clearance should ideally be between 3-5% of material
thickness.
3.2
Plasma Cutting
Plasma cutting and profiling of SAF 2205 is the
fastest and most economic thermal cutting method
available. Fast cutting speeds together with a
clean smooth surface finish are possible. Due to
the fast cutting speeds, the heat affected zone is
very narrow, minimizing the effect on the properties
of the material. Thin plates can be
stack-cut. Any discolouration of the cut edge
can be removed by grinding or by using a stainless
steel wire brush. If no subsequent welding is
undertaken, edge discolouration must be removed,
followed by passivation.
3.2.1
Cutting Gases
Oxygen-free nitrogen is the most commonly used primary
cutting gas by virtue of its cheapness. Other
gases which can be used include: Compressed air,
Argon/Nitrogen, Argon/Nitrogen/Hydrogen,
Argon/Hydrogen and Nitrogen/Hydrogen. The use of
Compressed air will necessitate the use of a modified
electrode arrangement.
The
secondary shielding gas can be one of many active
gases. Welding grade CO2 is often
used due to its relatively low cost.
3.3
Abrasive Disc Cutting
Abrasive disc cutting is acceptable for limited
lengths of cut. Only dedicated discs should be
used and suitable control of these must be
exercised. Excessive overheating must be
avoided.
Aluminium
oxide discs of the vitrified or resinoid bonded types
are suitable. Zirconia and silicon carbide discs
are not recommended.
3.4
Carbon-Arc Gouging
Carbon-arc gouging can be utilised for cutting
provided the recommended settings are adhered to in
order to produce acceptable cuts. All cut edges
must be ground back to a depth of approximately 2 mm
before welding. Edges not subsequently welded
must be descaled and passivated.
3.5
Slitting
SAF 2205 can be successfully slit on conventional
slitting equipment. Edges must be deburred after
cutting. Slitting knives should be cleaned of
all mild steel or other metal contamination.
Refer to section 3.1 for shearing thickness capacity.
3.6
Nibbling
Nibbling may be used provided the settings are correct
to produce an acceptable cut. Burred edges,
chipped edges or other metal contamination should be
avoided. Refer to section 3.1 for shearing
thickness capacity.
3.7
Cold Sawing
Cold sawing requires a high feed rate and low cutting
speeds to be maintained to produce an acceptable
cut. Cutting and cooling fluids (water soluble
oil type) should be used to flood the cut. More
than one tooth should be in contact with the workpiece
at all times, necessitating small pitched blades for
cutting thinner gauges and small diameters. As
the thickness/diameter increases the pitch should be
increased to minimize chip packing and to give better
clearance.
3.8
Blanking and Punching
These operations can be successfully carried out
provided that tools and equipment used have sufficient
strength and rigidity to account for the higher proof
strength of SAF 2205. It is essential that the
tools have sharp cutting edges.
Clearance
between the punch and the die is normally held to 5%
of the metal thickness per side, i.e. 10%
overall. Care must also be taken to ensure that
tools are free from any adhering mild steel particles
from previous jobs to avoid contamination.
4.
FORMING
The conditions applicable to each forming method
necessary to produce acceptable products must be
observed. It is important to note that due to
the higher proof strength of SAF 2205, more power is
required for most of these operations than for the
austenitic stainless steel. Caution should be
exercised to ensure that the forming tools e.g. rolls
and press brake tools are free of adhering mild steel
particles to avoid contamination.
4.1
Roll Forming
Rolling mill loadings are about 60% higher than for
mild steel. Slower speeds should be used.
4.2
Press-Brake Forming
See cold bending (Section 4.5)
4.3
Pressing
See blanking and punching (Section 3.8)
4.4
Deep Drawing
The formability of SAF 2205 is fair. The work
hardening rate is similar to that of Type 316
stainless steel. Severe deep draws may require
an intermediate annealing heat treatment (Section 13).
Specialized
lubricants or more generous tool radii may have to be
used to prevent galling or scoring.
Tooling
and equipment should have sufficient strength to
account for the higher proof strength of SAF 2205.
Care
must also be taken to ensure that equipment is clean
to prevent mild steel contamination.
4.5
Cold Bending
More power is required to bend SAF 2205 due to its
higher proof strength. The maximum capacity of
the bending press is therefore reduced by 50% for SAF
2205 as compared to the austenitic stainless
steels. SAF 2205 generally exhibits greater
springback during bending. This should be
compensated for by slight over-bending, e.g.
approximately 10% on a 90o bend. The
use of hydraulically operated press brakes is
recommended.
