Search Results (24)

Owing to its corrosion resistance, stainless steel is a sustainable alternative to carbon steel as a structural material in challenging seawater environments. Studies on carbon steel indicate that among all marine corrosion zones (i.e., atmospheric zone, splash zone, tidal zone, and immersed zone), the rate of corrosion is particularly high in the splash zone, above the seawater level, due to the recurrent splashing of seawater with high levels of oxygen and chloride content. Nevertheless, the information on the extent of localized corrosion (i.e., pitting and crevice corrosion) on stainless steel in the splash and tidal zones is scarce and, in most cases, limited to standard austenitic grades. In this work, we present the pitting and crevice corrosion results on lean duplex, duplex, and super duplex stainless steels after two years of field exposure in the North Sea (site at Heligoland South Harbour). The standard austenitic grade 1.4404 (316L) was also exposed as a reference material in atmosphere and splash zone conditions. Parallel exposure of coupons in splash, tidal, and immersed zones allows comparison of the extent of corrosion in each zone and enables proper material selection for structural applications in marine environments. Full article

Stainless steels have undergone more than a century of continuous development, during which various advanced grades—such as lean duplex, super austenitic, and high-nitrogen stainless steels—have been introduced. Despite remarkable progress, the manufacturing of stainless steel remains a complex process that spans multiple critical stages, including stainless steelmaking, solidification and casting, continuous casting, heat treatment, electroslag and vacuum arc remelting, as well as both hot and cold rolling operations. Ensuring excellent corrosion resistance and mechanical performance of the final products continues to be a central focus of research and production. The current Special Issue (SI) entitled ‘Advanced Stainless Steel—from Making, Shaping, Treating to Products’ has collected eight research papers focusing on various aspects of steel production, e.g., inclusions in steelmaking and continuous casting processes, continuous casting processes and the quality of stainless steel casting, heat treatment, corrosion of steels, and fatigue of steels. This summary aims to contribute to the state-of-the-art of the development of steel production. Full article

The corrosion behaviour of lean duplex S32101 (1.4162—X2CrMnNiN21-5-1) stainless steel was assessed in various corrosive environments relevant to the pulp and paper industry. Electrochemical techniques, including open-circuit potential measurements and cyclic polarisation, were used to evaluate the corrosion resistance of S32101 stainless steel in various acidic, saline, and industrial liquors such as black, green, and white liquors, as well as dissolved chlorine dioxide bleaching solutions. To evaluate the extent of damage and corrosion mechanisms, post-exposure surface analysis was conducted using scanning electron microscopy (SEM). The results showed that S32101 experienced pitting corrosion in chloride-containing solutions, particularly in salt and acidified-salt environments. Corrosion rates increased with rising temperatures across all solutions. The highest corrosion rate of 3.17 mm/yr was observed in the highly alkaline white liquor at 50 °C, whilst chlorine dioxide induced the least aggressive effects at all temperatures. The suitability of S32101 stainless steel in handling pulp and paper liquors is shown in its corrosion resistance against the bleaching medium and low-temperature saline solutions, but it is not recommended for prolonged exposure to high alkaline liquors or chloride-rich solutions. Full article

Herein, the corrosion performance of different stainless steel (SS) reinforcing bar grades in alkaline solution is presented, including UNS S32205 duplex stainless steel (DSS), UNS S32304 and UNS S32001 lean DDS (LDSS). The electrochemical dissolution kinetics were studied by potentiodynamic polarization and the Tafel slope method. The environmentally assisted cracking (EAC) mechanisms of the different SS grades in the presence of Cl⁻ were revealed with the slow strain rate test (SSRT). The higher activation of the anodic branch and the loss of toughness were related to the austenite-to-ferrite phase ratio. UNS S32205 DSS presented the slowest anodic dissolution kinetics, mainly due to the higher austenite content compared to the other LDSS; however, it suffered a more severe EAC than the UNS S32304 LDSS. In the case of UNS S32001 LDSS, even while having the lowest Ni content (i.e., large ferrite α-phase ratio), it experienced the least decrease in elongation as well as low anodic dissolution kinetics for Cl⁻ contents up to 8 wt.%, where the Cl⁻ threshold was reached. Full article

