Welding of

Stainless Steels & Duplex

Roshan Rampure

voestalpine Bohler Application Technology Centre

voestalpine Böhler Welding
voestalpine Böhler Welding
www.voestalpine.com/welding
 What is Stainless Steel?

• Iron alloy bearing >11% Chromium

and <0.12% Carbon

• Build-up of a self-healing surface

layer (passive layer ~ 0,0025 µm)
which provides the corrosion
resistance

voestalpine Böhler Welding

 Microstructure
Stainless Steels

Ferritic Martensitic Duplex Austenitic

Stainless X6Cr17 X2CrNiMo Austenitic Fully

Steels ASTM430 N with austenitic
2205 ferrite

X5CrNi 18- X1NiCrMoCu

10 N
ASTM 304 254 SMO

voestalpine Böhler Welding

Welding of austenitic stainless steels
Austenitic steels are very well suited for welding, but unsuitable handling
can cause problems in the base material and in the weld metal:

Sensitisation, i.e. a reduction in the resistance to corrosion due to the

formation of chromium carbide

Hot cracking, i.e. separation of grain boundaries during solidification, or

in the highly heated HAZ when rigidly fixed

Embrittlement, i.e. the precipitation of intermetallic phases such as

sigma phase through exposure to high temperatures or annealing

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Sensitization
Leads to intergranular corrosion in the HAZ
Chromium Carbide forms and precipitation at grain boundary in HAZ → 427
to 871˚C

High carbon content : Time at the critical mid-range: a few second at

649˚do more damage than several minutes at 454˚C or 788˚C

Control : ELC- Extra low carbon

Stabilized grades: → titanium 321,
niobium (columbium) 347→
stronger affinity for carbon than Chromium

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Welding of austenitic stainless steels
Welding technology:

Only grades corresponding to the base material and ferrite contents of

5-15 FN should be used. The ferrite content ensures sufficient
resistance to hot cracking.

Preheating is generally not necessary; interpass temperature should not

exceed 150°C.

Heat treatment after welding should be avoided.

Chipping hammers and brushes made from stainless steel are

necessary

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High-alloyed stick electrodes
Main difference between un&low-alloyed and high-alloyed electrodes:

Un&low-alloyed electrodes
• Core wire is unalloyed
• Addition of alloying elements over electrode coating
(synthetic electrodes)

High-alloyed electrodes
• Core wire is alloyed
• Electrode coating for arc stabilisation

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High-alloyed stick electrodes

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Designation system
High-alloyed stick electrodes acc. AWS A5.4
Avesta 316L/SKR E316L-17

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Designation system
High-alloyed stick electrodes acc. AWS A5.4
Avesta 316L/SKR E316L-17

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Designation system
High-alloyed stick electrodes acc. AWS A5.4
Avesta 316L/SKR E316L-17

basic

rutilebasic

rutile

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High-alloyed stick electrodes for
common austenitic stainless steels
Avesta 308L/MVR Basic/ Avesta 316L/SKR Basic
FOX EAS 2 (LF) Avesta 316L/SKR
Avesta 308L/MVR/FOX EAS 2-A FOX EAS 4 M-TS
FOX EAS 2-TS FOX EAS 4 M-VD
308L/EAS 2 316L/EAS 4 M
Extra low carbon Extra low carbon
without Mo with Mo
CrNi 19/9 L CrNiMo 19/12/3 L

CrNi 18/8
austenitic
Avesta 347/MVNb Basic steels FOX SAS 4
Avesta 347/MVNb Avesta 318/SKNb

347 318L/SAS 4
Nb-stabilised without Mo Nb-stabilised with Mo
CrNi 19/9 Nb CrNiMo 19/12/3 Nb
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High-alloyed stick electrodes for
common austenitic stainless steels
Coated stick electrode
AWS A5.4
EN ISO 3581-A

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High-alloyed stick electrodes for
common austenitic stainless steels
Böhler Fox EAS 4 M-VD

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 308L

Welding
Recommendable Product
Process Classification
AWS/EN
SMAW E 308L-16 Bohler FOX EAS-2 16

