Material for Winning Ideas

Outokumpu Duplex Stainless Steels

Contents

Find out how the right material choices can save enormous costs and accelerate your
business in the long run. See inspiring case studies from around the world.

Business & trends

Winning the future 4

Duplex revolution 8
Case studies 9
When to go with Outokumpu Duplex 13

What makes Outokumpu Duplex such a strong material? How to weld and form duplex?
See in-depth technical information and enjoy our tips for best results.

Composition and benefits

Chemical composition 14
Mechanical properties 15
Physical properties 17
Corrosion resistance in various environments 18
Advice for fabrication 20
Product assortment 23

Activating your ideas

• Pre-fabrication according
to your needs
• Suggestions for material
What’s your winning idea? replacements
• Computer simulations
and calculations to ease
design work
Case highlights Outokumpu is fast becoming the
• On-site testing options
undisputed number one in stainless. What
and administrative help
makes us special is total customer focus –
all the way, from R&D to delivery. You have
the idea. We offer you world-class stainless
steel, technical know-how and support.
Trend-setting Benefits in Reinforcing Building
duplex tank farm mass production the present the future
sustainable material with significantly longer service
Outokumpu Duplex – life in corrosive environments when the proper
See how Relisa S.A. managed Duplex is the material used for Brisbane’s six-lane Gateway The Marina Bay Pedestrian
to reduce construction material the water heaters of Kingspan Bridge is reinforced with Bridge in Singapore is stunning more strength, less material material selection is made.
by up to 50%. Hot Water Systems Ltd. making Outokumpu Duplex on its most in architectural design, taking
See page 9. them both easier to handle and critical parts, ensuring a design advantage of the possibilities of
Outokumpu Duplex allows you to realise your most
cheaper to produce. life of 300 years. Outokumpu Duplex. demanding projects: thanks to its superior strength, See interesting case studies and read all about material
See page 10. See page 11. See page 12. you can sometimes manage with even 50% less properties as well as fabrication hints for Outokumpu
material, which means considerable cost savings. Duplex. Together, let’s turn your winning ideas into a
Outokumpu Duplex is a highly environmentally successful project.

2 3

Winning the future – useful answers
for future challenges
The use of stainless steel is increasing
fast due to the material's durability,
corrosion resistance and aesthetics. If
the right grades are selected, stainless
steel lasts even hundred years. In the
long run, stainless steel is also often the
least expensive material, thanks to low
maintenance costs.
4 5
Cloud gate in Millenium Park in Chicago, USA.
Made out of Outokumpu stainless steel.
Trend 1:
Global economics and striving for
stability
When it comes to economics, all parties seek stability.
In large-scale construction projects, right material choices
can multiply savings. Outokumpu Duplex stainless steel
has excellent strength, which can often mean the same
structure can be built with less material: for example,
tank walls can be considerably thinner. Compared to
other grades with comparable corrosion resistance, also
the nickel content of Outokumpu Duplex is very low.
This means more price stability, less surprises and easier
budgeting.
Trend 2:
Rising environmental awareness
In previous years, temporary structures built for world
fairs and events for example, could be demolished
after the event. Such a waste of labour and disrespect
for the environment is simply not accepted anymore. Trend 3:
Environmental responsibility and legislation have an Ensuring safety, pleasing to the eye
increasing impact on companies’ operations in every In addition to corrosion-resistance and durability,
industry. Proof of responsibility is demanded for the constructors face increasing demands for a human
whole life cycle of the product. Those who can offer approach: it is not enough anymore that the tanks,
action instead of words in social and environmental vessels and buildings “do their job”. They need to be
responsibility will be the winners of tomorrow. safe for both the builders and the employees and be
aesthetically pleasing. Outokumpu Duplex makes it
Outokumpu Duplex is an environmentally sound possible to fabricate strong, fascinating structures while
choice from many different viewpoints: reducing the total weight.
• It uses recycled steel as main raw material and it is
100% recyclable.
• Very low level of metal ion is released in to the
environment.
• Less need for hazardous coatings.
• Thanks to high strength, it is possible to reduce the
weight of the structures and therefore lower energy
consumption in transport, construction and usage.
 Great combination of both high
Positioning of Duplex grades strength and adequate corrosion
Proof stress resistance.

