Welding News 1 2012

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Super duplex miscellanea

New colleagues
Product news
Fairs and seminars

Welding News 1 2012

Flexibility on firm
foundations
Even if some months have now passed since I took up
my new post, I am still rather new at the job. However,
I have already noted one thing: Bhler Welding Group
Nordic has the flexibility of a small company combined
with the stability that comes from having the backing of
a large group. We have excellent foundations!
Bhler Welding Group Nordic is the groups sales
company for the Nordic and Baltic countries. Here, we
are responsible for sales of all six of the groups brands:
Avesta Welding, Bhler Welding, T-PUT, UTP, Fontargen and Soudokay. Our head office is in Avesta and
we have local warehouses and offices in Norway and
Finland. Avesta is also where Avesta Weldings covered
electrodes are made and where global responsibility for
the groups only 100% stainless steel brand rests.
Having worked almost 10 years with stainless steel,
both in sales and as operations manager, it is thrilling
to take the step into welding. Not least as regards the
stainless products from Avesta Welding, I am looking
forward to actively contributing to developing the
Nordic market. As illustrated by the adjacent article, we
are also further establishing Avestas market position
by strengthening our export organisation. In this connection, I would also like to spotlight Avesta Finishing
Chemicals and its Malm factory where our chemicals
for the post-weld treatment and cleaning of stainless
steels are produced.
There is a lot happening in Avesta at the moment.
Rebuilding and customisation of our facilities (e.g. electrode production, welding lab, warehouse and goods
handling) are currently in progress. All of this is aimed
at providing even better service for our customers.
Initiatives to further improve our service levels and
become even more flexible and solid are, as ever, continuing. Good can always be better!
Finally, I would like to wish you all a wonderful
summer!

Niklas Nilsson
VD, Bhler Welding Group Nordic AB

Editorial

Eva Sderberg, Tel: +46 (0)226-857 05
eva.soderberg@avestawelding.com
Translations
Transtext 2000

New MD for Bhler

Welding Group Nordic
On the 1st of April 2012,
Niklas Nilsson became the
new MD of Bhler Welding
Group Nordic AB.
Niklas Nilsson is 34 and has a
Master of Science in Engineering
(process metallurgy) from Lule
University of Technology. His ten
years of experience in the stainless
steel industry include a period at Degerfors Stainless.
There, he started as the sales manager and later became
a unit manager. Most recently, he was the MD at Outokumpu Prefab in Avesta.
Niklas Nilsson is originally from Vrmland but, since
2008, has lived in Avesta with his wife and three children. Skiing and other forms of fitness sport are amongst
his favourite pastimes

Export sales engineer

Alexander Thulin has been
appointed as a technical
export sales engineer for
Avesta Welding.
Although his roots are in Helsingborg, Alexander Thulin comes
most recently from a position as a
research engineer at SwereaMEFOS, a metallurgical research institute in Lule.
Alexander read international materials technology
at Lule University of Technology and is an international
welding engineer (IWE). His background also includes a
period as a research engineer at Outokumpus research
unit in Avesta. There, he worked on alloy development
and the welding of stainless steel.
In his new position, he is looking forward to working
closely with customers on a range of technical and commercial issues.
Along with his colleagues in Avesta and the groups
sales companies, he will be contributing to further developing Avesta Weldings high levels of service and technical
support.

Cover picture
Super duplex stainless steels are becoming ever more common in all
industries where requirements in respect of corrosion resistance are
high. Stainless steel piping for corrosive media is a typical application
for this type of steel.

Welding News 1 2012

Flux cored wire

for welding
super duplex
Avesta Welding and Bhler
Welding Group are introducing two new flux cored
wires for super duplex stainless steels.
Super duplex stainless steels are
becoming increasingly common in
industries such as oil and gas, offshore, pulp and paper, foodstuffs,
water treatment and desalination.
They are also used in: oil and
chemical tankers; chemicals production; and, flue gas cleaning systems
in the power industry.
Right process in the right place
One of the trends in welding is the
reduction of labour costs by using
more economic welding processes
that have higher deposition rates.
TIG welding gives the highest quality welds, but the method is relatively slow. For this reason, it is
most often used for the root pass
and the subsequent hot pass(es).
The rest of the joint is then welded
using a more efficient method.
Covered electrodes are increasingly
being replaced by MIG welding
using solid wires or flux cored wires.
When welding super duplex
steels, flux cored wires give less
spatter and reduce the risk of there
being pores in the weld metal. In
any welding position, it is difficult
to avoid porosity when using solid
wires. Porosity when using flux cored wires is very limited and occurs
only in the overhead position (PE).
Additionally, flux cored wires give
good penetration and thus reduce
the risk of welding defects such as
lack of fusion. Shielding gas costs
are also usually lower. However,
one disadvantage of all slag forming
methods is that, compared with
TIG and MIG, the resultant impact
strength is lower.