The experimental quantification of retention factors related to the post-fire strength as well as the post-fire ductility of intentionally selected stainless steel grades applied in construction is the objective of the research presented here. These steel grades are characterized by a two-phase austenitic–ferritic microstructure of the duplex type. In this context, two mutually corresponding chromium–nickel–molybdenum steel grades are subjected to analysis, namely X2CrNiMoN22-5-3 steel belonging to the standard duplex group (DSS 22% Cr) and X2CrMnNiN21-5-1 steel belonging to the lean duplex group (LDSS). The similarities and differences in the mechanical properties exhibited by these steel grades after effective cooling, following more or less prolonged simulated fire action conforming to several development scenarios, are identified and indicated. The resistance of a given steel grade to permanent structural changes induced by the heating program proved to be the critical factor determining these properties and resulting in many cases in increased susceptibility to brittle fracture. The results obtained experimentally seem to confirm the quantitative estimates of post-fire retention factors forecast by Molkens and his team, specified for the steels exhibiting a duplex-type structure and tested by us. However, several of these estimates might be considered somewhat risky. Nevertheless, our results do not confirm the significant post-fire strengthening of steel grades belonging to the LDSS group following prior heating at a sufficiently high temperature, as reported earlier by Huang Yuner and B. Young. Full article

Duplex stainless steel welded metals were underwater local dry prepared on S32101 lean duplex stainless steel trapezoidal groove plates with a self-made drain cover employing Supercore 2205P flux-cored filler wire. Different heat inputs were employed to investigate the effects on mechanical characteristics and the microstructure of welded metals. The results demonstrated that as the heat was applied, austenite concentrations in the weld metals increased. It was found that the austenite concentration and the fraction of Σ3-austenite twin-grain boundaries followed the same trends. With increasing heat input, the recrystallized ferrite and austenite grains initially decreased and subsequently increased, whereas the fraction of interphase boundaries between special ferrite and austenite exhibited the reverse trend. With a heat input of 1.4 kJ/mm, the toughness and plasticity of the weld metals were enhanced by an increase in austenite content, Σ3 recrystallized grains, and austenite twin-grain boundaries. The plasticity and tensile strength values of the welded metal changed more when the heat input was raised from 1.0 to 1.2 kJ/mm than when it was raised from 1.2 to 1.4 kJ/mm. Considering energy conservation, it is recommended to adopt 1.2 kJ/mm for welding heat input. Full article

In newly developed 2101 lean duplex stainless steel, oxide inclusions have been detected on welded metal zones after subjecting them to flux-cored arc welding with an E2209T1-1 flux-cored filler metal. These oxide inclusions directly affect mechanical properties of the welded metal. Hence, a correlation requiring validation has been proposed between oxide inclusions and mechanical impact toughness. Accordingly, this study employed scanning electron and high-resolution transmission electron microscopy to assess the correlation between oxide inclusions and mechanical impact toughness. Investigations revealed that the spherical oxide inclusions comprised a mixture of oxides in the ferrite matrix phase and were close to intragranular austenite. The oxide inclusions observed were titanium- and silicon-rich oxides with amorphous structures, MnO with a cubic structure, and TiO₂ with an orthorhombic/tetragonal structure, derived from the deoxidation of the filler metal/consumable electrodes. We also observed that the type of oxide inclusions had no strong effect on absorbed energy and no crack initiation occurred near them. Full article