The
minimum inner bend radius recommended for SAF 2205 is
three times the plate thickness, but it is advisable
to use four times the plate thickness. Severe
bends should be carried out transverse to the rolling
direction.
Edge
cracks can be avoided by grinding the outside radius
point of the bend line into a rounded profile, thus
eliminating the natural stress concentration point.
SAF
2205 can be cold formed by the same methods as the
austenitic stainless steels. The high proof
strength, however, implies that a higher initial force
is required to induce plastic flow. When this
limit is reached, SAF 2205 flows as easily as the
austenitic stainless steels.
Heat
treatment after cold forming is normally not required,
as SSAF 2205 is highly resistant to stress corrosion
cracking. In cases of heavy cold deformation and
severe service conditions, heat treatment is
recommended. It is difficult to give specific
advice as to when heat treatment is necessary.
The decision is influenced by the many factors related
to the application, such as temperature, pH, chloride
content and tensile stresses both residual and
applied. Heat treatment should be considered
when the degree of cold reduction exceeds 25%.
If a lubricant has been used during cold forming, it
must be removed before any heat treatment.
Cold
bending of tubes leads to wall thinning on the outside
of the bend. The degree of thinning depends on
the bending radius and the method of forming but can
be up to 30%. This should be compensated for in
the design stage. When manufacturing butt
welding fittings according to ISO 5251 or ANSI B16.9
there is a requirement that the minimum wall of the
fitting must be at least 85% of the nominal wall
thickness.
4.6
Spinning
Dished ends can be produced using this method but it
is recommended that power spinning rather than manual
spinning be used to produce an acceptable product.
4.7
Hot Forming
Hot forming is used primarily for large tube
diameters, heavy wall thicknesses and for small
bending radii, it is performed at 1000o -
1100oC. If the temperature after the
forming is still above 1000oC, quenching
can be done directly from the working
temperature. If bending is finished at a lower
temperature, or if the temperature is uncertain, it is
recommended that a solution heat treatment be
undertaken (Section 10).
In
order to minimize the risk of carburization, the tools
must be thoroughly cleaned and carbon-containing
lubricants must not be used.
Depending
on the bending method, wall thinning should also be
considered.
In all
cases close control of temperatures must be
maintained. Descaling and passivation is
required subsequent to hot forming (Section 12).
5.
MACHINING
The machinability of the duplex steels differs
somewhat from that of carbon steels and austenitic
stainless steels owing to differences in strength and
microstructure. This does not imply that they
are difficult to machine, but they require adjustment
of machining parameters and technique. The
following general recommendations will assist in
obtaining good results in machining.
-
Machine
tools should be ground to close tolerances to
avoid the risk of excessive work hardening in the
outer layer of the stock.
-
Larger
tools should be used to give stability and
efficient heat dissipation.
-
Tools
with large rake angles, sharp edges and smooth
surfaces reduce the work hardening and the risk of
built-up edges.
-
Relatively
large feed rates and cutting depths minimize the
harmful effects of the work hardened surface layer
produced by previous machining.
-
A
suitable cutting fluid, primarily emulsion, should
be used to minimize the risk of built-up
edges. The work should be flooded to ensure
maximum heat withdrawal. Specific advice
should be obtained from your supplier.
The
mechanical machining of stainless steel always
requires adjustment of tool data and machining methods
to give satisfactory results.
The
following tables give recommended cutting fluids,
cutting feeds and speeds:
TABLE
2
Cutting Fluids for SAF 2205
|
Machining
Operation
|
Severity
(Decreasing)
|
|
Tapping
|
1
A,B
|
|
Threading
|
1
B,C
|
|
Gear
Cutting
|
2
A
|
|
Reaming
|
2
A
|
|
Drilling
|
3
E,A
|
|
Milling
|
4
C,B
|
|
Turning
|
5
E
|
|
Surface
Grinding
|
6
E
|
|
Thread
Grinding
|
6
A,B
|
Key
A = High Sulphur
(1.5-2.5%) Mineral - Fatty Oil
B = Medium Sulphur
(0.5-1.5%) Medium Chlorine (0.5-1.5%) Mineral - Fatty
Oil
C = Low Sulphur
(< 0.5%) Medium Chlorine (0.5-1.5%) Mineral - Fatty
Oil
D = Chlorinated
Mineral Oil
E = Water Soluble
Oil
TABLE
3
Suggested Cutting data for drilling
|
Drilling
diam.
mm
|
Feed/rev
mm
|
Speed
rpm
|
|
1
3
5
8
10
15
20
|
0.02
0.05
0.06
0.10
0.12
0.16
0.20
|
4000
1250
800
500
400
250
200
|
TABLE
4
Suggested Cutting data for turning. Cemented
carbide tools of Sandvik Coromant types.
