Complete Guide to Duplex and Super Duplex Stainless Steel
Are you struggling to choose the right stainless steel for your industrial needs, particularly when it comes to combating corrosion…
Imagine a material that offers unparalleled corrosion resistance, exceptional strength, and versatility across a range of demanding industries. Super Duplex Zeron 100 is precisely that alloy, setting new standards in performance and reliability. Whether you’re an engineer seeking detailed specifications, a procurement manager navigating the market landscape, or an industry professional exploring its diverse applications, this comprehensive guide is your go-to resource. Discover the unique properties that make Super Duplex Zeron 100 a top choice, understand its market dynamics, and explore its widespread use from oil and gas to power generation. Dive in to unlock the full potential of this remarkable material.
Zeron 100, also known as UNS S32760, is a super duplex stainless steel renowned for its exceptional strength and corrosion resistance. The alloy contains roughly 25% chromium, 7% nickel, and 3.6% molybdenum, along with copper and tungsten for enhanced performance. Its balanced 50–50 austenitic–ferritic microstructure significantly boosts its mechanical properties and resistance to corrosive environments. The addition of nitrogen increases its yield strength, making it more than twice as strong as standard 300 series stainless steels.
Zeron 100 stands out for its superior corrosion resistance, boasting a high pitting resistance equivalent number (PREn) of 40. This makes it highly resistant to pitting, crevice corrosion, and stress corrosion cracking, especially in chloride-rich environments. The inclusion of copper enhances its resistance to sulfuric acid and other non-oxidizing acids, making it suitable for a wide range of industrial applications exposed to aggressive chemicals.
Zeron 100 has robust mechanical properties, such as:
These ASTM A240-specified properties ensure consistent performance. The alloy remains tough across a broad temperature range, with minimal impact strength reduction down to -70°C.
Zeron 100’s exceptional properties make it ideal for various industries:
Zeron 100 is available in various forms to meet diverse industrial needs:
It complies with several ASTM standards, such as ASTM A182, ASTM A240, and ASTM A276, as well as international standards like NORSOK MDS 055. Additionally, it holds certifications including ISO 9001-2015, PED 2014/68/EC, and NACE MR0175/ISO 15156-2, ensuring its suitability for critical applications.
To cater to specific requirements, modified versions of Zeron 100 have been developed:
Zeron 100 was developed from a research project led by Dr. Cecil Roscoe at the University of Manchester to enhance duplex stainless steels’ corrosion performance. This project created the first ‘super duplex’ stainless steel. Initially marketed by Mather+Platt, Zeron 100 is now owned by Rolled Alloys.
Zeron 100, also known as UNS S32760, is a super duplex stainless steel renowned for its exceptional chemical composition, which includes:
Together, these elements improve the alloy’s performance, especially in corrosive settings.
Meeting industry standards ensures Zeron 100’s quality and reliability, making it a top choice for demanding applications. Zeron 100 adheres to several key standards, including:
These standards guarantee that Zeron 100 meets stringent quality and performance criteria, ensuring its suitability for various industrial uses.
Zeron 100 boasts impressive mechanical properties, which include:
These metrics highlight Zeron 100’s robustness and reliability, making it a preferred choice for industries requiring high-performance materials.
One of Zeron 100’s standout features is its exceptional corrosion resistance. This super duplex stainless steel is highly resistant to various forms of corrosion, including:
These properties make Zeron 100 an ideal material for use in highly corrosive environments.
Zeron 100 offers several key features that set it apart from other stainless steel alloys:
These features ensure that Zeron 100 can meet the demands of various industrial applications, providing reliable and efficient performance.
Super Duplex Zeron 100 is renowned for its exceptional corrosion resistance, making it an ideal choice for challenging environments.
Zeron 100 excels in resisting corrosion from mineral acids like hydrochloric and sulfuric acid due to its copper content (0.5% to 1.0%). This property makes it suitable for industries where exposure to harsh acidic conditions is common.
The alloy’s high levels of chromium, molybdenum, and nitrogen enhance its resistance to pitting and crevice corrosion. The Pitting Resistance Equivalent Number (PREN), which measures an alloy’s ability to resist localized corrosion, is 40 or greater for Zeron 100. This high PREN makes it highly effective in chloride-rich environments.
Zeron 100 is notably resistant to stress corrosion cracking, especially in chloride and sour environments. This includes resilience against sulphide-stress cracking, which is crucial in the oil and gas industry where such conditions are prevalent.
The alloy’s resistance to erosion corrosion and corrosion fatigue outperforms many other stainless steels, making it suitable for applications involving repeated mechanical stresses and corrosive environments.
