Welding in Stainless Steel

16-11-2016

1
Agenda
_________________________________________________________________

1. Stainless Steel

2. Stainless Steel- Characteristics & benefits

3. Stainless Steel- Welding

4. Stainless Steel Finish

5. Trends in Stainless Steel Development

6. Jindal Stainless Group

7. Q & A

2
Stainless steel !!!!

3
4
Sustainable development is the masterful balance of
meeting our own needs without jeopardizing future
generations' ability to do the same

STEEL Chromium saved it STAINLESS STEEL 5

Economic Impact

INR 330 Lakh Crore

World
USD 5
Trillion

India USA
USD 0.12 USD 1
Trillion Trillion
Corrosion
5-6%
INR 6 Lakh Crore of GDP
INR 66 Lakh Crore

6
 Localized Corrosion

Crevice Corrosion - appearance

Crevice corrosion underneath the
gasket of a flange is common.
 Intergranular Corrosion (IGC)

Weld

304

304L

The grain boundaries have been

corroded
 Galvanic Corrosion Requires..

Solution
• Prevent direct contact
– Inert washers
– Paint
– Other non-conducting barriers
Stainless steel plate/galvanized
steel fasteners
Surface area ratio is important!
 Most materials decay over time
Material Wood Steel Concrete

Type of decay Fungi Rust Cracking/

Insects Spalling
Sun+rain

Mitigating actions Chemicals Galvanising Corrosion resistant

Paint/varnish Painting rebar

10
 Most materials decay over time
Material Stone Glass Polymers

Type of decay Wear Breaks Become brittle

Damage by under UV light
Pollution

Mitigating actions Usually none taken Tempered glass Improved polymer

grades

11
 Most materials decay over time
Material Aluminum* Copper Stainless

Type of decay Pitting over time, Forms a green No decay

possible galvanic patina over time
corrosion

Mitigating actions Galvanic corrosion None None required

can be prevented

* Aluminum forms a thin protective oxide just like stainless, but with a much lower corrosion resistance

12
Stainless Steel

13
 APPLICATIONS

14
MTPA : Million Tons Per Annum
 ARCHITECTURE, BUILDING & CONSTRUCTION (ABC)
15
MTPA : Million Tons Per Annum
 RAILWAYS
16
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY (OIL & GAS)
17
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY (DESALINATION)
18
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY (FERTILIZER, STORAGE, CHEMICALS)
19
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY – DAIRY INDUSTRY
20
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY- FOOD PROCESSING
21
MTPA : Million Tons Per Annum
 PROCESS INDUSTRY (BREWERY, DISTILLERY & SUGAR)
22
MTPA : Million Tons Per Annum
 WHITE GOODS
23
MTPA : Million Tons Per Annum
 KITCHENWARE
24
MTPA : Million Tons Per Annum
 MINT
25
MTPA : Million Tons Per Annum
 PRECISION STRIPS
26
MTPA : Million Tons Per Annum
BLADE STEEL
27
 Shining !!!
• For standard finishes specify
“low sulfur”
– 0.005% or less
– Improved corrosion
performance
– Finish appearance
• For mirror finishes
– Specify 0.002% or less
• Low sulfur tube and pipe may
not be available
– Sulfur makes high speed
welding easier
Embossed patterns 9

29
 4, 5,7
Coloured finishes
This is only a selection of the colour effects that can be produced by
electrolytically colouring stainless steel

30
Electrochemical Colors
Color can be uniform or
deliberately varied

Bronze Blue Gold Red

Purple Black Green
 Sputtering or
Plasma Vapor Deposition
• Thin, adherent, abrasion resistant,
uniform, non-fading
• Color determined by coating
Gold (titanium nitride)
Black (titanium carbide)
Brown or Blue (titanium aluminum
nitride)
Others: Rose Gold, Silver Gold,
Brass
Perforated sheet 9

33
Standard 12-14

A very wide set of woven

shapes and patterns is
available, with adjustable

•stiffness
•open area
•light diffusion
•acoustic transparency
•color
•etc…

34
Outside decoration with Stainless
Wire mesh
Stainless wire mesh is widely
used for decoration. It allows
special effects such as lights
(with LEDs) as shown
(Swarovski Building
headquarters)

35
Woven stainless with LEDs 13

36
What is stainless steel ?

37
 What is Stainless Steel?
Cross-and-Balls
Stainless steel is an alloy of iron (Fe) and chromium (Cr).

Iron Chromium

38
 What is Stainless Steel?
Stainless Steel belongs to a family
of steels containing a minimum of
10.5% chromium.

A higher chromium content makes

stainless steel material more
Chromium
resistant to corrosion.