More strength, less material

rp0.2 [MPa]
750

Duplex
2507

Put simply, the benefit of Outokumpu Duplex lies in weight reduction. You gain more strength 500
LDX 2101® 2205
with less material. Below, you can see an example of what happens when standard austenitic 2304 Austenitic
steel is substituted with Outokumpu Duplex.
254SmO®
250
4301 4404 904L
High strength

Corrosion Resistance
(Pitting and crevice corrosion)
Low nickel content Wide range
for price stability of applications

Duplex saving potential

Potential savings with Duplex compared to austenitic grades compared to austenitic grades.
Savings in
costs
40%
Thinner material and Good corrosion
therefore possible lower cost resistance
30%

20%

10%

Calculate your weight savings Less material means benefits

on the Internet in every step of the project 0%
10% 20% 30% 40%
Steel professional tool at www.outokumpu.com With Outokumpu Duplex, you can purchase,
-10%
offers interactive tools for materials selection, rough transport, weld and assemble less material. Weight saving
estimation on wall thickness calculations etc. Visit When thinking of the cost of labour, savings can
our website and learn more! be tremendous.

Tank cost example 1: Tank cost example 2:

Austenitic steel versus Carbon steel versus Outokumpu Duplex
Pipes: reductions in wall thickness and weight Case: Duplex as a substitute Outokumpu Duplex When the same tank is manufactured from
between grades 1.4307 and LDX 2101® for austenitic in storage tank When the same tank is manufactured from Outokumpu Duplex instead of carbon steel, the
Outokumpu Duplex instead of conventional biggest savings come in the maintenance phase:
Grade 1.4307 Grade LDX 2101®
WT = 6.0 mm WT = 3.0 mm 4301 LDX 2101®
austenitic steel, the biggest savings are made in carbon steel needs to be properly protected in the
Weight = 90 tons Weight = 45 tons 61.5 ton 43.5 ton [m] manufacturing phase, thanks to less amount of manufacturing phase and again after certain periods
Design data material needed. The tank walls can be significantly of usage. All this means extra labour, which can be
Pressure = 16 bar 18
Temperature = 50°C
thinner, yet safe in use. avoided using Outokumpu Duplex.
Od = 610 mm 16

required 14
Pipe length = 1000 m 4301 LDX 2101® Carbon steel LDX 2101®
Required thickness Duplex
Min WT acc to en 13480-3: 12 Plate thickness 5-12 mm 5-7 mm Total initial cost* 125 kEUR 175 kEUR
Weld factor z = 0.7 Required thickness austenitic Surface protection cost 100 Euro/m2 No surface
10 Material cost* 144 kEUR 108 kEUR
1.4307 = 5.8 mm x 1000 m2 protection required!
ldx 2101® = 2.9 mm Welding cost** 55 kEUR 35 kEUR
8 Elapsed time between 15 years
Labour cost** 89 kEUR 49 kEUR maintenance events
6 (Welding and tank assembly)
Life cycle duration 30 years 30 years
Total manufacturing cost 144 kEUR 84 kEUR
4 Operating cost 64 kEUR 0 kEUR
Total initial cost 288 kEUR 192 kEUR Total LCC 189 kEUR 175 kEUR
2

Potential cost saving ~33% Potential cost saving ~8%

[mm] 12 11 10 9 8 7 6 5 4 3 2 1 Tank size: width 18.5 m, height 18 m. Tank size: width 17.5 m, height 17.5 m.
*Based on Outokumpu price list per 19 Oct 2009. *Assume equal initial cost level: lower material cost for carbon
**Based on actual costs provided by a Swedish Contractor 2008. steel equals the measures for protecting the plate surfaces.

6 7
 Stainless racing motorcycle Trend-setting duplex tank farm –
up to 50% weight savings
Highland Group, Sweden
Tank farm Biofuel plant expansion
Oostwouder, the Netherlands Agroetanol, Sweden