SAW ER 308L Avesta 308L/MVR with Avesta 805

GTAW ER 308L Bohler N ER 308L

GMAW ER 308L Avesta 308L

E 308LT1-4/1
FCAW Bohler ESA 2 PW-FD
E 308LT1

voestalpine Böhler Welding

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 316L
Welding
Recommendable Product
Process Classification

AWS/EN
Bohler FOX N
SMAW E 316L-16
EAS 4M-16

Avesta 316L
SAW ER 316L
Flux Avesta 807

GTAW ER 316L Bohler N ER 316L

GMAW ER 316L Avesta 316L

FCAW E 316LT1-4/1 Bohler EAS 4M PW FD

voestalpine Böhler Welding

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 309L
Welding
Recommendable Product
Process Classification
AWS/EN
SMAW E 309L Bohler FOX N CN 23/12-16

Avesta 309L
SAW ER 309L
Flux Avesta 807

GTAW ER 309L Bohler N ER 309L

GMAW ER 309L Avesta 309L

FCAW E 309LT1-4/1 Bohler CN 23/12 PW-FD

voestalpine Böhler Welding

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 347
Welding
Recommendable Product
Process Classification
AWS/EN
SMAW E 347-16 Bohler FOX SAS 2-16

SAW ER 347 Avesta 347/MVNb with Avesta 805

GTAW ER 347-Si Avesta 347-Si/MVNb- Si

GMAW ER 347- SI Avesta 347-Si/MVNb-Si

FCAW E 347 Bohler SAS 2 PW-FD

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High-alloyed stick electrodes for
common austenitic stainless steels
APPLICATION
Agitator vessel

BASE MATERIAL
AISI 316Ti / 1.4571 (vessel) 8 mm
AISI 321Ti / 1.4541 (Limpet coil) 2 mm

USED FILLER MATERIALS

Avesta 316L/SKR
Böhler EAS 4 M-FD
GTAW Avesta 316L

CUSTOMER/COUNTRY
Chemie Linz
Austria

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High-alloyed stick electrodes for
common austenitic stainless steels
APPLICATION
Casting component for a
recycling plant

BASE MATERIAL
AISI 316L / 1.4404 12-20 mm

USED FILLER MATERIALS

Avesta 316L/SKR
Böhler EAS 4 M-FD

CUSTOMER/COUNTRY
M/S Voith
Germany

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High-alloyed stick electrodes for
common austenitic stainless steels
APPLICATION
Heat exchanger

BASE MATERIAL
AISI 308L / 1.4306

USED FILLER MATERIALS

Avesta 308L/MVR
GTAW Avesta 308L/MVR –Si
BÖHLER EAS 2-FD

CUSTOMER/COUNTRY
Apparatebau Kapfenberg
Austria

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High-alloyed stick electrodes for
common austenitic stainless steels
APPLICATION
Pressure vessel with heating coil

BASE MATERIAL
AISI 316Ti / 1.4571 (Shell and bottom plates)
AISI 321 / 1.4541 (Limpet coil)

USED FILLER MATERIALS

Avesta 318L/ SKNb
GTAW Avesta 318/SKNb
GTAW Avesta 316L/SKR
BÖHLER EAS 4 M-FD

CUSTOMER/COUNTRY
Apparatebau Kapfenberg
Austria

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High-alloyed stick electrodes for
common austenitic stainless steels
APPLICATION
Refinery-Tank

MEDIUM
Natural oil

BASE MATERIAL
AISI 316 / 1.4436

USED FILLER MATERIALS

Avesta 316L/SKR
GTAW Avesta 316L/SKR
SAW Avesta 316L/SKR Flux Avesta 805

CUSTOMER/COUNTRY
Austrian Energy
Hungary

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Special low ferrite products
Especially for low temperature application (down to -196°C) Böhler Welding
is able to offer products with limited ferrite content e.g.