39
 Effect of Chromium Content on Atmospheric
Corrosion Resistance (uniform corrosion)
Corrosion Rate
mmpy
0.200
Plain Carbon Steel
0.175
0.150
0.125
0.100
0.075
Stainless Steels
0.050 > 10.5 Cr %
0.025

0 2 4 6 8 10 12 14 16
% Chromium
40
 Why Stainless Steel Does not Rust ?

Oxygen PASSIVE FILM on STAINLESS STEEL:

Oxy-hydroxides of Fe and Cr

2-3 nm thick
(0,002-0,003 µm)

Transparent
Adherent
Self repairing
Stainless Steel Surface Damage Self Repairing

SELF REPAIRING SURFACE

41
 42

Nitrogen (N)
• Enhances strength
and pitting and
crevice corrosion
Passive Film

Molybdenum
• Increases pitting and
crevice corrosion
resistance caused by
Stainless Steel salt & pollution

Nickel (Ni)
• Accentuate ductility,
toughness, and
weldability

>= 10.5% Cr Chromium (Cr)

• Improves Corrosion
Resistance

< 10.5% Cr
Iron (Fe) 42
 STAINLESS STEEL
Alloy of iron containing minimum 10.5% of chromium

• Chromium forms a passive film of Chromium Oxide, which

prevents corrosion

• Nickel, Manganese, Nitrogen help in forming austenitic

structure

• Molybdenum improves pitting corrosion

 What is Stainless Steel?
Why use Stainless Steel?
• Corrosion resistant,
• Exceptional hygienic properties,
• Amongst the easiest materials to fabricate products with,
• Excellent cryogenic properties,
• Stronger than carbon steels,
• Lifespan of many times that of carbon steel products, low maintenance,
• 100 % Recyclable,
• Non-toxic.
The Solution

Right Grade Of Stainless

Steel

The estimated savings in annual replacement material costs

due to upgrading with appropriate stainless steel grade can
go up to even 50%
 Stainless Steel Grades

300 Series
Classification Grade Major Applications
Railway rolling stock. Steel belt, metal
301L, 301
gasket, springs
Sundries, kitchen utensils, LNG tanks,
304, 304L others, Oil refinery and papermaking
equipment
Chemical and paper industry equipment
316/ 316L
and VTR guide rollers

Austenitic Chemical, paper, Dye and fertilizer

317/ 317L
Type Industry equipment
Chemical, paper, Dye and fertilizer
321
Industry equipment
Chemical, paper, Dye and fertilizer Industry
347
equipment
309, 309S, 310, 310S Furnace Parts, Burning Chambers,
Concentrated Acid Tanks
 Stainless Steel Grades

200 Series
Classification Grade Major Applications

Decorative trims, Pipes, Tubes for general non-

J4 corrosive usage, White goods, Polishing
application, ABC Sector

General usage such as Kitchen, Furniture,

JSL AUS Utensils, White Goods, suitable for Deep
Drawing
16% Cr grade, suitable for Utensils, White
Austenitic 204Cu
Goods, Polishing application, ABC Sector
Type

201LN Cryogenic Vessels

Recommended as replacement for 304 in low

201, 202
corrosive environments.

Recommended for pipes & tubes, Flatware,

JSL TUBE
Non-corrosive general application
 Stainless Steel Grades

400 Series
Classification Grade Major Applications

409/ 409L Automotive parts and exhaust purifiers

409M Automotive exhaust pipes

430 Kitchen utensils, sundries, stove reflectors

Automotive exhaust gas purifiers and

410S
exhaust pipes
Ferritic Type
Bicycle rims & automotive parts such as
439
wheel cover