|
Single
point turning
|
Forming
|
SAF
2205 Cutting speed
|
AISI
316 Cutting speed
|
SAF
2205, AISI 316 Cutting
speed
|
|
Feed
(mm/rev)
|
Feed
(mm/rev)
|
SIP
(m/min)
|
GC135
(m/min)
|
S6
(m/min)
|
SIP
(m/min)
|
GC135
(m/min)
|
S6
(m/min)
|
High-speed
steel
(m/min)
|
|
0.05
|
0.02
|
170
|
-
|
-
|
280
|
-
|
-
|
35
|
|
0.15
|
0.03
|
140
|
120
|
-
|
250
|
230
|
-
|
30
|
|
0.5
|
0.08
|
-
|
80
|
60
|
-
|
130
|
80
|
25
|
|
1.0
|
1.15
|
-
|
50
|
40
|
-
|
70
|
50
|
15
|
6.
WELDING
SAF 2205 has good weldability in most applications,
provided that the recommended procedures are
adopted. The quality and integrity of welds is a
crucial feature of any fabrication. When weld
quality standards are demanding, it is recommended
that recognized welding procedure testing (e.g. BS
4870 or equivalent) be carried out and that
experienced coded welders be used.
When
the modern duplex stainless steels were first
introduced, most steel producers and several
inspection authorities restricted the welding arc
energy to 1.5 kJ/mm and interpass temperature to 150oC.
It was generally believed that this would limit the
high temperature region of the HAZ and would avoid
precipitation of chromium nitrides in multilayer
welds, thus contributing to welds of acceptable
toughness and corrosion resistance. It has since
become known that the mechanical properties and
corrosion resistance of duplex stainless steel welds
depends on the proportions of ferrite and austenite in
the weld metal and HAZ, a high ferrite content
generally has an adverse effect.
During
welding, in the regions of the HAZ which attain
temperatures of over 1000oC, the austenite
fraction transforms to high temperature ferrite.
This tends to produce a fully ferritic
structure. The degree of grain growth is more
pronounced as the crystal structure becomes more
single phase.
On
cooling, reformation of austenite takes place.
Additional reformation of austenite also results from
the subsequent reheating to lower intermediate
temperatures in multi-pass welding.
The
mechanical properties (particularly toughness) are
critically dependent on achieving a sufficiently high
austenite content.
Due to
the higher heat conductivity of SAF 2205 as compared
to austenitic stainless steels, a faster cooling rate
is obtained.
The
extent of reformation of austenite depends on the
cooling rate. Rapid cooling associated with low
heat input (or other means of heat extraction from the
weld zone), depresses the extent of austenite
reformation. Generally it is recommended that
such conditions be avoided, which is in contrast to
the welding of other grades of stainless steel.
From
the above, it should be appreciated that the thermal
cycling during welding is of great importance.
Welding
conditions which result in higher heat input and/or
slow cooling tend to promote a greater reformation of
austenite (beneficial); and an increase in the ferrite
grain size, (non beneficial). Fast cooling rates
depress the reformation of austenite, resulting in a
higher level of retained ferrite which adversely
affect the ductility, toughness and corrosion
resistance.
A
critical balance between these two extremes must be
attained to optimise the crystal structure within the
HAZ. Welding conditions have to be determined
for different thicknesses and weld geometry as part of
the welding procedure qualification; and
thereafter controlled and monitored.
Because
of the relatively lower coefficient of thermal
expansion of duplex stainless steels, the stresses
imposed in the weld zone are less than those
experienced with austenitic stainless steels.
6.1
Welding Processes
Both Shielded Metal Arc (SMAW or MMA) and Gas Metal
Arc (GMAW or MIG) welding processes have been used
extensively with great success on SAF 2205. Gas
Tungsten Arc Welding (GTAW or MIG) is usually used to
weld the thinner sheet thicknesses e.g. 1.0 - 3.0
mm. The use of combined processes, e.g. GTAW
root followed by GMAW or SMAW filler and cap can be
considered. As a means of improving both quality
and productivity the Submerged Arc Welding Process can
be utilized.
Consumables
are available locally which are specially
formulated. Only those specified for SAF 2205
must be used. Ordinary austenitic stainless
steel consumables are not suitable.
6.1.1
Shielded Metal Arc Welding (SMAW or MMA).
Electrical Characteristics:
D.C.E.P. (Direct Current Electrode Positive) - Reverse
polarity.
Consumable:-
Typical chemical composition 22% Cr, 9% Ni, 3% Mo.