Celtic Gateway footbridge Storage tank farm

United Kingdom Gold Bridge, China

Road tankers World’s largest digester

Indox, Spain Jinhall Mill, China

Bilbao Bridge Natural gas flowline

Spain Sosta, Oman

Storage tanks Desalination plant

Emypro, Spain SIDEM

Trend-setting tank farm Bioethanol fermentation tanks

Relisa, Spain Cital, Italy
Clean coal technology
Enel, Italy

Courtesy of Emypro

Duplex revolution – Relisa S.A. of Spain stores liquid foods and chemicals in a new tank farm at the Port
of Barcelona: Spanish storage-tank fabricator Emypro S.A. has built the entire farm,
examples of ideas in action consisting of 22 units, using Outokumpu Duplex LDX 2101® plate. When engineering
the first phase of the farm, Emypro could see the advantages of the duplex grade
Avesta Järnverk AB of Sweden, today part of Outokumpu, produced its first commercial and partnered with Outokumpu to convince Relisa.
duplex alloy in 1930. Avesta 453S, contained 26% Cr, 5% Ni and 1,5% Mo, and was
in the beginning used as acid proof material for roughly the same purposes as type 316. As Emypro was putting the finishing touches to the Technical highlights
tanks, Relisa ordered 9 more using the same grade. Outokumpu Duplex has good weldability, and the
However, its higher strength was immediately noticed and then tested with certain The grade selection has offered the fabricator and tank material supports most known welding techniques.
components that were subjected to wear, such as spindles, pumps and shafts. When owner major competitive advantages thanks to the See welding tips on page 20.
industries developed further, the possibilities of duplex truly opened up. qualities of LDX 2101®. The grade’s strength is almost
twice that of standard austenitic grades. This has al- Interesting facts
To date, Outokumpu Duplex has proven its worth around the world. We are proud lowed Emypro to achieve major reductions in material Emypro’s and Outokumpu’s pioneering development
of the masterpieces realised by our customers. quantities compared to the austenitic alternatives continues a history of milestones achieved together,
1.4301/1.4307 (304/304L). The total weight saving including the world’s largest duplex storage tank (22
is more than 20%, in some sections of tanks, even m in diameter and 25 m in height) fabricated using
up to 50%. Outokumpu Duplex grade 2304.

8 9

Courtesy of Kingspan Hot Water Systems Ltd.
Multiplying benefits in mass production
When your household needs
a water heater, it’s a question of
reliability, right?
Manufacturers often want to give their products
warranties for longer periods even up to 30 years, so
it is understandable that they seek undisputed quality
in their materials. Kingspan Hot Water Systems Ltd,
a long-term customer of Outokumpu, is a market
leader in high performance hot water storage solutions
throughout the United Kingdom and Ireland.
Kingspan wanted to find a more cost efficient
alternative to mild carbon steel and copper, which
have been the industry standards for 50 years. The
answer was Outokumpu Duplex: it gives pioneering
manufacturers such as Kingspan a clear competitive
edge. The strength of the material allows at least a
30% wall thickness reduction, making the boiler both
10
easier to handle and cheaper to produce. The benefits
multiply in mass production. Warm water in thousands
of households is ensured for years to come.
Technical highlights
Outokumpu Duplex offers excellent resistance to stress
corrosion cracking. Read more on page 18.
Interesting facts
Water quality differs around Europe, and Outokumpu
can offer grades to match Kingspan’s needs. LDX 2101
or 2304 are perfect for European water quality. For
more demanding environments, 2205 is recommended.
Built to last for 300 years
Brisbane’s six-lane Gateway Bridge will be
duplicated as part of the Gateway Upgrade
Project. This is the largest road and bridge
project in Queensland’s history, delivered
by Queensland Motorways with design and
construction by the Leighton Abigroup Joint
Venture. Looking to the future, the new
bridge will have a design life of 300 years.
To ensure such a long lifespan, the bridge will have
stainless steel reinforcement bars (rebar) in the most
critical bridge structures; the pilecaps located in the
splash zone of the Brisbane river. Leighton Abigroup
Joint Venture approached Outokumpu as they were
searching for a stainless rebar supplier. We are one of
the leading producers of stainless steel long products
in the world.
Based on their thorough expertise and due to stainless
steel prices at the time, the bridge engineers set out
to find a low nickel content stainless steel, such as
®
Outokumpu LDX 2101 . The next task was, with the
help of Outokumpu, to convince the customer that
®
LDX 2101 had the required characteristics for the
environment. Based on concrete mix properties and
®
the corrosion resistance of LDX 2101 , the result
was a concrete cover of 75 mm, more than enough to
match the demanding durability requirements. The
result was a cost efficient and durable solution for the
customer.
®
Courtesy of Leighton Abigroup Joint Venture ABN.
11
Technical highlights
Outokumpu Duplex has excellent resistance to atmos-
pheric corrosion, which is caused by harsh conditions
that can be found, for example, in industrial sites,
near the sea and in big cities. Read more on page 19.
Interesting facts
In the United States, corrosion is estimated to cost
close to US$ 300 billion per year, eating away 3-4 %
of GDP. As much as 40 % of this could be prevented.
Corrosion of the carbon steel reinforcement is the
main reason why structures show premature failure
today. The annual direct cost of corrosion to bridges
alone in the USA, is estimated to be US$ 5.9 billion
to US$ 9.7 billion1. If indirect costs were to be
included, i.e. loss of economic revenue, the report
forecasts that this could be as much as ten times
higher. In Western Europe, the figures are not much
better, an estimation in a Nordic report stated that
€ 5 billion is spent yearly for repair of corroding
concrete infrastructures2.
References:
1
B. Elsener, L. Bertolini, R.B Polder, P. Pedeferri, Corrosion Of
Steel In Concrete Prevention, Diagnosis, Repair, John Wiley and
Sons Ltd., Weinheim, 2004.
2
D.B. McDonald, D.W. Pfeifer, Y.P. Virmani, Corrosion-resistant
reinforcing bars Findings of a 5-year FHWA Study. Int. Conf.
Corrosion and Rehabilitation of Reinforced Concrete Structures.
FHW, Orlando 7–11 December 1998.