Duplex stainless steels were first manufactured early in the 20th century, but it was the introduction in the 1970s of the argon-oxygen decarburisation (AOD) steel making process and the addition of nitrogen to these steels, that made the alloys stronger, more weldable and more corrosion resistant. Today, duplex stainless steels can be categorised into four main groups, i.e., “lean”, “standard”, “super”, and “hyper” duplex types. These groups cover a range of compositions and properties, but they all have in common a microstructure consisting of roughly equal proportions of austenite and ferrite, high strength, good toughness and good corrosion resistance, especially to stress corrosion cracking (SCC) compared with similar austenitic stainless steels. Moreover, the development of a duplex stainless-steel microstructure requires lower levels of nickel in the composition than for a corresponding austenitic stainless steel with comparable pitting and crevice corrosion resistance, hence they cost less. This makes duplex stainless steels a very versatile and attractive group of alloys both commercially and technically. There are applications where duplex grades can be used as lower cost through-life options, in preference to coated carbon steels, a range of other stainless steels, and in some cases nickel alloys. This cost benefit is further emphasised if the design engineer can use the higher strength of duplex grades to construct vessels and pipework of lower wall thickness than would be the case if an austenitic grade or nickel alloy was being used. Hence, we find duplex stainless steels are widely used in many industries. In this paper their use in three industrial applications is reviewed, namely marine, heat exchangers, and the chemical and process industries. The corrosion resistance in the relevant fluids is discussed and some case histories highlight both successes and potential problems with duplex alloys in these industries. The paper shows how duplex stainless steels can provide cost-effective solutions in corrosive environments, and why they will be a standard corrosion resistant alloy (CRA) for many industries through the 21st century. Full article

The block shear equations specified in the current AISC specification for structural steel buildings and North American cold-formed steel design specifications are based on research results of carbon steel bolted connections. These equations were found to be inapplicable for the welded connections in the literature. This issue is primarily associated with the use of the incorrect assumption on block shear failure mechanism. The present paper examines the accuracy of various block shear equations available in the design specifications and in the literature. The paper also examines the shear hardening capacity and the level of tensile stress over the critical net area with the results of finite element analysis, in which the fracture simulation is considered. It shows that the block shear capacities of lean duplex stainless steel welded connections can be predicted accurately using tensile stress equal to 1.25F_u, as proposed in the literature. Full article

Stainless steels are increasingly used in construction today, especially in harsh environments, in which steel corrosion commonly occurs. Cold-formed stainless steel structures are currently increasing in popularity because of its efficiency in load-bearing capacity and its appealing architectural appearance. Cold-rolling and press-braking are the cold-working processes used in the forming of stainless steel sections. Press braking can produce large cross-sections from thin to thick-walled sections compared to cold-rolling. Cold-forming in press-braked sections significantly affect member behaviour and joints; therefore, they have attained great attention from many researchers to initiate investigations on those effects. This paper examines the behaviour of residual stress distribution of stainless steel press-braked sections by implementing three-dimensional finite element (3D-FE) technique. The study proposed a full finite element procedure to predict the residual stresses starting from coiling-uncoiling to press-braking. This work considered material anisotropy to examine its effect on the residual stress distribution. The technique adopted was compared with different finite element techniques in the literature. This study also provided a parametric study for three corner radius-to-thickness ratios looking at the through-thickness residual stress distribution of four stainless steels (i.e., ferritic, austenitic, duplex, lean duplex) in which have their own chemical composition. In conclusion, the comparison showed that the adopted technique provides a detailed prediction of residual stress distribution. The influence of geometrical aspects is more pronounced than the material properties. Neglecting the material anisotropy shows higher shifting in the neutral axis. The parametric study showed that all stainless steel types have the same stress through-thickness distribution. Moreover, R/t ratios’ effect is insignificant in all transverse residual stress distributions, but a slight change to R/t ratios can affect the longitudinal residual stress distribution. Full article

Steel rebars of structures exposed to cyclic loadings and marine environments suffer an accelerated deterioration process by corrosion fatigue, causing catastrophic failure before service life ends. Hence, stainless steel rebars have been emerging as a way of mitigating pitting corrosion contribution to fatigue, despite the increased cost. The present study proposes a corrosion fatigue semiempirical model. Different samples of rebars made of carbon steel, 304L austenitic (ASS), 316L ASS, 2205 duplex (DSS), 2304 lean duplex stainless steels (LDSS), and 2001 LDSS have been embedded in concrete and exposed to a tidal marine environment for 6 months. Corrosion rates of each steel rebar have been obtained from direct measurement and, considering rebar standard requirements for fatigue and fracture mechanics, an iterative numerical model has been developed to derive the cycles to failure for each stress range level. The model resulted in a corrosion pushing factor for each material, able to be used as an accelerating coefficient for the Palmgren-Miner linear rule and as a performance indicator. Carbon steel showed the worst performance, while 2001 LDSS performed 1.5 times better with the best cost-performance ratio, and finally 2205 DSS performed 1.5 times better than 2001 LDSS. Full article

