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Corrosion resistance of duplex

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Corrosion resistance of duplex stainless steels

09 # by alloy
Oct
2015 The duplex steels offer an excellent range of corrosion resistance in the diverse media.
Following is the brief explanation of their resistance in the variety of application conditions.

Uniform Corrosion:

Uniform corrosion is featured by even attack on the steel surface that comes in contact of
the attacking media. The prevention of corrosion is assumed to be suitable if the attack
rate is lower than 0.1 mm per year. Duplex steel grades contain large magnitude of
chromium that enables them to offer good corrosion resistance in the different
environments.

Sulfuric acid

Following diagram shows the corrosion resistance in sulfuric acid. It describes duplex
stainless steel 2205 offers significantly better resistance (https://super-
metals.com/alloy/duplex-stainless-steel-2205/) than SS 904l.

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Corrosion resistance of duplex stainless steels Page 3 of 6

(https://super-metals.com/wp-content/uploads/2015/10/H2SO4-corrosion-resistance-by-
duplex-2205.jpg)

Hydrochloric Acid

Stainless steel grades offer controlled service in hydrochloric acid application due to
uniform and local corrosion attack. On the other hand Duplex stainless steel 2507 and
2205 provide adequate service in the aq. HCl. Pitting is generally not an issue however
crevice attack should be prevented.

Nitric Acid

In the powerful oxidizing chemicals including nitric acid, commonly used molybdenum-free
steels offer better corrosion resistance than molybdenum based steels.

Pitting and crevice attack

The prevention of pitting and crevice corrosion improves with increasing magnitude of
chromium (Cr), molybdenum (Mo) and Nitrogen (N) in the steel grades. It is normally
described by pitting resistance equivalent number for a specific material. This value is
significant for an estimation of performance of the various materials. Critical pitting
temperature (CPT) is also found to be more useful to rank the materials.

While considering the corrosion resistance by crevice, it is usual to determine the critical
temperature limit at which the attack begins in a specific solution. The general critical
crevice corrosion temperature determined in 6% ferric chloride (FeCl3) +1% Hydrochloric
acid (HCl) shows that duplex grades 2205 and 2507 need higher temperature to be
attacked as compare to traditional steels. Hence the latter is more sensitive to attack.

Stress corrosion cracking

Stainless steels are damaged by stress corrosion cracking in conditions containing chlorides
at the high temperatures. Traditional austenitic steels are found to be more susceptible to
such attack however duplex grades are less prone to it.

Various techniques are utilized to grade the steel types considering their resistance to SCC
and the outcomes vary on the base of test method and condition used. Following table
shows the comparative resistance offered by traditional steels and austenitic-ferritic duplex
steels.

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Corrosion resistance of duplex stainless steels Page 4 of 6

40% CaCl2
25% NaCl, 1500 ppm
45% MgCl 40% CaCl2 at 100oC, 25% NaCl,
Steel grade pH 1.5, Cl- at
at 155oC at 100oC 0.9 x 106oC
106oC 100oC
Rp0.2

4307 Probable Probable Probable Probable Probable Probable

4404 Probable Probable Probable Probable Possible Probable

Not Not Not Not Not

2201 Probable
probable probable probable probable probable

Not Not Not Not Not

2304 Probable
probable probable probable probable probable

Not Not Not Not

2404 Probable Possible
probable probable probable probable

Not Not Not Not

2205 Probable Possible
probable probable probable probable

Not Not Not Not Not

2507 Probable
probable probable probable probable probable

Not Not Not Not Not

254 SMO Probable
probable probable probable probable probable

It states that duplex steel grades are resistant to vigorous conditions including boiling
concentrated magnesium chloride (MgCl2), they resist stress corrosion cracking in the
diverse media where traditional steel grades usually damage.

Sulfide based stress corrosion cracking

The availability of hydrogen sulfide and chlorides cause the SCC attack at the minor
temperature limits. This type of corrosion may occur such as in boreholes for oil and gas
plants. The recommended alloys for use are duplex grades 2205 and 2507 that offer
suitable prevention of such attack however steels containing 13% chromium are prone to
SCC. Care should be taken while considering the environments with large partial pressure
of H2S and when the steel is exposed to large internal stress.

According to NACE MR0175/ ISO 1515, duplex stainless steel grades 2205 & 2507 are
proven for use in the petrochemical and natural gas refining units. They are fit for use in
the conditions containing H2S in the oil and gas production wells.

Corrosion fatigue

The pair of large mechanical strength and excellent resistance to corrosion offers duplex
grades good corrosion fatigue strength. The corrosion fatigue strength of steel 2205 is
larger than grade 4404.

Intergranular attack

The duplex microstructure and small carbon magnitude make duplex steel grades to offer
prevention against intergranular attack. The chemistry of steel confirms that austenite is
reproduced in the heat affected region subsequent to welding. The risk of unnecessary
precipitation of carbides and nitrides in the grain limits is hence reduced.

Erosion Attack

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Corrosion resistance of duplex stainless steels Page 5 of 6

Stainless steel normally provides good prevention of erosion attack. The duplex grades are
resistant to their combination of high surface toughness and offer large corrosion
resistance. Instances of applications where this is advantageous are systems that are
exposed to hard wear such as pipe systems comprising of water with sand or salt crystals.

Galvanic attack

Galvanic attack may take place when two unlike materials are joined. The noblest material
is secured while the less ideal material is more vigorously attacked. When the duplex steel
grades are passive, they are in generally conditions more ideal than other metallic
construction materials, stating that this steel is secured while the attack rate of such as
carbon steel is accelerated. The galvanic attack doesn’t happen between two unlike grades
of steels when the both types are passive.

Characteristics of Duplex steel grades

1. Excellent prevention of uniform corrosion, pitting and crevice attack

2. Prevents stress corrosion cracking and corrosion fatigue
3. Large mechanical strength
4. Suitable abrasion and erosion prevention
5. Nominal thermal expansion
6. High weldability

Applications

Paper and pulp processing, desalination, flue gas cleaning, transportation tanks and piping
in chemical tankers, seawater processing, firewalls and blast walls on offshore units,
bridges, parts for structural units, storage containers, pressure vessels, heat exchanger,
water heaters, rotors, impellers and shafts and strengthening bars for concrete structures.

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Corrosion resistance of duplex stainless steels Page 6 of 6

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