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I often receive questions on the correct parameters for welding duplex stainless steels.
There seems to be a lot of confusion on which practices and quality checks are best. I
also notice that each industry treats duplex stainless differently. These materials do
take care and proper procedure to maintain corrosion and mechanical properties.
First, it is important to mention that Rolled Alloys and other suppliers have welding
guidelines with details on shielding gases, amps, volts and other settings you will need
to have a successful procedure. Here are links for welding 2205 duplex and for ZERON
100 super duplex. The notes below are shortened rules of thumb, so please consult the
full welding guides for details.
Filler Metal
Most duplex stainless steels have an over alloyed filler. For example, 2205 uses 2209
and ZERON 100 uses ZERON 100X. These filler metals are nearly identical in chemistry
to the base metal, except for an extra 2% nickel. The increased nickel content aides in
forming the 50/50 mix of austenite and ferrite phases. The benefit of these over
alloyed fillers is that you do not need to post weld heat treat the fabrication. There are
some variations that can be used, for example, LDX 2101 is often welded with 2209
filler metal because it is more readily available. Using this filler metal with higher
nickel, chromium, and molybdenum increases the corrosion resistance and makes a
sound weld.
Quality Checks
Because welding duplex stainless steel is not fool-proof it is important to perform
quality checks. We normally suggest that when developing a weld procedure it is
critical to test the corrosion resistance, the impact toughness, and the ferrite/austenite
mix in the weld qualification. The welding guides have more detail on which test is
appropriate for each material. Once your WPS is written to provide good corrosion,
toughness, and ferrite the final production weld should also yield good results. Since it
is often impossible to fully test the final product, we usually suggest testing the weld
bead for ferrite content. Typically incorrect ferrite levels will be the first indication of a
problem. If a problem is found, further testing should be performed.
Hopefully this helps. If you have any other questions, please contact us
at Metallurgical-Help@RolledAlloys.com