The deformation behaviors of the austenite phase in lean duplex stainless steels were investigated through uniaxial tension tests with different amounts of deformation. Microstructural analysis showed that in the initial deformation stage the deformation in austenite grains had a predominant effect on the strain hardening behavior of the LDX-2101 steel. The initial deformation in the austenite grains was found to be mainly accommodated by the formation of stacking faults. As the deformation increased further, mechanical twins were generated by the initial stacking faults and sequentially interacted with dislocations to accommodate the strain. The analysis of dislocation behavior revealed that the deformation twinning process followed the three-layer twin formation mechanism. Full article

On newly developed Fe_balance-18Cr-7Mn-3Mo-3W-0.4N-(0.03, 0.57)Ni (in wt%) lean duplex stainless steels, the microstructure, element partitioning behavior, and resistance to pitting corrosion were investigated. After solution treatments, the two alloys were found to have similar microstructures in terms of phase fraction and grain size, and have a precipitation-free matrix. The polarization tests revealed that the addition of Ni was beneficial to improve the resistance to pitting corrosion, which was confirmed by the rise in pitting and repassivation potentials. The uniform corrosion behavior and galvanic corrosion rate of the matrix were investigated to explain the improved pitting corrosion resistance of the Ni-added lean duplex stainless steel. As a result, it was found that the addition of Ni enhanced the resistance to uniform corrosion by reducing the galvanic corrosion rate between the ferrite and austenite phases in the lean duplex stainless steel; thus, the pit growth rate was decreased, leading to improvement of the resistance to pitting corrosion. Full article

This study presents results of experimental tests on quality of dissimilar welded joints between 316L austenitic and 2304 lean duplex stainless steels, welded without ceramic backing. Fiber laser welded butt joints at a thickness of 8 mm were subjected to non-destructive testing (visual and penetrant), destructive testing (static tensile test, bending test, and microhardness measurements) and structure observations (macro- and microscopic examinations, SEM, element distribution characteristics, and ferrite content measurements). Non-destructive tests and metallographic examinations showed that the welded joints meet the acceptance criteria for B level in accordance with EN ISO 13919–1 standard. Also the results of the destructive tests confirmed the high quality of the joints: specimens were fractured in base material with lower strength—316L austenitic stainless steel and a 180° bending angle was obtained confirming the high plasticity of the joints. Microscopic examination, SEM and EDS analysis showed the distribution of alloying elements in joints. The microhardness of the autogenous weld metal was higher by about 20 HV0.2 than that of the lean duplex steel. Ferrite content in the root was about 37% higher than in the face of the weld. The Schaeffler phase diagram was used to predict the phase composition of the welded joints and sufficient compliance with the magnetic method was found. The presented procedure can be used for welding of 316L–2304 stainless steels dissimilar welded joints of 8 mm thickness without ceramic backing. Full article

The characteristics of texture and microstructure of lean duplex stainless steels with low Ni content produced through hot rolling followed by annealing were investigated locally with electron backscatter diffraction and globally with neutron diffraction. Then, the ductile–brittle transition (DBT) behavior was studied by Charpy impact test. It is found that the DBT temperature (DBTT) is strongly affected by the direction of crack propagation, depending on crystallographic texture and microstructural morphology; the DBTT becomes extremely low in the case of fracture accompanying delamination. A high Ni duplex stainless steel examined for comparison, shows a lower DBTT compared with the lean steel in the same crack propagating direction. The obtained results were also discussed through comparing with those of cast duplex stainless steels reported previously (Takahashi et al., Tetsu-to-Hagané, 100(2014), 1150). Full article