Fees: Member: $550, Nonmember: $685

Welcoming Remarks
Robert R. Irving, Chairman
Donald J. Tillack, Chairman

1. OVERVIEW OF THE HIGH-PERFORMANCE STAINLESS STEELS
   Ralph Davison, Technical Marketing Resources, York, ME

   High performance stainless steels (HPSS) are not limited to highly alloyed grades. The term high performance embodies optimized combinations of corrosion resistance, strength, and specialized fabrication capabilities achieved with lowest total cost through best selection of alloy elements and processing techniques. High performance stainless steels are useful wherever corrosion resistant parts are required. This discussion focuses on austenitic and duplex stainless steels showing the advantages of high performance stainless steels in large applications of great economic significance in a wide range of industries and application types. The discussion addresses new stainless steel grades, and examples of common grades with special properties achieved by within-grade variation of composition and process.

2. BASIC GUIDELINES FOR THE WELDING OF STAINLESS STEELS
   Donald J. Tillack, Tillack Metallurgical Consulting, Inc, Catlettsburg, KY

   This presentation will emphasize the proper pre-weld precautions (cleanliness, etc.), the differences between welding the ferritic steels and the stainless steels, how to avoid weld-related defects, and post-welding concerns such as post welding heat treatment and pickling/cleaning.

REFRESHMENT BREAK

3. HOW SHIELDING GAS SELECTION CAN OPTIMIZE THE STAINLESS STEEL WELDING PROCESS
   Kevin A. Lyttle, Praxair, Inc., Tonawanda, NY

   To meet the increasing demands for high quality stainless steel welding, shielding gas blends have been formulated to enhance weld quality and appearance while improving welding productivity. Additions of hydrogen and nitrogen have complemented the benefits of argon and helium to meet the requirements of more stringent applications and new base materials. Examples of improvements in joining austenitic and ferritic materials through process and shielding gas modification will illustrate process optimization.

4. SEAM WELDED DUPLEX STAINLESS STEEL TUBING
   Joseph W. McEnerney, Gibson Tube Inc., North Branch, NJ

   Seam welded duplex stainless steel (DSS) tubing grades are available to meet the needs of various service environments. These grades include lean DSS such as 19D and 2101, conventional DSS such as 2205, and super DSS such as 2507. This presentation will cover the characteristics of each grade, applicable service environments, and important issues regarding successful use of these materials.

LUNCH BREAK 12:05 PM-1 PM

5. IS WELDING STAINLESS STEEL FOR LNG APPLICATIONS EASY?
   W. F. Newell, Jr., Euroweld, Ltd., Mooresville, NC

   This presentation will discuss options to ensure achievement of good weld metal toughness. Although stainless steels are easy to weld, achieving good weld metal toughness at the temperatures an LNG plant requires can be problematic. Both 304L and 316L stainless steel base materials have a fully austenitic microstructure that yields very good toughness at cryogenic temperatures. For LNG applications, which generally involve joining of pipework, specially designed 308L and 316L consumables are the favored solution. An extensive database of all-weld metal data demonstrates that careful consumables design can achieve consistently good toughness. Successful projects using LNG dedicated consumables will be described.

6. WELDING OF AL6XN^®
   Kris J. Schott, ATI Allegheny Ludlum, Brackenridge, PA

   The 6%Mo superaustenitic stainless steels have grown from laboratory curiosities through "exotic" to become standard construction materials. They displace the Ni-Cr-Mo alloys at about half the cost, while retaining the field weldability of stainless steels and nickel alloys. This presentation will describe welding technology for AL-6XN^® superaustenitic stainless steel, with emphasis on filler metal selection.

REFRESHMENT BREAK

7. WELDING (SUPER) DUPLEX AND SUPERMARTENSITIC STAINLESS STEELS
   Vincent van der Mee, Lincoln Electric Europe, The Netherlands

   This presentation provides an overview of welding consumables and processes with their relevant mechanical and corrosion properties for welding (Super) Duplex and Supermartensitic stainless steels, in relation to their application and requirements. The presentation also reports the results of investigations on weld metal for all processes.

ADJOURNMENT

TUESDAY, NOVEMBER 15, 2005

8. MITIGATING THE HEALTH EFFECTS OF WELDING STAINLESS STEELS
   Susan R. Fiore, Edison Welding Institute, Columbus, OH

   In October, 2004, the Occupational Safety and Health Administration (OSHA) announced a proposal to amend the eight-hour time-weighted average permissible exposure limit for hexavalent chromium (Cr(VI)). The proposal reduces the limit from 52 micrograms per cubic meter (mg/m³) of air to 1 mg/m³, based on a finding that employees exposed to Cr(VI) face a significant risk of health effects, including lung cancer, asthma, nasal septum ulcerations and perforations, skin ulcerations (or chrome holes), and allergic and irritant contact dermatitis. One group of workers specifically cited by OSHA as being at risk are those involved with welding of stainless steels. This presentation will discuss ways of minimizing the risks and challenges associated with welding stainless steel, including general and source-capture ventilation improvements, and the use of respirators to protect welders and other nearby workers.

