Zeron 100 – Alternative Material for Severe Conditions
This web blog provides you a transient data of Zeron 100® Alternative Material for Severe conditions, its mechanical, physical, chemical properties, applications, standards, design stresses, thermal conductivity, impact strength etc. This material is used as alternative material, where other materials are not suitable for aggressive environmental conditions.
Introduction
Zeron 100® is a highly alloyed duplex stainless steel. This is mostly used in aggressive environments. Its properties are as below:
- Corrosion performance is great. (PREN>40)
- Pitting and crevice corrosion resistance is high.
- Resistance to stress corrosion cracking in both chloride and sour environments is excellent.
- Erosion corrosion and corrosion fatigue resistance is high.
- Mechanical properties are well excellent.
- There are possibilities to reduce weight compared to austenitic, standard duplex and nickel base alloys.
- Weldability is good.
The above indicated excellent properties makes Zeron 100 as an ideal choice in many industries. Applications of Zeron 100 includes in oil and gas plants in process, sub-sea, firewater and even sea water piping, with relevant pressure vessels, valves, exchangers, manifolds etc. In addition to oil and gas, there are diversified use in engineering vessels for pollution control, fuel gas desulphurisation, chemical, pharma plants, desalination, power plants, paper and pulp industries, mining, marine and even metallurgical industries.
Chemical Composition of Zeron 100
| C | Si | Mn | S | P | Cr | Ni | Mo | W | Cu | N | Fe | |
| MIN | – | – | – | – | – | 24.0 | 6.0 | 3.0 | 0.5 | 0.5 | 0.2 | BAL |
| MAX(S32760) WROUGHT | 0.03 | 1.0 | 1.0 | 0.01 | 0.03 | 26.0 | 8.0 | 4.0 | 1.0 | 1.0 | 0.3 | |
| MAX (J93380) CAST | 0.03 | 1.0 | 1.0 | 0.025 | 0.03 | 26.0 | 8.5 | 4.0 | 1.0 | 1.0 | 0.3 |
PREN = % Cr + 3.3% Mo +16% N
PREN>40
PHASE BALANCE = 50 + 15% FERRITE
UNS S32760 just compositional range specified is broad, however Zeron 100 composition is firmly controlled as per requirements of Zeron 100 in house MDS specs. This in house control ensures a reliable quality product to produce and all mechanical, physical properties and even carrion properties are maintained.
Standards
| UNS | EN No. | EN Name | ACI | |
| Wrought | S32760 | 1.4501 | X2CrNiMoCuWN 25-7-4 | |
| Cast | J93380 | 1.4508 | G-X2CrNiMoCuWN 25-8-4 | CD3 MWCuN |
| NACE MR0175 | ||||
| P.D. 5500 Enquiry Case 5500/111 | ||||
| ASME VIII Division 1 Cases 2244-1 and 2245-1 | ||||
| ASME B31.3 | ||||
| ASME B16.5, ASME B16.34, ASME B16.47 | ||||
| API 5LC | ||||
| Pipe and Tube: | ASTM A790, A928, A789, prEN 10216–2, prEN 10217–2 | |||
| Forged Flanges, Fittings, etc.: | ASTM A182 grade F55 | |||
| HIP Flanges, Fittings, etc.: | ASTM A988 | |||
| Plate and Sheet: | ASTM A240, BS EN 10028-7, BS EN 10088–2 | |||
| Bars and Shapes: | ASTM A276, A479, BS EN 10088–3, EN 10273 | |||
| Forgings: | ASTM A473 | |||
| Forging Stock: | ASTM A314 | |||
| Fittings: | ASTM A815 | |||
| Castings: | ASTM A351, A890, A995 | |||
| Fasteners: | ASTM A320* | |||
*Currently available in accordance with the above standard.
Product Forms of Zeron 100
In addition to the preceding product forms, Zeron 100 is available as welding wire and covered electrodes.
Mechanical Properties
The following guaranteed minimum properties are available in the solution annealed condition.