436LM Automotive trim, muffler

Suitable for replacing 304 in most of the

441
application
 Stainless Steel Grades

400 Series
Classification Grade Major Applications

Turbine blades, spoons, forks, Sundries and

410
distillation columns trays

420 Machine parts, table knives

Martensitic
Type

415 Hydro turbine components

JBS Razor Blades

SUGGESTED GRADES OF SS DEPENDING ON APPLICATION

Ferritic/Ferritic-
Austenitic
Martensitic

304/L, 316L, J4, JSLAUS,

409M, 410, 439, 441 204Cu

Mainly suitable for applications which require

1. Excellent oxidation and atmospheric corrosion
resistance Mainly suitable for applications involving
2. Very high abrasion resistance 1. Higher corrosion due to the low pH of raw mixed
3. Very high wet sliding abrasion resistance juice
4. Higher thermal conductivity and excellent 2. Presence of SO2 and other chemicals during
weldability processing.
5. Low maintenance and stable price and where
corrosion allowance on thickness is not required.
Stainless Steel Welding
Welding Processes Selection

52
 Weldability of Stainless Steel

• Austenitic Stainless Steels:

– Insensitive to hot cracking
– Good resistance to intergranular corrosion
– Excellent toughness and ductility
– Embrittlement can occur after long exposures between 550 and
900 Deg C.

53
 Weldability of Stainless Steel

• Ferritic Stainless Steels:

– Sensitive to embrittlement by grain coarsening above 1550 Deg C
– Poor Toughness and Ductility
– Sensitive to intergranular corrosion
– Post Weld heat treatment at about 800 Deg C restores the
mechanical properties & intergranular corrosion resistance.

54
 Weldability of Stainless Steel

• Austenitic – Ferritic Duplex Grade

– Insensitive to hot cracking
– Excellent toughness and good ductility in the range of 40 Deg C
to 275 Deg C.

• Martensitic Stainless Steel

– Sensitive to Cold Cracking
– High tensile strength and hardness
– Good toughness, particularly for low carbon grades.

55
56
NiDI
NiDI
Weldability of Stainless Steel

59
Bad Fit-up
Three common
mistakes.

NiDI
Good Fit-up

NiDI
 Avoid Distortion

First welds

NiDI
Performance of various grades
Stainless Steel Finishing

64
SS Finish

A Pattern Created on Stainless Steel for

Aesthetic cum Functional reasons is known
as Finish. It is either;

1. Transferred
2. Mechanical
3. Blasted
 Bad Polishing

Environment
Deicing Salt exposure
Good Polishing
Local Weather Pattern
Design Considerations
Maintenance Schedule
Finishes with
respect to
Flatness
 Dull or Embossed Finishes Look
Flatter Than Reflective Finishes
• Both samples are equally flat
 Achieving Flatness
• Use adequate panel
thickness
Column Covers 2 – 2.8 mm
Wall panels 0.5 – 3 mm
Roofing, supported 0.5 – 0.6 mm
Countertops 2 - 2.8 mm

• Avoid long or wide unsupported

panels
• Provide for thermal expansion!
 Pickling
with mixed nitric – hydrofluoric acids

Before After
 Use wood or plastic separators on shelves. Mild steel
shelves should not be in direct contact with stainless steel
 Do not mark with crayon on
bare sheets. Mark on Polythene
protective sheets
Stainless steel Development?

74
Metals Annual Growth
_________________________________________________________________

75
Metals Annual Growth
_________________________________________________________________

76
World Stainless Steel Melt Production

41.6 MT 41.5 MT

2015

Source : Stainless Steel in Figures 2015 by ISSF Source : ISSF

 Stainless Steel Melt Production (tons) : India
3500000

3080000
2950000
3000000 28500002858000
2669000
2540000
2500000 2415000

20320002010000
2000000 1921000
1816000
1706000

14,50,000
1500000
12,00,000

1000000
780000 760000

500000

0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
 3

Stainless Steel Apparent Consumption – India in 000 tonnes

2.5

2
Million tons

1.5

0.5

0
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Source : JPC Market Survery Report, Ministry of Steel, GOI Source : ISSDA
Jindal Stainless

80
Under the able stewardship of:
Shri. Prithvi Raj Jindal

Jindal Saw Ltd, has grown many fold and has diversified
its product line by offering total pipe solutions to wide
array of sectors; Energy, Water, Sewage transportation
and Industrial applications.

Turn over: $ 1.6 billion

Under the visionary leadership of:

Shri. Sajjan Jindal

The JSW Group has grown to become one of the largest

integrated Steel producer with an capacity of 14.3 MTPA.
Today the group has expanded in other core sectors of
the economy such as Power, Cement and Infrastructure.

