Corrosion Test Fail For Duplex Steel

[Ashish Chacko]

I am currently working on developing a Procedure Qualification Record (PQR) for Duplex Steel. In the process, I conducted welding using the base material SA 790 (UNS:32205) and utilized two different filler wires: ER-2594 and ER-Nicr-Mo-14 for different coupons. Size of the coupon 6" Thick:10.97 mm.

However, I encountered a concern during the corrosion testing phase, as per ASTM A923-03 standards. Both test materials failed the corrosion test. I'm seeking guidance from the experts in this group to understand the possible reasons for the failure and to explore potential solutions or alternative approaches.

If anyone has experience with similar issues or insights into the matter, I would greatly appreciate your assistance.

[Vishwas Keskar]

What was the backing and shielding gas ?

Sent from my iPhone

On 18-Jul-2023, at 10:56 AM, Ashish Chacko <iamash...@gmail.com> wrote:



I am currently working on developing a Procedure Qualification Record (PQR) for Duplex Steel. In the process, I conducted welding using the base material SA 790 (UNS:32205) and utilized two different filler wires: ER-2594 and ER-Nicr-Mo-14 for different coupons. Size of the coupon 6" Thick:10.97 mm.

However, I encountered a concern during the corrosion testing phase, as per ASTM A923-03 standards. Both test materials failed the corrosion test. I'm seeking guidance from the experts in this group to understand the possible reasons for the failure and to explore potential solutions or alternative approaches.

If anyone has experience with similar issues or insights into the matter, I would greatly appreciate your assistance.

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[Vishwas Keskar]

Pl share the test results 

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On 18-Jul-2023, at 10:56 AM, Ashish Chacko <iamash...@gmail.com> wrote:



I am currently working on developing a Procedure Qualification Record (PQR) for Duplex Steel. In the process, I conducted welding using the base material SA 790 (UNS:32205) and utilized two different filler wires: ER-2594 and ER-Nicr-Mo-14 for different coupons. Size of the coupon 6" Thick:10.97 mm.

However, I encountered a concern during the corrosion testing phase, as per ASTM A923-03 standards. Both test materials failed the corrosion test. I'm seeking guidance from the experts in this group to understand the possible reasons for the failure and to explore potential solutions or alternative approaches.

If anyone has experience with similar issues or insights into the matter, I would greatly appreciate your assistance.

--

[Ashish Chacko]

Backimh and shieldimg gas was argon grade 4.7 b ( 99.997%)

[james gerald]

1. The suitable welding consumable for welding SA 790 (UNS32205) is ER2209.

2. To pass ASTM G48 test, some  prefer using ER 2594  for the root pass (though it is a super Duplex SS).

3. The formation of Intermetallic compounds as detected IN ASTM A923 is because of below reasons.

    a.  Use of higher Alloy content consumable.

    b.  High Heat Input which in turn  reduces the cooling rate and inturn increase the time spent in the higher         

         temperature region which results in forming Intermettalic phases like Sigma phase and Chi phase.

Please provide a copy of WPS to understand the welding conditions. 

Also provide ASTM A923 Test Report.

Thanks & Regards

J.Gerald Jayakumar

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[Ashish Chacko]

Dear Kindly find the test report

On Tuesday, 18 July 2023 at 11:10:50 UTC+3 Vishwas Keskar wrote:

[Ahmad el-sharkawy]

Please share with us the corrosion report and photos for corrosion testing as well, porposed WPS and PQR as run sheet.

To view this discussion on the web visit https://groups.google.com/d/msgid/materials-welding/AF42C56D-0158-4AAC-BE4C-2867152229ED%40gmail.com.

[Babur Khan]

Greetings,

In pas we faces same issue and after that we get recommendations from test laboratories to use mixture gases for shielding and purging.

Argon + 2% Nitrogen mixer with ER2594 filler wire.a

 Babur Khan Lashari 

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On 18 Jul 2023, at 2:16 PM, Ashish Chacko <iamash...@gmail.com> wrote:

Backimh and shieldimg gas was argon grade 4.7 b ( 99.997%)

To view this discussion on the web visit https://groups.google.com/d/msgid/materials-welding/7068eff6-31d3-4d90-b0a0-84266c712e75n%40googlegroups.com.

[G Neethipathi]

Better try with ER347 Filler wire.for duplex steel this filler material is suitable.

T/R

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[Pham Thanh Tinh]

Hi 

Send to me all PQT report from your conduct I will support to you.