Building the Future
The Marina Bay Pedestrian Bridge in
Singapore, stunning in architectural and
engineering design, will both link key sites
of development and be an attraction in
itself, symbolising Singapore’s aspirations
as a biomedical hub. Nearly 300 metres
long, the bridge is unique in many ways.
It is composed of two spiraling tubular
stainless steel members, resembling
the structure of DNA. According to
the designers, the DNA-like structure
symbolises “life and continuity, renewal
and growth”.
The stainless double-helix structure takes bridge
architecture and engineering to entirely new
directions. The inner spiral of the double helix is
used to support fritted-glass and stainless-steel mesh
canopies to provide shading to pedestrians. The bridge
engineers selected Outokumpu Duplex 2205 (EN
1.4462) as the appropriate stainless grade for the
12
Courtesy of Urban Redevelopment Authority, Singapore.
Project checklist – when to go with Duplex?
double-helix and support structures. In the hot and The more boxes you can check below, the more likely it is that
humid, maritime climate of Singapore, this highly Outokumpu Duplex might be your material of choice.
corrosion resistant grade ensures low maintenance
costs and good appearance during a service life of at Demands for material No need for
least 100 years. The high strength of duplex 2205 also
resistance to chemicals sharp bend radius
enables the development of a cost-efficient design.
resistance to uniform corrosion demanding forming techniques
This duplex contract follows a series of demanding
bridge projects worldwide for which Outokumpu has resistance to pitting and crevice corrosion
supplied duplex stainless products in several different resistance to stress corrosion cracking and
grades. corrosion fatigue
high mechanical strength
Technical highlights good abrasion and erosion resistance
With the right tools and parameters for equipment, good fatigue resistance
duplex grades can be shaped in to exciting and high energy absorption
functional forms. Read more about forming of low thermal expansion
Outokumpu Duplex on page 22.
good weldability
Interesting facts within temperature range -40°C to +250°C
The stainless steel surfaces will provide spectacular pressure vessel, beams
night-time illumination by reflecting a series of lights
programmed to enhance the design.
13
The recipe for success: Mechanical properties:
ingredients according to your needs superior strength
What makes Outokumpu Duplex such a strong material? The secret lies in connecting the The mechanical and physical properties are beneficial generally approved for use between -40°C to +250°C.
best of both microstructures: mixing austenite and ferrite. The result is two crystallographic characteristics of Outokumpu Duplex. The Work is in progress to get a European material
phases, each with a composition sufficient to make it corrosion resistant. The phases in mechanical strength is superior compared to austenitic ® ®
approval for LDX 2101 . (LDX 2101 . is partly
duplex grades are a body centered cubic phase (ferrite), and a face centered cubic phase or ferritic stainless steels, and the physical properties listed in EN 10088.)
(austenite). Favorable properties of both phases can be utilised in one alloy. offer new possibilities. The dual phase matrix with
very fine lamellae and the addition of nitrogen give ASME: In ASME II-D 2007 (Metric) edition grades
Outokumpu Duplex grades very high mechanical S31803 (1.4462), S32304 (1.4362) and S32750
The chemical composition of duplex grades gives Nitrogen adds strength and corrosion resistance strength at room temperature. This is a clear advantage (1.4410) are listed for general use between -30°C to
good corrosion resistance and desired mechanical Nitrogen is a very important addition as it gives a for structural applications, such as pressure vessels and ®
+325°C. Data for LDX 2101 can be found in ASME
and physical properties. Outokumpu can supply you substantial increase in strength and pitting corrosion beam constructions. code case 2418.
with stainless grades especially designed to meet your resistance. At the same time it strongly stabilises the
Pressure vessel approvals
needs. austenite phase. Furthermore, nitrogen improves
welding properties. European standards: All duplex grades, except for
Alloying elements and their purpose
Molybdenum improves corrosion resistance ®
LDX 2101 , are listed in EN 10028-7 and are
Chromium makes it stainless
Molybdenum improves corrosion resistance in most
At least about 11% chromium has to be added to a
environments, particularly in chloride-containing
steel to form the passive layer that makes it stainless.
environments.
These contents improve the corrosion and oxidation
resistance. Outokumpu Duplex steels have a high Table 2. Mechanical properties for flat products at room temperature.
chromium level, between 21.5 and 25%. Duplex microstructure.
Longitudinal cross section of
Minimum values, Outokumpu
Nickel adds ductility hot rolled plate, light phase
austenite, darker (blue) according to EN 10088 typical values
Nickel obtains the desired phase balance and provides phase ferrite.
ductility. Duplex steels contain a relatively small P H C P(15mm) H (4mm) C (1mm)
amount of nickel, between 1.5 and 7%. If corrosion LDX 2101 ®

initiates, a higher Ni level is beneficial for repassivation. Proof strength Rp0.2 MPa *450 *480 *530 480 570 600
Tensile strength Rm MPa *650 *680 *700 700 770 800
Elongation A5 % *30 *30 *30 38 38 35