With its broad resistance to both organic and inorganic acids, including strong alkalis and non-oxidizing acids, Zeron 100 is versatile across numerous industrial applications, such as chemical processing and pollution control.
Zeron 100 is highly resistant to corrosion in warm seawater conditions, making it ideal for marine and desalination applications. This ensures long-term durability and reliability in marine environments.
Zeron 100 boasts impressive mechanical properties that ensure its performance in demanding applications.
The thermal conductivity, coefficient of thermal expansion, and modulus of elasticity of Zeron 100 vary with temperature, crucial for applications involving temperature fluctuations.
Zeron 100 is not suitable for prolonged exposure to temperatures above 572°F (300°C), as this can lead to reduced toughness and the formation of brittle microstructures. Additionally, machining Zeron 100 requires careful handling to maintain performance, and in some cases, stress-relieving heat treatment may be necessary.
Zeron 100’s superior properties make it valuable across various industries:
In the oil and gas sector, Zeron 100 is ideal for subsea and sour-gas environments due to its resistance to stress corrosion cracking. For example, it is used in offshore platforms and pipelines exposed to harsh seawater and corrosive gases.
Zeron 100 is effective in pollution control applications, handling corrosive chemicals involved in scrubbing processes and waste management systems.
The alloy’s resistance to aggressive chemicals makes it suitable for equipment in the pulp and paper industry, where it withstands the corrosive substances used in processing.
In power generation, Zeron 100 is used in seawater and desalination plants, ensuring durability in marine conditions.
The alloy’s broad chemical resistance makes it suitable for various applications in the chemical and pharmaceutical industries, where it withstands a wide range of corrosive substances.
Zeron 100’s resilience in seawater conditions makes it an excellent choice for marine applications, including shipbuilding and offshore construction.
Super Duplex Zeron 100 is a critical material in the oil and gas industry due to its ability to withstand extremely harsh environments. Its exceptional resistance to corrosion caused by chloride and sulfide exposure makes it indispensable for offshore applications. Typical uses include:
In the pulp and paper industry, Zeron 100’s resistance to the corrosive chemicals used in the papermaking process is highly valued. It is used in various stages of production, including:
Zeron 100 is favored in power generation facilities, especially those involving seawater or desulfurization processes. Its applications include:
The chemical processing industry leverages Zeron 100 for its superior resistance to various corrosive substances. Applications include:
Zeron 100’s excellent resistance to seawater corrosion makes it ideal for marine applications. This alloy is crucial for:
Seawater Reverse Osmosis (SWRO) desalination plants convert seawater into potable water, a process that requires materials resistant to severe corrosion. Zeron 100 has demonstrated its high resistance to chloride pitting, crevice corrosion, and stress corrosion cracking in these applications. This ensures long-term reliability and reduced maintenance costs, making it a preferred choice for critical components in desalination systems.
Zeron 100AFP, an advanced forging grade of Zeron 100, has been developed specifically for subsea oil and gas applications. It maintains excellent mechanical properties even at temperatures as low as -70°C, making it suitable for demanding subsea environments. This grade’s enhanced durability ensures operational reliability and safety in harsh conditions.
The copper content in Zeron 100 provides excellent resistance to sulfuric acid, making it a preferred material for acid leach mining and steel pickling applications. This resistance helps extend the service life of equipment, reducing the need for frequent replacements and ensuring continuous, efficient operations in highly acidic environments.
Super Duplex Zeron 100 bars are priced based on form, dimensions, and supplier, with notable variations. Here are some general price ranges to provide an overview:
Several factors impact the pricing and market trends of Super Duplex Zeron 100 bars:
The market for Super Duplex Zeron 100 is driven by its exceptional performance in highly corrosive environments. For instance, it is highly resistant to chloride-induced stress corrosion cracking, which makes it ideal for use in subsea and sour-gas environments in the oil and gas industry. Additionally, the increasing need for materials that can withstand aggressive chemicals in the chemical processing industry contributes to its growing demand.
Specialized versions of Super Duplex Zeron 100, such as Zeron 100FG for fasteners and Zeron 100AFP for advanced forging applications, offer enhanced strength and suitability for specific uses.
In conclusion, due to its exceptional performance in harsh environments, Super Duplex Zeron 100 remains in high demand across industries like oil and gas, desalination, and chemical processing.
Super Duplex Zeron 100 is available in various forms to meet different industrial needs. Understanding these forms helps in selecting the appropriate type for specific applications.
Round bars, available in various diameters, are commonly used in applications requiring high strength and corrosion resistance, such as machining into components like shafts and fasteners.
Square bars are ideal for structural applications where uniform strength distribution is necessary. They are often used in construction, fabrication, and other engineering projects that demand high durability.
