G-TECH 2595B

SMAW
  • DUPLEX - SUPERDUPLEX
ZERON 100

Description

Basic coated electrode for Zeron® 100 alloy
Offshore applications exploit the high resistance to pitting and stress-corrosion cracking in seawater. It is also highly resistant to caustic alkalis and phosphoric acid. Service temperature range is usually limited to –50°C to 280°C. It is widely used in oil and gas production and process pipework, risers, manifolds, pressure vessels, valves, pumps, desalination plant, systems for flue-gas desulphurisation (FGD) and also in the mining, chemical and pharmaceutical industries. Its basic coating ensures excellent positional welding characteristics with good gap bridging ability.
Specifications
EN ISO 3581-A
E 25 9 4 N L B 42
AWS A5.4
E2595-15
Shielding
-
Positions
PA, PB, PC, PD, PE, PF
Current
DC+;
Packaging Type
Carton box
Asme qualifications
F-No (QW432)
5
A-No (QW442)
-

Ferrite

% 30-60

Pren

42.54
Chem. Comp. %
DEFAULT
C
0.035
Mn
0.9
Ni
9.5
Cr
25.5
N
0.24
P
0.02
S
0.01
Mo
4
Si
0.7
Cu
0.7
Mechanical Properties
min
variant
Tensile strength Rm MPa
620
850
Yield strength Rp0.2 MPa
550
630
Elongation A (L0=5d0) %
18
22
Impact Charpy ISO-V
-
40J @ -40°C
Impact Charpy ISO-V
-
-
Welding Parameters
2.5 mm
3.2 mm
4 mm
Ampere
50A - 80A
70A - 110A
100A - 160A
Voltage
-
-
-
Packaging
56 pcs/kg
30 pcs/kg
19 pcs/kg
Packaging Type
Carton box
Carton box
Carton box
ZERON 100
Description

Application

Zeron® 100 stands out for its extraordinary ability to resist corrosion and erosion in a wide range of aggressive environments. The special Cu+W combination significantly improves resistance to sulfuric and hydrochloric acids, compared to similar alloys without such additives. Thanks to its high resistance to pitting and stress corrosion cracking, Zeron® 100 is widely used in offshore applications, especially in seawater contexts. This material also offers excellent resistance to caustic alkalis and phosphoric acid. Its service temperature range generally varies between -50 °C and 280 °C, with the upper limit due to thermal instability (450 °C and sigma phase embrittlement). Zeron® 100 is highly valued in the oil and gas production sector and is used in a wide range of applications, including process piping, risers, manifolds, pressure vessels, valves, pumps, desalination plants, flue gas desulfurization (FGD) systems, and in the mining, chemical, and pharmaceutical industries. Furthermore, Zeron® 100 wires are ideal for joining supermartensitic stainless steels.

Alloy Type

25%Cr ferritic-austenitic superduplex stainless steels matching the proprietary Zeron® 100 alloy.

Microstructure

Austenite-ferrite duplex microstructure in AW or solution annealed condition with an approximate 30- 60% ferrite level, depending on heat cycle conditions.

Materials

  • EN W.Nr.: 1.4508, 1.4501, 1.4469
  • ASTM: A890 6A, A182 F55, A890 5A
  • UNS: S32760, J93380, S32750, S32550, S32520, S39274, S32950, J93404
  • PROPRIETARY: Zeron 100 (Rolled Alloys) DP3W (Nippon Steel Corporation), 7-Mo Plus (Carpenter), SAF 2507 (Sandvik)

Welding & PWHT

For welding Zeron® 100, preheating is generally not required. The interpass temperature should not exceed 150 °C. A heat input between 1.0 and 2.0 kJ/mm (based on the material thickness) is considered optimal, though many industrial codes set a maximum limit of 1.5 or 1.75 kJ/mm. While welds in wrought duplex stainless steels are usually left as is, major repairs on castings often require a solution treatment. Field tests confirm that good properties are obtained by following a water quench treatment at 1120 °C for a period between 3 and 6 hours.

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