Table 1. Chemical composition Hardness HB 220 230 230

2304
Outokumpu International Chemical composition, % by weight Proof strength R p0.2 MPa 400 400 450 450 520 545
steel name steel No Typical values
Tensile strength Rm MPa 630 650 650 670 685 745
EN ASTM C N Cr Ni Mo Others Elongation A5 % 25 20 20 40 35 35
LDX 2101 ®
1.4162 S32101 0.03 0.22 21.5 1.5 0.3 5Mn Hardness HB 210 220 225
2205
2304 1.4362 S32304 0.02 0.10 23 4.8 0.3 –
Duplex

Proof strength R p0.2 MPa 460 460 500 510 620 635
2205 1.4462 S32205* 0.02 0.17 22 5.7 3.1 – Tensile strength Rm MPa 640 700 700 750 820 835

2507 1.4410 S32750 0.02 0.27 25 7.0 4.0 – Elongation A5 % 25 25 20 35 35 35

Hardness HB 250 250 250
4307 1.4307 304L 0.02 – 18.1 8.1 – –
2507
Austenitic

4404 1.4404 316L 0.02 – 17.2 10.1 2.1 – Proof strength R p0.2 MPa 530 530 550 550 590 665
Tensile strength Rm MPa 730 750 750 820 900 895
904L 1.4539 N08904 0.01 – 20 25 4.3 1.5Cu
Elongation A5 % 20 20 20 35 30 33
254 SMO® 1.4547 S31254 0.01 0.20 20 18 6.1 Cu Hardness HB 250 265 255

*Also available as S31803 Table 2 summarises mechanical properties for flat rolled products, P = hot rolled plate and bar
(data according to EN 10088). The allowed design values may H = hot rolled strip
vary between product forms. The appropriate values are given in C = cold rolled coil and strip, cold drawn bar
the relevant specifications/design standards. Grade 4501 is only * Mechanical properties according to ASTM A240
produced as hot rolled plate by Outokumpu. and to internal standard, AM 611.

14 15
Temperature and embrittlement
Duplex steels are more prone to precipitation
applications like blast walls at oil rigs and car body
components. Physical properties:
of phases than austenitic stainless steels, causing
embrittlement and reduced corrosion resistance. Good fatigue strength in base material new opportunities
The formation of intermetallic phases such as sigma The high tensile strength of Outokumpu Duplex also
phase occurs in the temperature range 600-950°C implies high fatigue strength in the base material. The Easy to weld to carbon steel Table 4. Physical properties of duplex
and reformation of ferrite occurs in the range 350- fatigue strength of the duplex steels follows the proof stainless steels, according to EN 10088.
Outokumpu Duplex grades have a lower thermal
525°C (475°C embrittlement). Exposures at these strength of the material. Our research personnel can
expansion ratio (approximately 13 × 10-6/°C) Physical property 20°C 200°C
temperatures should therefore be avoided. In normal provide you with more detailed information, if needed.
and higher thermal conductivity than austenitic
welding and heat treatment the risk of embrittlement Density [g/cm3] 7.8 7.8
steels. This means that there are less problems with
is low. However, certain risks exist, for example at heat What comes to welds, the benefit of the high fatigue
temperature expansions caused by connecting Modulus of Elasticity [GPa] 200 186
treatment of thick sections, especially if the cooling strength of the parent or base material is limited.
Outokumpu Duplex with carbon steels. Duplex is a Poisson´s ratio [Dimensionless] 0.3 0.3
rate is low. The fatigue strength is reduced by unfavorable weld
good alternative for lining mild steel vessels that are
geometry, residual stresses, distortions and weld Linear expansion from
running with large cyclic temperature variations. - 13.5
Due to the risk of embrittlement, the duplex steels defects. 20°C to 200°C (x10-6/°C)
should not be used in applications above 250°C Magnetic properties Thermal conductivity [W/m°C] 15 17
for a longer period (See figure 1). The maximum
Duplex stainless steels are more magnetic than aus- Thermal capacity [J/kg°C] 500 560
temperature and strength value depends on grade and Table 3. Impact toughness. Minimum values
according to EN 10028-7 transverse direction. tenitic grades due to higher ferrite content. Magnets
the design rules being used. Electric resistivity [μΩ/m] 0.8 0.9
cannot, and must not be used to lift Duplex sheets.
LDX 2101 * ®
2304 2205 2507
High energy absorption
The combination of high strength and ductility 20°C 60 60 60 60
gives Outokumpu Duplex a very good ability to
-40°C 27 40 40 40
absorb energy. This makes it a perfect material for
*according to internal specification

Fig. 1. Curves for reduction of impact

toughness to 50% compared to solution
annealed condition.