Room Temperature
| CAST (UNS J93380) | WROUGHT (UNS S32760) | |
| YIELD STRENGTH (0.2% offset) | 450 MPa (65 ksi) | 550 MPa (80 ksi) |
| TENSILE STRENGTH | 700 MPa (101 ksi) | 750 MPa (109 ksi) |
| ELONGATION IN 50mm | 25% | 25% |
| HARDNESS | 24 HRC MAX | 28 HRC MAX |
Elevated Temperature
| PRODUCT FORM | TEMP | YIELD STRENGTH 0.2% OFFSET | TENSILE STRENGTH | |||
| (°C) | (°F) | (MPa) | (ksi) | (MPa) | (ksi) | |
| CAST | 20 | 68 | 450 | 65 | 700 | 101 |
| 50 | 122 | 410 | 59 | 675 | 98 | |
| 100 | 212 | 380 | 55 | 650 | 94 | |
| 150 | 302 | 360 | 52 | 630 | 91 | |
| 200 | 392 | 350 | 51 | 600 | 87 | |
| 250 | 482 | 330 | 48 | 570 | 83 | |
| 300 | 572 | 320 | 46 | 540 | 78 | |
| FORGINGS BAR & PLATES (up to 30mm) | 20 | 68 | 550 | 80 | 750 | 109 |
| 50 | 122 | 500 | 73 | 725 | 105 | |
| 100 | 212 | 470 | 68 | 700 | 102 | |
| 150 | 302 | 450 | 65 | 680 | 99 | |
| 200 | 392 | 430 | 62 | 670 | 97 | |
| 250 | 482 | 400 | 58 | 650 | 94 | |
| 300 | 572 | 385 | 56 | 635 | 92 | |
| PLATES (31 to 70mm) | 20 | 68 | 550 | 80 | 750 | 109 |
| 50 | 122 | 470 | 68 | 700 | 102 | |
| 100 | 212 | 430 | 62 | 670 | 97 | |
| 150 | 302 | 400 | 58 | 620 | 90 | |
| 200 | 392 | 380 | 55 | 610 | 88 | |
| 250 | 482 | 370 | 54 | 600 | 87 | |
| 300 | 572 | 360 | 52 | 590 | 86 | |
Above indicated properties are checked with section thickness up to 300mm solid or 250mm in an annulus including a minimum bore of 100mm forgings.
As the properties from forgings are very dependent upon the product route and the actual forging ratio then properties and design are by agreement for other than standard items.
Some of the cons for Zeron 100 use is not recommended to use in extended exposure to temperatures greater than 300° Celsius (600° Fahrenheit) as this results in toughness reduction drastically.
Design Stresses for Zeron 100
| Design stresses for wrought Zeron 100 | |||||||
| Temperature | ASME B31.3 | ASME VIII Div.1* | PD 5500 + | ||||
| (°C) | (°F) | (MPa) | (ksi) | (MPa) | (ksi) | (MPa) | (ksi) |
| 20 | 68 | 250 | 36.3 | 214 | 31.1 | 319 | 46.3 |
| 38 | 100 | 250 | 36.3 | 214 | 31.1 | 319 | 46.3 |
| 50 | 122 | 250 | 36.3 | 214 | 31.1 | 319 | 46.3 |
| 93 | 200 | 248 | 35.9 | 214 | 31.0 | 303 | 43.9 |
| 100 | 212 | 246 | 35.7 | 212 | 30.7 | 300 | 43.5 |
| 150 | 300 | 237 | 34.4 | 203 | 29.4 | 281 | 40.8 |
| 200 | 392 | 235 | 34.1 | 200 | 29.0 | 269 | 39.0 |
| 204 | 400 | 234 | 34.0 | 200 | 29.0 | 267 | 38.8 |
| 250 | 482 | 234 | 34.0 | 200 | 29.0 | 250 | 36.3 |
| 260 | 500 | 234 | 34.0 | 200 | 29.0 | 248 | 36.0 |
| 300 | 572 | 234 | 34.0 | 200 | 29.0 | 241 | 35.0 |
| 316 | 600 | 234 | 34.0 | 200 | 29.0 | ||
- Code Case 2245-1
- + Enquiry Case 5500/11; formerly BS 5500
| Design stresses for cast Zeron 100 | |||||
| Temperature | ASME B31.3 | ASME VIII Div.1** | |||
| (°C) | (°F) | (MPa) | (ksi) | (MPa) | (ksi) |
| 20 | 68 | 230 | 33.3 | 197 | 28.6 |
| 38 | 100 | 230 | 33.3 | 197 | 28.6 |
| 50 | 122 | 230 | 33.3 | 197 | 28.6 |
| 93 | 200 | 230 | 33.9 | 197 | 28.6 |
| 100 | 212 | 228 | 33.1 | 196 | 28.4 |
| 150 | 300 | 220 | 31.9 | 188 | 27.2 |
| 200 | 392 | 216 | 31.3 | 184 | 26.6 |
| 204 | 400 | 215 | 31.2 | 183 | 26.6 |
| 250 | 482 | 215 | 31.1 | 183 | 26.6 |
| 260 | 500 | 214 | 31.1 | 183 | 26.6 |
| 300 | 572 | 214 | 31.1 | 183 | 26.6 |
| 316 | 600 | 214 | 31.1 | 183 | 26.6 |
** Code Case 2244-1
Impact Strength
Impact strength of Zeron 100 is good as compared to other materials. While testing impact strength, as temperature is lowered, there is no true ductile brittle transition, only a gradual decrease in impact energy. Based on product type or production route, the impact energy varies. Some of the impact energy values are indicated in figure 1. If we see below graphical view, welded Zeron 100 impact strength is slightly less than that of parent metal.