Forged bars have enhanced mechanical properties due to the forging process, making them ideal for high-stress applications like heavy machinery and aerospace components.
Hollow bars provide a balance between weight reduction and strength, making them suitable for applications that require both durability and lightness. They are often used in the manufacturing of cylindrical components like bushings and sleeves.
Selecting the right dimensions and customization options is crucial for meeting specific project requirements. Zeron 100 bars come in various standard dimensions, including diameter and length, and can be customized to meet unique specifications.
Customization options include cutting to specific lengths, applying surface finishes, and other modifications to meet the exact specifications of the application. This flexibility ensures that the material can be tailored to fit unique project requirements.
By carefully considering these factors, engineers and procurement managers can select the most appropriate forms and dimensions of Super Duplex Zeron 100 to meet their specific needs.
Super Duplex Zeron 100 offers exceptional corrosion resistance compared to other stainless steel alloys due to its high chromium, molybdenum, and nitrogen content.
Compared to 300 series stainless steels like 304 and 316, which are commonly used for their corrosion resistance, Zeron 100 excels in chloride-rich environments. Similarly, while duplex steels such as 2205 provide good corrosion resistance, Zeron 100’s higher alloy content offers even better protection. This makes Zeron 100 suitable for aggressive environments like seawater and chemical processing.
Zeron 100 boasts a minimum yield strength of 80,000 psi and an ultimate tensile strength of 109,000 psi, making it nearly twice as strong as 300 series stainless steels and superior to standard duplex steels like 2205. This high strength makes it ideal for applications involving high mechanical loads and extreme conditions.
Though more expensive upfront, Zeron 100 offers long-term savings through its durability and reduced maintenance. It is also easier to machine than many high-performance alloys, though it requires careful handling.
300 series stainless steels are ideal for general-purpose use, while Zeron 100 is perfect for demanding applications like subsea oil and gas equipment, chemical plants, and desalination facilities due to its superior strength and corrosion resistance. Standard duplex steels offer a balance of cost and performance but fall short in the most aggressive environments where Zeron 100 excels.
Below are answers to some frequently asked questions:
Super Duplex Zeron 100 steel, designated as UNS S32760, is known for its exceptional properties, including a specific chemical composition with high chromium, nickel, and molybdenum content, which enhances its corrosion resistance and mechanical strength. It complies with ASTM standards such as A276 and A479. Zeron 100 exhibits a minimum tensile strength of 109,000 psi and yield strength of 80,000 psi, with excellent pitting and crevice corrosion resistance, making it suitable for demanding environments. Its versatility allows for applications in oil and gas, chemical processing, and marine industries, among others, as discussed earlier in the article.
Super Duplex Zeron 100 is commonly used in several industries due to its exceptional strength and corrosion resistance. Key sectors include the oil and gas industry for pipes and mechanical components, the chemical and pharmaceutical industries for handling corrosive acids, and power generation for Flue-Gas Desulfurization systems. It is also employed in the pulp and paper industry, desalination plants, mining, pollution control systems, and marine applications, where its durability in aggressive environments is crucial. These industries benefit from Zeron 100’s unique properties, making it a preferred choice for demanding applications.
Super Duplex Zeron 100 is widely used across various industries due to its exceptional corrosion resistance and high strength. In the oil and gas sector, it is ideal for subsea equipment and pipelines due to its resistance to chloride-induced corrosion. It is also employed in power generation for flue-gas desulfurization systems and in chemical processing for handling mineral acids. The pulp and paper industry uses it for processing equipment, while its resistance to seawater corrosion makes it suitable for desalination plants. Additionally, it is used in mining, pollution control, pharmaceutical processing, marine applications, and industrial heat exchangers.
The price of Super Duplex Zeron 100 bars varies based on several factors, including form, thickness, geographic location, and supplier. Prices generally range from approximately US $8 to US $13 per kilogram. Variations occur depending on whether the material is a plate, sheet, or round bar, and location-specific market conditions can also influence cost. Suppliers may offer different pricing structures based on inventory and logistical factors, and specific standards and specifications required can further impact prices, as discussed earlier.
Super Duplex Zeron 100 bars are available in a variety of forms and dimensions to cater to diverse industrial needs. The key forms include round bars (diameters from 5 mm to 495 mm), flat bars (thickness from 2 mm to 100 mm), square bars, half-round bars, hex bars, rectangle bars, channel bars, angle bars, and hollow bars (outer diameters from 32 mm to 250 mm). Lengths typically range from 100 mm to 6000 mm. These bars also come in billets, profiles, blocks, rods, threaded bars, forgings, rings, and triangles, providing extensive customization options for different applications.