Palm oil tank farm,

photo courtesy of Loders Croklaan

16 17

Corrosion resistance
in a wide range of environments
The corrosion resistance of Outokumpu Duplex is generally very good.
The resistance is especially good in environments like halide-containing
media, oxidising acids, and hot alkaline solutions. This means that for
example, heat exchangers, water heaters, offshore equipment, storage
tanks, evaporators and flue gas cleaning equipment greatly benefit from
the material properties of duplex steels greatly.
Uniform corrosion
The uniform corrosion resistance is generally consid-
ered good if the corrosion rate is less than 0.1 mm/
year Due to their high chromium content, duplexes
offer excellent corrosion resistance in many media,
®
especially in alkalic solutions. LDX 2101 has, in
most cases, a better resistance than 4307 and in some
cases as good as 4404. Grade 2304 is in most cases
equivalent to 4404, while the other more highly-
alloyed duplex steels show even better resistance.
Pitting and crevice corrosion: heat
exchangers, water heaters, offshore
equipment, storage tanks etc.
The resistance to pitting and crevice corrosion is often
illustrated by the pitting resistance equivalent (PRE)
for the material. The most commonly used formula
for PRE is:
Corrosion fatigue
and intergranular corrosion
The combination of high mechanical strength and
very good resistance to corrosion gives duplex steels
superior corrosion fatigue strength. Due to the
duplex microstructure and low carbon content, the
duplex grades have a good resistance to intergranular
(intercrystalline) corrosion.
Erosion corrosion
Stainless steel in general offers good resistance to
erosion corrosion. Duplex grades are especially good
due to their combination of high surface hardness and
good corrosion resistance.
Galvanic corrosion
Galvanic corrosion may occur when two dissimilar
metals are electrically connected (as by welding) in
an electrolyte. Stainless steel is in most cases nobler
than other metallic materials. The most noble metal is
protected while the less noble metal is more severely
attacked. Stainless steel in contact with carbon steel
Outokumpu steel name
4307
LDX 2101 ®
4404
2304
904L
2205
rebars in concrete does not cause galvanic corrosion
of the carbon steel due to the high pH in concrete.
Galvanic corrosion does not occur between different
grades of stainless steels as long as both grades are
passive.
Atmospheric corrosion
Atmospheric corrosion is not a unique form of cor-
rosion, but a collective term to denote the corrosion
of surfaces in the atmosphere. When stainless steel is
exposed to an aggressive atmosphere it is primarily
stained, this is sometimes referred to as tea staining,
but it can also be attacked by localised corrosion with
time, particularly at high chloride levels as in marine
atmospheres. Today there is a duplex grade available
for all types of atmospheres.
The Outokumpu Corrosion Handbook
For more information on corrosion and corrosion
resistance in different media is plural of medium,
please see the Outokumpu Corrosion Handbook. You
can obtain your own copy from your local sales office.
Table 5. shows PRE values for different grades. LDX 2101®
PRE has a higher pitting and crevice corrosion resistance than
4307. Grade 2304 is on the same level as the conventional
18
molybdenum alloyed steel 4404, while 2205 is on a level with
26 904L. The duplex grade 2507 has a similar resistance as 254
SMO®.
24
26
34
35

PRE = %Cr + 3,3x%Mo + 16x%N 254 SMO ®

43
2507 43
The PRE value can be used for a comparison of
different stainless steels. A more in-depth way to rank Fig. 2. Typical critical
pitting corrosion tempera-
steels is measuring the Critical Pitting corrosion Tem- CPT, °C
tures (CPT) in 1M NaCl
perature (CPT). Outokumpu uses an electrochemical 100 measured according to
method, ASTM G150, involving our own developed ASTM G150 using the
90 Avesta Cell. Test surfaces
Avesta Cell, see Fig. 2., and we can provide you with wet ground to 320 mesh.
necessary data when requested. 80 CPT varies with product
form and surface finish.
70
Sulphide induced stress corrosion
60
cracking: boreholes and gas wells etc.
50
In the presence of hydrogen sulphide and chlorides
the risk of stress corrosion cracking, at low tempera- 40
tures, increases. Such environments can exist, for 30
example, in boreholes for oil and gas wells. Duplex
20
grades, especially 2205 and 2507, have demonstrated
good resistance. 10

4307 ldx 2101® 4404 2304 4436 2205 904l 2507 254 SMO®

span Cpt min. - Cpt max.

