STUDY OF MECHANICAL AND CORROSION PROPERTIES OF DUPLEX STAINLESS STEEL WELDS BY TIG AND ATIG WELDING PROCESS A PROJECT

REPORT Submitted by ARUN KUMAR.S DHARMESH.C.M DINESH KUMAR.M (42009114008) (42009114018) (42009114021)

in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING

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MECHANICAL ENGINEERING

TAGORE ENGINEERING COLLEGE, CHENNAI-48 ANNA UNIVERSITY: CHENNAI 600025 APRIL 2012
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ANNA UNIVERSITY: CHENNAI 600025 BONAFIDE CERTIFICATE

Certified that this project Study of Mechanical and Corrosion Properties of Duplex Stainless Steel Welds by TIG and ATIG Welding Process is the bonafide work done by ARUN KUMAR.S(42009114008), DHARMESH.C.M (42009114018), DINESH KUMAR.M (42009114021) who carried out the project work under my supervision.

Signature
[Link] [Link]., Ph.D Professor and Head, Department of Mechanical Engineering, Tagore Engineering College, Rathinamangalam, Vandalur, Chennai-48.

Signature
[Link] Associate Professor, Department of Mechanical Engineering, Tagore Engineering College, Rathinamangalam, Vandalur, Chennai-48.

Submitted for viva-voice examination of Anna University, Chennai held at Tagore Engineering College, Chennai on.

INTERNAL EXAMINER
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EXTERNAL EXAMINER

ACKNOWLEDGEMENT
We take this opportunity to extend our sincere and hearty thanks to our Chairperson [Link] M.A., [Link]., for providing as an opportunity and facilities to propose our course in this institution. We express our gratitude to the Principal [Link] Pandian, B.E., M.S, Ph.D., F.I.E., M.I.S.T.E for his constant encouragement and guidance. We express our special thanks to [Link], [Link], Ph.D Professor and Head, Department of Mechanical Engineering for his valuable guidance to complete our project. We take great pleasure in thanking our Internal guide, [Link], M.E., (Ph.D), Associate Professor, Department of Mechanical Engineering for his motivation and remarkable guidance in success of our project. We extend our since thanks to all teaching and non-teaching staff members of Mechanical Department, Tagore Engineering College, Chennai-48

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ABSTRACT

The aim of the project is to study the Mechanical and Corrosion Properties of Duplex Stainless Steel welds by using Tungsten Inert Gas Welding(TIG) and Activated Tungsten Inert Gas Welding(ATIG) methods . Duplex Stainless Steels possess excellent mechanical properties and high resistance to corrosion due to their composition and structural [Link],the ferrite- austenite ratio of duplex stainless steel gets affected on welding due to rapid cooling rates associated with the [Link], the properties of duplex stainless steel welds varies with respect to the method of welding [Link] study investigates the effects of two welding methods i.e.,Tungsten Inert Gas welding(TIG) and Activated Tungsten Inert Gas weiding(ATIG) on the mechanical and the corrosion behaviour of the welds (hardness,impact, tensile,corrosion testing). The chemical composition of duplex stainless steel welds is found using Optical Emission Spectroscopy (OES) and the microstructure is studied using Metallurgical Microscope. The study is expected to find the optimal welding method to obtain better composition and phase balance in duplex stainless steel welds and henceforth better properties.

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TABLE OF CONTENTS CHAPTER TITLE ABSTRACT LIST OF FIGURES LIST OF TABLES ABBREVIATIONS 1 2 3 3 GENERAL INFORMATION OF STAINLESS STEEL AND WELDING 3.1 Stainless Steel 3.2 Types of Stainless Steel 3.3 Austenitic Stainless Steel (ASS) 3.3.1 Applications of ASS 3.4 Martensitic Stainless teel (MSS) 3.4.1 Advantages of MSS 3.4.2 Applications of MSS 3.5 Ferritic Stainless Steel (FSS) 3.5.1 Difference between ASS and FSS 3.5.2 Advantages of FSS 3.5.3 Application of FSS
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PAGE NO iv ix x xii 1

INTRODUCTION LITERATURE SURVEY

6 6 6 6 7 7 8 8 8 9 9 10

3.6 Duplex Stainless Steel (DSS) CHAPTER TITLE 3.7 Precipitation Hardening Stainless Steel 3.8 Welding 3.8.1 Weldability 3.8.2 Types of Welding 3.8.3 Types of Weld Joints
3.9 Tungsten Inert Gas welding