Welding with flux cored wire.

Because of the high heat input,

submerged arc welding is not normally recommended for welding
super duplex steels. Slow cooling
increases the risk of precipitation
of intermetallic phases (sigma, chi).
This has a negative effect on corrosion resistance and impact strength.
The precipitation risk increases with
high heat input and time spent at
sensitive temperatures. Multipass
welding further increases the
risk. For this reason, it is recommended that the heat input in the
hot pass(es) should be 70 80%
of that in the root pass. Generally
speaking, the heat input must not
exceed 1.5 kJ/mm and the interpass
temperature should be kept below
100C. A heat input lower than 1.0
kJ/mm is appropriate for fill passes.
New products
Avesta Welding and Bhler Welding
Group are introducing two new flux
cored wires: Avesta 2507/P100-PW
and Avesta 2507/P100-PWNOR.

To ensure that the required mechanical properties and corrosion

resistance are attained, both are
over-alloyed with nickel (to give the
optimum ferrite-austenite balance).
Even in chloride-containing environments, the weld metal has very
good resistance to pitting corrosion
and stress corrosion. In accordance
with ASTM G48-A, the critical
pitting temperature is above 40C.
These wires have been developed
for welding in all positions. They
give a stable arc and full control of
the weld pool and slag.
The standard wire, Avesta 2507/
P100-PW, gives excellent slag
removal and the weld metal has
an impact strength of 32 J at 40C.
This wire is particularly suitable
for overlay welding and all types
of weld joints where the impact
strength requirements are moderate.
Avesta 2507/P100-PWNOR has been
developed to satisfy severe requirements such as those in NORSOK

Welding News 1 2012

M-601 and similar standards. The

weld metal can achieve an impact
strength of 45 J at 50C. However,
slag removal is then slightly poorer.
Best weldability is obtained using
Ar + 15 25% CO2 as the shielding
gas at 15 20 l/min. Increasing the
voltage by 2 V also allows the use
of 100% CO2. The current should be
130 220 A, the voltage 23 31 V
and the wire feed 8 12 m/min.
Many applications
Avesta 2507/P100-PW and Avesta
2507/P100-PWNOR have already been
introduced in France, Germany, the
UK, Denmark and Spain. In these
countries, they are used for welding
duplex and super duplex steels.
Avesta 2507/P100-PW has proven
to be particularly suitable for repair
welding in foundries and for the
manufacture of water pumps, shafts
and bearings used in the marine
industry. A further application is the
overlay welding of separators for
sludge, paper pulp, milk, etc.
With good results, Avesta 2507/
P100-PWNOR has been used for
welding pipelines for the offshore

A typical application for super duplex stainless steels.

industry and pressure vessels that

are subject to severe impact strength
requirements.
The demand for super duplex
steels is rising in line with the toughening of industrys requirements.

Already offering several types of

covered electrodes, solid wires and
flux cored wires, Avesta Weldings
wide programme of filler metals for
super duplex steels is now being
further expanded.

Flying start for the new flux cored wire

Avesta Weldings new flux
cored wire, FCW 2507/P100PWNOR, broke quickly into the
market and has just now been
used for an oil separator.
The customer is an international
manufacturer of various types of
industrial equipment and uses flux
cored wires as a productive alternative to TIG welding.
Using Avesta FCW 2507/P100PWNOR enabled productivity to
be increased while also satisfying
NORSOK requirements.
The customer benefit of this product is a clear result of the dedicated
research and development carried
out by Bhler Welding Group.

Oil separator welded using Avesta FCW 2507/P100NOR

Welding News 1 2012

Welding procedure for thick-walled pipes

in super duplex 2507
Super duplex 2507 is most often used in applications
where corrosion resistance requirements are extra
high. A correctly executed welding procedure is critical
in satisfying these requirements.