Turn Over: $ 10 billion

Under the futurist leadership of:

Shri. Rattan Jindal

Jindal Stainless group has grown to become the largest

integrated stainless steel manufacturer in the country and
amongst the top 10 in the world. With a melting capacity
of 1.8 MT

Turn Over: $ 2.65 billion

Under the visionary leadership of:

Shri. Naveen Jindal

JSPL produces economical & efficient steel & power

through backward integration. JSPL sports the whole
range of flat and long products to cater to the needs of
steel market.

Turn Over: $ 3.75 billion

3
JINDAL STAINLESS GROUP
• India’s Largest and only fully integrated Stainless Steel Manufacturer.

• Market Leadership through technology with state of Art Production Facilities.

• Ranked amongst the Top 10 Stainless Steel Companies in the World with
capacity of 1.8 Million tonnes

• Over 11,500 Employees worldwide

• 4 Manufacturing Locations, 37 Sales/Rep Offices, 7 Service Centers

4
 CAPACITIES

Capacities (MT/Annum) JS(H)L JSL Indonesia

Steel Melting 800,000 1,000,000 -

Steckel Mill 800,000 - -

Strip/Tandem Mill 250,000 1,600,000 -

Plate 100,000 96,000 -

CRAP 275,000 400,000 150,000

SPD 25,000 - -

QTY : MT

7
 PRODUCTS

Width (mm) Thickness (mm)

Products
Max Min Max

Slab 1650 160 250

Hot Rolled Coil 1650 2.0 10

Plates / Sheets 1650 3.0 100

HRAP Coil / 2E 1650 1.4 10

CRAP Coil 1600 0.3 5.0

Precision Strips 435 0.05 0.5

5mm CR 2B Coil & 10mm HRAP Coil also available

8
GRADES & FINISHES
301, 304/L/LN/H, 316/L/LN,
300 Series 317/L/LN, 321, 347,
316 Ti, 309, 310/S

200 Series 201, 201 LN, 204Cu, 216, J4,

(Cr–Mn Series) JSLAUS, JSL U DD,
JSL U SD, JSL U KP, JT

400 Series 409/L, 410/S, 415, 420, 430, 436/L,

439/L, 440 A/B/C, 441

Duplex &
Super-austenitic 2205, 2304, 904L

Finishes: N1, 2D, 2B, 2E, BA, N3, N4, Scotch Brite, Moon-rock, Embossed

9
 Product Visuals

STRIPS
SLABS BLOOMS

HOT-ROLLED COLD-
COIN BLANKS
COILS ROLLED
COILS
 CERTIFICATIONS

 ISO 9001:2008  CPD/89/106/EEC

Quality Management System European Certificate (CE) Recommended
 ISO 14001:2004 by TUV Germany
Environment Management System  MD00/3110/0004/1
 BS OHSAS 18001:2007 Steelmaking- Certified by Lloyds’s Register
Organization Health & Safety EMEA
 AD 2000 W0  ISO/IEC 17025:2005
Pressure Equipments (Germany) General Requirements for the Competence
of Testing & Calibration Laboratories
 PED/97/23/EC
Pressure Equipments (EU)

10
 JINDAL STAINLESS STEELWAY LIMITED

MTPA : Million Tons Per Annum 21

 Research & Development
• Strong in-house R&D

• Various developmental activities undertaken:

• Stainless Steel for Nuclear Power Plant Applications
• Stainless Steel For Railways & Metros (301, IRSM44-97, 301LN etc.)
• Razor Blade Stainless Steel
• Ferrite Steel For Petrochemical Sector
• Stainless Steel Low Ni-200 series
• Stainless Steel For Auto-sector: Exhaust Systems, Brakes etc.
• Cu-Ni CR Coils & Blanks
• 15CDV6 for rocket canisters
• 17-4Ph & 15-5Ph for Aerospace segment
 Jindal Stainless : At Service

World Class Bulk Extensive Quality

Modern Plant Capacities Product
Range

Product Approvals & Value Distribution

Innovation Accreditation Creation for Network
and R & D Customers

Customer Dedicated Commitment

Supply Mgmt Team
 Activities Pursued

• Training
– Industrial Sectors
– Fabricators
• Institute Courses
– Architecture
– Sugar, Dairy etc.
– Metallurgy
• Association Coordination
• Research & Development
 Jindal Stainless on Social Media

• More than 35000 Followers on different platforms.

• Join us on Social Media to get latest updates on Stainless Steel
developments

92
Thank You

93