Böhler FOX EAS 2 (LF) FN 3-8

Böhler EAS 2 PW-FD (LF) FN 3-6
Böhler FOX EAS 4 M (LF) FN 3-8
Böhler EAS 4 PW-FD (LF) FN 3-6
Standard FOX EAS 2/4 FN 4-10

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Effects of Delta-ferrite
The effect of Delta-ferrite in an austenitic weld metal (basically, also applies
to the steel material):
Reasons Consequences of too much or too little
Delta-ferrite content is unwanted
• Requirement for non-magnetic weld FN=0 • Magnetisability
metal
• Particular corrosion stress FN<0.5 • Selective corrosion
• Use at very low temperatures FN<0.5 • Loss of toughness
• Use at very high temperatures FN<0.5 • Phase precipitation
Low delta-ferrite proportion is
advantageous
• High resistance hot cracking, including
thick-walled components • Risk of hot cracking FN<3
• Usage temperatures between -100 and FN=3-15 • Loss of toughness FN>15
+400°C • Phase precipitation FN>15
• No unusual chemical stress • Selective corrosion FN>15
High delta-ferrite content is
required
• Resistance to stress corrosion cracking FN=30-75 • Reduced resistance to stress corrosion cracking FN<30
• Increase in strength FN=30-75 • Reduced toughness FN<75
• Compensation for the dilution when • Reduced strength FN<30
welding dissimilar joints FN=15-25 • Risk of hot cracking from dilution FN<15

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Determining the ferrite content of the weld metal
Measuring with
Feritscope MP30

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Determining the ferrite content of the weld metal

Austenite forming elements:

Ni, Co, C, Mn and N

Ferrite forming elements:

Cr, Al, Ti, Ta, Si, V, Mo

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Böhler Welding high-alloyed stick electrodes
Stick electrodes for cladding and dissimilar welding:

Product EN ISO 3581-A AWS A5.4

Böhler Fox A7 E 18 8 Mn B 2 2 E307-15 (mod.)

Böhler Fox CN 19-9 M E 20 10 3 R 3 2 E308Mo-17 (mod.)

Avesta 309L E 23 12 L R 3 2 E309L-17

Avesta P5 E 23 12 2 L R 3 2 E309LMo-17

Böhler Fox CN 24/13 Nb E 23 12 Nb B 2 2 E309Nb-15 (mod.)

Böhler Fox CN 29/9-A E 29 9 R 3 2 E312-17

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Welding dissimilar joints

Area 1
Grain growth
over 1150°C

Area 2
Hardening crack
under 400°C

Area 3
Sigma embrittlement
550 – 900 °C

Area 4
Hot cracks
over 1250°C

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 Welding dissimilar joints

Cr- Ni-
Base and filler material C Si Mn Cr Ni Mo Nb Pt
Eq. Eq.

1.0114 S235JO 0,15 0,50 1,0 - - - - 0,75 5,0 A

1.4580 X6CrNiMoNb17-12-2 0,05 0,50 1,2 17,0 11,9 2,2 0,5 20,2 14,0 B

Avesta 309L 0,02 1,0 1,2 23,0 12,0 - - 24,5 13,2 C

Cr-Equivalent = % Cr + % Mo + 1,5 x % Si + 0,5 x % Nb

Ni-Equivalent = % Ni + 30 x % C + 0,5 x % Mn

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Welding dissimilar joints
Cr- Ni-
Base and filler material Pt
Eq. Eq. Area 1
1.0114 S235JO 0,75 5,0 A
Grain growth
over 1150°C
1.4580 X6CrNiMoNb17-12-2 20,2 14,0 B
Area 2
Avesta 309L 24,5 13,2 C
Hardening crack
under 400°C

Area 3
Sigma embrittlement
550 – 900 °C

Area 4
Hot cracks
over 1250°C

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Welding dissimilar joints
Dilution:
Welding process Dilution in vol-%
Rutile stick electrode (SMAW) 15-25
Basic stick electrode (SMAW) 20-30
Solid wire (GMAW) 20-30
Flux-cored wire (FCAW) 15-25
SAW 20-60
GTAW up to 100 (100 for autogenous)

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Welding dissimilar joints

Area 1
Grain growth
over 1150°C

Area 2
Hardening crack
under 400°C

Area 3
Sigma embrittlement
550 – 900 °C

Area 4
Hot cracks
over 1250°C

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Welding dissimilar joints
Dissimilar joint