Current data recommends that 40J (30ft.lbf) is a suitable acceptance criterion for duplex stainless steels and figure 1 shows that 40J is reachable with all product forms of Zeron 100 down to very low temperatures.
Figure 1: Typical impact strengths
Fasteners
On account of high strength level of solution annealed Zeron 100, it is used or suitable for many fastener applications.
Zeron 100 is even available in two additional grades, where higher tensile properties are required.
Zeron 100 FG complies the minimum tensile strength properties specified in ASTM A193-B7 and furthermore has a Charpy impact toughness of 40 Joules (29.5 ft.lbf.) minimum at -46°C (-50°F).
Zeron 100 FLT complies the minimum tensile and Charpy impact test properties specified in ASTM A320-L7.
Both Zeron 100 FG and FLT complies the requirements of ASTM A276 S32760 Condition S.
Physical Properties of Zeron 100
Density
The density of both wrought and cast Zeron 100 is 7.84 g/cm³ (7840 kg/m³ or 489 lb/ft³) at 20°C (68°F).
Specific Heat
Typical specific heats for both wrought and cast Zeron 100:
| TEMP (°C) |
SP. HT. (J/KgK) |
| 20 | 482 |
| 100 | 500 |
| 150 | 513 |
| 200 | 523 |
| 250 | 535 |
| 300 | 547 |
| TEMP. (°F) |
SP. HT. (Btu/lb°F) |
| 68 | 0.115 |
| 100 | 0.116 |
| 200 | 0.119 |
| 300 | 0.122 |
| 400 | 0.125 |
| 500 | 0.128 |
Thermal Conductivity
Typical values for wrought Zeron 100:
| TEMP (°C) |
THERMAL COND (W/mK) |
| 20 | 12.9 |
| 100 | 14.4 |
| 150 | 15.4 |
| 200 | 16.3 |
| 250 | 17.3 |
| 300 | 18.2 |
| TEMP (°F) |
THERMAL COND (Btu/hr ft°F) |
| 68 | 7.5 |
| 100 | 7.7 |
| 200 | 8.3 |
| 300 | 8.9 |
| 400 | 9.5 |
| 500 | 10.1 |
Thermal Expansion
Thermal expansion coefficient for Zeron 100 (wrought and cast) is much lower as compared to austenitic stainless steel and practically close to that of carbon steel, as follows:
| SI (Metric) Units | |||
| LINEAR THERMAL EXPANSION COEFF (10-6 K-1) | |||
| Temperature, ºC | 20-100 | 20-200 | 20-300 |
| Zeron 100 | 12.8 | 13.3 | 13.8 |
| Carbon steel | 11.5 | 12.2 | 12.9 |
| Austenitic stainless steel | 16.8 | 17.2 | 17.6 |
| Inch-Pound Units | |||
| LINEAR THERMAL EXPANSION COEFF (10-6in/inºF) | |||
| Temperature, ºF | 70-200 | 70-400 | 70-600 |
| Zeron 100 | 7.0 | 7.4 | 7.7 |
| Carbon steel | 6.4 | 6.8 | 7.2 |
| Austenitic stainless steel | 9.3 | 9.6 | 9.8 |
Resistivity
Typical values of resistivity are shown below.
| RESISTIVITY (10-6 ohm m) | |||
| TEMP (ºC) | TEMP (ºF) | WROUGHT Zeron 100 | CAST Zeron 100 |
| 20 | 68 | 0.851 | 0.916 |
| 100 | 212 | 0.897 | 0.955 |
| 150 | 302 | 0.927 | 0.980 |
| 200 | 392 | 0.956 | 1.005 |
| 250 | 482 | 0.985 | 1.030 |
| 300 | 572 | 1.014 | 1.055 |
Magnetic Permeability
At room temperature the peak relative magnetic permeability of Zeron 100 is typically 29.
Young’s Modulus (Modulus Of Elasticity In Uniaxial Tension)
The modulus is a function of austenite/ferrite ratio and production route. Variations of +5% are found with both wrought and cast products. The typical value for Zeron 100 at room temperature is 190 GPa (27600 ksi).
Poisson’s Ratio
At room temperature the typical value for Zeron 100 is 0.32.
Modulus Of Elasticity In Torsion (Sheer or Rigidity Modulus)
At room temperature the typical value for Zeron 100 is 74 GPa (10700 ksi).
Bulk Or Volumetric Modulus Of Elasticity
At room temperature the typical value for Zeron 100 is 180 GPa (26100 ksi).
