Duplex

DUPLEX

Centrifugally cast duplex stainless steel

Discussion of benefits
Shawn Martin, Greg Mooren, Alan Holtz, Spuncast, Inc, USA

Introduction

Benefits

Principles of centrifugal castings

Process Control

When it comes to metal forming,

casting metal can be one of the simplest, most cost-effective routes to a
near net shape manufactured good.
Centrifugal casting in particular has
the capability of utilizing these desirable benefits during the production of cylindrical stainless steel
products.

Significant cost savings can be a result of process control.

At Spuncast raw materials purchased
are received and the chemistry evaluated. The chemistries are acquired
through one of three methods: auditing pieces from various locations
in that lot on the spectrometer, the
purchased scrap comes with a certified chemistry, or a 100lb sample of
material is melted down and a
chemistry slug evaluated. This
known/averaged chemistry creates
the necessary control needed when
working with low carbon alloys
(such as Duplex). Charge sequence
and temperature control also play a

Centrifugal casting is a process

where molten metal is funneled
into a rotating mold (commonly
700 to 1300 rpm). The rotation of
the die creates centrifugal force
which thrusts the metal towards the
mold wall.

Figure 1: Cross-Section of a Horizontal Die with a Line Designating its Axis of Rotation.

Centrifugal casting can be performed

horizontally or vertically. The aspect
ratio of the part to be cast is what determines which of these two techniques are used. When the diameter
of the desired part is large in comparison to the overall-length (ring
shaped), vertical casting is most
commonly used. Likewise, when the
length is larger compared to the diameter (tube shaped), horizontal
casting setups are used.

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large role in controlling process

variables. Charge sequence can control the amount of elemental recovery, as well as the cycle time of each
melt. Temperature control allows
the melter opportunity to avoid superheating the melt, ultimately affecting the chemistry, and tap the
furnace with the exact amount of
temperative increase needed to pour
the casting above but close to its
liquidus temperature. Another way

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temperature control plays a key role

is during the casting solidification
process. Centrifugal casting promotes directional grain growth during solidification, as shown in the
pictures below.

Figure 2: Casting cross-section macro-etched with Hydrogen

Peroxide and Muriatic Acid, displaying direction solidification
and grain growth from the outer diameter to the inner
diameter.

Secondary Refining
The centrifugal forces promote metal cleanliness by forcing the nonmetallics (less dense) to the inner
diameter of the casting. As solidification takes place, the inner surface
acts as a riser feeding the outer diameter with the metal it needs to
produce a solid, dense casting. The
less dense materials (the dirt, dross,
or slag) that were forced to the bore
of the casting can now be subsequently machined off. Since the use
of gating and risers are eliminated,
the productions of these castings
have an extremely high casting
yield.

Shapes and Sizes

Centrifugal casting is most appropriate when producing relatively simple cylindrical shaped parts. The list
that follows shows the size ranges
and limitations for the production
of parts using this unique casting
process.

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Size Limits: [1]

Diameter: Up to 3 m (10 feet)
Length: 15 m (50 feet)
Wall Thickness: 2.5 mm to 125 mm (0.1 - 5.0 in)
OD Tolerance: as fine as 2.5 mm (0.1 in)
ID Tolerance: can be 3.8 mm (0.15 in)

Spuncast Avg.
Wrought Spec.
(S32205)

Advantage and Limitation

Centrifugal castings can be more
cost effective than forgings and
have properties that surpass those of
most other casting processes. This
centrifugally cast dense structure
creates castings with a longer life.
These parts also can withstand
greater loads and impacts without
fracturing.

Forged Roll
(Billet)

Wrought Material Properties

Double Energy Costs

Significant amount of Machining.
Low Tooling Costs

Sand
Casting

Centrifugal
Casting

High material cost

Low Manufacturing Costs

Improved Proprieties
Secondary Refining (denser)
Directional Solidification

Strength Limitations
Micro-porosity
Inherent Inclusions

Duplex Stainless Steel

Property Comparison
Mechanical Property Comparison:
Wrought vs. Centrifugally Cast
The primary U.S specification for
cast duplex stainless steels is ASTM
A890. There are eight grades within
this specification. To date there is
no accepted specification for a cast
lean duplex. The following data is a
comparison of achievable cast properties to wrought specifications for
duplex grades 4A and 1B. These
two were selected because they both
have an abundance of history and
data available. There are other duplex grade properties available, but
the information is fairly limited.