Service temperatures ≤350°C Service temperatures >350°C

without PWHT with PWHT

Low dilution High dilution High dilution

18 8 Mn 20 10 3 23 12 2 L 18 16 5 Mn N L NiCr20Mn3Nb NiCr22Mo9N
A7 CN 19 9 M Avesta P5 ASN 5 Nicro 182
Thermanit 625
No hot cracks No hot cracks No hot cracks
No martensite No martensite No martensite
Corrosion-resistant Corrosion-resistant
Heat-resistant
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Welding dissimilar joints
Examples:
Dissimilar joint type Weld metal acc. EN ISO
Avesta 309L
un&low-alloyed steel with
Avesta P5
austenitic stainless steel
A7
un&low-alloyed steel with CN 20/25
full-austenitic CrNiMoN stainless steel Thermanit Nicro 82
Avesta P5
alloyed Cr steel with
A7
austenitic steel
Thermanit Nicro 82
ferritic creep resistant steel with Thermanit Nicro 182
austenitic steel Thermanit Nicro 82
Thermanit Nicro 182
ferritic/austenitic steel with
Thermanit 625
nickel-based
NIBAS C24

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 DUPLEX STEELS - Microstructure

+ =

Austenitic Ferritic Duplex

Duplex steels combine the austenitic and

ferritic properties

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 DUPLEX STEELS - Microstructure
BASE MATERIAL WELD METAL
Cooling rate can vary
Controlled cooling
→ Ferrite 20-70%
→ Ferrite 50%

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 DUPLEX STEELS - Chemical composition

Chemical composition (typical values wt-%)

Grade ASTM EN C N Cr Ni Mo Mn
(max)
LDX S32101 1.4162 0.02 0.22 21.5 1.5 0.3 5
2101®
Filler LDX - (23 7 N L) 0.03 0.16 23.5 7 <0.5 0.8

2304 S32304 1.4362 0.02 0.10 23 5 <0.3 1.5

Filler 2304 - (23 7 N L) 0.02 0.12 24.5 8 <0.3 0.8

2205 S32205 1.4462 0.02 0.17 22 6 3.1 1.5

Filler 2205 E2209 22 9 3 N 0.02 0.16 23 9.5 3.2 0.8

L
2507 S32750 1.4410 0.02 0.27 25 7 4 1.5

Filler 2507 E2594 25 9 4 N 0.03 0.23 25.5 10 4 1.2

L

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 DUPLEX STEELS – Mechanical properties

EN, min. values ASTM, min. values

Grade ASTM EN Rp0,2 Rm A5 Rp0,2 Rm A5
[MPa] [MPa] [%] [MPa/ksi] [MPa/ksi [%]
]
LDX S32101 1.41 4501 6501 301 4502/65 6502/94 302
2101® 62

2304 S32304 1.43 400 630 25 400/58 600/87 25

62
2205 S32205 1.44 460 640 25 450/65 655/95 25
62
4307 304L 1.43 200 500 45 170/25 485/70 40
07
4404 316L 1.44 220 520 45 170/25 485/70 40
04
1. Values still not officially, but no deviations from ASTM are expected.
2. According to ASTM A240 for hot rolled plate. For cold rolled sheet, Rp0,2 min. 530 and Rm
min. 700 MPa.
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Stainless steel welding by FCAW process

 Principle of FCAW process

 Slag systems
 Parameter settings
 Economical Aspects

 Welding techniques
 Wire production & QA/QC
 FCAW wire Product range
 Principle of MCAW process
 MCAW wire Product range

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Concepts of flux cored wires

Profiles

For un- and alloyed For high alloyed

MC wires FCAW wires

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Slag viscosity of filling systems

Slag of „ AWS T-1“ Slag of „AWS T-0“

positional welding downhand
wires wires
100000

10000
Viscosity [mPa.s]

EAS4PW-FD EAS4M-FD
E316LT1-4(1) E316LT0-4(1)
1000

100

10
1550 1500 1450 1400 1350 1300 1250
Temperature [°C]

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Welding with stainless steel flux cored wire

 Makes the welding process easier

 Increases productivity
 Decreases the total welding costs
 Reduces the risk of weld defects
 Designed to meet highest quality requirements