10 PAGE NO 10 11 11 11 12

13
14 14 15 16 16 18 18 18 18 19 19 19 19 19 20 20 20

3.9.1 Advantages of TIG welding 3.9.2 Disadvantages of TIG welding 3.9.3 Applications of TIG Welding 4 DUPLEX STAINLESS STEEL 4.1 Overview of DSS 4.2 Effect of alloying additions 4.2.1 Carbon 4.2.2 Nickel 4.2.3 Chromium 4.2.4 Molybdenum 4.2.5 Manganese 4.2.6 Silicon 4.3 Properties of Duplex Stainless Steel 4.3.1 Mechanical Properties 4.3.2 Physical Properties 4.3.3 Impact Properties 4.3.4 Fatigue Properties
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4.4 Corrosion Resistance of Duplex Stainless Steel CHAPTER TITLE 4.5 Heat Resistance of Duplex Stainless Steel 4.6 Microstructure of DSS 4.7 Machinability of DSS 4.8 Welding of Duplex Stainless Steel 4.9 Applications of Duplex Stainless Steel

21 PAGE NO 21 21 22 23

5
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EXPERIMENTAL WORKS AND RESULTS

5.1 Material Selection 5.2 Welding 5.2.1 Welding Process 5.2.2 Tungsten Inert Gas Welding (TIG) 5.2.3 Edge Preparation 5.3 Specimen preparation 5.3.1 Cutting Operation 5.3.2 Grinding Operation 5.4 Hardness Testing 5.4.1 Procedure For Micro Vickers Hardness Test 30 5.5 Microstructure Analysis 5.5.1 Microstructure of Pure Argon specimen (Sample 1) 33
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24 24 24 24 26 28 28 28 29

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5.5.2 Microstructure of Ar + N2 10 LPM specimen (sample 2) 33

CHAPTER

TITLE 5.5.3 Microstructure of Ar + N2 15 LPM specimen (sample 3) 34 5.5.4 Microstructure of Ar + N2 20 LPM specimen (sample 4) 34 5.6 Tensile Testing 5.7 Chemical Analysis of DSS using OES

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35 37 40 41 42-49

6 7

CONCLUSION REFERENCES
ANNEXTURE-1

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LIST OF FIGURES FIGURE NO 3.1 3.2 4.1 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 TITLE Types of weld joints Tungsten Inert Gas Welding setup Microstructure of Duplex Stainless Steel TIG Weld samples Edge Preparation for TIG welding Wire EDM Test specimen Polishing and Grinding machine Micro Vickers Hardness testing machine Metallurgical Microscope setup Microstructure of sample 1 Microstructure of sample 2 Microstructure of sample 3 Microstructure of sample 4 schematic view of Tensometer Optical Emission Spectrometer PAGE NO 12 13 22 25 27 28 28 29 29 32 33 33 34 34 36 38

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LIST OF TABLES TABLE NO. TITLE PAGE NO.

3.1 3.2 3.3 4.1 4.2 4.3 4.4 5.1 5.2 5.3 5.4 5.5 5.6

Chemical Composition of Austenitic Stainless Steel Chemical Composition of Martensitic Stainless Steel Chemical Composition of Ferritic Stainless Steel Typical Compositions of some Duplex Stainless Steels (Weight %) Typical Mechanical properties of Duplex Stainless Steel Physical properties of Duplex Stainless Steel Alloys Industrial Applications of Different Grades of DSS

7 8 9 17 19 20 23

Chemical Composition of DSS UNS S32205 (weight %) 24 Welding Parameters of TIG Vickers Hardness Test results for TIG Specimen Vickers Hardness Test results for Base Metal Phase Balance Ratio Tensile strength of DSS
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26 30 31 35 37

5.7

Composition of Nitrogen in Weld Samples

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ABBREVIATIONS

TIG GTAW WEDM OES ASS MSS FSS LPM

Tungsten Inert Gas Gas Tungsten Arc Welding Wire cut Electrical Discharge Machining Optical Emission Spectroscopy Austenitic Stainless Steel Martensitic Stainless Steel Ferritic Stainless Steel Liters Per Minute

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