Piping systems in offshore plants

and desalination facilities are typical applications for super duplex
steels. Here, relatively heavy gauge
pipes (OD 300 500 mm, wall
thickness 10 20 mm) are common. A correctly executed welding
procedure is critical in satisfying
the severe requirements presented
by these types of applications. For
example, in NORSOK M-601, a
pickled weld subjected to pitting
(ASTM G48-A) at at least 40C must
not show any indication of attack
greater than 4 g/m2.
Studies have shown that secondary (sigma) phase content has a great
impact on corrosion resistance. Weld
oxides also have a clear impact on
corrosion resistance, but to a slightly
lesser extent than does secondary
phase content.
For a super duplex 2507 pipe
with OD 300 mm and t 12 mm, a
typical procedure is for the root
to be TIG welded (2 passes) using
Avesta 2507/P100 ( 2.40 mm). Filler and cap beads are then welded
using covered electrodes, Avesta
2507/P100-4D ( 3.25 mm). Welding
parameters are set out in the procedure detailed below.

Edge preparation
Correctly executed edges are important in achieving a suitable root
side and just the right amount of
parent metal fusion. Too high a degree of dilution can give a high ferrite content in the root. This reduces
corrosion resistance.
Figure 1a shows suitable edge preparation for single-sided welding of
super duplex with a wall thickness
of 4 16 mm. A correctly selected
and even root gap is important for
an even and good quality root side.
A good way of securing pipes is to
use distance pieces welded into the
joints (see figure 1b).
Welding
The root bead (bead 1) must be
welded relatively thickly, i.e. using
a high heat input of around 1.3 1.5
kJ/mm.

6070; D = 2.04.0 mm; C= 0.51.5 mm

Figure 1a: Suggested joint geometry

Figure 1b: Securing pipes

Figure 2a: Incorrectly welded root

Figure 2b: Correctly welded root

Subsequent beads must be welded

using a heat input that is 70 80% of
that for bead 1 (i.e. 0.9 1.2 kJ/mm).
This is to minimise the sigma phase
that will be formed in the root bead
due to heating by subsequent beads
(see figure 2).
Filler beads can then be welded
using a normal/low heat input (i.e.
1.0 1.3 kJ/mm).
Shielding gases and backing gases
have a great impact on results,
corrosion resistance in particular.
By adding nitrogen to the weld, an
Ar + 1.8% N2 shielding gas gives optimum corrosion resistance. Because
it can lead to increased wear of the
tungsten electrode, the nitrogen
content should not exceed 2%.
Suitable backing gases are pure
Ar (99.995%) or Formier gas (90%
N2 + 10% H2). The latter gives an
exceptionally clean root side.

Welding News 1 2012

Corrosion
To investigate the impact of weld
oxide on the corrosion resistance of
super duplex welds, there have been
studies of joints in 2507.
CPT testing in accordance with
ASTM G48E showed that the
difference between a blue oxide
and a yellow oxide (see figure 3) is
small. Both passed the test at 40C,
but showed small attacks in the root
at 42.5C. In comparison, a correctly welded and then pickled joint
achieved better corrosion resistance.
In this study, it tolerated 47.5C
without attack.

Figure 3a: Yellow weld oxide.

Figure 3b: Blue weld oxide.

Mechanical testing
Results from mechanical testing of a welded joint
KC RT KV 40C Bend test,
Bend test,
Rm
(J)
(J)
reinforcement out root out
(N/mm2)
800, break in weld

44

41

Microstructure
In both root and reinforcement, the
microstructure is completely normal. The ferrite content in the root
(TIG) varies between 41 and 54%.
For the reinforcement (MMA), the
figures are 35 and 40%. The structure
is generally free from secondary
precipitation. However, traces of
sigma phase can be detected in the
root bead.

180, OK

180, OK

Conclusions
Thick-walled super duplex pipes
are used in many demanding applications. Well planned and executed
welding is essential for satisfying
the severe requirements in, for
example, NORSOK.
Correct joint geometry, tacking
and welding parameters are very
important. The root bead must
be welded relatively thickly, i.e.
using a relatively high heat input.
Subsequent beads must be welded
using a lower heat input (around
70 80% of that used for the first
bead). This is to reduce the harmful
sigma phase that otherwise forms
when too much heat goes into preceding beads.
Cleanliness before, during and
after welding is also extremely
important. Contamination from,
for example, carbon steel, striking
scars, lack of fusion and spatter can
easily damage the passive layer and
serve as an initiation point for corrosion. Grinding scars can also be
harmful and coarse grinding (e.g.
using 80 paper) must be followed
by finer grinding and polishing (e.g.
using 320 paper).
Weld oxides also have an impact
on corrosion resistance. A yellow
to blue oxide gives good resistance.
Stronger oxidation is not acceptable.
Post-weld pickling gives by far the
best results.

