Zeron 100 – Alternative Material for Severe Conditions

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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

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

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.

Zeron001

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

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).