9. THE WELDING OF SUPER DUPLEX STAINLESS STEEL PIPING
   Michael D. Hayes, Acute Technological Services, Inc., Houston, TX

   This presentation will cover the fundamental welding and metallurgical variables that must be controlled for successful welding of super duplex stainless steel pipe and tube. It will discuss examples of welds produced in the shop and in the field, consider various welding techniques (including automatic orbital gas tungsten arc welding), and emphasize welding procedure qualification, including the special tests applied to super duplex stainless steels.

REFRESHMENT BREAK

10. DISSIMILAR METAL WELDING - AUSTENITIC TO FERRITIC
    Donald J. Tillack, Tillack Metallurgical Consulting, Inc., Catlettsburg, KY

    This presentation provides guidelines for determining whether two metallurgically different metals can be welded successfully, with emphasis on joining austenitic to ferritic steels. Usually a dissimilar metal weld involves three different compositions: the filler metal, and the two sides of the joint. The welder or engineer must know the composition of the weld to determine whether its quality will be acceptable. The speaker will present techniques for estimating the composition of the weld metal, noting each method's advantages and disadvantages. Also, guidelines for determining the compositional limits to prevent cracking of the welds will be presented, and the use of ferrite diagrams to determine weld composition will be demonstrated.

11. FERRITE - WHAT IS IT AND SHOULD I WORRY ABOUT IT?
    Frank Lake, ESAB Welding and Cutting Products, Hanover, PA

    Much stainless steel welding occurs without the fabricator and his customer giving any thought to ferrite. Manufacturers of stainless steel electrodes and rods build in ferrite levels that work for most stainless steel welds, but certain circumstances require controlling the ferrite content of welds. This presentation will discuss the structure of the duplex and the 300 series stainless steel weld metals in terms of composition and the effects of high temperature (solidification) and ambient temperatures. The presence of ferrite has an effect on the properties of the weld metal and the benefits must be weighed against any liabilities. The balance in a particular situation should reflect the subsequent service of the weldment. The speaker also will discuss measurement of ferrite and why different methods exist.

LUNCH BREAK 12:05 PM-1 PM

12. THE ROLE OF TYPE 2205 DUPLEX STAINLESS STEEL IN FLUE GAS DESULPHURIZATION SCRUBBER APPLICATIONS
    Gary M. Carinci, TMR Stainless, Pittsburgh, PA

    North America's abundant coal reserves make coal an attractive fuel for energy supply, but fossil fuels can exacerbate environmental pollution. Because acid rain caused by SO2 and NOx emissions, and air pollution caused by exhaust particulates, have become major concerns in recent years, flue gas desulfurization (FGD) of fossil-fired power stations is becoming mandatory for electricity generation in the United States. The majority of FGD units worldwide employ wet scrubbing processes using limestone. Established construction materials for wet scrubbers include coated carbon steels, fiberglass reinforced plastics, stainless steels, and nickel alloys. Stainless steels have given reliable, cost-effective service for almost three decades as construction material for absorber towers, internals, dampers, and outlet ducts. Alloys must be selected according to the corrosive environment (chlorides, acidity, and temperature) and plant design. This presentation reviews the cost-effective use of Type 2205 stainless steel for scrubber applications and reports on recent application of this grade in various parts of FGD units.

13. EFFECTIVE PROCESS VESSEL RESTORATION AND PROTECTION
    Ronald L. Workman, GE Energy, Olathe, KS

    This presentation will discuss the use of automated weld overlays to restore worn vessels to their original pressure rating and protect many of industry's most valuable assets from corrosive and erosive wear. This automated weld overlay process delivers highly productive, consistent, repeatable weld overlays economically and with minimal lead time. More than two decades of industrial experience in refining, petrochemical, pulping, steel, and other major industries has proven the ability of this process to reduce maintenance costs and minimize the threat of unscheduled downtime.

REFRESHMENT BREAK

14. ZERON 100 - A HIGHLY ALLOYED DUPLEX STAINLESS STEEL
    Roger Francis, Weir Materials and Foundries, Manchester, UK

    Zeron 100 is a duplex alloy. Its benefits include guaranteed corrosion performance (PREN>40), high resistance to pitting and service corrosion, excellent resistance to stress corrosion cracking in chloride and sour environments, and high resistance to erosion corrosion and corrosion fatigue.

ADJOURNMENT

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