Welding News 1 2012

Avesta Welding develops new electrode

for nuclear power
Development work in close collaboration with customers
has always been one of Avesta Weldings fundamental
strategies. Thus, when a customer recently approached us
with an enquiry about developing a welding electrode for
use in the nuclear power industry, we immediately gave a
positive reply.
In this case, the customer wanted
a 316L electrode of the basic type,
but with an analysis that varied
from the standard. It also had to
satisfy a comprehensive requirements specification. After a few
months of development work, the
electrode was ready to be tested
against the specification.
As shown by the tables below, the
newly developed electrode met all
the customers requirements.

When its a question of odd

chemical compositions and special
requirements, we always try to
rapidly come up with customised
solutions that meet the customers
wishes, explains Hans strm,
development manager. Our flexible
production process also enable us
to manufacture comparatively small
orders; in some cases, as small as
150 kg. Naturally enough, this is yet
another great advantage.
Chemical composition
Chemical
analysis

Si

Mn

Cr

Ni

Mo

Requirement

0.045
0.055

0.4
0.7

1.2
1.8

18.0
19.0

11.0
12.0

1.92.2

<0.020

<0.025

Result

0.049

0.41

1.33

18.57

11.66

2.06

0.019

0.015

Mechanical properties at room temperature

Cu

Co

Nb

<20ppm <0.5

<0.2

<0.10

0.0005

0.035

0.033

0.05

Ferrite content

Requirement

Result

As per WRC 92

Result

Yield strength, Rp0,2 (MPa)

>350 N/mm2

493 N/mm2

37 FN

4.0 FN

Tensile strength, Rm (MPa)

>550 N/mm

641 N/mm

Elongation, A5 (%)

>35 %

38 %

Mechanical properties at 550C

Corrosion testing

Requirement

Result

Requirement

Result

Yield strength, Rp0,2 (MPa)

>116 N/mm2

325 N/mm2

As per ASTM A262 E

OK

Tensile strength, Rm (MPa)

>380 N/mm2

464 N/mm2

Elongation, A5 (%)

>20 %

26 %

Impact strength, Charpy U (daJ/cm2)

Requirement

Result

Untreated weld metal

7.0

7.6

Aged weld metal/weld,

750C/100 hours

3.0

4.0

Welding News 1 2012

Customer seminar in St. Petersburg

Welding in the petrochemical industry
A seminar on welding in
the petrochemical industry
was recently held in Saint
Petersburg.
The OMZ Group (also known as
the Uralmash-Izhora Group) is a
Russian conglomerate that manufactures heavy industrial equipment
for, amongst others, the petrochemical and mining industries.
Towards the end of March, the
Bhler Welding Group visited one
of the OMZ Groups largest manufacturing units, Izhorskiye Zavody
in St. Petersburg.
Bhler Welding Group Russia had
taken the initiative for the seminar
and, aided by representatives from
the groups brands (Soudokay, T-Put,
Bhler Welding and Avesta Welding),
presented its offerings for the welding and overlay welding of heavy
gauge CrMoV carbon steel. In total,
10 representatives from 5 countries
had assembled to present Bhler
Welding Groups product programme for the petrochemical industry.
Also presented were Avesta
Finishing Chemicals products
and the great benefits these have
for steels stainless properties,
maintenance, general cleaning and

Overlay welding using Avesta Weldings covered electrodes.

cleaning after transport to customers (e.g. sea transport can leave

products prone to corrosion attacks).
As experts in the welding of
stainless steels, Avesta Welding can,

along with the groups other brands,

present a complete proposition to
the industry and, in this way, make
full use of the wide programme that
the group, as a whole, has to offer.