18 19
 Table 6. Characteristic heat treatment temperatures, °C, for duplex stainless steels.

Fabrication – strong opportunities LDX 2101® 2304 2205 2507

Hot forming 1100 - 900 1100 - 900 1150 - 950 1200 - 1025

Quench annealing 1020 - 1080 950 - 1050 1020 - 1100 1040 - 1120
Outokumpu Duplex offers excellent opportunities to constructing
challenging and durable structures. However, due to the high Stress relief annealing 1020 - 1080 950 - 1050 1020 - 1100 1040 - 1120
strength of the material, the working process is in some points
different than with austenitic or ferritic steels. Outokumpu is here
to help you with every possible technical detail. We can provide
you with necessary training, computer simulations and further Table 7. Welding consumables.

instructions.
Product form ISO Designation Typical composition, % Ferrite

C Cr Ni Mo N FN
Welding Welding of LDX 2101®
Outokumpu Duplex can be welded with most of the
Covered electrode 23 7 NL* 0.04 23.5 7.0 0.3 0.14 45
methods used for austenitic stainless steel:
• Shielded metal arc welding (SMAW) Solid wire (MIG, TIG, SAW) 23 7 NL* 0.02 23.0 7.5 0.3 0.14 40
• Gas tungsten arc welding TIG (GTAW) Flux cored wire 23 7 NL* 0.03 24.0 9.0 0.3 0.14 35
• Gas metal arc welding MIG (GMAW)
Welding of 2304
• Flux-cored arc welding (FCAW)
• Plasma arc welding (PAW) Covered electrodes 23 7 NL* 0.02 24.5 9.0 0.2 0.12 30

• Submerged arc welding (SAW) Solid wire 23 7 NL* 0.02 23.5 7.5 0.3 0.14 40
• Others: Laser, resistance and high frequency (HF)
Flux cored wire 23 7 NL* 0.03 24.5 9.0 0.2 0.14 35
welding
Welding of 2205
In general, the biggest issue with welding Outokumpu
Duplex is to maintain the phase balance in the heat Covered electrodes (ISO 3581 22 9 3 NL 0.02 23.0 9.5 3.0 0.15 30
affected zone without precipitations. The chemical
Solid wire (ISO14343) 22 9 3 NL 0.02 23.0 8.5 3.1 0.17 45
composition balances the microstructure, and it is
important to have the right welding consumable and Flux cored wire (ISO 17633) 22 9 3 NL 0.03 23.0 9.0 3.2 0.13 45
the right procedure.
Welding of 2507
Different welding procedure: basic rules
Covered electrode (ISO 3581) 25 9 4 NL 0.03 25.5 10.0 3.6 0.23 30
1. weld without preheating
2. allow the material to cool between passes, Solid wire (ISO 14343) 25 9 4 NL 0.02 25.0 9.5 4.0 0.25 45
preferably to below 150°C. For 2507 ≤ 100°C
* Filler for 2205 can be used for most applications
3. duplex filler material is needed and recommended
with the exception for LDX 2101® which may be
welded without filler material in some cases
Welding to other steels including carbon steels Post Fabrication treatment
4. the arc energy recommended by Outokumpu Outokumpu Duplex can be easily welded to other In order to restore the stainless steel surface and
should be kept
steels including carbon steels. The filler type can be achieve good corrosion resistance, it is often necessary
5. the heat input should be adapted to the steel considered, e.g. for stress relieving, it should be car- of duplex. When duplex steels are welded to carbon to perform a post fabrication treatment. Outokumpu
grade and adjusted to the thickness of the welded ried out in accordance with the temperatures stated steels an alternative is to use a filler of 23Cr13Ni2Mo Duplex supports all different methods available, such
material in Table 6, but with the minimum temperature type. The risk of galvanic corrosion can be avoided by as brushing, blasting, grinding and pickling. Which
6. edge preparation angle should be about 10°C increased with 30-50°C, to secure full dissolution shielding the joints from moistening. In most cases method to apply depends on what type of imperfec-
greater and the land should be somewhat smaller of intermetallic phase in the weld metal. duplex filler offers more strength and better corrosion tions shall be removed, but also on needs to corrosion
compared to welding standard austenitics 8. GTAW and PAW methods: addition of resistance. When joining duplex to super austenitic resistance, hygiene and aesthetics.
7. if welded with filler, post-weld annealing is nitrogen (1-2%) in the shielding/purging gas steels, please contact Outokumpu for assistance. Filler
not necessary. In cases where heat treatment is is recommended metals for joining similar duplex steels, see table 7.