Grade 4A

Yield
(MPa)

Yield
(ksi)

Elongation
(%)

802.5

116.4

557.1

80.8

32.7

760

110

550

80

15

2205 - J92205

Grade 1B
2550 - J92205

Two samples of centrifugally cast Duplex Stainless Steel parts:

UTS

UTS

(MPa)

(ksi)

Yield
(MPa)

Yield
(ksi)

Elongation
(%)

731

106

534

77.4

28.4

621

90

450

65.3

25.0

Spuncast Avg.
Wrought Spec.
(S32550)

Table 3: Mechanical property summary for 16 cast and

heat treated Tensile bars (1120C Water Quench)

Several wrought material grades

have recently been introduced that
accomplish cost saving by lowering
the amount of Ni, but none of these
were designed for castability (specifically centrifugal casting).

SCLean
SCLean - Spuncasts Cast Grade of
Lean Duplex
Table 4: SCLean - Nominal Chemistry
y

C
0.025

Mn
4.2

Si
0.68

P
0.02

S
0.005

Cr
22.25

Ni
1.5

W
0.013

Cu
1

Nb
0.06

V
0.05

Al
0.005

Zr
0.007

N
0.19

Test Sample

Shape and Size

Table 1: Above is a list of advantages and limitations to acknowledge when selecting a form of product manufacturing.

UTS
(ksi)

Table 2: Mechanical property summary for 70 cast and

heat treated tensile bars (1120C Water Quench)

Figure 3: Size Limitations for Centrifugal Casting

Utilizing a vertical casting orientation, more complex shapes are quite

possible by the use of either chemically bonded sand inserts or investment (lost-wax) shell inserts.

UTS
(MPa)

1 - 7489
2 - 7490
3 - 7496
4 - 7497
Average

UTS
(MPa)
639
632
628
623
630

UTS
(ksi)
92.71
91.71
91.12
90.35
91

Yield
(MPa)
483
476
470
486
479

Yield
(ksi)
70.01
69.06
68.17
70.45
69

Mo
0.49

Elongatio
n (%)
32.31
39.20

Furnace /
HT
1120oC WQ
1120oC WQ

34.56
32.13
34.6

1120oC WQ
1120oC WQ

Table 5: Mechanical property breakdown for tensile

bars cut from the heat treated castings (1120F Water
Quench)
Stress-Stain Diagram

Decanter Centrifuges

Duplex
Stainless
Steel
Duplex
Stainless
Steel

Solids Discharge

Main Effluent

Figure 4: Decanter Centrifuges - Separating solids from liquids plays a key role in countless industrial, food and waste treatment processes.

On-ship Hydraulic Accumulators

Figure 6: Stress-Strain curve recorded from one of the
SCLean tensile bars pulled (Sample 1-7497).

Figure 5: On-Ship Hydraulic Accumulators - Energy storage basin in which hydraulic fluids are held
under pressure by a peripheral source.

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As stated earlier, maximizing mechanical properties while minimizing the use of expensive raw materials was the primary objective. One
without the other (mechanical
properties / lower cost per kg) is of
no use.

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Duplex

The previously shown mechanical

properties were made at the following price:
SCLean = $1.67 / Kg (based on
$44.31/Kg Ni - LME)
For reference: That same week had
the following prices:
CD4MCuN = $ 3.88 / Kg
Duplex4A = $ 4.54 / Kg

Conclusion
Centrifugal castings use directional
solidification and pressure from the
centrifugal force to create castings
with a denser more sound structure
exhibiting superior physical properties to that of statically poured castings.
It has been made clear that centrifugal casting is a versatile process with
benefits in the areas of mechanical
properties and overall process costeffectiveness. The utilization of
this process can be beneficial when
producing a variety of products.
One particular example shown was
the specific development of SCLean
as a castable lean duplex.

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Reference(s)
Centrifugal Casting. (2007) In efunda, engineering fundamentals.
Retrieved 13:08, July 2nd. 2007, from http://www.efunda.com/processes/metal_processing/centri_casting.efm

About the authors

Shawn Martin
Academic Education & Degrees:
Bachelors of Science - Material Science & Engineering,
Michigan Technological University
Current Position:
Metallurgist,
Spuncast, Inc, Watertown, WI USA

Greg Mooren
Academic Education & Degrees:
Bachelors of Science - Material Science & Engineering,
Michigan Technological University
Current Position:
Metallurgist, Spuncast, Inc, Watertown, WI USA

Alan Holtz
Academic Education & Degrees:
Bachelor of Arts - History,
University of Pennsylvania
Bachelor of Science - Metallurgical Engineering,
University of Missouri - Rolla
Current Position: Vice President - Sales & Engineering,
Spuncast, Inc, Watertown, WI USA

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