Avesta vacuum packs

Avesta Welding now offers
vacuum-packed electrodes
in several formats capsules
and single-layer trays
Vacuum-packed electrodes and
capsules are an efficient and flexible
option in damp outdoor conditions
where it is difficult to maintain a
controlled storage environment for
covered electrodes.
Where climate control is proble-

matic during work, the vacuum

maintains the electrodes in factory
condition.
The altogether simplified storage
and handling makes things far
easier for welders.
Small packs facilitate flexible
use of electrodes and minimum
wastage.
The moisture protection does
away with the redrying (baking)
that is otherwise necessary after
long periods of storage.

Vacuum-packed electrodes.

There will be a more detailed

presentation of Avestas vacuumpacked electrodes in a future issue
of Welding News.

Welding News 1 2012

Full speed ahead at new welding fair!

Throughout the three days, Bhler Welding Group Nordics stand was full of happy faces and activity.

Expectations were high when Swedens first dedicated

welding fair, Elmia Welding & Joining Technology, opened
its doors in Jnkping at the beginning of May.
Bhler Welding Groups stand
received a steady stream of visitors.
These took the opportunity to network and discuss welding, not only
with our expert staff, but also with
other visitors.
As always, there was great interest
in the welding demonstrations.
Many enthralled spectators flocked
round Stefan Holmberg. Amongst
other things, Stefan demonstrated
Avesta Weldings 2D, 3D and 4D
electrodes. Spectators were, of
course, allowed to try their own
hands at welding.
Arranged in collaboration with the
Swedish Welding Commission, the
fair was well attended and appreciated by exhibitors and visitors alike.
There was never any doubt that
we would take part. As there had
never previously been a dedicated
welding fair in Sweden, you could
say it was overdue, comments
Johnny Runvik, sales manager in
Sweden. The industry needs its
own market place and the visitors
who came here were really genuinely interested in welding.

The fair also offered a rich

programme of seminars. Johan
Ingemansson, technical manager,
took part in this with a presentation
on the theme trends and developments in welding. Hkan Frangeur
of Avesta Finishing Chemicals
spoke on how to keep stainless steel
100% stainless.

With almost 6,200 visitors and 73

exhibitors, the new welding fairs
success was evident.
The high expectations were easily
exceeded and Elmia Welding &
Joining Technology will surely be
a regular high point for Swedens
welding industry.

Many visitors took the opportunity to have a go at welding stainless steel.

Welding News 1 2012

10

Jointing Days 2012

Every year, the Swedish Welding Commission assembles
industry and welding representatives for presentations
on, and discussions of, developments, innovations and
other current issues. Interesting study visits are often
part of the programme. Jointing Days 2012 got under
way in Gothenburg, 18 19 April. There was a study
visit to Cryo AB in Gothenburg.
Martin Larn of Bhler Welding Group and Mikael
Johansson of Outokumpu Stainless R&D gave a joint
presentation: How to weld the new duplex stainless
steel, Outokumpu LDX 2404. Amongst other things,
this included the background to the development of
LDX 2404, the steels properties, its high strength in
comparison with austenitic stainless steels and how the
steels corrosion resistance compares with that of other
stainless steels.
Besides a review of developments in filler metals and
the welding of LDX 2404, the presentations conclusion
also included points to be borne in mind when welding.
The message was simple: Welding LDX 2404 is not
difficult just a little different from welding ordinary
stainless steels.
Welding News 4-2011 features a report of the welding
trials carried out by Avesta Welding and Outokumpu.
Study visit to Cryo AB, Gothenburg stainless steel storage tanks
are one of the companys products.

Fresh off the printing press

How to weld fully austenitic stainless steels

Pickling handbook in over twenty languages

This entirely new

brochure includes
information on nearly
everything anyone
needs to know about
welding high-alloy
fully austenitic steels.
Applications, properties, pre-welding
preparations, suitable
welding methods and
filler metals, possible
pitfalls and how to
avoid them, post-weld
cleaning and much
else are just some of
the topics covered.
Swedish and
English editions of the brochure
can be downloaded from www.avestawelding.com.
Printed copies can be ordered from eva.soderberg@
avestawelding.com.

When it comes to how

to keep steel 100%
stainless and how to
avoid corrosion problems, Avestas pickling
handbook has been
a trailblazer in informing and training the
stainless steel industry.
The need for this
sort of information has
proven to be global
and the first edition
of the manual has, so
far, been translated
into over 20 languages.
Almost 100,000 copies
have been printed.
An updated, second edition is already available in
English, Italian and Spanish. A German version has now
also just left the printing press. The book can be ordered
via www.avestafinishing.com.