20 21
Forming Sharp Tools
Outokumpu Duplex is suitable for all forming
techniques. The higher strength and the lower
Use cutting tools with a positive geometry. The duplex
grades are very adaptive to work hardening. A dull
Product assortment and services
elongation compared to austenitic stainless steel geometry will generate a hard surface and decrease the
will however impose some differences in forming tool life.
behaviour: generally higher force is needed. On Outokumpu Duplex is available in various
the other hand, since duplex design often implies Avoid “build up edge” shapes and sizes to suit your needs.
downgauging, the force level can be similar to Stainless steels have a tendency to stick to the tool.
austenitics. If the forming technique is not already Problems occur when the cutting speed is too low. • HRP(P), Quarto Plate
decided, we recommend to choose the most The biggest difference between carbon steel and • CPP(H), coil and plate
appropriate one for duplex stainless steels. stainless steels when machining is that you face into • CR (C), coil and sheet
problems if you are running too slow. The result will
Machining • Billet, wire rod, bar and rebar
be bad surface finish and short tool life. The problem
• Welded tube, pipe, fittings and threaded fittings
The high strength will of course effect the is solved by increasing the cutting speed.
machinability, but not as much as expected. • Structural sections, DUPROFTM
• Fasteners and fittings
Some information, good to have in mind when LDX 2101 ®
machining duplex, is given below: ®
The lean duplex grade LDX 2101 have superior
Our Added value services ease your project and offer
machinability compared to other duplex grades.
Stable setup Even if you compare with the low alloyed standard ways to save expenses at critical points
Due to the higher strength the cutting forces will be ®
austenitic grades LDX 2101 , is easier to machine.
• Edge preparation
higher. That will increase the risk of vibrations. The
trick is to have a stable setup. Use the shortest possible For more information on various topics, • Cut to shape
tool extension good and rigid clamping. please contact us. • Bending
• Surface finishing: 2B, 2E, 1D
• Polishing
Table 8. • Construction kits
• Prefabrication
Things to consider • Modified chemical analysis
• Slitted coils
Cutting, Maximum thickness for shearing and punching is 80-85% of that • Package solutions
shearing of austenitic steel
• Welding advice
• Technical support/Project administration
Roll bending More bending force will be needed compared to other stainless
steels. Through the downgauging, this effect will however be
smaller than anticipated. The springback due to the higher strength ‘2B’ surface finish – perfect for surface finish in duplex stainless steels, which most
is large when roll bending.
food & health sectors often fulfills the industry surface requirements
Surface finish characteristics are not merely a question without any further surface treatment – saving both
Break Avoid sharp bending radius. Minimum ratio between inner radius Cane Creek’s World Bicycle of appearance. The quality affects to the corrosion time and money.
bending to sheet thickness should not be less than 2. Relief Reserve Headset made resistance as well as cleansability of dirt and bacteria,
out of LDX 2101®.
which is paramount in the food industry and health See our product programme at
sector. Outokumpu can additionally offer a ‘2B’ www.outokumpu.com/prodprog
Deep If drawing is dominant, formability is comparable to austenitic
drawing stainless steel. If stretching is dominant, formability is closer to
ferritic steels.

Table 9.
Roll forming The high strength of the sheet has to be considered in the design
of the rolls. If this is made properly there are no problems in roll Product Type of process route Surface finish
forming Duplex.
1D Hot rolled, heat treated, pickled. Rough and dull. Standard for the most steel types to ensure good
corrosion resistance; also common finish for further
Tooling use Strong, durable tools (hardness, HRC larger than 500, Ra-value processing.
preferably lower than 0.2 micrometers).
2E Cold rolled, heat treated, mechanically descaled Rough and dull. Light cold rolling can be carried out
followed by pickling. for thin hot rolled strips
Lubrication Because of the high strength of Outokumpu Duplex and extreme
pressure additives are useful in complex forming operations. 2B Cold rolled, heat treated, pickled, skin passed or by Smooth surface with low lustre
levelling (as in Avesta Works).

22 23
This document does not constitute a recommendation or a contractual commitment on the part of Outokumpu.

1434EN-GB:1. Lönnberg, Finland, February 2010.

Product selection is the responsibility of the specifiers, designers and builders, who are solely responsible for
rendering the finished unit suitable for the use for which it is intended. It is the customer’s sole responsibility
to ensure that the product is suitable for the use for which it is intended. Outokumpu shall not provide any
guarantee in this respect.

Copyright© Outokumpu Group. All rights reserved.

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