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Penetration compared to solid wire

 Flux cored wire have a wider arc

 Operate therefore with a very safe penetration
 The risk of lack of fusion is minimized

Flux cored Solid wire

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Parameter box for SS flux cored wires

38
36 Formation of spatters Solid wire Ø 1,2 mm
34
32 FCW Ø 0,9 mm
30
28
26
24 Solid wire Ø 1,0 mm

22 FCW Ø 1,2 mm
20 Worse bead appearance
18
100 150 200 250 300
Amperage (A)

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Comparison of weld length

Throat thickness 3 mm, welding time 1 min

Flux cored wire

Ø 1,2 mm
800 mm

Solid wire
Ø 1,0 mm
670 mm

Covered
electrode
280 mm Ø 3,2 mm

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Comparison of deposition rates

Flux cored wire ø 0,9 mm

Theoretical deposition rate Flux cored wire ø 1,2 mm

Flux cored wire ø 1,6 mm
Solid wire ø 1,0 mm
100% d.c. (kg/h)
Solid wire ø 1,2 mm
Coated electrode

Welding position: 1G PA

Amperage (A)

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Comparison of weld length

Flux-cored wire Solid wire Flux cored wire

Covered electrode
E316LT1-4(1) ER316L-(Si) A = 180
E316L-17 
EAS 4 PW-FD EAS 4 M-IG (Si)
FOX EAS 4 M-A  V= 27,5
Ø 1,2 mm Ø 1,0 mm
Ø 3,2 mm WS = 8,3 m/min
M 21 M 12 

[cm]  L = 220 mm/min

[cm]
30 30
Solid wire pulsed
[cm]
25 30 25  A = 100
 V = 20
20 25 20
 WS = 5,5 m/min
20
15 15  L = 145 mm/min
15
10 10 Covered electrode
10
 A = 90
5 5
5  V = 26
0 0 0  L = 75 mm/min

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Comparison between FCAW/GMAW

Welding position: vertical up

FCAW Ø 1,2 mm Solid wire Ø 1,0 mm FCAW Ø 1,2 mm Solid wire Ø 1,0 mm
8,3 m/min, 27,5 V 6,4 m/min, 22 V 8,3 m/min, 27,5 V 5,5 m/min, 20 V

180 A 115 A 180 A 100 A

Spray arc Pulsed arc Spray arc Pulsed arc

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Some practical advise

Ceramic backing Slight weaving is recommended for all

welding positions

Root

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Some practical advise

Butt weld Fillet weld

Slight weaving is
recommended
for all welding
positions

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Recommended welding parameters

Root
Vertical up
PF/3G, 3F 130-200A 22-30V 6-11cm/min

Overhead
PE/4G, 4F 130-200A 22-30V 6-11cm/min

Horizontal PC/2
flat position PA/1G 130-250A 22-32V 6-13cm/min

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Wire stick out (mm)

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Minimum wall thicknesses for welding
with SS-flux cored wires
Min. wall thickness (mm)

Type of weld Welding position Ø 0,9 mm Ø 1,2 mm

2F (horizontal) 1,5 3,0
Fillet weld 3F (vertical down) 1,5 3,0
3F (vertical up) 5,0 5,0
1G (flat) 1,5 3,0
Butt weld 3G (vertical down) 2,0 3,0
3G (vertical up) 5,0 5,0

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Welding with SS FCAW – Conclusion

In spite of higher costs compared to SMAW & GMAW flux cored wire
offers when considering all the production related costs noticeable

 Gain of time
 Increase in productivity
 Post weld savings

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Welding with SS FCAW – Conclusion

Reasons named from end users for their changing towards FCAW

 High deposition rates resp.  No problems with porosity and

productivity lack of fusion
 Easy handling  Low and easy post weld work
 Smooth bead appearance  Low shielding gas costs

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Product Application

Project Details
Customer  Bronswerk Heat Transfer BV
Fabrication shop Nijkerk – the Netherlands
Component
 High pressure gas coolers
description

Base materials  Duplex & AISI 321 stainless steels

 Full package of solid wires,

fluxcored wires and wire-flux
Filler metal type combinations for stainless steel
Quantity  BÖHLER SAS2-FD FCAW
 BÖHLER CN 22/9N-FD FCAW

