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Fabricators are looking for ways to simplify the welding process and minimise the potential for costly rework or, worse, field failures of welded products. In the present article, we will discuss selecting the right filler metal to weld duplex stainless steel (SS).
There are three main categories of SS in reference to its microstructure: martensitic, austenitic and ferritic. Martensitic is outside the focus of duplex grades, so we'll leave it out of this discussion.
Austenitic SS (the 3XX series) are typically used in applications requiring good weldability. They are highly formable and offer a low-temperature service option. Ferritic SS have good strength, moderate ductility and are relatively inexpensive.
Duplex SS (DSS) were engineered to be the best of both worlds. DSS gets its name from its metallurgical microstructure made up of approximately 50 per cent austenite and 50 per cent ferrite. DSS are materials that feature improved toughness and almost twice the strength of austenitic SS and ferritic SS, along with improved corrosion resistance, including stress corrosion cracking (SCC).
For a pressure vessel application in which the designer/engineer has selected a specific grade of DSS and determined the required material thickness, the welding engineer needs to select a filler metal that is at least a matching filler metal to deliver the same properties as outlined previously. You also have the added responsibility of selecting an appropriate welding process that won't degrade the base metal properties in the heat-affected zone (HAZ).
For example, if the job calls for a 2205 grade of DSS to be welded to itself, an ER2209 filler metal would be a solid match. However, if the base material is 2101, it's important to realise that a lean DSS was selected because the material is less expensive than other DSS but still delivers high strength with good fatigue resistance and good corrosion resistance. The best consumable option is the matching consumable, which is ER2307, but ER2209 would be an acceptable second choice.
If the higher amount of molybdenum in the ER2209 is not a concern for the application of the finished product, it would be a fair match to weld all three of the stated DSS base materials. Because of the higher amounts of alloy in this filler metal, the cost will probably be higher.
The primary factors to consider selecting the best filler metal are:
Again, the information presented is far from exhaustive. If additional information is required, more specific details about the application of products would be needed. Additionally, many great resources are online that may be able to answer specific questions or concerns.
What is the best filler metal for welding duplex stainless steel?
The best filler metal for duplex stainless steel depends on the base metal grade, mechanical properties, and service conditions. For 2205 duplex stainless steel, ER2209 is a commonly recommended filler metal because it provides compatible strength and corrosion resistance. For lean duplex grades such as 2101, ER2307 is typically preferred, while ER2209 may be an acceptable alternative depending on application requirements.
What is the difference between duplex and austenitic stainless steel?
Duplex stainless steel contains a mixed microstructure of approximately 50% austenite and 50% ferrite, combining properties of both stainless steel types. Compared with conventional austenitic stainless steel, duplex grades generally offer higher strength and improved resistance to stress corrosion cracking. These characteristics make duplex stainless steel suitable for demanding industrial applications, including pressure vessels and chemical processing equipment.
Can you weld 2205 duplex stainless steel with ER2209 filler metal?
es. ER2209 is a commonly used filler metal for welding 2205 duplex stainless steel. Its alloy composition is designed to help achieve suitable mechanical properties and corrosion resistance in the completed weld. However, welding parameters and heat input must also be controlled to maintain the required microstructure and prevent degradation of properties in the heat-affected zone.
What factors should be considered when selecting filler metal for duplex stainless steel?
Key considerations include the base metal grade, operating temperature, chemical environment, mechanical strength requirements, and corrosion resistance. The pitting resistance equivalent number (PREN) is particularly important for applications exposed to corrosive conditions. Welding process compatibility, filler metal cost, and the required mechanical properties of the finished joint should also influence selection.
Can ER2209 filler metal be used for lean duplex stainless steel?
ER2209 can be used for certain lean duplex stainless steel applications, including some joints involving grade 2101. However, ER2307 is generally the preferred matching consumable for 2101 because it is designed for the alloy's composition and performance requirements. ER2209 contains higher alloying levels, including molybdenum, which may increase consumable costs and should be evaluated against the intended service conditions.