Vào Th 3, 18 thg 7, 2023 vào lúc 08:26 Ashish Chacko <iamash...@gmail.com> đã viết:

I am currently working on developing a Procedure Qualification Record (PQR) for Duplex Steel. In the process, I conducted welding using the base material SA 790 (UNS:32205) and utilized two different filler wires: ER-2594 and ER-Nicr-Mo-14 for different coupons. Size of the coupon 6" Thick:10.97 mm.

However, I encountered a concern during the corrosion testing phase, as per ASTM A923-03 standards. Both test materials failed the corrosion test. I'm seeking guidance from the experts in this group to understand the possible reasons for the failure and to explore potential solutions or alternative approaches.

If anyone has experience with similar issues or insights into the matter, I would greatly appreciate your assistance.

--

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https://www.linkedin.com/groups/122787
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--

Best & Regard

Pham Thanh Tinh

QC Manager

China National Chemical Engineering Third Co.LTD

South Ghawar Gas Separation Plant & Associated Facilities Project

Email: tinh...@gmail.com / ph...@sinotcc.com

Mobile phone +966. 556802308 

[Ashish Chacko]

Kindly find the attachment for test report

[Aneesh]

HI Ashish Chacko

You may use 87% Argon + 10%Helium +3% Nitrogen. (as backing and shielding)

Maintain inter pass temperature below 100 C. 

Use ER2594 Filler Wire (ESAB or DAIKO Brand)

Most importantly, make sure you do pickling and passivation after welding, for the time specified for Super duplex materials. ( you will find the time in 

pickling and passivation gel itself. We used S weld gel)

Im sure you will reap the result. we got Corrosion value as = 0 MDD

Thanks and Regards

Aneesh Kizhakkekalam

QA/QC Manager (Saudi Aramco Project)

[Thanh Tĩnh Pham]

Share to me all run sheet records 

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On 19 Jul 2023, at 08:10, Ashish Chacko <iamash...@gmail.com> wrote:

Kindly find the attachment for test report

To view this discussion on the web visit https://groups.google.com/d/msgid/materials-welding/c189ed1b-0017-4b38-9e11-6cf67e7ba901n%40googlegroups.com.

<SKM_C30823071715530.pdf>

[james gerald]

Just to add a portion from API RP582.

Thanks & Regards

J.Gerald Jayakumar

https://groups.google.com/d/msgid/materials-welding/E4B944BA-2609-43FF-B9E5-6E01105B2565%40gmail.com

.

[james gerald]

Gentlemen excuse me if I have interrupted. This is a  Forum where everybody shares their  Technical knowledge and experience so that it is useful to the concerned. Sometimes we may be wrong also and take it sportively without being offended.

Argon + 2% N2 mixture is highly recommended for purging and shielding for the below purposes.

1.  Nitrogen is an Austenite stabilizer and promotes Austenite formation in the duplex matrix.

2. It improves Pitting corrosion resistance.

3. The maximum solubility of Nitrogen in DSS A32205 is 0.2% and anything more than that will come out of the solution.

4. Nitrogen delays the formation of Intermetallic phases.

 

5. Nitrogen may be more efficient in aiding ASTM G48 corrosion test.

But in ASTM A923, the weight loss is mainly due to Intermetallic Phases as higher PREN electrodes used such as Super duplex and Nickel base electrodes does not cause in weight loss due to pitting corrosion. I feel the main reason is higher alloy contents of Cr, Mo,W in the welding consumable which causes Intermetallic phases. Though N2 mixture has some effect but unless care is taken on correct welding consumable it is difficult to prevent and also equally dependent on WElding conditions like Heat Input, Preheat and Interpass temperature.

Some portions below on sigma phase.

Thanks & Regards

J.Gerald Jayakumar

On Wednesday, 19 July, 2023 at 09:08:39 am IST, Babur Khan <mbabu...@gmail.com> wrote:

https://groups.google.com/d/msgid/materials-welding/E4B944BA-2609-43FF-B9E5-6E01105B2565%40gmail.com

.

[J Prinsen]

Gents,

In the past a had a project with Super-Duplex with the same problem.

To solve this we liked to use Ar-N2 as a backing gas, but this was not in stock.

We switched to 100% N2 as a backing gas, and this worked out well for the corrosion test (40 degrees centigrade for Super DSS) and the complete PQR

In all cases the use of cold pass technique (thicker root pass (HI 1.2 kJ/mm max, thin second pass) interpass max 150 centigrade, overall HI max 1 kJ/mm has to be maintained 

Regards

Ir. Jurgen Prinsen IWE

Metallurgical and Welding Engineer

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Van: "materials-welding" <material...@googlegroups.com>
Aan: "materials-welding" <material...@googlegroups.com>
Verzonden: Woensdag 19 juli 2023 15:36:34
Onderwerp: Re: [MW:34431] Corrosion Test Fail For Duplex Steel

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