Engineering
 Vetco Aibel AS, Norway
company
Success story: active support to WPQS,
Owner  Petrobras, Brasil
excellent consumables, in time delivery
 FPSO P53 floating production unit
Project name
– compression modules

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Product Application

© Bronswerk Heat Transfer, Netherlands

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Product Application

Base metal:
 AISI 316Ti/1.4571

Filler metal:
 EAS4M-FD (E316LT0-4(1)

Customer/Country:
 M/S Andritz AG/A

Worm Shaft

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Pipe welded with CN22/9PW-FD
Ø1,2 mm

pipe Ø 508 mm
49 mm
UNS 31803 UNS 31803
1.4462 1.4462

2 1 GTAW 3

 Shielding gas: Ar + 20%CO2

 IPT: 150°C (300°F)
 Preheating: ~100°C (~210°F)
 Welding position: 5G

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Product Application

Base metal:
 UNS S 31803/1.4462 15-25mm

Filler metal:
 CN22/9PW-FD (E2209T1-4(1)
 CN22/9N-FD (E2209T0-4(1)

Customer/Country:
 M/S Frank Mohn/Norway

Water injection system for a fire

fighting equipment

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Product program of SS FCW –
Standard Type
For downhand/horizontal position
Designation EN AWS Diameter mm
Böhler EAS 2-FD T 19 9 L R M (C) 3 E 308 LT 0-4 (1) 0,9 1,2 1,6
Böhler SAS 2-FD T 19 9 Nb R M (C) 3 E 347 T 0-4 (1) - 1,2 1,6
Böhler EAS 4 M-FD T 19 12 3 L R M (C) 3 E 316 LT 0-4 (1) 0,9 1,2 1,6
Böhler SAS 4-FD T 19 12 3 Nb R M (C) 3 E 318 T 0-4 (1) - 1,2 1,6
Böhler E 317L-FD TZ 19 13 4 L R M (C) 3 E 317 LT 0-4 (1) - 1,2 -
Böhler CN 22/9 N-FD T 22 9 3 N L R M (C) 3 E 2209 T 0-4 (1) - 1,2 -
Böhler CN 23/12-FD T 23 12 L R M (C) 3 E 309 L T 0-4 (1) 0,9 1,2 1,6
Böhler CN 23/12 Mo-FD T 23 12 2 L R M (C) 3 E 309 L Mo T 0-4 (1) 0,9 1,2 1,6
Böhler A7-FD T 18 8 Mn R M (C) 3 E 307 T 0-G - 1,2 1,6
Böhler E 308 H-FD TZ 19 9 H R M (C) 3 E 308 HT 0-4 (1) 1,2 -
Böhler NIBAS 70/20-FD Ni 6082 ENiCr-3TO-4 - 1,2 1,6
Böhler NIBAS 70/20 Mn-FD Ni 6082 ENiCr-3TO-4 (mod.) 1,2 -

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62 02-04-2016 Welding of stainless steel
Product program of SS FCW – “PW” Type