Many
proprietary electrodes are available locally with
similar chemical compositions.
Electrodes
having acid-rutile, neutral or basic flux coatings are
all acceptable, although acid rutile or neutral fluxes
are generally preferred as they reduce the likelihood
of slag inclusions.
Note:
Welding electrode storage, handling and operating
conditions are detailed on the electrode
container. For more detailed information the
electrode manufacture should be contacted.
6.1.2
Gas Metal Arc Welding (GMAW or MIG)
GMAW welding is very versatile, in that a wide range
of material thicknesses and positions can be
accommodated. Weld quality and achievable weld
speeds are high with GMAW welding. Lack of side
wall fusion problems commonly associated with this
process must be guarded against by employing the
correct welding techniques.
Electrical
Characteristics:
D.C.E.P. (Direct current electrode positive)-
Reverse polarity.
Consumables:
(a) Filler Wire: Typical chemical composition
22% Cr, 8% Ni, 3% Mo.
(b)
Shielding Gas: Argon, 1% or 2% O2
Note:
The electrode supplier should be contacted for the
appropriate welding parameters.
The gas
flow rate under shielded welding conditions must be in
accordance with the manufacturer's
recommendations. Higher gas flow rates will be
required if welding is being carried out in draughty
or exposed conditions.
9.1.3
Gas Tungsten Arc Welding (GTAW or TIG)
This process is generally used for welding light gauge
sheet. Autogenous welding (using no filler wire)
is acceptable for sheet thicknesses up to 3.0
mm. Above 3.0 mm, filler wire should be used in
order to ensure adequate ductility and corrosion
resistance in the weld metal.
Electrical
Characteristics:
D.C.E.N. (Direct current electrode negative) Straight
polarity.
Electrode:
1-2% thoriated tungsten.
Consumables:
(a) Filler Wire: Typical chemical
composition 22% Cr, 8% Ni, 3% Mo
(b) Shielding Gas: Argon
Typical
flow rates are between 8 and 14 L/min depending on
material thickness, join geometry, welding position,
location etc.
Technique:
Tungsten
inclusions occur most commonly on striking the arc and
the use of striker pads is recommended. Use of a high
frequency spark initiation unit is preferred.
The use
of a backing gas shield (purging) is necessary. Argon
is generally used for this purpose, although cheaper
gasses such as nitrogen or a gas mixture consisting of
argon and nitrogen may also be used. The additional
gas shield at the rear of the groove enables a fine,
oxide-free root surface to be more easily achieved.
This is of particular advantage when the root surface
is not accessible for grinding, or pickling and
passivating.
10.
SOLUTION ANNEALING HEAT TREATMENT
The
recommended solution anneal heat treatment parameters
are as follows:
Heat
slowly and evenly up to 1040oC. Hold at
temperature for 10 minutes. Quench in an agitated
water bath down to room temperature.
It is
vitally important that the recommended cooling cycle
is adhered to, as an air cool or furnace cool will
result in the precipitation and formation of brittle
intermetallic sigma phase which will adversely affect
the mechanical properties, more specifically the cold
formability and toughness of the material.
Removal
of scale is required followed by passivation (Section
12)
11.
FASTENERS
Mild
steel and coated bolts should be avoided as they will
corrode rapidly and cause staining of the SAF 2205
material. Stainless steel bolts are recommended when
they will not be exposed to the same corrosion
environment as the SAF 2205 material. Material with
similar corrosion resisting properties should be used
if it will be in contact with the same corrosion
environment.
12.
SURFACE CLEANING
12.1
Descaling
After
hot working and/or heat treatment, the material is
covered with a scale that can be removed by machining,
shot blasting or pickling. In the case of pickling,
the following procedure is recommended.
1.
Pretreatment in alkaline KMnO4 solution for
2 hours at 90 - 100oC.
Composition:
75 g/l KMnO4 (potassium permanganate)
75 g/l NaOH (sodium hydroxide)
Water
2.
Rinsing in water.
3.
Pickling in HF-HNO3, 20 - 60 minutes, 40 -
50oC.
Composition:
160 - 250 g/l HNO3 (nitric acid)
40- -50 g/l HF (hydrofluoric acid)
Water
4.
Rinsing in water.
12.2
Post-Weld Cleaning
Post
weld cleaning should be undertaken on all weld areas
(weld metal and HAZ), arc strikes, and points where
cleats, lugs, etc have been ground off. Where
practical, the root side and face side of all welds
should be treated.