For positional welding

Designation EN AWS Diameter mm
Böhler EAS 2 PW-FD T 19 9 L P M (C) 1 E308LT1-4 (1) 1,2 1,6
Böhler EAS 2 PW-FD (LF) T 19 9 L P M (C) 1 E308LT1-4 (1) 1,2 1,6
Böhler SAS 2 PW-FD T 19 9 Nb P M (C) 1 E347T1-4 (1) 1,2 –
Böhler SAS 2 PW-FD (LF) T 19 9 Nb P M (C) 1 E347T1-4 (1) 1,2 -
Böhler EAS 4 PW-FD T 19 12 3 L P M (C) 1 E316LT1-4 (1) 1,2 1,6
Böhler EAS 4 PW-FD (LF) T 19 12 3 L P M (C) 1 E316LT1-4 (1) 1,2 1,6
Böhler SAS 4 PW-FD T 19 12 3 Nb P M (C) 1 E318T1-4 (1) 1,2 –
Böhler CN 22/9 PW-FD T 22 9 3 N L P M (C) 1 E2209T1-4 (1) 1,2
–
Böhler CN 24/9 LDX PW-FD T Z 24 9 N L P M (C) 1 E2209 T1-G 1,2
–
Böhler CN 25/9 PW-FD TZ 25 9 4 N L P M21 2 - 1,2
Böhler CN 23/12 PW-FD T 23 12 L P M (C) 1 E309LT1-4 (1) 1,2 1,6
Böhler CN 23/12 Mo PW-FD T 23 12 2 L P M (C) 1 E309LMoT1-4 (1) 1,2 –
Böhler E 317L PW-FD T Z 19 13 4 L P M(C) 1 E317LT1-4 (1) 1,2 –
Böhler A 7 PW-FD (LMn) T 18 8 Mn P M (C) 2 E307T1-G 1,2 –
Böhler E 308 H PW-FD T Z 19 9 H P M (C) 1 E308HT1-4 (1) 1,2 –
Böhler NIBAS 625 PW-FD Ni 6625 ENiCrMo-3T1-4 1,2 –

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63 02-04-2016 Welding of stainless steel
 Stainless Steel – Passive layer
Is stainless steel always stainless?
• Above 11% Chromium ⇒ Thin invisible surface of chromium oxide =
passive layer

• Passive layer ~ 25 Å (0,0025 µm)

• Local break-down of passive layer or disturbance of the self healing

process gives ⇒

⇒ CORROSION

Answer: NO!
voestalpine Böhler Welding
 Stainless Steel – Surface defects

voestalpine Böhler Welding

 Cleaning methods

To help protect y our priv acy , PowerPoint has block ed automatic download of this picture.

MECHANICAL CHEMICAL
• Grinding • Pickling
• Blasting • Electropolishing
• Brushing

What to choose?
• Damage
• Contamination
• Quality

voestalpine Böhler Welding 02-04-2016 Welding of stainless steel

66
 Mechanical methods

• Grinding
Removes weld slag, deep scratches, heat oxide and the chromium depleted
zone.
The surface quality depends on the roughness achieved through the choice
of the grit used. The finer the better! At least 180 grit.

• Blasting
Removes weld slag and heat oxide but not the chromium depleted zone.
Surface quality depends on: Blasting material, particle size, pressure.
Gives a uniform appearance but may introduce compressive stresses.

• Brushing
Removes heat oxide and slag. Stainless steel brush / Scotch Brite

Use the right tool (stainless)!

Finish with a passivation!
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67 02-04-2016 Welding of stainless steel
 Stainless Steel – Chromium depleted
zone
Heat treatment or welding disturbs the chromium content of the metal.

1. Heat oxide 50-60 wt % Cr

2. Chromiumdepleted zone <10 wt % Cr 1

3. Base metal >18 wt % Cr

2-8 µm

2
3

Layers 1 and 2
MUST BE REMOVED!

voestalpine Böhler Welding

 Chemical method: Pickling
Removes surface defects through a controlled corrosion that selectively
removes the least corrosion resistant areas, (the chromium depleted
zone).

• Removes heat oxide, Chromium

depleted zone and Iron contaminations.
• The acid combination of Hydrofluoric/
Nitric-acid penetrates the heat oxide and
dissolves the weak points through
corrosion.
• Finally promotes the reformation of the
passive layer.

PICKLING DOES NOT DISSOLVE OIL

AND GREASE.

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 Stainless Steel – Chromium depleted zone

voestalpine Böhler Welding

 Cleaning methods – Comparison

Pickling produces superior results compared

to other surface treatment methods

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 Pickling - Applications

voestalpine Böhler Welding

 Complete range of products for pickling and
cleaning stainless steel

• Paste / Gel
• Solution
• Bath
• Cleaning
• Neutralising
• Passivating
• Accessories

All pickling products conform to

international standards:
ASTM A-380, BSI CP-3012, KWU RE-AVS 8, RCCM F-
5000-6000

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73 02-04-2016 Welding of stainless steel
Thank you
Roshan Rampure
Manager - Application Technology
M. 8879779889
roshan.rampure@voestalpine.com

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74 02-04-2016 Welding of stainless steel