It is
considered absolutely essential that this procedure be
carried out if the material is in contact with aqueous
solutions in its working environment. In some
instances, eg welded tube, both exposed weld surfaces
must be treated. Irrespective of which post-weld
cleaning method is used (eg mechanical or chemical),
it is essential to remove all surface discolouration
and scale from weld areas.
12.3
Mechanical Cleaning
(a)
Wire brushing: It is often possible to remove a
substantial amount of discolouration and detritus from
weld areas by vigorous brushing with stainless steel
wire brushes. Brushes must not previously have been
used on materials other that stainless steel.
(b)
Grinding: Dressing of welds and removal of
discolouration can be carried out by grinding. Only
dedicated grinding wheels and discs should be used.
The presence of iron, iron-oxide and other undesirable
materials in the grinding medium can adversely affect
corrosion resistance.
(c)
Abrasive blast cleaning. The abrasive should be
stainless steel shot, copper slag (angrit) or alumina,
free of metallic iron, iron oxides or chlorides. A
surface finish equivalent to SA 3 (as per Swedish
Standard SIS 05 5900) is recommended. Surface profile
is not considered critical for most applications.
12.4
Pickling
(a)
Composition: Pickling of SAF 2205 should be carried
out using formulations based on nitric (HNO3)
and hydrofluoric (HF) acid.
Formulations
based on hydrochloric acid (HCL) are unsuitable.
Pickling
formulations made up of 15 - 20% HNO3; 1 -
2% HF; balance H2O are considered suitable.
The acids used must conform to commercial purity
standards and the water must be of potable quality.
(b)
Application procedure: The formulation must be
generously applied to weld areas by brush, cloth,
spray or dipping. The formulation should not be
allowed to dry while in contact with the steel surface
as significant staining of the SAF 2205 can result.
Use of
thixotropic pastes is recommended to ensure that
contact with the steel surface is maintained for the
required period.
Intermittent
scrubbing with a stainless steel wire or fibre bristle
brush can assist in removal of the discolouration. The
temperature of the pickling formulation should not
exceed 30oC.
(c)
Exposure period. The exposure time required for
pickling will vary according to a number of factors
(strength of pickling formulation, ambient
temperature, extent and nature of discolouration, weld
metal composition). No specific recommendation
concerning exposure time can be made. Pickling
formulations are aggressive towards SAF 2205 and
pickling should be supervised to ensure that exposure
times are no longer than the minimum required to
remove discolouration. If necessary, the pickling
operation must be repeated in areas where complete
removal of discolouration has not been achieved.
(d) Use
of proprietary pickling formulations: Proprietary
Pickling formulations based on nitric and hydrofluoric
acid are available and are suitable for post-weld
cleaning of SAF 2205.
The
manufacturer's directions concerning application
procedure must be adhered to.
Proprietary
pickling formulations can vary significantly in terms
of acid concentration (and quite commonly contain acid
levels greater than those noted previously). Such
formulations may therefore be particularly corrosive
towards SAF 2205 and close control and supervision
must be exercised in limiting exposure times to the
minimum required to remove discolouration and scale.
Intermittent
vigorous brushing using stainless steel wire brushes
or fibre bristle brushes can assist in removing
discolouration.
(e)
Washing: Thorough washing with copious quantities of
clean cold water is required after pickling to remove
all traces of acids used.
12.5
PASSIVATING
Passivation
of SAF 2205 should be carried out within as short a
period after post-weld cleaning as possible.
A
solution made up of 10 - 20% HNO3; balance
H2O is suitable for passivating SAF 2205.
The acid used must conform to commercial purity
standards and the water must be of potable quality.
The temperature of the passivating solution should not
exceed 30oC.
The
solution must be generously applied to the steel by
brush, cloth, spray or dipping. The solution should
not be allowed to dry on the steel surface as staining
can result. Use of thixotropic pastes is recommended
to ensure that contact with the steel surface is
maintained for the required period.
Thorough
washing with clean cold water after passivation is
necessary to remove all traces of the acid used.
12.6
GENERAL
Post-weld
cleaning (particularly pickling) and passivation are
operations which are affected by a number of factors -
some of which are peculiar to local conditions. It is
not possible therefore to provide procedure details
which satisfy all possible conditions.
Individual
fabricators are advised to develop procedures which
take into account all those factors which influence
the post-weld cleaning and passivation of SAF 2205
fabrications.
Pickling
and passivation is normally undertaken using
formulations based on acids which are harmful if
ingested or allowed to come into contact with the
skin. Suitable precautions (eg. protective face masks,
rubber gloves, availability of first aid) must be
observed.
Disposal
of pickling and passivation formulations (eg. via
municipal drainage systems) may be controlled and this
should be clarified with the relevant authorities.
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